MANUFACTURING PROCESS

(DMFG 1323)

LECTURE 1

INTRODUCTION TO MANUFACTURING

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DEFINITION OF MANUFACTURING

What is manufacturing?

“the process of converting raw materials into products”.

he word “manufacturing” is derived from the Latin manu factus, meaning made
y hand.

“the conversion of stuff into things” – (by DeGarmon, 1998).

processing or making a product from raw materials, especially as a large scale

peration using machinery” – (by Collin English Dictionary, 1998).

economic term for making goods and services available to satisfy customer”
(by T.Black, 1991).

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In modern context
the making of products from raw materials using various processes,
quipments, operations and manpower according to a detailed plan”.

uring processing, the raw material undergoes changes to allow it to become

art of a product(s).

Once processed, it should have worth in the market or a value.

- Therefore, it encompasses:
- The design of the product.
- The selection of raw materials.
- The sequence of processes through which the product will be manufactured.

Word production is often interchangeably with word manufacturing.

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Manufacturing can be defined two ways:

Technology – manufacturing is the application of physical and chemical
ocesses to alter the geometry, properties, and/or appearance of a given
arting material to make parts or products.
anufacturing also includes the assembly of multiple parts to make products.
The processes to accomplish manufacturing involve a combination of
machinery, tools, power, and manual labor.

) Economic – manufacturing is the transformation of materials into items of

greater value by means one or more processing involve. Therefore,
manufacturing is “added value” to the material.

- “Added value” – by changing the material’s shape or properties or by

combining it with other materials that have been similarly altered.

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Two ways models to define manufacturing:

1) As a technical process

Machinery

Tooling

Power

Labor
Product
Raw materials Manufacturing
Process Profit

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2) As an economic process.

Manufacturing
Process

Value
added

Starting Material in Processed

material processing material

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acturing activities must be responsive to several demands and trends:

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Industries can be classified as:

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Types of industries

1) Primary industry
Those that cultivate and exploit natural resources; eg: agriculture, mining.

2) Secondary industry
Take the outputs of the primary industries and convert them into consumer and
apital goods.

3) Tertiary industry
- Constitute with service sector of the economy.

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TYPE OF MANUFACTURING OPERATIONS

1) Project – 1 to 10 units.
[Low production]
2) Job shop – 10 to 100 units.

3) Batch – 100 to 10,000 units.[Medium production]

4) Mass – Above 10,000 units. [High production]

duction quantity: number of unit produced annually of a particular product

type.

duct variety: different product designs or types that are produced in the plant.

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Low

Medium

High

Product quantity

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Above 10,000 units

Mass
100 to 10,000 units
Batch
10 to 100 units
Job shop
1 to 10 units
Project

Product variety

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YPE OF MANUFACTURING OPERATIONS

1) PROJECT
- Product position – remains stationary during the manufacturing process – size,
weight, location of the product.
- Materials, people, machinery are brought to the product or product site.
- Based on customer specifications.

- Example: bridge, building construction, aircraft, ships, locomotive.

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YPE OF MANUFACTURING OPERATIONS

2) JOB SHOP

Low volume and production quantities called lot sizes with high product variety.

- Satisfies a market for nonstandard or unique product.

Layout – different machines with similar functional or processing capabilities

are grouped together as department.
Require high skill levels labor – to operate a variety of equipments.
- A short duration activities to provide custom goods.

Example: space vehicles, reactor vessels, turbines, aircraft components.

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YPE OF MANUFACTURING OPERATIONS

3) BATCH

Batch production produce or process any product in groups which is called

“batches”.
Can produce a variety of products – opposed to a continuous production
process, or a one time production.
Useful for industries that makes seasonal items/products for which it is
difficult to forecast the demand.
Example: Similar standard items made periodically in batches: bakery, paint,
and tools.
- Same facilities used to manufacture all the different items.
Layout of machine – functional layout (based on its function to be performed –
rom section to another section).

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Advantages

Reduce initial capital outlay – due to a single production line can be used to
everal products – machines can be used more effectively, materials can be
ought in bulk, workers can specialize in that task.

Disadvantages
Requires very careful production planning & control – next batches; when, types.
When switching to another batches – takes time (“down time”) – can cause
oss of output (low yield).
Resulted “WIP” or create inventory/stock – increases costs such as inventory
ost, cost because of damage to stock.

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The example production line (shown below) is that of an engineering company, manufacturing small
steel products such as hinges and locks. They manufacture batches of five hundred at a time. The
workers are unskilled and semi skilled. As each task is completed the item being manufactured is
passed down the production line to the next worker, until it is complete.

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YPE OF MANUFACTURING OPERATIONS

4) MASS

Also known as flow production, repetitive flow production, series production.

Producing goods in large quantities at low cost per unit and produce in a short
eriod of time.
Machinery (eg: robots, machine press) that is needed to set up the mass
roduction line is so expensive.
- Involved fewer labor cost and a faster rate of production.
- Plant and equipments are arranged in a flow line layout.
Operation is done base on specific product and thus make the production
ontrol easily.
Work piece is transfer automatically from one machine to another.
- Example: light bulbs, refrigerator, tv.
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TYPE OF MANUFACTURING
OPERATIONS
ean Production and Agile Manufacturing

Lean Production

A systematic approach to identifying and eliminating waste in manufacturing

ocess through continuous improvement by following the product at the
mand of the customer.
elated to a word “less”: less time, inventory space, people, developing the
oduct, – minimize the cost.

