Supporting Slides

1
Supporting Slides
X
Systems for Planning Control in
Manufacturing Systems and Management for
Competitive Manufacture
Professor David K Harrison Glasgow Caledonian
University Dr David J Petty The University of
Manchester Institute of Science and Technology
ISBN 0 7506 49771
0000
2
Manufacturing Systems
01

• Objectives
• To Understand the Concept of a Manufacturing
  System
• To Understand the Different Types of
  Manufacturing Systems
• To Appreciate the Importance of Manufacturing
  Strategy
• Overview
• Manufacturing and the Enterprise
• Classification of Manufacturing Organisations
• Design of Manufacturing Systems

0101
3
Economic Role of Manufacturing
01
Agriculture and Construction
0102
4
Definitions
01

• Material Removal
• Material Forming
• Casting/Sintering
• Chemical/Mixing
• Painting
• Assembly

Process. A means of transforming material from
one form into another System. A number of
entities acting together as a whole Manufacturing
System. A series of value adding manufacturing
processes to convert raw materials into more
useful forms and eventually finished product.

0103
5
History
01
Craft
Mechanisation
Soft Eng.
Power
Low
High
Reduced
Technology
Simple
Complex
Modular
Organisation
Small
Large
Hierarchical
Low
High
Formalisation
0104
6
The Manufacturing System
01
Process
Queue
Process
Process
Queue
Warehouse
Warehouse
Process
Process
Queue
Finished Product
Raw Materials
Warehouse
Process
Process
Warehouse
Process
Queue
0105
7
The Manufacturing Organisation
01
Sales
Purchasing
Accounts
Design
Production
Product
Planning
Development
Control
Quality
Production
Engineering
Process
Process
Process
Queue
Warehouse
Warehouse
Queue
Process
Queue
Process
Supplier
Customer
Process
Base
Warehouse
Base
Raw
Finished
Process
Warehouse
Materials
Product
Process
Queue
0106
8
Scope of Manufacturing Management
01
10 Years
Decisions
Low Frequency
Strategic
High Significance
1 Year
Tactical
1 Month
Operational
Decisions
High Frequency
Low Significance
1 Day
Physical
0107
9
Classification and Characteristics
01

• Small
• Medium
• Large
• Chemical
• Metal working
• Electronic
• MTS
• MTO
• CTO
• ETO
• Fixed Position
• Process
• Product
• Cellular
• CNC

Variety
"D"
Finished Goods
P"

• Size
• Type of Product
• Market
• Machine Layout
• Technology
• Material Flow

Components Or Sub-Assemblies
Raw Materials
High
High
Control
Complexity
Product Complexity
Low
Low
Mass
Job
Batch
0108
10
Stock and Manufacturing Systems - 1
01
Make
Warehouse
Buffer
Buffer
Buffer
Process
Process
Process
to Stock
Configure
Warehouse
Process
Process
Process
Buffer
Buffer
Buffer
to Order
Make
Warehouse
Process
Process
Process
Buffer
Buffer
Buffer
to Order

• It is Desirable to Commit Material as Late as
  Possible
• Holding Material at a Low Level will Minimise
  Stockholding

0109
11
Strategy
01
What is the Purpose of the Organisation?
Statement of Aims
Mission Statement
1
What is the Status of the Organisation?
Analysis of Environment
SWOT Analysis Matrix Analysis
Formulation
2
What is the Desired State of the Organisation?
Statement of Objectives
Targets
3
How Will the Desired State be Achieved?
Marketing Strategy Manufacturing Strategy I.T.
Strategy
Strategic Choice
4
Actions
5
Implementation
Monitoring and Control
6
0110
12
SWOT Analysis/Matrix Analysis
01
Strengths Weaknesses Opportunities Threats
Engineering Students

• Cows. These generate cash.
• Calves. These consume cash, but will generate
  money in the future.
• Dogs. These consume cash and always will.

