LECTURE # 1

Manufacturing is the process to convert raw materials into finished products. It encompasses the design and production of goods by using different production techniques. Manufacturing is important technologically, economically and historically. Technology means the application of science to provide society and its members with those things which are needed or desired. Manufacturing is an essential factor that makes technology possible.

Combination of physical and chemical processes. Alter the geometry properties and appearance of a starting material to ma!e parts or products. "achining tooling po#er and human labor involved.

Transformation of materials into items of greater value. Value is added to the product by manufacturing/processi ng techniques. For example: iron into steel petroleum into plastic sand into glass.

TECHNICAL PROCESS

ECONOMIC PROCESS

TECHNICAL PROCESS

ECONOMIC PROCESS

The word manufacturin and !roduction are often u"ed interchan ea#$%& Production ha" #roader meanin than Manufacturin & 'or e(am!$e) crude oi$ !roduction&

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Com!onent" of a Manufacturin S%"tem A C$a""ification Scheme for Manufacturin S%"tem" O,er,iew of the C$a""ification S%"tem

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-A co$$ection of inte rated e.ui!ment and human re"ource"/ who"e function i" to !erform one or more !roce""in and0or a""em#$% o!eration" on a "tartin raw materia$/ !art/ or "et of !art"1 $quipment includes
Production machine" and too$" 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 "%"tem runnin

Sin $e3"tation ce$$" Machine c$u"ter" Manua$ a""em#$% $ine" Automated tran"fer $ine" Automated a""em#$% "%"tem" Machine ce$$" 4ce$$u$ar manufacturin 5 '$e(i#$e manufacturin "%"tem"

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Production machine" Materia$ hand$in "%"tem Com!uter "%"tem to coordinate and0or contro$ the !recedin com!onent" Human wor2er" to o!erate and mana e the "%"tem

In ,irtua$$% a$$ modern manufacturin "%"tem"/ mo"t of the actua$ !roce""in or a""em#$% wor2 i" accom!$i"hed #% machine" or with the aid of too$"&

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$e under "ome form of !ro ram contro$/ and a wor2er attend" the machine for re"t of the c%c$e& +& 'u$$% automated machine" o!erate for e(tended !eriod" of time with no human attention&

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.

A "emi3automated machine !erform" a !ortion of the wor2 c%c$e under "ome form of !ro ram contro$/ and a wor2er tend" to the machine for the remainder of the c%c$e& T%!ica$ wor2er ta"2" inc$ude $oadin and un$oadin !art"

Machine o!erate" for e(tended !eriod" 4$on er than one wor2 c%c$e5 without wor2er attention 4!eriodic tendin ma% #e needed5&

In mo"t manufacturin "%"tem" that !roce"" or a""em#$e di"crete !art" and !roduct"/ the fo$$owin materia$ hand$in function" mu"t #e !ro,ided)
1& *& +& 6& Loadin wor2 unit" at each "tation Po"itionin wor2 unit" at each "tation Un$oadin wor2 unit" at each "tation Tran"!ortin wor2 unit" #etween "tation" in mu$ti3"tation "%"tem" 7& Tem!orar% "tora e of wor2 unit"

Two enera$ cate orie" of wor2 tran"!ort in mu$ti3"tation manufacturin "%"tem")

1& 'i(ed routin
8or2 unit" a$wa%" f$ow throu h the "ame "e.uence of wor2"tation" Mo"t !roduction $ine" e(em!$if% thi" cate or%

1& 9aria#$e routin

8or2 unit" are mo,ed throu h a ,ariet% of different "tation "e.uence" Mo"t :o# "ho!" e(em!$if% thi" cate or%

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 !ro ram" to com!uter3contro$$ed machine" Contro$ materia$ hand$in "%"tem Schedu$e !roduction 'ai$ure dia no"i" when ma$function" occur and !re,enti,e maintenance Safet% monitorin 4!rotect #oth the human wor2er and e.ui!ment5 <ua$it% contro$ 4detect and re:ect defecti,e wor2 unit" !roduced #% the "%"tem5 O!eration" mana ement 4mana e o,era$$ o!eration"5

