Part 1. System Management.

Ch 5. Manufacturing & Method Engineering.

Edited by Dr. Seung Hyun Lee (Ph.D., CPL)IEMS Research Center, E-mail : lkangsan@iems.co.kr

- 1 -

Manufacturing Strategy[Other Resources]

Definition. ￭ Manufacturing Environment

․ The frame work in which manufacturing strategy is developed and implemented. Elements of the manufacturing environment include external environmental forces, corporate strategy, business unit strategy, other functional strategy such as marketing, engineering, finance, etc., product selection, product/process design, product/process technology, and management competencies.

․ Manufacturing Environment is 1. Make-to-stock. 2. Assemble-to-order. 3. Make-to-order. 4. Engineering-to-order.

- 2 -

Manufacturing Strategy[Other Resources]

Manufacturing Environment. ￭ Make to Stock.

A manufacturing process strategy where finished product is continually held in plant or warehouse inventory to fulfill expected incoming orders or releases based on a forecast.

- 3 -

Manufacturing Strategy[Other Resources]

Manufacturing Environment. ￭ Assemble to Order.

A production environment where a good or service can be assembled finally after receipt of a customer's order.

- 4 -

Manufacturing Strategy[Other Resources]

Manufacturing Environment. ￭ Make to Order.

A manufacturing process strategy where the trigger to begin manufacture of a product is an actual customer order or release, rather than a market forecast.

- 5 -

Manufacturing Strategy[Other Resources]

Manufacturing Environment. ￭ Engineer to Order.

A process in which the manufacturing organization must first prepare (engineer) significant product or process documentation before manufacture may begin.

- 6 -

Manufacturing Strategy[Other Resources]

Characteristics of Manufacturing Strategy.

MTS ATO MTO ETO

Interface between production and customer Low Medium High High

Customer delivery time Short Medium Long LongProduction volume of each unit High Medium Low Low

Product range Narrow Medium Broad InfiniteBasis for productionplanning Forecast Forecast & Backlog Backlog Backlog

Seasonality High Medium Low Non

Order Promising Based on availability of finished goods

Based on availability of subassemblies and components

Based on availability of capacity and some engineering

Based on availability of capacity and engineering.

Handling of demand Uncertainty Safety stock

Overplanning of components and subassemblies

Little uncertaintyexists

Very little uncertainty exists

FAS Identical to the MPS

Determined by customer orders

Used for most assembly operations

Determined by customer orders.

Bill of material Standard BOM for each product Planning BOM BOM unique for

each orderBOM unique for each order

- 7 -

Manufacturing Process[Other Resources]

Product Volume/Variety

Varie

ty

V o lu m e

1

3

4

2

J o b s h o p

B a tc h

L in e

C o n t in u o u s

L o w H ig h

H ig h

- 8 -

Manufacturing Process[Other Resources]

Manufacturing Layouts. ￭ Fixed Position Layout.

The position of a product is fixed. Materials, equipment, and workers are transported to and from the product or customer. Used in industries where the product are very bulky, massive, or heavy.

Raw Materials

Grinders

CuttersDrills

Welding Machines

Workers

Raw Materials

Grinders

CuttersDrills

Welding Machines

Workers

- 9 -

Manufacturing Process[Other Resources]

Manufacturing Layouts. ￭ Process Focus Layout.

Lathe D rill

Assem ble W eld

A shop floor configuration characterized by locating machine tools that perform similar functions in the same area or department. The flow of jobs through the shop is jumbled.

- 10 -

Manufacturing Process[Other Resources]

Manufacturing Layouts. ￭ Product Focus Layout. The product layout arranges workstations in the order in which the product is manufactured of the service is rendered. Referred to as a production line or assembly line. In order to maximize the workflow, the product line must be balanced. Some characteristics of product layout are as follows. ․ A limited range of similar products is produced. ․ Workstations are dedicated to specific operation. ․ Demand must be sufficient to justify setting up the process. ․ It is capital-intensive. ․ Little buildup of work-in-process inventory. ․ Short throughput and manufacturing lead times. ․ Generally lower unit cost.

- 11 -

Manufacturing Process[Other Resources]

Manufacturing Layouts. ￭ Product Focus Layout.

WS = Work StationProduct A Product B

Line 2

WS12 WS13 WS14 WS15

WS22

Line 1

WS11

WS23WS21

FinishedMaterialsStorage

RawMaterialsStorage

Line 2

WS12 WS13 WS14 WS15

WS22

Line 1

WS11

WS23WS21

FinishedMaterialsStorage

RawMaterialsStorage

- 12 -

Manufacturing Process[Other Resources]

Manufacturing Layouts. ￭ Cellular Manufacturing.

U -S haped C e llC -S haped C e ll

A cell is a manufacturing unit consisting of a number of workstations plus the material transport mechanism and storage buffers that interconnect the cells. This manufacturing process produces families of parts within a single line or cell of machines operated by machines who work only within the line or cell. Forming cells within a plant that has a functional layout is often likened to creating miniature flow line.

