Ch 1 Introduction

Sections:
1. Production Systems
2. Automation in Production Systems
3. Manual Labor in Production Systems
4. Automation Principles and Strategies

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 Manufacturing and Production
Systems
 The word manufacturing was derived from two Latin
words; it means made by hand
 As years passed, factories were developed and the work
had to be organized using machines rather than handicraft
techniques, workers had to specialize in their tasks, More
up-front planning was required, and more coordination of
the operations in the factory was needed.
 As a result, Production systems, which rely on many
separate but integrating functions, were evolving.

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 The Realities of Modern
Manufacturing
Modern enterprises that manage production systems must
cope with today’s economic realities; these are:
 Globalization - became important once underdeveloped
countries (e.g., China, India, Mexico) are becoming major
players in manufacturing
 International outsourcing - Parts and products once made
(locally) in the United States by American companies are
now being made offshore (overseas) or near-shore (in
Mexico and Central America). Leeds to loss of jobs locally
 Local outsourcing - Use of (local) suppliers within the U.S.
to provide parts and services. (why local outsourcing?)

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 More Realities of Modern
Manufacturing
 Contract manufacturing - Companies that specialize in
manufacturing entire products, not just parts, under
contract to other companies
 Trend toward the service sector in the U.S. economy
(why?)
 Quality expectations - Customers, both consumer and
corporate, demand products of the highest quality
 Need for operational efficiency - U.S. manufacturers
must be efficient in in their operations to overcome the
labor cost advantage of international competitors

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 Modern Manufacturing Approaches
and Technologies
Manufacturers can compete by applying modern
manufacturing approaches and technologies such as:
 Automation - automated equipment instead of labor
 Material handling technologies - because
manufacturing usually involves a sequence of activities
 Manufacturing systems - integration and coordination
of multiple automated or manual workstations (examples?)
 Flexible manufacturing - to compete in the low-
volume/high-mix product categories
 Quality programs - to achieve the high quality expected
by today's customers (example: ISO)
 CIM - to integrate design, production, and logistics using comp.

 Lean production - more work with fewer resources

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 Production Systems “PS”

PS defined as a collection of people, equipment, and

procedures organized to accomplish the
manufacturing operations of a company
PS can be divided into two levels:
 Facilities – the factory and equipment and the way
the equipment is organized (blue collar workers)
 Manufacturing support systems – the set of
procedures used by a company to manage
production and to solve technical and logistics
problems in ordering materials, moving work through
the factory, and ensuring that products meet quality
standards (white collar workers)
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 The two Levels of a Production System

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 Production System: Facilities

Facilities include the factory, production machines and

tooling, material handling equipment, inspection
equipment, computer systems that control the
manufacturing operations, and the plant layout.
 Plant layout – the way the equipment is physically
arranged in the factory
 Manufacturing systems – logical groupings of
equipment and workers in the factory. Examples are:
 Production line
 Stand-alone workstation and worker

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 Manufacturing Systems
Three categories in terms of the human participation in the
processes performed by the manufacturing system:
1. Manual work systems - a worker performing one or
more tasks without the aid of powered tools, but
sometimes using hand tools (example: worker using hammer
and chisel to engrave building-stones )
2. Worker-machine systems - a worker operating powered
equipment (example: machinist operating a lath)
3. Automated systems - a process performed by a
machine without direct participation of a human
(example: plastic injection molding plant, oil refineries ). What is
fully-automated and smi-automated machines?
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 Manual Work System

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 Worker-Machine System

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 Automated System

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 Manufacturing Support Systems
Involves a cycle of information-processing activities that consists of four functions:
1. Business functions - sales and marketing, order
entry, cost accounting, customer billing (communicating with
customers). (What are the forms of production order?)
2. Product design - research and development, design
engineering, prototype shop. (especially when customer
specifications of a product are given)
3. Manufacturing planning - process planning, MPS,
MRP, capacity planning. (you have to know what does each term mean)
4. Manufacturing control - shop floor control: monitoring the
progress of the product, inventory control: quantity to order & when to order ,

quality control: to insure that the quality of the product meets the standard specifications. It
depends on inspection activities (material and parts, product in process, and finished product inspections.)
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 Information Processing Cycle in
Manufacturing Support Systems

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 Automation in Production Systems

Two categories of automation in the production system:

1. Automation of manufacturing systems in the
factory
2. Computerization of the manufacturing support
systems
 The two categories overlap because manufacturing
support systems are connected to the factory
manufacturing systems
 Computer-Integrated Manufacturing (CIM): term
used to indicate extensive use of computers in production
systems.

