manufacturing process & systems

8/13/2019 Manufacturing Process & Systems

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LECTURE # 1


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Manufacturing is the process to convert rawmaterials into finished products. It encompassesthe design and production of goods by usingdifferent production techniques.

Manufacturing is important technologically,economically and historically. Technology meansthe application of science to provide society and

its members with those things which are neededor desired. Manufacturing is an essential factorthat makes technology possible.


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TECHNICAL PROCESS ECONOMIC PROCESS

Transformation ofmaterials into items ofgreater value.

Value is added to the

product bymanufacturing/processing techniques.

For example: iron intosteel

petroleum into plastic sand into glass.

Combination of physicaland chemicalprocesses.

Alter the geometry

properties andappearance of astarting material toma!e parts or products.

"achining toolingpo#er and human laborinvolved.


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TECHNICAL PROCESS ECONOMIC PROCESS


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The word manufacturin and !roduction are

often u"ed interchanea$%&

Production ha" roader meanin thanManufacturin&

'or e(am!$e) crude oi$ !roduction&


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1& Com!onent" of a Manufacturin S%"tem

*& A C$a""ification Scheme for ManufacturinS%"tem"

+& O,er,iew of the C$a""ification S%"tem


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-A co$$ection of interated e.ui!ment andhuman re"ource"/ who"e function i" to!erform one or more !roce""in and0ora""em$% o!eration" on a "tartin raw

materia$/ !art/ or "et of !art" $quipment includes

Production machine" and too$"

Materia$ hand$in and wor2 !o"itionin de,ice"

Com!uter "%"tem" Human re"ource" are re.uired either fu$$3

time or !eriodica$$% to 2ee! the "%"temrunnin


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Sin$e3"tation ce$$" Machine c$u"ter" Manua$ a""em$% $ine"

Automated tran"fer $ine" Automated a""em$% "%"tem" Machine ce$$" 4ce$$u$ar manufacturin5 '$e(i$e manufacturin "%"tem"


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1& Production machine"

*& Materia$ hand$in "%"tem

+& Com!uter "%"tem to coordinate and0or

contro$ the !recedin com!onent"6& Human wor2er" to o!erate and manae the

"%"tem


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In ,irtua$$% a$$ modern manufacturin "%"tem"/mo"t of the actua$ !roce""in or a""em$% wor2i" accom!$i"hed % machine" or with the aid oftoo$"&

Classification of production machines:1& Manua$$% o!erated machine" are contro$$ed or

"u!er,i"ed % a human wor2er&

*& Semi3automated machine" !erform a !ortion of

the wor2 c%c$e under "ome form of !roramcontro$/ and a wor2er attend" the machine forre"t of the c%c$e&

+& 'u$$% automated machine" o!erate for e(tended!eriod" of time with no human attention&


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Manually operated machines are controlled or supervised by a human

worker. The machine provides the power for the operation and the

worker provides the control. The entire work cycle is operator controlled.


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A "emi3automated machine !erform" a !ortion of the wor2c%c$e under "ome form of !roram contro$/ and a wor2ertend" to the machine for the remainder of the c%c$e& T%!ica$wor2er ta"2" inc$ude $oadin and un$oadin !art"


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Machine o!erate" for e(tended !eriod" 4$oner than onewor2 c%c$e5 without wor2er attention 4!eriodic tendin ma%e needed5&


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In mo"t manufacturin "%"tem" that !roce""or a""em$e di"crete !art" and !roduct"/ thefo$$owin materia$ hand$in function" mu"t

e !ro,ided)1& Loadin wor2 unit" at each "tation*& Po"itionin wor2 unit" at each "tation

+& Un$oadin wor2 unit" at each "tation

6& Tran"!ortin wor2 unit" etween "tation" inmu$ti3"tation "%"tem"

7& Tem!orar% "torae of wor2 unit"


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Two enera$ cateorie" of wor2 tran"!ort inmu$ti3"tation manufacturin "%"tem")1&1& 'i(ed routin'i(ed routin 8or2 unit" a$wa%" f$ow throuh the "ame

"e.uence of wor2"tation" Mo"t !roduction $ine" e(em!$if% thi" cateor%

1&1& 9aria$e routin9aria$e routin 8or2 unit" are mo,ed throuh a ,ariet% of

different "tation "e.uence"

Mo"t :o "ho!" e(em!$if% thi" cateor%


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T%!ica$ com!uter function" in a manufacturin "%"tem) Communicate in"truction" to wor2er" 4recei,e !roce""in

or a""em$% in"truction" for the "!ecific wor2 unit5

;own$oad !art !roram" to com!uter3contro$$edmachine"

Contro$ materia$ hand$in "%"tem Schedu$e !roduction

'ai$ure diano"i" when ma$function" occur and!re,enti,e maintenance

Safet% monitorin 4!rotect oth the human wor2er and

e.ui!ment5


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'actor" that define and di"tinui"hmanufacturin "%"tem")1& T%!e" of o!eration" !erformed

