Manufacturing Systems-Lecture 2
Eng. Inoka Kirindegedara
B.Sc. Eng.(Peradeniya), MBA In MOT (Moratuwa)
Definition ;
Manufacturing is the production of merchandise for use or sale using labour
and machines, tools, chemical and biological processing, or formulation
Manufacturing system gives a method of organizing production.
Different types of manufacturing systems includes assembly lines, batch
production, computer-integrated manufacturing etc.
Manufacturing systems
Manufacturing System plays an important role in daily
manufacturing operation
Objective;
To have efficient control of the organizational structure in order to
produce high quality products at lower prices within a shorter period
of time.
Components of a Manufacturing System;
Physical system –
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
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.
Production machines conti..
Types of production machines which are based on the complexity
and how advance the tool:
Manually operated
Semi-automated
Fully automated
Manually operated machines
Operator at the machines continuously to engage the feed, position the tool,
load and unload work parts and perform other task related to the operation.
Machines provides the power for operation and the worker provides the
control .
Example: conventional machine
Normally found in small and medium industry such as milling machine and
drill presses machine.
Metrology, where this machine help to ease the job but need an operator to
operate .
Machine do not have any program to control or to perform the task.
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.
Worker must attend to the machine every cycle but doesn’t need to be continuously
present during the cycle.
Machine requires a operator to unload the finished part and load the next part at the end
or beginning of each cycle.
Operator can attend/operate more than one machine at one time & extra time required for
each machine to make sure it continuously running with high productivity
Ex: CNC machine/programmable production machine that under the tool control for one
work cycle.
Fully automated machines
Capable to operate automatically with no human attention for a periods of time
That is longer than one work cycle.
Worker attention 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
If some error on the machine that require operator to solve before tool can start running again.
Most of the advance or high tech factory will have this type of machine.
Machine will help to reduce cycle time & labor cost
Reduces the number of product scrap or reject due to less human involvement in the cycle time.
Work station.
Combination of machines in one workplace are normally call as workstation
In this workstation, some specific task or operation performed with combination
of this 3 type of machines.
A complete manufacturing system may consist of one or more work stations.
A manufacturing system, with multiple workstation is called production line,
assembly line, machine cell or other name depending on its configuration and
function.
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.
Functions ;
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.
The Operation
Refers to all aspects of decision structures that determine how the system
functions.
Example,
Does it use a Toyota style pull production, or does it depend on an MRP II
system with forecasts driven production?
How does the plant manager determine the size and sequence of the jobs to be
done on each machine, on each day?
The Information
Refers to all data that will be accessed by some function/person/decision-
maker/software etc., and whose value may be used deciding upon an action.
Examples include design data, machine data, tool data, inventory status,
process data, vendors, clients, personnel data and so on.
It is likely that for any MS of reasonable complexity, one will need automated
data handling facilities, e.g. a DBMS.
Mechanisms that are required for the flow of information, that is, Information
Technology (IT). This includes communication protocols (such as MAP, TOP,
ISO-OSI), etc.
Humans
Refers to all personnel, vendors, customers, etc.
Personnel related issues include:
❖What is the capability level of available labour,
❖What is the working culture (1-shift, 2-shift availability),
❖How many do we need to hire for a given MS,
❖What is the level of training needed,
❖What policies will lead to better working environment etc.
❖ Customers are another essential human element in the design of MS.
Operational aspects.
This includes,
Production Control. including:
▪Lot sizing;
▪Scheduling;
▪Process Planning;
Operational aspects conti..
When design the physical systems, then concerned with the
capability to produce the designed part.
When studying the operational aspects, more concerned
with the efficiency at which are working.
Essentially know about goals, when make operational
decisions
Human Resources
To operate and manage the system/process•
Required either fulltime or periodically to keep the system running
Humans refers to all personnel , operators, vendors customers etc.
System manufacturing is value added system to produce parts and products•
In manufacturing system human perform some or all of the value added
work that is accomplished on the parts/products.
Performing either manual (direct)work on it or by controlling the machines.
Human Resources conti..
In fully automated machine, direct labour is still needed
Example : loading or unloading parts, changing tools,
resharpening tools etc.
In Automated Manufacturing System, workers also are needed to
support the system
Example : computer programmers/operators, maintenance and
repair
Personnel related issues
what is the capability level of available labour
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
Thank you
