Chapter 4

CHAPTER 4 INTRODUCTION TO MANUFACTURING SYSTEMS

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Outline
Components of a Manufacturing System A Classification Scheme for Manufacturing Systems Overview of the Classification Scheme

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Outline
Components of a Manufacturing System Production Machines Material Handling System Computer Control System Human Resources A Classification Scheme for Manufacturing Systems Type of Operations Performed Numbers of Workstations System Layout Automation & Manning Levels Part or Product Variety Overview of the Classification Scheme Single Station Cell Multi-Station Systems with Fixed Routing Multi-Station Systems with Variable Routing

Introduction to Manufacturing Systems

The position of the manufacturing system in the larger production system

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Introduction to Manufacturing Systems

Manufacturing System Definition:
A collection of integrated equipment & human resources, whose function is to perform one or more processing and/or assembly operations on a starting raw materials, part, or set of parts.

Introduction to Manufacturing Systems

Equipment includes:
Production machines and tools Material handling and work positioning devices Computer systems

Human resources
are required either full-time or periodically to keep the system running

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Introduction to Manufacturing Systems

Manufacturing system is where the value-added work is accomplished on the part or product Manufacturing Systems examples includes:
Single-station cells One worker tending one production machine that operates on semi-automatic cycle.

Introduction to Manufacturing Systems

Manufacturing system is where the value-added work is accomplished on the part or product Manufacturing Systems examples includes:
Single-station cells Machine clusters One worker tends a group of semi-automatic machines.

Chapter 4

Introduction to Manufacturing Systems

Manufacturing system is where the value-added work is accomplished on the part or product Manufacturing Systems examples includes:
Single-station cells Machine clusters Manual assembly lines Human workers perform assembly tasks as the product is moved along the line, usually by mechanized conveyor.

Introduction to Manufacturing Systems

Manufacturing system is where the value-added work is accomplished on the part or product Manufacturing Systems examples includes:
Single-station cells Machine clusters Manual assembly lines Automated transfer lines Series of automated workstations that perform processing operations such as machining.

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Introduction to Manufacturing Systems

Manufacturing system is where the value-added work is accomplished on the part or product Manufacturing Systems examples includes:
Single-station cells Machine clusters Production machines and workstations laid out Manual assembly lines in a U-shaped configuration. Produce parts / Automated transfer lines products that are similar but not identical. Automated assembly systems Machine cells (cellular manufacturing) Flexible manufacturing systems
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Introduction to Manufacturing Systems

Manufacturing system is where the value-added work is accomplished on the part or product Manufacturing Systems examples includes:
Single-station cells Machine clusters Manual assembly lines Automated transfer lines Highly automated machine cell that produces Automatedpart assembly systems / product families. Machine cells (cellular manufacturing) Flexible manufacturing systems
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Components of a Manufacturing System

A manufacturing system consists of several components:
1. Production machines plus tools, fixtures & other

related hardware 2. Material handling system 3. Computer systems to coordinate and/or control the above components 4. Human workers

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1. Production Machines
In virtually all modern manufacturing systems, most of the actual processing or assembly work is accomplished by machines or with the aid of tools. Machines can be classified as: Manually operated Semi-automated Fully automated

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1. Production Machines
Manually Operated: control or supervised by a human worker. machine provides the power for the operation and the worker provides the control. worker must be at machine continuously. i.e. lathes, milling machines, drill presses. Semi-Automated: performs a portion of the work cycle under some from of program control, and human worker tends to the machine for the remainder of the cycle, by loading and unloading it or performing some other task each cycle. i.e. CNC lathe controlled. Fully Automated: operates for extended periods of time with no human attention (attention is required not during each cycle but maybe required periodically after certain no. of cycles i.e. to load raw materials). i.e. injection molding machines.

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1. Production Machines

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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1. Production Machines

A semi-automated machine performs a portion of the work cycle under some form of program control, and a worker tends to the machine for the remainder of the cycle. Typical worker tasks include loading and unloading parts

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1. Production Machines

A fully-automated machine operates for extended periods (longer than one work cycle) without worker attention
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1. Production Machines
In manufacturing systems, term workstation is used to refer to a location in the factory where some well-defined task/operation is accomplished by an automated machine, a worker-and-machine combination, or a worker using hand tools and/or portable power tools

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2. Material Handling System

The following material handling functions must be provided: 1. 2. 3. 4. Loading work units at each station Positioning the work units at each station Unloading work units at each station Transportation of work units between station in multi-station manufacturing systems 5. Temporary storage function
To ensure that work is always present for the respective stations.

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2. Material Handling System

Work Transport Between Stations
Work transport moving parts between workstations in a multi-station system Can be accomplished either manually or using equipment 2 general categories:
Fixed routing: Work units always flow through the same sequence of workstations. It means that works units are identical or similar enough that the processing sequence is identical. Most production lines exemplify this category. Variable routing: Work units are transported through a variety of different station sequences. It means that the manufacturing system is processing or assembling different work units. Most job shops exemplify this category.

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2. Material Handling System

Two types of routing in multi-station manufacturing systems (a) Fixed Routing (b) Variable Routing
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2. Material Handling System

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3. Computer Control System

required to control automated & semi-automated equipment, and to participate in the overall coordination & management of the manufacturing system Typical functions:
Communicate instructions to workers Download part programs to computer-controlled machines Control material handling system Schedule production Failure diagnosis when malfunctions occur Safety monitoring Maintain quality control Operations management directly / indirectly

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4. Human Resources
Direct labor
Perform some or all of the value-added work that is accomplished on the parts or products. They directly add to the value of the work unit by performing manual work on it or by controlling the machines that perform the work.

