PRODUCTION SYSTEMS

DEFINITION

MANUFACTURING PROCESS

Application of physical and chemical process to alter the geometry properties and/or appearance of a given started material to make parts or products. This definition includes assembly process.

PRODUCTION SYSTEM

A production system is a collection of people, equipment and procedures organized to perform the manufacturing operations of a company.

MANUFACTURING SYSTEM

A manufacturing system is a collection of integrated equipment designed for some special mission, such as machining a defined part family or assembling certain product. Include people.

LEVELS IN PRODUCTION SYSTEM

Facilities Manufacturing support systems

FACILITIES

Factory Production machines Tooling Material handling equipment Inspection equipment Computer system Plant layout

MANUFACTURING SUPPORT SYSTEMS

Procedures or process needed to manage the production operations

Involve a cycle of information processing

Figure 1.3

Functions:

1. Business functions communication with the customer Marketing Forecasting Order entry

Cost accounting Customer billing

2. Product design Research and development Design engineering Prototype shop

3. Manufacturing planning Process planning. Operation sequence Master scheduling Planning. MPS. Listing of product to be make Material Requirement planning. MRP. Raw material and purchasing parts. Capacity resource planning. CRP

4. Manufacturing control Shop floor control Inventory control Quality control

MANUFACTURING SYSTEM CATEGORIESIn terms of human participation in the process,

1. Manual work system

One or more workers performing one or more tasks with the aid of hand tools.

Hand tools: Is a small tool that is manually operated by the strength and skill of the human user.

2. Worker-machine systemA human worker operates powered equipment

3. Automated system

The process is performed by a machine without the direct participation of a human worker

Requirement: Program of instructions and control system

AUTOMATIZATION IN PRODUCTION SYSTEMS

1- Automation of manufacturing system2- Computerization of manufacturing support systems

Automated Manufacturing System

The process is performed by a machine without the direct participation of a human worker

Basic types:

1- Programmable automation2- Flexible automation3- Fixed automation

Programmable automation

The equipment are designed with the capability to change the sequence of operation to accommodate different product configuration

Features:

1- High investment in general purpose equipment2- batch production3- Low production rates4- Certain flexibility to change product configuration

Example

CNC machine tools with manual part charge lost time

Flexible automation

Is an extension of programmable automation.

1- High investment in custom-engineered equipment2- Continuous production of variable mixture product3- Medium production rates4- Flexibility to deal with product design variation. Virtually no time lost for changeover

Example

Machining operation with automated part charge

Fixed automation

System in which the sequence of processing operation is fixed by the equipment configuration

1- High initial investment for custom-engineered equipment2- High production rates3- Relative inflexibility of the equipment to accommodate product variety

Example

Machining lines transfers

Automated assembly machines – assembly lines

Figure 1.5

AUTOMATION PRINCIPLES AND STRATEGIES

USA Principles

1- Understand the existing process2- Simplify de process3- Automated the process

Strategies

1- Specialization de operation2- Combined operations3- Simultaneous operation4- Integration of operation 5- Increase of flexibility6- Improve material handling and storage7- On line inspection8- Process control and optimization9- Plant operation control10- Computer integrated manufacturing (CIM)

MIGRATION

1- Manual production2- Automated production3- Automated integrated production