*& Numer of wor2"tation"+& S%"tem $a%out

6& Automation and mannin $e,e$

7& Part or !roduct ,ariet%


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Proce""in o!eration" on wor2 unit" ,er"u" a""em$%o!eration" to comine indi,idua$ !art" into a""em$edentitie"

T%!e4"5 of materia$" !roce""ed Si=e and weiht of wor2 unit" Part or !roduct com!$e(it%

'or a""em$ed !roduct"/ numer of com!onent" !er!roduct

'or indi,idua$ !art"/ numer of di"tinct o!eration" to

com!$ete !roce""in Part eometr%

'or machined !art"/ rotationa$ ,"& non3rotationa$


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Con,enient mea"ure of the "i=e of the"%"tem Let n> numer of wor2"tation"

Indi,idua$ wor2"tation" can e identified %"u"cri!t i/ where i = 1, 2,...,n

Affect" !erformance factor" "uch a" wor2$oadca!acit%/ !roduction rate/ and re$iai$it% A" nincrea"e"/ thi" u"ua$$% mean" reater wor2$oad

ca!acit% and hiher !roduction rate

There mu"t e a "%neri"tic effect that deri,e"from nmu$ti!$e "tation" wor2in toether ,"& n"in$e "tation"


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A!!$ie" main$% to mu$ti3"tation "%"tem" 'i(ed routin ,"& ,aria$e routin

In "%"tem" with fi(ed routin/ wor2"tation" are

u"ua$$% arraned $inear$% In "%"tem" with ,aria$e routin/ a ,ariet% of

$a%out" are !o""i$e

S%"tem $a%out i" an im!ortant factor in

determinin the mo"t a!!ro!riate t%!e ofmateria$ hand$in "%"tem


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Le,e$ of wor2"tation automation Manua$$% o!erated

Semi3automated

'u$$% automated

Mannin $e,e$ Mi= pro!ortion of time wor2er

i" in attendance at "tation i

Mi> 1 mean" that one wor2er mu"t e at the

"tation continuou"$%

Mi1 indicate" manua$ o!eration"

Mi? 1 u"ua$$% denote" "ome form of automation


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-The deree to which the "%"tem i" ca!a$e of dea$in with,ariation" in the !art" or !roduct" it !roduce"

Three ca"e")

1&1& Sin$e3mode$ ca"eSin$e3mode$ ca"e3 a$$ !art" or !roduct" are identica$4"ufficient demand0fi(ed automation5

*&*& @atch3mode$ ca"e@atch3mode$ ca"e3 different !art" or !roduct" are!roduced % the "%"tem/ ut the% are !roduced inatche" ecau"e chaneo,er" are re.uired 4hard!roduct ,ariet%5

+&+& Mi(ed3mode$ ca"eMi(ed3mode$ ca"e3 different !art" or !roduct" are

!roduced % the "%"tem/ ut the "%"tem can hand$ethe difference" without the need for time3con"uminchane" in "etu! 4"oft !roduct ,ariet%5


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(a) ingle!model case, (b) batch model case, and (c) mi"ed!model case


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Identification of the different wor2 unit"Identification of the different wor2 unit" The "%"tem mu"t e a$e to identif% the difference"

etween wor2 unit" in order to !erform the correct!roce""in "e.uence


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Sin$e3"tation ce$$" n> 1

Manua$ or automated

Mu$ti3"tation "%"tem" with fi(ed routin n 1

T%!ica$ e(am!$e) !roduction $ine

Mu$ti3"tation "%"tem" with ,aria$e routin

n 1


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n> 1 Two cateorie")

1&1& Manned wor2"tation"Manned wor2"tation"3 manua$$% o!erated or"emi3automated !roduction machine 4M> 15

*&*& 'u$$% automated machine'u$$% automated machine4M? 15

Mo"t wide$% u"ed manufacturin "%"tem 3rea"on") Ea"ie"t and $ea"t e(!en"i,e to im!$ement

Mo"t ada!ta$e/ ad:u"ta$e/ and f$e(i$e "%"tem

Can e con,erted to automated "tation if demandfor !art or !roduct :u"tifie"


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n 1 Common e(am!$e > !roduction $ine!roduction $ine3 a "erie"

of wor2"tation" $aid out "o that the !art or!roduct mo,e" throuh each "tation/ and a

!ortion of the tota$ wor2 content i" !erformedat each "tation

Condition" fa,orin the u"e of !roduction$ine")


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n 1 ;efined a" a rou! of wor2"tation" orani=ed

to achie,e "ome "!ecia$ !ur!o"e/ "uch a") Production of a fami$% of !art" re.uirin "imi$ar 4ut

not identica$5 !roce""in o!eration"

A""em$% of a fami$% of !roduct" re.uirin "imi$ar4ut not identica$5 a""em$% o!eration"

Production of a com!$ete "et of com!onent" u"ed

to a""em$e one unit of a fina$ !roductT%!ica$ ca"e in ce$$u$ar manufacturin

manufacturing process & systems

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