- 13 -

Method Engineering[Other Resources]

Definitions ￭ Method Engineering. Methods engineering is defined as a systematic procedure for subjecting all direct and indirect operations to close scrutiny to produce improvements resulting in making work easier to perform and allowing work to be done in less time and with less investment per unit.

￭ Activities of Method Engineering. ․ Work methods studies. ․ Estimating parts and manufacturing operation costs. ․ Determining job skill requirements. ․ Estimating personnel quantities and grades. ․ Designing subassembly and assembly operations. ․ Analyzing overall production operations.

- 14 -

Method Engineering[Other Resources]

Work Measurement. ￭ Time Study. A time study is generally made with a stop watch and a note-taking observer. Sometimes it may involve motion pictures or video cassette recording of the operation under study. A number of observations are made and the collected data is averaged. To this is added a performance factor and allowances for personal factors (restroom, break, etc.) to achieve a normal time - the standard for that task. The efficiency expert of the movies and books in the 50's is usually thought of with stopwatch in hand writing notes about what the subject is doing.

- 15 -

Method Engineering[Other Resources]

Work Measurement. ￭ Elemental Standard Time Data. Elemental standard time data generally are in tabular form containing performance times for operations common to many applications. These are frequently data sheets from many studies of the past. They might include times for moving certain weight objects over certain distances, for example. To use them, the analyst must evaluate the job and identify the standard elements it contains. Then, the standard elemental data can be applied.

- 16 -

Method Engineering[Other Resources]

Work Measurement. ￭ Predetermined Time Standard. Predetermined motion-time data are found in tables usually published by a professional association or research agency. These tables are used much as indicated above - a Job is divided into standard elements and each element is rated as to difficulty. The table provides time for each difficulty-rated element. All the element times are added together for the job time.

￭ Work Sampling. Work sampling requires the observation of some part (the sample) of the job. Based on the findings of the sample, something may be said about the whole job.

- 17 -

Performance Check.

1. Which of the following is NOT a function of manufacturing engineering ? A. Identifying man-machine of actions. B. Designing special tools. C. Setting product price. D. Assisting in make-or-buy decisions.

2. Product specifications are usually developed by : A. The design engineer. B. The manufacturing engineer. C. The customer. D. The product development team.

3. A layout drawing would be MOST useful in what stage of product development ? A. Product conceptualization. B. Establishing product specifications. C. Functional design. D. Production design.

- 18 -

Performance Check.

4. Normally, the decisions selecting production processes are made in coordination with all but one of the following elements of the company. Which one is normally NOT involved ? A. Manufacturing Engineering. B. Sales Department. C. Metallurgy Department. D. Legal Department.

5. CAD/CAM/CAE are system and processes : A. Employing numeric control devices. B. Used in hazardous areas to limit human exposure. C. Relying on the computer and generally a common data base. D. Used in industrial operations only.

- 19 -

Performance Check.

6. A basic aim of methods engineering is to : A. Provide greater return to the stockholders. B. Eliminate all but direct labor in production. C. Eliminate all unnecessary time in the production process. D. Make it easier for management to get more out of the labor force.

7. Methods engineering includes time, motion, labor, cost, and : A. Production standards in studies. B. Human relations in studies C. Supplier delays in studies. D. Training standards in studies.

- 20 -

Performance Check.

8. The customary unit of measure for labor standards might be : A. The time required for a highly skilled worker to do the task. B. The time required for a new worker to do the task. C. The time required for the normal worker working at fast pace. D. The time required for the task by-the normal worker working with normal effort and skill.

9. The oldest approach to setting time standards is : A. Predetermined standard element times. B. Established element times for this industry. C. Using data from past performances. D. Work sampling.

- 21 -

Performance Check.

10. Methods engineering normally does NOT include which of the following objectives ? A. Setting time and cost standards. B. Deciding who will do what job. D. Initiating change requirements. D. Estimating personnel quantities.

11. Standards are MOST helpful for : A. Comparing other organizations with yours. B. Making management more effective. C. Keeping labor costs in line with goals. D. Comparing actual versus planned.

- 22 -

Performance Check.

12. Which of the following questions should be asked when analyzing the environment of a job ? Ⅰ. What is the best physical environment in which to accomplish this job ? Ⅱ. Is the best physical environment economically feasible ? Ⅲ. What compromises can be made in the environmental setting ?

A. Ⅰ B. Ⅱ, Ⅲ C. Ⅲ D. Ⅰ, Ⅱ, Ⅲ

13. Work measurement really applies only to the production force of a manufacturing plant. A. True, because the methods engineer is in production. B. False, because the methods engineer is a manager. C. True, because it requires repetitive tasks and they are found in production. D. False, because the concept applies, or can apply, to all kinds of jobs.

- 23 -

Performance Check.

Solutions :

1 2 3 4 5 6 7 8 9 10 11 12 13

C D D D C C A D C B D D D