manufacturing systems design

LEAN MANUFACTURING SYSTEMSManufacturing System Design

By:Kiran Hanjar S1MS12MIA03III Sem, IE (M.Tech)Dept. of IEM, MSRIT

Department of IEM, MSRIT 1

Factors influencing the system designs in an emerging industrial space

More companies serve global markets by making products for customers worldwide.

As production of a variety of products increases, decreases in lot sizes and quantities result.

Requirements for closer tolerances continue to increase. Requirements demand higher levels of accuracy, precision, and quality.

Product reliability is increasing in response to excessive product liability lawsuits.

The time between an initial design concept and a resulting product continues to shorten due to concurrent or simultaneous engineering.

Ergonomics and worker safety continue to grow in importance as worker-compensation costs escalate and humanistic trends continue

Green manufacturing strategies continue to help protect the earth from further pollution


Facility Layout and Work Flow

Arrangement within a factory of: Machines Departments Workstations Storage areas Aisles and common areas

Ensures a smooth flow of work, material, people and

information through the system

Introduction


Types of Layouts

• 3 three basic types of layout: • Process layout• Product layout• Fixed-Position layout

• 3 hybrid layouts: • Cellular Manufacturing• Flexible Manufacturing Systems• Mixed-model Assembly Lines


Process Layout• Similar activities grouped together in work areas• Suitable for low volume or batch production• Flexible• Not very efficient• Storage space – large receiving, small shipping • Large aisles for movement of material

Lathe Department Milling Department Drilling Department

Grinding Department Painting Department

Receiving and ShippingAssembly

L L

L L

L

L

L

L

M M M

G G G G

D D D D

D D D D

P

P

A A ADepartment of IEM, MSRIT 5

Product Layout• Arrange activities in sequence of operation• Line set up for one product• Specialised machines• Suitable for mass production • More automated than process layouts• Efficient• Line flow – avoid bottlenecks • Not flexible IN

OUTDepartment of IEM, MSRIT 6

Fixed Position Layout• Large projects too big to move• Equipment and parts moved in and out of work area• Highly skilled workers - costly


Hybrid Layouts

Try to mix flexibility of process layout with efficiency of product layout

Cellular Layouts:

• Machines grouped into cells

• Cells process parts with similar features

• Work cell resembles a small assembly line (product)

• Layout between cells treated as process layout


Comparison

4 6

5

1

2

11

9

8

7

12

10

3

Raw Materials

Assembly

4

6

51

211

98

7

12

10

3

Raw Materials

Assembly

Design of work cellProcessed based layout


Flexible Manufacturing Systems

• Automates the entire manufacture of a product

• Very costly

• Complex software

• Small number of FMS worldwide

• Flexible Manufacturing Cell:• Smaller version of FMS

• One manufacturing process is automated


Progressive FMS• Progressive FMS:

• All parts follow same progression through the work stations

• Best where group technology can be applied

Progressive FMS

Load StationUnload StationPallet


Closed Loop FMS• Larger variety of parts

• Parts can follow different paths

• Parts can skip stations

Closed Loop FMS

Pallet

UnloadLoad


Ladder FMS layout• Parts moved to and from any machine in any

sequence

• More flexible than progressive and closed loop systemsLoad/Unload


Mixed Model Assembly Lines• More than one product is processed by the line

• Workers trained to work on more than one station

• Layout of line changed

• Long and short operations arranged to cancel each other

Traditional line

U Shaped LineDepartment of IEM, MSRIT 14

Limitations

• System size and complexity inhibit modeling and control, due to implied-time expenditures.

• Systems are dynamic and unstable. The environment can change the system and vice versa.

• Relationships may be awkward to express in analytical terms, and interactions may be nonlinear. Thus, well-behaved functions often do not apply.

• Data or information may be difficult to secure, inaccurate, conflicting, missing, or too abundant to digest.

• Objectives may be difficult to define, particularly in systems that have an impact on social and political issues. Goals may conflict.

• The act of observing and trying to control a system changes the behavior of the system.

• Analysis and control algorithms for systems can be subject to errors of omission and commission. Some errors will be related to breakdowns or delays in feedback elements.


THANK YOU


manufacturing systems design

Education

process layout product

system department of

shippingdepartment of

flexibledepartment of

automateddepartment

youdepartment of iem

msrit department of

pollution department