S Well Qualified in Engineering as a Technical
Discipline W Lack of Business/Financial
Knowledge to Achieve Promotion to Senior
Management O Solid Analytical Background Could
Provide the Chance to Move into Systems/IT
Related Areas T Manufacturing Declining in the
West and Wages Could be Further Depressed
0111
13
Corporate/Manufacturing Strategy
01
0112
14
Choice of Technology - 1
01
100,000
Volume
Increasing Cost per Piece
10,000
Increasing Flexibility
1000
100
10
100
1,000
Variety
0113
15
Choice of Technology 2
01
Soft Automation is Becoming Increasingly Common
0114
16
FMS and FMC
01
0115
17
Flexible Assembly Line
01
Manual Station
Magazines
Pallets
Non-synchronous transfer machine
Work carrier
0116
18
Flexible Assembly Cell
01
Parts presented in pallet
General purpose gripper
Assembly robot
Parts presented in magazines
Conveyor for completed assembly
Work fixture
Gripper/Finger storage rack
Conveyor for base parts
Vibratory bowl feeder
0117
19
Equipment Layout - 1
01
Fixed Position
1
8
2
7
Equipment
Types
Material
1 - 8.
3
6
4
5
0118
20
Equipment Layout - 2
01
Functional
Lathe
Lathe
Drill
Drill
Drill
Drill
Lathe
Lathe
Mill
Grinder
Mill
Grinder
Grinder
Grinder
Mill
Mill
0119
21
Equipment Layout - 3
01
Group
Flowline 1
Lathe
Grinder
Drill
Lathe
Drill
Lathe
Cell 1
Flowline 2
Mill
Grinder
Mill
Grinder
Drill
Mill
Flowline 3
Lathe
Mill
Grinder
Drill
Drill
Lathe
Cell 2
Flowline 4
Mill
Grinder
Lathe
Mill
Grinder
Drill
0120
22
Equipment Layout 4
01
Flow
Process
Process
Process
Process
1
2
3
4
0121
23
Hierarchical Organisation Example
01
Corporate
AutoComp plc
Other Divisions
Division
AutoComp Braking
Other Sites
Site
AutoComp Braking Products UK
Original Equipment
Business Unit
Aftermarket
Railways
Press Form Disc Brake Pads
Press Cure Disc Brake Pads
Mixing
Block
Linings
Plate Preparation
Pressing
Finishing
Dept.
Cell A
Cell B
Cell C
Cell D
Group
M/C 1
M/C 5
M/C 2
M/C 3
M/C 4
M/C 6
Machine
0122
24
Geographical Location
01

• Proximity to Materials/Sub-Contractors
• Proximity to Markets
• Availability of Space
• Quality of Infra-structure
• Availability of Labour
• Availability of Grants
• Political Stability

0123
25
Functional Layout Design
01

• Sometimes Called Process Orientated
• Traditional Layout Method
• Unfashionable, but has Several Advantages
• Obligatory in Some Circumstances
• Common in Service Environments
• Layout is a Universal Problem

0124
26
Functional Layout Design
01

• Physical Modelling
• Computer Heuristic Methods
• Simulation Methods
• Cross and Relationship Charts

0125
27
Cross Chart Example
01
To Process
B
C
D
E
J
F
G
H
I
A
1635
200
65
2000
50
50
A
B
1635
1600
35
C
1800
1750
25
25
D
1815
1815
E
1815
40
1775
From Process
F
1885
1885
G
2000
2000
H
1500
500
2000
I
J
500
1500
1635
2000
1800
1815
1815
1885
2000
0126
28
Generation of a Cross Chart
01
Number of
Projected
Product
Product
Sales
Batches
ADS1029
ADS1029
1000
10
Sales
ASS5431
ASS5431
2000
10
DDF8897
DDF8897
2500
20
Planning
HGF6509
HGF6509
1500
15
UAC9875
UAC9875
750
7
Data
To Process
B
C
D
E
J
F
G
H
I
A
Lot
Product
1635
200
65
2000
50
50
A
B
1635
1600
35
Size
C
1800
1750
25
25
ADS1029
100
D
1815
1815
E
1815
40
1775
ASS5431
200
From Process
Planning
F
1885
1885
DDF8897
125
G
2000
2000
HGF6509
100
Data
H
1500
500
2000
UAC9875
150
I
J
500
1500
1635
2000
1800
1815
1815
1885
2000
Routing
Product
ADS1029
A
B
C
D
E
F
G
H
I
ASS5431
A
C
F
G
H
J
Routing
DDF8897
A
B
C
D
E
F
G
H
I
HGF6509
A
B
C
D
E
F
G
H
J
Data
UAC9875
A
F
G
H
I
0127
29
Layout Representation 1
01
165
A
B
C
A
B
E
Minimise Non-Adjacent Loads
D
E
F
C
D
F
300
A
B
C
D
E
F
To
From
A
150
75
B
300
75
C
60
75
90
D
150
150
200
E
75
F
150
150
0128
30
Layout Representation 2
01