Indirect Labor
Manage/support manufacturing systems, even for fully automated manufacturing systems i.e. computer programmers, computer operators, maintenance & repair personnel, etc.

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A Classification Scheme of Manufacturing Systems

Explore variety of manufacturing system types and develop a classification scheme based on factors that define & distinguish them Factors that define and distinguish manufacturing systems:
1. Types of operations 2. Number of workstations 3. System layout 4. Automation and manning level 5. Part or product variety

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A Classification Scheme of Manufacturing Systems

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1. Types of Operations Performed

Manufacturing systems are distinguished by the types of operations they perform (Processing versus assembly operations) At the highest level, the distinction is between:
Processing operations on individual work units Assembly operations to combine individual processing and assembled entities

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1. Types of Operations Performed

Additional parameters of the product that play a role in determining the design of manufacturing systems:
Type of material processed
Processing operation used for metals are different from those used for plastics or ceramics. Differences affect the type of equipment and handling method.

Size and weight of work units Part or product complexity

For assembled products, number of components per product For individual parts, number of distinct operations to complete processing

Part geometry
For machined parts, rotational vs. non-rotational
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2. Number of workstations
Convenient measure of the size of the system
Let n = number of workstations Individual workstations can be identified by subscript i, where i = 1, 2, ..., n

Affects performance factors such as workload capacity, production rate, and reliability
As n increases, this usually means greater workload capacity and higher production rate There must be a synergistic effect that derives from n multiple stations working together vs. n single stations
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3. System Layout
The way the system is laid out. Applies mainly to multi-station systems Fixed routing vs. variable routing
In systems with fixed routing, workstations are usually arranged linearly In systems with variable routing, a variety of layouts are possible

System layout is an important factor in determining the most appropriate type of material handling system
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3. System Layout
Number of Workstations and System Layout
No. of workstations is a key factor in this classification scheme (applicable to both processing or assembly operations) Type I Single station - the simplest case, consisting of one workstation (n=1), usually including a production machine that can be manually operated, semi- automated, or fully automated. Multiple stations with variable routing. Consist 2 or more stations (n>1) that are designed and arranged to accommodate the processing or assembly of different part or product styles. Multiple stations with fixed routing. This system has 2 or more workstations (n>1), which are laid out as a production line.

Type II

Type III

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4. Automation and Manning Levels

Level of Automation - another factor that characterizes the manufacturing system. Level of workstation automation
Manually operated Semi-automated Fully automated

Manning Level (Mi ) of a workstation proportion of time that a worker is in attendance at the station.
If Mi = 1 station i one worker must be at station i continuously. If one worker attends 4 machines, then Mi = 0.25 for each of the 4 machines. In general; Mi 1 indicate manual operations at the workstations

Mi < 1 indicate some form of automation operations at the workstations

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4. Automation and Manning Levels

The average manning level of multi-station manufacturing system:
n

wu + wi M=
i =1

w n

M = average manning level for the system Wu = no. of utility workers assigned to the system Wi = no. of workers assigned specifically to the station i, for i=1,2, W = total no. of workers assigned to the system n=number of workstations

,n

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A Classification Scheme of Manufacturing Systems (Additional Information)

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5. Part of Product Variety

5th factor in manufacturing system characterization is the degree to which the system is capable of dealing with variations in the parts or products it produces Possible variations examples:
Variations in type and/or color of plastic of molded parts in injection molding. Variations in electronic components placed on a standard size printed circuit board. Variations in the size of printed boards handled by a component placement machine. Variations in geometry of machine parts. Variations in parts and options in an assembled product on a final assembly line.
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5. Part of Product Variety

3 cases of product variety in manufacturing systems: 1) Single-model case all parts or products are identical 2) Batch-model case different parts or products are produced by the system, but they are produced in batches because changeovers are required 3) Mixed-model case different parts or products are produced by the system, but the system can handle the differences without the need for time-consuming changes in setup
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5. Part of Product Variety

(a) Single-model case, (b) batch model case, and (c) mixed-model case
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5. Part of Product Variety

In order to be flexible, a manufacturing systems must possess the following capabilities: Identification of the different work units
The system must be able to identify the differences between work units in order to perform the correct processing sequence

Quick changeover of operating instructions

The required work cycle programs must be readily available to the control unit

Quick changeover of the physical setup

System must be able to change over the fixtures and tools required for the next work unit in minimum time

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5. Part of Product Variety

Medium or high part or product complexity (high total work content)

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5. Part of Product Variety

Low part or product complexity (low total work content)

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Overview of the Classification Scheme

Single-station cells
n=1 Manual or automated

Multi-station systems with fixed routing

n>1 Typical example: production line

Multi-station systems with variable routing

n>1 Typical case in cellular manufacturing
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1. Single Station Cells

n=1 Two categories:
Manned workstations - manually operated or semiautomated production machine (M = 1) Fully automated machine (M < 1)

Most widely used manufacturing system - reasons:

Easiest and least expensive to implement Most adaptable, adjustable, and flexible system Can be converted to automated station if demand for part or product justifies
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2. Multi-Station Systems with Fixed Routing

n>1 Common example = production line - a series of workstations laid out so that the part or product moves through each station, and a portion of the total work content is performed at each station Conditions favoring the use of production lines:
Quantity of work units is high Work units are similar or identical, so similar operations are required in the same sequence Total work content can be divided into separate tasks of approximately equal duration
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3. Multi-Station Systems with Variable Routing

n>1 Defined as a group of workstations organized to achieve some special purpose, such as:
Production of a family of parts requiring similar (but not identical) processing operations Assembly of a family of products requiring similar (but not identical) assembly operations Production of a complete set of components used to assemble one unit of a final product

Typical case in cellular manufacturing

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