'actor" that define and di"tin ui"h manufacturin "%"tem")

1& *& +& 6& 7& T%!e" of o!eration" !erformed Num#er of wor2"tation" S%"tem $a%out Automation and mannin $e,e$ Part or !roduct ,ariet%

Proce""in o!eration" on wor2 unit" ,er"u" a""em#$% o!eration" to com#ine indi,idua$ !art" into a""em#$ed entitie" T%!e4"5 of materia$" !roce""ed Si=e and wei ht of wor2 unit" Part or !roduct com!$e(it% 'or a""em#$ed !roduct"/ num#er of com!onent" !er !roduct 'or indi,idua$ !art"/ num#er of di"tinct o!eration" to com!$ete !roce""in Part eometr% 'or machined !art"/ rotationa$ ,"& non3rotationa$

Con,enient mea"ure of the "i=e of the "%"tem

Let n > num#er 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$oad ca!acit%/ !roduction rate/ and re$ia#i$it%
A" n increa"e"/ thi" u"ua$$% mean" reater wor2$oad ca!acit% and hi her !roduction rate There mu"t #e a "%ner i"tic effect that deri,e" from n mu$ti!$e "tation" wor2in to ether ,"& n "in $e "tation"

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$$% arran ed $inear$% In "%"tem" with ,aria#$e routin / a ,ariet% of $a%out" are !o""i#$e

S%"tem $a%out i" an im!ortant factor in determinin the mo"t a!!ro!riate t%!e of materia$ hand$in "%"tem

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"$% Mi 1 indicate" manua$ o!eration" Mi ? 1 u"ua$$% denote" "ome form of automation

-The de ree to which the "%"tem i" ca!a#$e of dea$in with ,ariation" in the !art" or !roduct" it !roduce"1 Three ca"e") 1& Sin $e3mode$ ca"e 3 a$$ !art" or !roduct" are identica$ 4"ufficient demand0fi(ed automation5 *& @atch3mode$ ca"e 3 different !art" or !roduct" are !roduced #% the "%"tem/ #ut the% are !roduced in #atche" #ecau"e chan eo,er" are re.uired 4hard !roduct ,ariet%5 +& Mi(ed3mode$ ca"e 3 different !art" or !roduct" are !roduced #% the "%"tem/ #ut the "%"tem can hand$e the difference" without the need for time3con"umin chan e" in "etu! 4"oft !roduct ,ariet%5

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

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

<uic2 chan eo,er of o!eratin in"truction"

The re.uired wor2 c%c$e !ro ram" mu"t #e readi$% a,ai$a#$e to the contro$ unit

<uic2 chan eo,er of the !h%"ica$ "etu!

S%"tem mu"t #e a#$e to chan e o,er the fi(ture" and too$" re.uired for the ne(t wor2 unit in minimum time

Sin $e3"tation ce$$"

n>1 Manua$ or automated

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

nA1 T%!ica$ e(am!$e) !roduction $ine

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

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n>1 Two cate orie")

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

Mo"t wide$% u"ed manufacturin "%"tem 3 rea"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 demand for !art or !roduct :u"tifie"

nA1 Common e(am!$e > !roduction $ine 3 a "erie" of wor2"tation" $aid out "o that the !art or !roduct mo,e" throu h each "tation/ and a !ortion of the tota$ wor2 content i" !erformed at each "tation Condition" fa,orin the u"e of !roduction $ine")

<uantit% of wor2 unit" i" hi h 8or2 unit" are "imi$ar or identica$/ "o "imi$ar o!eration" are re.uired in the "ame "e.uence Tota$ wor2 content can #e di,ided into "e!arate ta"2" of a!!ro(imate$% e.ua$ duration

nA1 ;efined a" a rou! of wor2"tation" or ani=ed to achie,e "ome "!ecia$ !ur!o"e/ "uch a")

Production of a fami$% of !art" re.uirin "imi$ar 4#ut not identica$5 !roce""in o!eration" A""em#$% of a fami$% of !roduct" re.uirin "imi$ar 4#ut 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$ !roduct

T%!ica$ ca"e in ce$$u$ar manufacturin