• Minimises Transport Distances
• An Iterative Process
• Needs Quantitative Data
• Can be Used for Service Layouts

A
B
C
D
E
F
A
B
E
C
D
F
0129
31
Relationship Chart
01
To Process
B
C
D
E
J
F
G
H
I
A
A
1635
200
65
2000
50
50
A
A
B
1635
1600
35
B
E
C
1800
1750
25
25
A
I
D
1815
1815
C
E
1815
40
1775
U
U
From Process
F
1885
1885
I
A
U
G
2000
2000
D
I
O
U
H
1500
500
2000
U
U
O
A
I
E
U
U
U
O
J
U
U
U
U
A
500
1500
1635
2000
1800
1815
1815
1885
2000
F
I
U
U
U
U
U
A
U
Absolutely Important
Ordinarily Important
G
U
U
U
A
O
U
U
A
H
U
U
Especially Important
E
U
Unimportant
U
A
I
A
U
Undesirable
I
X
Important
J
0130
32
Relationship Chart Example
01
A 2 to 5 E 3 to 10 I 5 to 15 O 10 to
25 U Remainder
Production 1
A
Production 2
I
O
U
Offices
A
X
E
X
I
Despatch
E
O
U
U
Original
Revised
R D
U
U
Tool Room

• No X Lines

0131
33
Location of New Resources
01
0132
34
Cost Surface
01
0133
35
Summary
01

• Functional Layout has Advantages
• Movement is Non-Value Adding
• Many Techniques for Layout
• Good Layout is Critical

0134
36
Cellular Manufacturing Overview
01

• No Universal Definition But Common Themes
• A Grouping Within a Larger Organisation
• Produces a Family of Products
• Has Significant Autonomy
• Self-Contained to Some Degree
• Can be Measured Independently

0135
37
Functional Layout Disadvantages
01

• Distance Travelled by Components
• High Levels of Material Handling
• Queuing is Uncontrolled
• High WIP
• Long Lead Time
• Difficult to Understand the System
• Difficult to Simplify

There Are Some Fundamental Disadvantages in Terms
of Material Flow
0136
38
Group Technology
01
Flowline 1
Grinder
Drill
Lathe
Lathe
Flowline 2
Grinder
Mill
Drill
Mill
Flowline 3
Lathe
Mill
Grinder
Drill
Flowline 4
Grinder
Lathe
Mill
Drill
0137
39
Coding Systems - The Salford Method
01
4th Digit
5th Digit
6th Digit
1st Digit
2nd Digit
3rd Digit
Geometry or
Complexity
Technological
Tool Class
External Shape
Internal Shape
Flange Detail
Factor
0
Single
Station
Shape
Definition
Number
1
Number of
Complexity
Aperture
Compound
of Contour
Factor
Definition
and/or Dias
Vectors
Flat, Bent,
Hollow
2
Fine
Combinations
Blanking
3
Progressive
4
Transfer
Definition
Definition
(Moving Punch)
Complexity
Flange
of Number
of Component
Features
Characteristics
Factor
of Dias and
Reversal
5
Transfer
Tapers
(Moving Die)
6
Four Slide
(Single)
7
Four Slide
(Double)
Number
Definition
Complexity
Aperture
Number
of Contour
of Contour
8
Factor
Definition
of Bends
Vectors
Special
data
9
Production Flow Analysis was also Used
0138
40
GT Cells
01
Flowline 1
Drill
Lathe
Lathe
Grinder
Drill
Lathe
Cell 1
Flowline 2
Mill
Grinder
Lathe
Grinder
Drill
Mill
Flowline 3
Lathe
Grinder
Drill
Lathe
Drill
Lathe
Cell 2
Flowline 4
Grinder
Mill
Lathe
Lathe
Grinder
Drill
0139
41
Product/Process Matrix 1
01
Product
1
11
10
9
8
6
5
4
3
2
7
15
16
17
21
18
22
19
23
20
24
14
12
13
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Process
15
0140
42
Product/Process Matrix 2
01
A
B
C
D
Product
23
19
22
7
20
3
11
14
24
18
21
4
6
12
2
5
8
13
17
1
9
10
15
16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Process
15
0141
43
Pre-Requisites for the GT Approach
01
Both GT Flowlines and GT Cells Might be Called
Cells Today

