Manufacturing Process - Intro to Manufacturing

LECTURE 1

INTRODUCTION TO MANUFACTURING

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MANUFACTURING PROCESS

(DMFG 1323)

INTRODUCTION TO MANUFACTURINGINTRODUCTION TO MANUFACTURING 1

DEFINITION OF MANUFACTURINGDEFINITION OF MANUFACTURING

What is manufacturing?

“the process of converting raw materials into products”.

The word “manufacturing” is derived from the Latin manu factus, meaning madeby hand.

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

“processing or making a product from raw materials, especially as a large scaleOperation 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 contextIn modern context

- “the making of products from raw materials using various processes, equipments, operations and manpower according to a detailed plan”.

- During processing, the raw material undergoes changes to allow it to becomea part of a product(s).

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

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- 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:

1) Technology – manufacturing is the application of physical and chemical processes to alter the geometry, properties, and/or appearance of a given starting material to make parts or products.Manufacturing also includes the assembly of multiple parts to make products.

2) Economic – manufacturing is the transformation of materials into items ofgreater value by means one or more processing involve. Therefore, manufacturing is “added value” to the material.

The processes to accomplish manufacturing involve a combination ofmachinery, tools, power, and manual labor.

- “Added value” – by changing the material’s shape or properties or bycombining it with other materials that have been similarly altered.

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Two ways models to define manufacturing:

1) As a technical process

ManufacturingProcess

Raw materialsProduct

Profit

Ma

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To

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Po

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La

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2) As an economic process.

ManufacturingProcess

Valueadded

Startingmaterial

Material inprocessing

Processedmaterial

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Manufacturing activities must be responsive to several demands and trends:

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Industries can be classified as:

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Types of industriesTypes 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 andcapital goods.

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

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TYPE OF MANUFACTURING OPERATIONSTYPE OF MANUFACTURING OPERATIONS

1) Project – 1 to 10 units.

2) Job shop – 10 to 100 units.

3) Batch – 100 to 10,000 units.

4) Mass – Above 10,000 units.

Production quantity:Production quantity: number of unit produced annually of a particular product type.

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

[Low production]

[Medium production]

[High production]

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Low

Medium

High

Product quantityProduct quantity

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ProjectProject

Job shopJob shop

Batch

MassMass

Product varietyProduct variety

1 to 10 units

10 to 100 units

100 to 10,000 units

Above 10,000 units

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TYPE OF MANUFACTURING OPERATIONSTYPE OF MANUFACTURING OPERATIONS

1) PROJECT1) 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.

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

- Based on customer specifications.

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TYPE OF MANUFACTURING OPERATIONSTYPE OF MANUFACTURING OPERATIONS

2) JOB SHOP2) 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.

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

- A short duration activities to provide custom goods.

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TYPE OF MANUFACTURING OPERATIONSTYPE OF MANUFACTURING OPERATIONS

3) BATCH3) BATCH

- Batch production produce or process any product in groups which is called“batches”.

- Can produce a variety of products – opposed to a continuous productionprocess, or a one time production.

- Example: Similar standard items made periodically in batches: bakery, paint,hand tools.

- Same facilities used to manufacture all the different items.

- Useful for industries that makes seasonal items/products for which it isdifficult to forecast the demand.

- Layout of machine – functional layout (based on its function to be performed –from section to another section).

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AdvantagesAdvantages

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

DisadvantagesDisadvantages

- Requires very careful production planning & control – next batches; when, types.

- When switching to another batches – takes time (“down time”) – can cause loss of output (low yield).

- Resulted “WIP” or create inventory/stock – increases costs such as inventorycost, 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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TYPE OF MANUFACTURING OPERATIONSTYPE OF MANUFACTURING OPERATIONS

4) 4) MASSMASS

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

- Machinery (eg: robots, machine press) that is needed to set up the mass production line is so expensive.

- Involved fewer labor cost and a faster rate of production.

- Producing goods in large quantities at low cost per unit and produce in a shortperiod of time.

- Plant and equipments are arranged in a flow line layout.

- Operation is done base on specific product and thus make the productioncontrol easily.

- Work piece is transfer automatically from one machine to another.

- Example: light bulbs, refrigerator, tv.

