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Manufacturing Systems

Manufacturing Systems. Manufacturing System Design & Control. Manufacturing System Design & Control. Facility Layout and Work Flow Arrangement within a factory of: Machines Departments Workstations Storage areas Aisles and common areas

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Manufacturing Systems

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  1. Manufacturing Systems Manufacturing System Design & Control

  2. Manufacturing System Design & Control • Facility Layout and Work Flow • Arrangement within a factory of: • Machines • Departments • Workstations • Storage areas • Aisles and common areas • Ensures a smooth flow of work, material, people and information through the system

  3. Manufacturing System Design & Control • 3 three basic types of layout: • Process • Product • Fixed-Position • 3 hybrid layouts: • Cellular • Flexible Manufacturing Systems • Mixed-model Assembly Lines

  4. Milling Department Drilling Department Lathe Department D D D D M M M L L D D D D L L Grinding Department Painting Department P L L G G G G P L L Receiving and Shipping Assembly A A A Manufacturing System Design Control • Process Layout: • Similar activities grouped together in work areas • Suitable for low volume or batch production • Flexible • Not very efficient • Storage space – large receiving, small shipping • Large aisles for movement of material

  5. IN OUT Manufacturing System Design Control • Product Layout: • Arrange activities in sequence of operation • Line set up for one product • Specialised machines • Suitable for mass production • More automated than process layouts • Efficient • Line flow – avoid bottlenecks • Not flexible

  6. Manufacturing System Design Control • Fixed Position Layout: • Large projects too big to move • Equipment and parts moved in and out of work area • Highly skilled workers - costly

  7. Manufacturing System Design Control • Hybrid Layouts: • Try to mix flexibility of process layout with efficiency of product layout • Cellular Layouts: • Machines grouped into cells • Cells process parts with similar features • Work cell resembles a small assembly line (product) • Layout between cells treated as process layout

  8. Assembly 7 9 4 6 5 8 2 10 12 1 3 11 Raw Materials Manufacturing System Design Control Processed based layout

  9. Assembly 12 8 10 4 9 6 2 11 5 7 3 1 Raw Materials Manufacturing System Design Control Design of work cell

  10. Manufacturing System Design Control • Flexible Manufacturing Systems: • Automates the entire manufacture of a product • Very costly • Complex software • Small number of FMS worldwide • Flexible Manufacturing Cell: • Smaller version of FMS • One manufacturing process is automated

  11. Load Station Unload Station Pallet Progressive FMS Manufacturing System Design Control • Progressive FMS: • All parts follow same progression through the work stations • Best where group technology can be applied

  12. Load Unload Pallet Closed Loop FMS Manufacturing System Design Control • Closed Loop FMS: • Larger variety of parts • Parts can follow different paths • Parts can skip stations

  13. Load/Unload Manufacturing System Design Control • Ladder FMS layout: • Parts moved to and from any machine in any sequence • More flexible than progressive and closed loop systems

  14. Manufacturing System Design Control • Mixed Model Assembly Lines: • More than one product is processed by the line • Workers trained to work on more than one station • Layout of line changed • Long and short operations arranged to cancel each other Traditional line U Shaped Line

  15. Manufacturing System Design Control • Capacity Management: • Demand for product can fluctuate over time • Capacity < demand - Lose business • Excess capacity: storage cost, labour cost etc. • Capacity planning: match capacity to present and anticipated demand • Capacity Planning • Capacity Lead Strategy • Capacity Lag Strategy • Average Capacity Strategy

  16. Capacity Quantity Demand Time Manufacturing System Design Control • Capacity Lead Strategy • Capacity expanded in anticipation of demand • Expect to gain customers from competitors

  17. Demand Quantity Capacity Time Manufacturing System Design Control • Capacity Lag Strategy • Capacity increased after increased in demand • Common where competition is weak

  18. Capacity Quantity Demand Time Manufacturing System Design Control • Average Strategy Lag • Capacity expanded to coincide with average expected demand

  19. Manufacturing System Design Control • How much to increase capacity? • 100% capacity not efficient • 20% cushion is generally used • 20% capacity allows for unexpected demand • Negative capacity can be used - Airlines

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