• Natural Product Groups
• Light Components
• Few Indivisible Processes
• A Stable Product Mix
• Cross Skilled Personnel/Excess Machine Capacity
• Willingness to Undertake Variety Reduction
• Availability of Funds

Inappropriate Use of GT Can Reduce Utilisation
and Flexibility
0142
44
Capacity and Flowlines
01
12 Units/Hr 5 Mins/Unit
10 Units/Hr 6 Mins/Unit
12 Units/Hr 5 Mins/Unit

• Overall Production Rate 10 Units per Hour
• Simple Case Slowest Work Centre Determines Rate

0143
45
Multi-Machine Manning
01
How Should Labour be Allocated?
0144
46
Line Balancing - Precedence Diagram
01
3.2
E
4.5
2.0
6.0
I
B
F
2.5
3.5
2.7
3.8
4.3
A
L
C
G
J
4.0
7.0
5.0
D
H
K
Particularly Applied for Repetitive Assembly
Problems
0145
47
Line Balancing Precedence Table
01
Same Data as Previous Slide But in Tabular Form
0146
 
48
Largest Candidate Method - 1
01
3.2
E
Work Centre Sum
4.5
2.0
6.0
Work Centre
Element
Time
I
B
F
3.5
2.7
2.5
3.8
4.3
C
G
A
J
L
5.0
4.0
7.0
H
K
D
7.0
H
6.0
I
5.0
K
4.5
B
4.3
L
4.0
D
Elements Sorted into Size Order
3.8
J
3.5
C
3.2
E
2.7
G
2.5
A
2.0
F
0147
49
Largest Candidate Method 2
01
Twc Total of All Elements d Balance Delay
(or Balance Loss)
In the previous example, Twc 48.5 and n 6
0148
50
RPW Method 1
01

• Ranked Positional Weight (RPW) Similar to Largest
  Candidate
• Only Difference is in Choosing Elements
• The RPW Value for an Element is the Sum of
  Downstream Elements

Examples of RPW Calculations RPW for J J
L 8.1 Minutes RPW for F F J L
10.1 Minutes RPW for B B E I L F J
23.8 Minutes Thus to Find the RPW value for an
Element, Trace All of the Paths Through the
Network to the End
0149
51
RPW Method 2
01
3.2
E
Work Centre Sum
4.5
2.0
6.0
Work Centre
Element
Time
B
F
I
3.5
2.7
2.5
3.8
4.3
C
G
J
A
L
4.0
7.0
5.0
K
D
H
48.5
A
26.8
D
23.8
B
16.3
H
13.6
C
Elements Sorted into RPW Order
13.5
E
10.8
G
10.3
I
10.1
F
9.2
K
8.1
J
4.3
L
0150
52
RPW Method 3
01
In the previous example, Twc 48.5 and n 5

• In this case, the RPW Gives the Best Result
• In Other Cases, Largest Candidate Might Give the
  Best Result

0151
53
Material Flow Rules
01
5 Mins/Unit
6 Mins/Unit
5 Mins/Unit
4 Mins/Unit
A
B
C
D
Sequential Slowest Rate
Parallel Work Centres Sum of Rates
6 Mins/Unit
4 Mins/Unit
B
B
B
C
6 Unit/min
6 Unit/min
Shared Resource Sum of Times
0152
54
Course Book
X
Systems for Planning Control in
Manufacturing Systems and Management for
Competitive Manufacture Professor David K
Harrison Dr David J Petty ISBN 0 7506 49771
0000