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TYPE OF MANUFACTURING OPERATIONSTYPE OF MANUFACTURING OPERATIONS

Lean Production and Agile ManufacturingLean Production and Agile Manufacturing

Lean ProductionLean Production

- A systematic approach to identifying and eliminating waste in manufacturing process through continuous improvement by following the product at the demand of the customer.

- Related to a word “less”: less time, inventory space, people, developing theproduct, – minimize the cost.

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

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Benefits of Lean ManufacturingBenefits 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 ManufacturingPrinciple of Lean Manufacturing

- Voice of the customer.

- Continuous improvement.- Recognize & eliminating waste of:

- Over production.- Inventory.- Defects (Non-zero defect rates).

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

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Principle of Lean Manufacturing (cont’)Principle of Lean Manufacturing (cont’)

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AGILE MANUFACTURINGAGILE MANUFACTURING

- Agile manufacturing is a term applied to an organization that has created theprocesses, tools, and training to enable it to response quickly to customer needs andmarket changes while still controlling costs and quality.

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

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TYPE OF MANUFACTURING OPERATIONS/PRODUCTIONTYPE OF MANUFACTURING OPERATIONS/PRODUCTION

GROUP TECHNOLOGYGROUP TECHNOLOGY

- 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.

- Also known as “families of parts”.

- Parts will pass through a similar sequence of manufacturing operations and will beprocessed on the same machine tools.- Example of GT: Cylindrical parts – they may look almost the same, but it has differencein the materials, tolerances, and surface finishes and thus causing them to be madeon different machine tools.- The set-up of an automated machine only requires small changes between theindividual batches and some of the individual set-up times will be drastically reduced.

- Having different machine in one section, so that each parts is completed in that particular section.

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

TYPE OF MANUFACTURING OPERATIONSTYPE OF MANUFACTURING OPERATIONS

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JUST IN TIME (JIT)JUST IN TIME (JIT)

- Raw materials, parts & components are delivered to the manufacturer just intime to be used, parts & components are produced JIT to be made into subassemblies & assemblies, and products are finished JIT to be delivered tothe customer.

- JIT is also known as “pull system”.

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Benefit s/Advantages of JITBenefit s/Advantages of JIT

- Low inventory – carrying cost.

- Fast detection of defects in the production or the delivery of supplies and, hence,low scrap loss.

- Reduced inspection and reworking of parts.

- High quality products made at low cost.

- Reduction of :

60% to 80% in inventory. Up to 90% in rejection rates. 90% in lead times. 50% in scrap & rework.

20% to 40% in product cost.

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Benefit s/Advantages of JIT (cont’)Benefit s/Advantages of JIT (cont’)

Increases:

- 30% to 50% in labor productivity.

KANBAN SYSTEMKANBAN SYSTEM

- Integrated with the implementation of JIT concept.

- Kanban – means “visible record”.

- Originally consisted of two types of cards:

i) Production card: authorizes the production of one container or cart of identical,specified parts at a workstation.

ii) Conveyance/move card: authorizes the transfer of one container or cart of parts from that particular w/station to the w/station where the parts will be used.

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KANBAN SYSTEM (cont’)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 LAYOUTTYPE OF LAYOUT/PLANT LAYOUT

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1) FIXED POSITION LAYOUT1) 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 bebrought to the product.

- Involve with longer lead time.

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2) FUNCTIONAL (PROCESS) LAYOUT2) 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

FUNCTIONAL (PROCESS) LAYOUTFUNCTIONAL (PROCESS) LAYOUT

L

L L

MM MM

MM MM

GG GG

GG GG

D D

D D

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3) FLOW LINE (PRODUCT) LAYOUT3) 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 stations(line balancing).

- High level of machine and manpower utilization.

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L L M DProduct A

LL MM MM DDProduct B

LL GG GG DProduct C

M W G DDProduct D

FLOW LINE (PRODUCT) LAYOUTFLOW LINE (PRODUCT) LAYOUT

AdvantagesAdvantages

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- Reduced work handling leads to short cycle time/piece.- Less WIP.- Simple planning and control.- Reduced labor skill.- Good space utilization.

DisadvantagesDisadvantages

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

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4) CELLULAR LAYOUT4) CELLULAR LAYOUT

- Plant divided into groups or cells in a small unit (individual cell), consisting of one to several workstations.

- A w/station can contains either one machine (known as a single machine cell), orseveral machines (known as a group machine cell) with each machine performing adifferent 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 composition ofparts 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 product lines within the same family of parts.

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