1. Part I OVERVIEW OF MANUFACTURING
Chapters:
Manufacturing Operations
Manufacturing Models and Metrics
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2. Ch 2 Manufacturing Operations
Sections:
Manufacturing Industries and Products
Manufacturing Operations
Production Facilities
Product/Production Relationships
Lean Production
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3. Manufacturing Defined - Technological Definition
“Application of physical and chemical processes to alter the geometry, properties, and/or appearance of a given starting material to make parts or products”
Manufacturing also includes the joining of multiple parts to make assembled products
Accomplished by a combination of machinery, tools, power, and manual labor.
Almost always carried out as a sequence of operations
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4. Manufacturing Defined - Technological Definition
Fig. 2.1.a
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5. Manufacturing Defined - Economic Definition
“Transformation of materials into items of greater value by means of one or more processing and/or assembly operations”
Manufacturing adds value to the material
Examples:
Converting iron ore to steel adds value
Transforming sand into glass adds value
Refining petroleum into plastic adds value
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6. Manufacturing Defined - Economic Definition
Fig. 2.1.b
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7. Classification of Industries
Primary industries – cultivate and exploit natural resources
Examples: agriculture, mining
Secondary industries – convert output of primary industries into products
Examples: manufacturing, power generation, construction
Tertiary industries – service sector
Examples: banking, education, government, legal services, retail trade, transportation
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8. Manufacturing Industries
ISIC Code
Food, beverages, tobacco
Textiles, apparel, leather and fur products
Wood and wood products, cork
Paper, printing, publishing, bookbinding
Chemicals, coal, petroleum and their products 35
Ceramics, glass, mineral products
Basic metals, e.g., steel, aluminum
Fabricated products, e.g., cars, machines, etc
Other products, e.g., jewelry, toys
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9. More Industry Classifications
Process industries, e.g., chemicals, petroleum, basic metals, foods and beverages, power generation
Continuous production
Batch production
Discrete product (and part) industries, e.g., cars, aircraft, appliances, machinery, and their component parts
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10. Process Industries and Discrete Manufacturing Industries
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11. Manufactured Products
Consumer goods: products purchased directly by consumers
Ex: cars, personal computers, Tvs, toys...
Capital goods: products purchased by other companies to produce goods and supply services
Ex: commercial aircraft, mainframe computers, machine tools, construction machinery...
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12. Manufacturing Operations
There are certain basic activities that must be carried out in a factory to convert raw materials into finished products
For discrete products:
Processing and assembly operations
Material handling
Inspection and testing
Coordination and control
A processing operation transforms a work material from one state of
completion to a more advanced state using energy to alter its shape,
properties or appearance to add value to the material.
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13. Classification of manufacturing processes
Fig. 2.3
Classification of manufacturing processes
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14. Processing Operations
A processing operation transforms a work material from one state of completion to a more advanced state that is closer to the final desired part or product.
Adds value to the material using energy to alter a work part’s shape, physical properties or appearance.
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15. ©2008 Pearson Education, Inc. , Upper Saddle River, NJ
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16. Processing Operations
Shaping operations apply mechanical force and/or heat or other forms and combinations of energy to change the geometry of the work material. Classification is based on the state of the starting material.
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17. Processing Operations
Shaping operations
Solidification processes
Casting (metal)
Molding (plastic/glass)
Particulate processing – pressing then sintering powder material (ceramics)
Deformation processes – forging/extrusion/rolling
Starting material is ductile metal
Material removal processes – turning/drilling/milling/grinding
Starting material is solid
Excess material is removed so that resulting product has the desired geometry
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18. Processing Operations
Property-enhancing operations are designed to improve mechanical or physical properties of the work material
heat treatments (sintering)
Surface processing operations
Cleaning (remove contaminants)
Surface treatments – mechanical work
Coating and thin-film deposition – coating of material to exterior surface
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19. Assembly Operations Joining processes Welding Brazing and soldering
Adhesive bonding
Mechanical assembly
Threaded fasteners (e.g., bolts and nuts, screws)
Rivets
Interference fits (e.g., press fitting, shrink fits)
Other
An assembly operation joins two or more components to create
a new entity which is called an assembly, subassembly, etc.
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20. Other Factory Operations
Material handling and storage
Inspection and testing
Coordination and control
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21. Material Handling
“A means of moving and storing materials between processing and/or assembly operations”
Material transport
Vehicles, e.g., forklift trucks, AGVs, monorails
Conveyors
Hoists and cranes
Storage systems
Unitizing equipment
Automatic identification and data capture (AIDC)
Bar codes
RFID
Other AIDC equipment
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22. Time Spent in Material Handling
Fig. 2.4 A typical part in a batch production machine shop
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23. Inspection and Testing
Inspection – examination of the product and its components to determine whether they conform to design specifications
Inspection for variables - measuring
Inspection of attributes – gaging
Testing – observing the product (or part, material, subassembly) during actual operation or under conditions that might occur during operation
Inspection and Testing are quality control activities to determine whether the manufactured product meets the established design standards and specifications.
