Topic 1: Manufacturing Systems

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Topic 1 Manufacturing Systems

• 1.1 Manufacturing Classification
• System ???????

A set of components that are connected in a
rational way to perform something Manufacturing
systems are to make products
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• ltQuestion 1gt
• Company (1) produces Bloom, Slab, and Billet
• Company (2) produces a pressing machine

Figure 1.1
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Do they belong to the same type of
manufacturing system?
From the viewpoint production process, we have
Figure 1.2. Raw materials
Completed Capital equipment Production
Products Production tooling
Process Energy Scrape Labor Figure
1.2
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Differences of production process will be based
on - product - technology Clearly
manufacturing systems should not be classified in
terms of the above, as there will be enormous
types Manufacturing system classification
follows (1) project, (2) job shop, (3)
repetitive, (4) line and (5) continuous
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Project

• One of a kind (such as ship and nuclear power
  plant)
• Complex
• Site building (production tools must get to the
  site

Job Shop

• Low volume and production quantities, called lot
  sizes
• Not site building (traditional workshop, see
  Figure 1.3)

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Figure 1.3
Figure 1.4
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• Repetitive
• Orders for repeat business approach 100.
• Blanket contracts with customers for multiple
  years occur frequently.
• Moderately high volume with lot sizes varying
  over wide range
• Fixed routing for products

In the plant, the production is organized in the
manner either Figure 1.3 or Figure 1.4
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• Line
• Delivery time (often called lead time) required
  by the customer is often shorter than the total
  time it takes to build the product
• Product has many different models and options
• An inventory of subassemblies is normally present
• Examples Car and Truck.
• Production follows Figure 1.4.

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• Continuous
• Manufacturing lead time gt the lead time quoted
  to the customer.
• Product demand is predicable
• Product inventory is held
• Volume is high
• Products have few options
• Production follows Figure 1.4
• Examples Chemical components.

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Summary of Types of Manufacturing Systems
Figure 1.5
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1.2 Production strategy classification deals with
how to make the product. Criteria for
classification - customer lead time (CLD) and
- manufacturing lead time (MLD)
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Engineer to order Product is either in the
first stage of the life-cycle curve or a complex
product with a unique design produced in
single-digit quantities. Example construction
industry (bridge, etc.) Customer is willing to
accept long MLD - permitting this strategy
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Make to order All the engineering and design
are complete and the production process is
proven. Example new residential homes. The
customers demand is unpredictable.
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Assemble to order - Primary reason of this
strategy MLD gt CLD. - Order is statistically
predicable. Examples automobiles, personal
computers - This strategy is especially adopted
in the line manufacturing type
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Make to stock - Reasons for this strategy (1)
CLD lt MLD (2) product configuration has few
options so that the demand can be predicated
accurately. - Product parts are often stocked
in distribution warehouses located in major
population centers.
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Production strategy versus MLD
Maximal MLD ETO Minimal MLD MTS (0)
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It is important to be aware that the production
strategy can be changed with the product
evolution. MTO may not suit the product which has
a high component of RD however MTO may be
applied when that product goes to maturity.
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1.3 Enterprise organization
Aim examine different function units and their
communications Manufacturing organization see
Figure 1.6 where boxes represent different
function units and arrowhead lines indicate the
communications.
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Figure 1.6
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Product and Process Definition (Figure 1.7)
Finance and management
Product Design
Sales and Marketing
Production Engineering
Production engineering
Product design
Engineering release
Engineering release
Manufacturing planning and control
Quality
Quality
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Manufacturing planning and control (See Figure
1.8) Manufacture process planning determine the
type of machines required to process the parts
and the production sequence, called the routing,
to be used Production planning -gt scheduling
(time factors included)
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Figure 1.8
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Figure 1.9 Manufacturing Planning and Control
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MPC versus others
Figure 1.10
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Production sequence (Figure 1.11)