Production System
- collection of people, equipment and procedures organized to perform the manufacturing operations for a company.
- Facilities
- Manufacturing Support System
Facilities
- Factory
- Machine and tooling
- All equipment
- Computer systems to control equipment
- Plant layout
Facility Manufacturing System (Facilities)
- Groupings of equipment and workers
- Work cell (one machine+ one worker)
- Production line (multiple machines and workers) - People Come in direct contact with equipment
Human Participation Categories (Worker-Machine Systems)
- Humans operated powered equipment
- Combines human and machine strengths
Human Participation categories
- Manual Work Systems
- Worker-machine systems
- Automated systems
Human Participation Categories (Manual Work systems)
- Workers perform tasks without power tools
- Common tasks: manual material handling, using hand tools, positioning parts
Human Participation Categories (Automated Systems)
- Machine performs processes without direct human participation
- Levels of automation:
- Semiautomated
- Fully automated
Manufacturing Support System
- These systems manage production through people and procedures
- Does not directly contact the product but plans and controls its flow through the factory
Four Functions of manufacturing support
- Business Functions
- Product design
- Manufacturing Planning
- Manufacturing control
Four Functions of Manufacturing Support (Business Functions)
- Main communication link between company and customers
- Start and end of information processing sequence
- Marketing, Sales, Customer billing, order entry, production orders
Four Functions of Manufacturing Support (Product design)
- Customer design provided (manufacturing design department not involved)
- Customer specifications (manufacturer is contracted)
- Proprietary product: manufacturer responsible for design and development
Four Functions of Manufacturing Support (Manufacturing Planning)
Translates product design into actionable production plans
- Process planning: define sequence of processing and assembly operations
- Master scheduling: Lists product delivery dates and quantities
- Material Requirement Planning: Raw materials, components etc.
- Capacity planning: feasibility with available machines and manpower
Four functions of manufacturing support (manufacturing control)
Manages physical factory operations to implement plans
- Shop floor control: Monitor product progress during life cycle
- Inventory Control: balance risk of shortages vs. carrying cost of excess
- Quality control: ensure product meets specified standards
Automated Manufacturing Systems
- Operate directly on physical products
- Automation: reduce human participation and in some cases no human participation
Three types of automated manufacturing systems
- Fixed Automation
- Programmable Automation
- Flexible Automation
Three types of automated manufacturing system (Fixed Automation)
Best for high volume production of a single product
Three types of automated manufacturing (Programmable automation)
- Batch production; product can change from batch to batch
- Coded instructions read and executed by system
- Lower production than fixed
- Flexible for product variations and changes
Three types of automated manufacturing (Flexible automation)
- Continuous production of various products with minimal setup time.
- Produces different products without stopping production for reprogramming/setup
- Minimal downtime because part variations are small
Computerized manufacturing support systems
- CAD (Computer aided design)
- CAM (Computer aided manufacturing)
Economical Justifications for manual labour
- Wage costs
- Remains feasible due to human attributes that provides advantages over machines in certain tasks.
- Preferred when flexibility and adaptability is required, problem solving and judgement, low production volume, tasks requiring creativity, too difficult to automate.
Why humans are necessary in manufacturing support systems
Decision making, learning, engineering, evaluating, managing, programming and maintenance of automated equipment.
USA Principle
U- Understand the existing process
S- Simplify the process
A- automate the process
USA (Understand the existing process)
- Comprehend the process in detail
- Tools and techniques (charts, steps, math models)
- Goals (key output variables, measurement requirements for feedback, process control algorithms)
USA (Simplify the process)
- questions/checklists
- Strategies for simplification