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 Computer Integrated Manufacturing

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 Automated Manufacturing Systems “AMS”
AMS operate in the factory on the physical product.
Examples of AMS:
 Automated machine tools (Injection Molding)
 Automated transfer lines
 Automated assembly systems
 Industrial robots that perform processing or
assembly operations
 Automated material handling and storage systems to
integrate manufacturing operations
 Automatic inspection systems for quality control

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 Automated Manufacturing Systems

AMS can be classified into three basic types:

1. Fixed automation
2. Programmable automation
3. Flexible automation

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 Fixed Automation
A manufacturing system in which the sequence of
processing (or assembly) operations is fixed by the
equipment configuration is called Fixed AMS
Typical features of fixed AMS:
 Suited to high production quantities
 High initial investment in special purpose equipment
 High production rates
 Relatively inflexible to accommodate product variety
Examples: automated assembly machines, production lines
of tomato-paste cans.

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 Programmable Automation
A manufacturing system designed with the capability to change
the sequence of operations to accommodate different product
configurations is called programmable AMS. (There is lost time
between jobs)
Typical features of programmable AMS:
 High investment in general purpose equipment
 Lower production rates than fixed automation
 Flexibility to deal with variations and changes in product
configuration
 Most suitable for batch production
 Physical setup and part program must be changed between
jobs (batches)
Examples: CNC milling machines, Industrial robots
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 Flexible Automation
An extension of programmable automation in which the
system is capable of changing over from one job to the
next with no lost time between jobs
Typical features of Flexible AMS:
 High investment for custom-engineered equipment
 Continuous production of variable mixes of products
 Medium production rates
 Flexibility to deal with soft product variety
Examples: machining operations of a family of similar parts

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 Product Variety and Production
Quantity for Three Automation Types

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 Computerized Manufacturing Support
Systems
Objectives of automating the manufacturing support
systems:
 To reduce the amount of manual effort in product
design, manufacturing planning and control, and the
business functions
 Integrates computer-aided design (CAD) and computer-
aided manufacturing (CAM) in CAD/CAM
 CIM includes CAD/CAM and the business functions of
the firm

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 Reasons for Automating

1. To increase production rate and labor productivity

2. To reduce labor cost
3. To mitigate the effects of labor shortages (machinists)
4. To reduce or remove routine manual tasks
5. To improve worker safety (explain how?)
6. To improve product quality (machining)
7. To reduce manufacturing lead time (time between order and delivery)
8. To accomplish what cannot be done manually (Producing
mathematically defined surfaces using CNC milling machines)

9. To avoid the high cost of not automating (explain how?)

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 Manual Labor in Production Systems

Is there a place for manual labor in the modern production

system?
 Answer: YES
 Two aspects:
1. Manual labor in factory operations
2. Labor in manufacturing support systems

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 Manual Labor in Factory Operations
The long term trend is toward greater use of automated
systems to substitute for manual labor
 When is manual labor justified?
 Some countries have very low labor rates and
automation cannot be justified
 Task is too technologically difficult to automate (inspection)
 Short product life cycle (toys)
 Customized product (customer requires one-of-a kind item)
 To cope with ups and downs in demand
 To reduce risk of product failure
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 Labor in Manufacturing Support
Systems
Even if all the production system is automated, there will still
be a need for labor to perform the following kinds of work:
 Product designers who bring creativity to the design task
 Manufacturing engineers who
 Design the production equipment and tooling
 And plan the production methods and routings
 Equipment maintenance
 Programming and computer operation
 Engineering project work (upgrading machines)
 Plant management
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 Automation Principles and Strategies

1. The USA Principle

2. Ten Strategies for Automation and Process Improvement
3. Automation Migration Strategy

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 U.S.A Principle
1. Understand the existing process
 Input/output analysis
 Value chain analysis
 Charting techniques (flow process chart) and mathematical
modeling (relating output variables with input parameters to formulate algorithms for automatic
process control)

2. Simplify the process

 Reduce unnecessary steps and moves
3. Automate the process
 Ten strategies for automation and process improvement
 Automation migration strategy
 Ten Strategies for Automation and
Process Improvement
1. Specialization of operations (explain each strategy)
2. Combined operations
3. Simultaneous operations
4. Integration of operations
5. Increased flexibility
6. Improved material handling and storage
7. On-line inspection
8. Process control and optimization
9. Plant operations control
10. Computer-integrated manufacturing
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 Automation Migration Strategy
For Introduction of New Products
1. Phase 1 – Manual production
 Single-station manned cells working independently
 Advantages: quick to set up, low-cost tooling
2. Phase 2 – Automated production
 Single-station automated cells operating
independently
 As fare as demand grows and automation can be
justified
3. Phase 3 – Automated integrated production
 Multi-station system with serial operations and
automated transfer of work units between stations
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Automation
Migration
Strategy

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 Organization of the Book
1. Overview of Manufacturing
2. Automation and Control Technologies
3. Material Handling and Identification Technologies
4. Manufacturing Systems
5. Quality Control in Manufacturing Systems
6. Manufacturing Support Systems

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 Organization of the Book

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