Types of Manufacturing

System
– Classifying components of
manufacturing system
Prepared by Group A2:
2. Izham Hazizi
3. Nor Shahril
4. Md Fairul
5. Ahmad Fauzie
 Introduction
Manufacturing System plays very important role in daily
manufacturing operation. The objective is to have efficient control
of the organizational structure in order to produce high quality
products at lower prices within a shorter period of time.

Companies that having a good manufacturing system normally

can execute their operation very well as they become more
productive and to make more efficient use of resources.

Manufacturing information systems, material handling,

computer-integrated manufacturing (CIM), and production planning
control are just some of the areas that have help companies
improving their understanding and awareness in the manufacturing
and service sectors in order to stand in the very competitive
industry.
 Component in Manufacturing System
Manufacturing system can be elaborated as system which
having the combination of integrated equipments and human
resource, whose give a guideline for material processing.

A Manufacturing system consist of several components, which

can be listed as below;

Production Machines
Material Handling System
A integrated computer system to control components
Human Resource/ worker to operate and manage the system
 Component in Manufacturing System

MATERIAL HANDLING
PRODUCTION MACHINES
SYSTEM

MANUFACTURING
SYSTEM

COMPUTER SYSTEM HUMAN RESOURCES

 Production Machines
 In any manufacturing systems, almost all the operation or
assembly work was help by the machines or with the aid of the
tools.
 All this machine will be help to achieve high productivity and
also shorter cycle time.
 There are many type of production machine and this
combination of production machine in one production floor can
be called as a workstation.
 There are 3 type of production machines as below and all this
was based on the complexity and how advance the tool:
 Manually operated
 Semi-automated
 Fully automated
 Manually Operated Machine
 Manually operated machines are controlled/operated or
supervised by worker/operator(human resource).
 This manually operated machines provides the power for
operation and the worker provides the control.
 Some example of the machine that fall into this category was a
conventional machine that was normally found in small and
medium industry such as milling machine and drill presses
machine.
 All this type of machine need the worker to operate is as this
machine do not have any program to control or to perform the
task.
 In a modern age factory some example of this type of machine
such as metrology, where this machine will help to ease the job
but need an operator to operate the machine.
 Manually Operated Machine
 The operator must be at the machines continuously to engage
the feed, position the tool, load and unload work parts and
perform other task related to the operation.

Worker
Manually
operated

Load Unload
Machine

Work cycle

Worker controlled
 Semi Automated Machine
 Semi automated machines can perform a task without any
operator attend to the tool. By using software/hardware control
machine able to operate without any assistant for one cycle of
task.
 An example of machine that fit into this category is CNC
machine or other programmable production machine that under
the tool control for one work cycle. But this type of machine
requires a operator to unload the finished part and load the next
part at the end or beginning of each cycle.
 In these cases, the worker must attend to the machine every
cycle but doesn’t need to be continuously present during the
cycle.
 Semi Automated Machine
 With this, one operator can attend/operate more than one
machine at one time as only extra time required for each
machine to make sure it continuously running with high
productivity.
Program
Worker
Control

Load Unload
Semi Automated Machine

Work cycle

Worker controlled Program controlled

 Fully Automated Machine
 Fully automated machines was a machines that capable to
operate automatically with no human attention for periods of
time that are longer than one work cycle.
 Although a worker attention is not required during each cycle,
some form of machine tending may be needed periodically
 Time to time operator might be need to attend the tool
periodically to add in new material.Also some error on the
machine that require operator to solve the error before tool can
start running again.
 Normally this type of machine will be link with AMHS system
too.
 Fully Automated Machine
Most of the advance or high tech factory will have this type of
machine. This type of machine will help to reduce cycle time and
also to reduce labor cost.
This fully automated machine also can reduce the number of
product scrap or reject due to less human involvement in the cycle
time.
Program
Worker
Control
Periodic
attention