It is all about “speed” and getting it right at the first time.

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Benefits of Lean Manufacturing

- Overhead operating costs reduces by 30%.

- Sales ($) per employee 10 times higher.
- Profits 4 times.
- Lead time cut by 50% to 90%.
- Process queues cut by 70%.

Principle of Lean Manufacturing

- Voice of the customer.
- Continuous improvement.
- Recognize & eliminating waste of:
- Over production.
- Inventory.
- Defects (Non-zero defect rates).

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rinciple of Lean Manufacturing (cont’)

- Waiting time.
- People’s talents, & motivations.
- Motion.
- Transportation.

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AGILE MANUFACTURING

The implementation of the principles of lean production on a broad scale.

gile manufacturing is a term applied to an organization that has created the
ocesses, tools, and training to enable it to response quickly to customer needs a
arket changes while still controlling costs and quality.

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PE OF MANUFACTURING OPERATIONS/PRODUCTION
GROUP TECHNOLOGY
- Also known as “families of parts”.
Parts can be grouped and then produced by classifying them into families.
- This can be done according to similarities in:
i) design.
ii) manufacturing process to produce the part.
Parts will pass through a similar sequence of manufacturing operations and will
rocessed on the same machine tools.
Example of GT: Cylindrical parts – they may look almost the same, but it has diff
the materials, tolerances, and surface finishes and thus causing them to be mad
n different machine tools.
The set-up of an automated machine only requires small changes between the
ndividual batches and some of the individual set-up times will be drastically redu
Having different machine in one section, so that each parts is completed in that
articular section.
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YPE OF MANUFACTURING OPERATIONS

JUST IN TIME (JIT)

aw materials, parts & components are delivered to the manufacturer just in

me to be used, parts & components are produced JIT to be made into
bassemblies & assemblies, and products are finished JIT to be delivered to
e customer.

- JIT is also known as “pull system”.

t tends to simplify and break the whole system into small, autonomous units.

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Benefit s/Advantages of JIT

- Low inventory – carrying cost.

ast detection of defects in the production or the delivery of supplies and, hence,
scrap loss.
- Reduced inspection and reworking of parts.
- High quality products made at low cost.
- Reduction of :
 20% to 40% in product
cost.to 80% in inventory.
 60%
 Up to 90% in rejection rates.
 90% in lead times.
 50% in scrap & rework.

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Benefit s/Advantages of JIT (cont’)

Increases:
- 30% to 50% in labor productivity.

KANBAN SYSTEM
- Integrated with the implementation of JIT concept.
- Kanban – means “visible record”.
- Originally consisted of two types of cards:
Production card: authorizes the production of one container or cart of identical
specified parts at a workstation.
Conveyance/move card: authorizes the transfer of one container or cart of part
from that particular w/station to the w/station where the parts will be used.

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KANBAN SYSTEM (cont’)

The cards contain information on:

i) Type of parts.
ii) Location where issued.
iii) Part number.
iv) Number of items in container.

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TYPE OF LAYOUT/PLANT LAYOUT

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1) FIXED POSITION LAYOUT

Involved with huge parts; eg: construction of aeroplane, bridge, buildings.

All resources such as manpower, raw materials, tools, machinery and etc will be
ought to the product.
- Involve with longer lead time.

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2) FUNCTIONAL (PROCESS) LAYOUT

- Plant grouped according to type of process.

- Specialization of skills.
- Higher machine utilization.

- Queues of work.
- Longer lead times.

- Flexibility of operation.
- Low volume and high variety of manufacturing.

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L L M M G G D D

L L M M G G D D

FUNCTIONAL (PROCESS) LAYOUT

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3) FLOW LINE (PRODUCT) LAYOUT

- Plant arrangement to facilitate material processing in the same order.
- Machines and equipment are positioned along a flow line.
- Product passes from workstation to another workstation along the flow line.
- Suitable for mass production system.
- Several flow lines may come together to feed the final assembly line.

Need to categorize operations to ensure equal processing time at all work statio
line balancing).
- High level of machine and manpower utilization.

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Product A
L L M D

Product B
L M M D

Product C
L G G D

Product D
M W G D

FLOW LINE (PRODUCT) LAYOUT

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Advantages

- Reduced work handling leads to short cycle time/piece.

- Less WIP.
- Simple planning and control.
- Reduced labor skill.
- Good space utilization.

Disadvantages
- Limited flexibility.
- Machine breakdown causes major problem.
- High setting up cost.
- Uses expensive special purpose machine.

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4) CELLULAR LAYOUT

Plant divided into groups or cells in a small unit (individual cell), consisting of on
everal workstations.
A w/station can contains either one machine (known as a single machine cell), o
several machines (known as a group machine cell) with each machine performing
different operation on the part.
Cells can process a complete family of parts – need to form families of products

The flow among the equipment in the cells can vary depending on the composit
arts within the part family.
Good example for the implementation of the concept of group technology.

The machines at w/stations can be modified, retooled, and regroup for different
roduct lines within the same family of parts.

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