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24. Coordination and Control
Regulation of the individual processing and assembly operations
Process control
Quality control
Management of plant level activities
Production planning and control
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25. Production Facilities
A manufacturing company attempts to organize its facilities in the most efficient way to serve the particular mission of the plant
Certain types of plants are recognized as the most appropriate way to organize for a given type of manufacturing
The most appropriate type depends on:
Types of products made
Production quantity
Product variety
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26. Production Quantity
Number of units of a given part or product produced annually by the plant
Three quantity ranges:
Low production – 1 to 100 units
Medium production – 100 to 10,000 units
High production – 10,000 to millions of units
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27. Product Variety
“Refers to the number of different product or part designs or types produced in the plant”
Inverse relationship between production quantity and product variety in factory operations
Product variety is more complicated than a number
Hard product variety – products differ greatly
Few common components in an assembly
Soft product variety – small differences between products
Many common components in an assembly
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28. Product Variety vs. Production Quantity
Manufacturing plants tend to specialize in a combination of production quantity and product variety that lies somewhere inside the diagonal band in the figure.
Manufacturing plants tend to specialize in a combination of production quantity and product variety that lies somewhere inside the diagonal band.
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29. Low Production Quantity
Job shop – makes low quantities of specialized and customized products
Also includes production of components for these products
Products are typically complex (e.g., specialized machinery, prototypes, space capsules)
Equipment is general purpose
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30. Low Production Quantity
Plant layouts:
Fixed position: The product remains in a single location during its entire fabrication and workers/equipment are brought to the product rather than moving the product. Ex: ships, aircraft, heavy machinery
Process layout: The equipment is arranged according to function or type.
Different parts, each requiring a different operation sequence, are routed through the departments in the particular order needed for their processing, usually in batches.
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31. Fixed-Position Layout
Fig. 2.6 (a)
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32. Process Layout
Fig. 2.6 (b)
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33. Medium Production Quantities
Batch production – A batch of a given product is produced, and then the facility is changed over to produce another product
Changeover takes time – setup time
Typical layout – process layout
Hard product variety
Cellular manufacturing – A mixture of products is made without significant changeover time between products
Typical layout – cellular layout
Soft product variety
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34. Cellular Layout Fig. 2.6 (c)
Each cell is designed to produce a limited variety of part configurations; that is, the cell specializes in the production of a given set of similar parts or products (group technology).
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35. High Production (mass production)
Quantity production – Equipment is dedicated to the manufacture of one product
Standard machines tooled for high production (e.g., stamping presses, molding machines)
Typical layout – process layout
Flow line production – Multiple workstations arranged in sequence and parts or assemblies are physically moved through the sequence to complete the product
Product requires multiple processing or assembly steps
Product layout is most common
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36. Product Layout
Fig. 2.6 (d)
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37. Relationships between Plant Layout and Type of Production Facility
Fig. 2.7
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38. Product/Production Relationships
Parameters that influence to determine how the products are manufactured:
Production quantity
Product variety – number of products
Product complexity (of assembled products) – number of parts
Part complexity – number of operations
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39. Product/Production Relationships
Total number of product units = Qf =
Qj: annual quantity of style j
Qf: total quantity of all parts/products made in the factory
P: total number of different part or product styles
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40. Product/Production Relationships
Let
P1: number of distinct product lines produced-hard variety
P2: number of models in a product line-soft variety
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41. Product/Production Relationships
Product variety
Hard product variety = differences between products
Soft product variety = differences between models of products
Product and part complexity
Product complexity np = number of parts in product
Part complexity no = number of operations per part
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42. Product and Part Complexity
npj: number of parts in product j
npf: total number of parts manufactured by the plant per year (pc/yr)
nof: total number of operation cycles performed (ops/yr)
nojk: number of processing operations for each part k for all parts of product j
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43. Factory Operations Model
Simplified for purposes of conceptualization:
Total number of product units Qf = PQ
Total number of parts produced npf = PQnp
Total number of operations nof = PQnpno
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44. Production Plants no>1
Parts producer: makes individual components, each component requires multiple processing steps, no assembly.
Vertically integrated plant: makes all its parts and assembles them into its final products.
no=1
Handicraft shop: not really a production plant, makes one part per year.
Assembly plant: produces no parts, purchases all parts from suppliers, one operation is required to assemble each part to the product.
np=1
np>1
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45. Limitations and Capabilities of a Manufacturing Plant
Manufacturing capability - the technical and physical limitations of a manufacturing firm and each of its plants
Three dimensions of manufacturing capability:
Technological processing capability - the available set of manufacturing processes
Physical size and weight of product
Production capacity (plant capacity) – max production quantity that can be made in a given time under assumed operating conditions
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46. Lean Production
“Operating the factory with the minimum possible resources and yet maximizing the amount of work accomplished”
Resources include workers, equipment, time, space, materials
Also implies completing products in the minimum possible time and achieving a very high quality level to completely satisfy the customer
In short, lean production means doing more with less, and doing it better
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47. Lean Production and Manufacturing Activities
Manufacturing activities can be divided into three categories:
Value-adding activities - contribute real value to the work unit. Ex: processing/assembly operation
Auxiliary activities - support the value-adding activities but do not contribute value to the product. Ex: loading/ unloading machines
Wasteful activities - do not add value nor do they support the value adding activities
If not performed, there would be no adverse effect on the product “ELIMINATE !”
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48. Programs Associated with Lean Production
Just-in-time delivery of parts: refers to the manner in which parts are moved through the production system when a sequence of manufacturing operations is required to make them.
Worker involvement: Workers with greater responsibility and training that allow them to be flexible.
Continuous improvement: Search for ways to make improvements in products and manufacturing operation (Kaizen)
Reduced setup times: Minimize the time needed to change over from one setup to the next in batch production
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49. Programs Associated with Lean Production
Stop the process when something is wrong
Error prevention: Refers to the use of low-cost devices and design features at each workstation that prevent errors occuring.
Total productive maintenance: A program that includes preventive maintenance and other procedures to avoid machine breakdowns that disrupt production operations.
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