Load Unload
Fully Automated Machine

Work cycle
Program controlled
 Workstation
 Combination of machines in one workplace are normally call as
workstation.
 In this workstation, some specific task or operation was
performed with combination of this 3 type of machines.
 A complete manufacturing system may consist of one or more
workstations.
 A manufacturing system, with multiple workstation is called
production line, assembly line, machine cell or other name
depending on its configuration and function.
 Material Handling System
 Material Handling System can be defined as an aspect of
materials management relating specifically to the physical
transfer of materials.
 The movement of materials (raw materials, scrap, semi-finished
and finished) to, through and from productive processes; in
warehouses and storage; and in receiving and shipping areas
 The work machines which normally semi- automated or fully
automated machines are connected by a material handling
system to optimize parts flow and the central control computer
which controls material movements and machine flow.
 Normally the machines can be segregate to 3 parts; loading
unit, positioning unit & unloading unit.
 Anyhow, transporting work unit between machines to machines
(stations to stations) is also required
 Material Handling System
 Conveyors, handling robots, automated material handling
system (AMHS) are most other automated material handling
systems fall into this category.
Illustration of Material Handling System
Positioning
Unit &
Processing

Loading Unloading
Unit Unit

Machine A
 Material Handling System

Machine A Machine B

START

END- FINISHING
GOOD

Machine D Machine C

Transporting work unit between machines to machines

 Material Handling System

Manual WIP trolley

AHMS
 Computer Control System
 Computer is required to control the automated and semi –
automated equipment and to participate in the overall
coordination and management of the manufacturing system.

 Even in manually computer system is useful to support

production, such as a completely manually assembly line.
 Computer Control System
Computer control system divide into:
ii. Communicate instructions to workers
 communicate to the operator by given complete
instructions.
 Download part programs to computer
 send instructions to computer controlled. i.e CNC machine
tools
iv. Material handling system control.
 Controlling the material handling system to the coordinate
at the workstations.
v. Schedule production
 accomplished at the site of the manufacturing system.
 Computer Control System
i. Failure diagnosis
 diagnosis equipment malfunctions, preparing preventive
maintenance schedule and maintaining spare parts
inventory.
ii. Safety monitoring
 to ensure that the system operate in the safe mode and at
the same time to protect workers and the equipment in the
system.
iii. Quality control
 Functions to detect any possibility reject product from the
production line.
iv. Operations management
 managing all manufacturing operations whether direct or
indirect.
example
Computer Control System

computer
Management CD/DVD mastering
management
centre Production centre
Control room

Stores and Distribution

 Human Resources
 Humans refers to all personnel, operators, vendors, customers
etc.

 To operate and manage the system/process

 Required either fulltime or periodically to keep the system

running

 System manufacturing is value added system to produce parts

and products

 In context of manufacturing system, human perform some or all

of the value added work that is accomplished on the
parts/products.
 Human Resources
 Performing either manual (direct) work on it or by controlling the
machines.

 In fully automated machine, direct labour is still needed.

 For example : loading or unloading parts, changing tools,
resharpening tools etc.

 In Automated Manufacturing System, workers also are needed

to support the system.
 For example : computer programmers/operators, maintenance and
repair.
 Human Resources
 Personnel related issues include what is the capability level of
available labor, working culture (one shift or two shift), how
many workers need to hire, what is the level of training needed,
what policies to drive a good working environment.

 As a conclusion Manufacturing system need all these four

component to make up the system (running the system).

 Each component plays an important role in manufacturing

system. If either one of the components is not included, this
systems is not call a manufacturing system.
 Conclusion
With the combination of this 4 manufacturing system components will
help to improve company competitiveness in the global market.
This is essential for company to have good system for in each
components so that the company can satisfy the customer need and keep
growing.

Video.mp4

Example of factory that using combination of 4

components of Manufacturing System
 Reference

• Groover, M.P., Automation, Production Systems, and Computer

Integrated Manufacturing. Prentice-Hall Int. 2001
• http://www.daifukumalaysia.com/company/mhglossary.php
• http://www.technologystudent.com/prddes1/flexbl2.html
• http://www.nuigalway.ie/staff/david_osullivan/documents/ch13.ppt
• http://www.his.se/PageFiles/9234/AUB161-L19-handouts.pdf?
epslanguage=sv