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Strategies for Matching Manufacturing Lead Time with Customer Lead Time in Production Systems

Discover the four key strategies used to align manufacturing lead time with customer lead time in production systems: Engineer to Order (ETO), Make to Order (MTO), Assemble to Order (ATO), and Make to Stock (MTS). Explore the product development cycle, enterprise organization implications, and considerations for product design and production engineering.

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Strategies for Matching Manufacturing Lead Time with Customer Lead Time in Production Systems

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  1. Manufacturing Systems

  2. Production Strategy Classification • Based on:- • customer lead time - max time taken between placing an order and delivery • Manufacturing lead time - max time between receipt of an order and delivery of the product • Need to match manufacturing lead time with customer lead time • Four strategies used to match these lead times: Manufacturing Systems

  3. Engineer to Order (ETO) • New product, complex product, unique designs produced in single units (examples - construction) • Very common in Project type manufacture • Long manufacturing lead times Manufacturing Systems

  4. Make to Order (MTO) • Existing designs with proven production processes • Unpredictable demand(examples - special spec computer) • Assemble to Order (ATO) • customer lead time less than manufacturing lead time • forecasts of product mixes certain or response to customer orders Manufacturing Systems

  5. Make to stock (MTS): • customer lead time less than manufacturing lead time - stock the products so the the manufacturing lead time is minimized • product has few options but good demand Manufacturing Systems

  6. Product Development Cycle • starts from MARKET RESEARCH, to REVIEWS, DESIGN ENGINEERING, PRODUCTION ENGINEERING, MANUFACTURING, CUSTOMER USE • Can be a new product or existing product changes • New Product: • Form, fit and function; • order winning criteria • CONCURRENT ENGINEERING Manufacturing Systems

  7. Existing product: • activity can start from any where Enterprise Organization • CIM implementation affects all facets of the enterprise • Various sections of the enterprise are: • sales and marketing - provide useful information required in pricing, product design, suppliers, e.t.c Manufacturing Systems

  8. Finance and management - coporate goals, financial functions, long-term plans • Product/process definition - design, conceptualization, materials, documentation (CAD/CAD/CAE) • Manufacturing planning and control -interface between engineering and shop floor - MPS , MRP, PAC, Capacity planning • Shop floor - processes, material movement, floor control - AUTOMATION • Support organization Manufacturing Systems

  9. Overview of Product Design and Production Engineering Manufacturing Systems

  10. Considerations: • product design - critical design steps • software for drawing, analysis, modeling, simulations, testing and design • Concurrent engineering • design for quality Manufacturing Systems

  11. Product Design • need for automating design process in CIM • generates the initial product data and drawings • Functional automation - islands of design automation; • potentially productive but has negative enterprise related effects • Single Enterprise database with a single image of all product information - ENTERPRISE DATA INTEGRATION • Communications:- • LAN - supports inter-departmental design activities • WAN - will link enterprises and their contractors/suppliers Manufacturing Systems

  12. Organization Model • Design team - • product design • analysis • materials selection • documentation (both design and production) • Production engineering • production standards(labor, process, quality) • Integrated Product and Production design Manufacturing Systems

  13. Design Process • Form, Fit and Function • Form - desired shape, style and character • Fit - relates more to market functions • Function - performance, reliability, maintanability • Conceptualization: • Typical - similar to previous designs - repetitive design • Atypical - product need that is totally new - concept approach • (Discuss some examples) Manufacturing Systems

  14. Synthesis: • material specification • initial additions of geometric features to the conceptualized design • dimensional details • DFA and DFM (DFMA) • Analysis: • analytical techniques such as Mass property analysis or Finite element methods Manufacturing Systems

  15. Evaluation • checks design against all requirements, form, fit, dimensions, etc • match manufacturing and assembly requirements • Rapid prototyping • Documentation • detailed drawings and assembly drawings • details of materials and parts • BOM • Product electronic data files Manufacturing Systems

  16. Concurrent Engineering • design and production design considered together Manufacturing Systems

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