1 / 17

ISE 115 Lecture 1/29/14 Manufacturing Systems Overview

ISE 115 Lecture 1/29/14 Manufacturing Systems Overview. Manufacturing - Then. Mfg. – Modern Day. Fabrication. Mfg.-Modern Day. Assembly. Mfg – Now. Fabrication. Mfg. – Now. Final Assembly. Manufacturing System.

york
Download Presentation

ISE 115 Lecture 1/29/14 Manufacturing Systems Overview

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. ISE 115 Lecture1/29/14Manufacturing Systems Overview

  2. Manufacturing - Then

  3. Mfg. – Modern Day. Fabrication

  4. Mfg.-Modern Day. Assembly

  5. Mfg – Now. Fabrication

  6. Mfg. – Now. Final Assembly

  7. Manufacturing System Fabrication & Assembly – Value adding activities: Shaping (Casting, Forming, Machining), Property enhancement (Heat treating, Surface processing, Coating), Assembly (Insertion, Joining, Fastening) Support Activities - Planning & Control, Purchasing, Order processing, Shop floor control, Material Handling, Equipment Maintenance, Quality Assurance, Process Engineering Equipment – Process machines, CNC machines, Robots, Feeders, Conveyors, AGVs, Special transporters, Flow control systems Facilities - Job shop, Process shop, Machine centers, Assembly lines, Clean rooms, Parts & products warehouses, WIP storage

  8. Process Improvement Strategy and Trend Build to order, not to stock. Minimize the on-site inventory by farming out low-level parts and S/A. Keep inhouse capability for on-demand F/A. Minimize MLT and WIP inventory by moving away from batch production to mixed, continuous flow production. Minimize/eliminate: Bottleneck, Wait time, Material/parts transfer, Setup time, and Lot sizing (Batching). Facilitate flexible manufacturing – Flexibility in terms of volume, schedule, process routing, and product mix. Process Improvement is a prerequisite for automation and integrated system . Improvement via Simplification first.

  9. QA Functions. What Happened? • Incoming Part Inspection • Extended In-line Function Test • 48 hour Burn-in • Random Product Sampling • Out-of-box Packaging Audit

  10. Material Handling Simplification • Avoid kitting and staging. Deliver bulk to point of use. • Link S/A lines to F/A lines. Add buffers if required. • Sub out most Fabrication operations. • Packaging and palletizing at end of line. • Have vendor deliver parts directly to line. • Eliminate Work-In-Process storage. • Ship directly from end of line. Eliminate material handling all together?

  11. Computer Integrated Manufacturing Low-level integration – For in-line part/product flow control and process data collection. High-level Integration – Mfg. system integrated with other enterprise resource planning and execution. 6 Composition – Process equipment, MH robots, inspectors, transporters, storage systems, flow controllers. Implementation - Product DFM, part/product grouping, tooling for reduced set up time, migration from batch to flow process, material handling automation, integration.

  12. Process Time, Flow Rate & Volume Cycle Time = Loading/Unloading Time + Tool Indexing Time + Unit Run Time Time between outputs Batch Process Time = Setup Time + Batch Size · Cycle Time Unit Process Time = Batch Process Time / Batch Quantity Production Rate = 1 / Unit Process Time Manuf. Lead Time = ∑ (Batch Process Times, Wait Time) Work-In-Process (WIP) Volume = Prod. Rate x MLT

  13. Discrete Manufacturing Automation Fabrication – Casting, molding, extrusion, material removal, press work, heat treating, surface processing Assembly - Part insertion, joining (welding, brazing, bonding), fastening, packaging Material Handling – Loading/unloading, in-line transfer, off-line transport, parts/WIP/FG storage Measurement & Test- Go/No-Go gauge, machine vision, function test, early life failure test Equipment – Process machines, Press m/c’s, CNC m/c’s, Robots, Conveyors, AGVs, Machine vision, PLC’s, AS/RS

  14. Automated Guided Vehicle

  15. Auto. Storage & Retrieval System

  16. Automation Type - Volume & Variety Fixed – For high volume, multi-year life cycle products . Example: “Detroit” type automation Requires product stability and large investment. Programmable – For low volume, high variety parts. Example: Job shop equipped with CNC machines. Applicable to singular parts or small batch runs. Flexible – For medium volume, small variety parts & products Example: FMS machine centers with QDC. Fully automated process with mixed input stream.

  17. Automation Strategy USA Principle – Understand and simplify the process before weighing the pros and cons of automation. Implementation Strategy – Partial, step-wise automation USA - Design a streamlined process. Start from scratch, not a patch work, not bound by existing process. Then, automate. Step Improvement - Build and link the islands of automation without creating bottleneck processes in between. Continuous Improvement - Fine tune and optimize the key processes that are automated before taking the next step. No pain, no gain. Seamless Transition ≡A missed opportunity

More Related