1. Manufacturing Systems
Materials + Machine Time + Labor =
Manufactured Goods

2. STRATGIEG AND DESIGNE OF MANUFACTURING SYSTEM

3. Manufacturing Systems
Custom Manufacturing
Continuous Manufacturing
Intermittent Manufacturing
Flexible Manufacturing
Just-In-Time Manufacturing

4. Custom Manufacturing Oldest production system
Used to produce a smaller number of products to a customer’s order
Highly skilled workers machines to produce individual parts
Examples – spacecraft, stamping dies, special purpose machines

5. Continuous Manufacturing
Special purpose machines are used to produce large quantities of products
Products have limited variations
Uniform parts flow from station to station
Semiskilled workers operate the stations
Examples – automobiles, household appliances, furniture, paper, and lumber

6. Intermittent Manufacturing
Used when continuous manufacturing is not practical
Producing products in lots
All of the parts are processed through the station together
Often referred to as job-lot manufacturing

7. Flexible Manufacturing
Use of special tools and machines
Computer-controlled machines allow production run to be small
Reduced set-up time
Increased quality control with the use of the computer
Lots as small as one product can be produced at the cost of continuous manufacturing

8. Just-In-Time Manufacturing
Computer-based monitoring system
Developed in Japan
JIT stresses effective use of resources
Focus is placed on eliminating tasks, such as transportation, inspection, and storage which are wasteful
Raw materials arrive JIT for production, parts are produced JIT to be assembled, and products are produced JIT to meet the customer delivery orders

9. 1. Which answer choice defines custom manufacturing?
Stop
for
Questions
Special purpose machines are used to produces a large number of goods as parts move from one station to the next
Computer controlled machines are used to produce lots as small as one product but at the cost of continuous manufacturing
Raw materials arrive JIT for production, parts are produced JIT to be assembled, and products are produced JIT to meet the customer delivery orders
Producing products in lots
Oldest form of manufacturing that is used to produce a smaller number of goods

10. 2. Which answer choice defines continuous manufacturing?
Stop
for
Questions
Special purpose machines are used to produces a large number of goods as parts move from one station to the next
Computer controlled machines are used to produce lots as small as one product but at the cost of continuous manufacturing
Raw materials arrive JIT for production, parts are produced JIT to be assembled, and products are produced JIT to meet the customer delivery orders
Producing products in lots
Oldest form of manufacturing that is used to produce a smaller number of goods

11. 3. Which answer choice defines intermittent manufacturing?
Stop
for
Questions
Special purpose machines are used to produces a large number of goods as parts move from one station to the next
Computer controlled machines are used to produce lots as small as one product but at the cost of continuous manufacturing
Raw materials arrive JIT for production, parts are produced JIT to be assembled, and products are produced JIT to meet the customer delivery orders
Producing products in lots
Oldest form of manufacturing that is used to produce a smaller number of goods

12. 4. Which answer choice defines flexible manufacturing?
Stop
for
Questions
Special purpose machines are used to produces a large number of goods as parts move from one station to the next
Computer controlled machines are used to produce lots as small as one product but at the cost of continuous manufacturing
Raw materials arrive JIT for production, parts are produced JIT to be assembled, and products are produced JIT to meet the customer delivery orders
Producing products in lots
Oldest form of manufacturing that is used to produce a smaller number of goods

13. 5. Which answer choice defines just-in-time manufacturing?
Stop
for
Questions
Special purpose machines are used to produces a large number of goods as parts move from one station to the next
Computer controlled machines are used to produce lots as small as one product but at the cost of continuous manufacturing
Raw materials arrive JIT for production, parts are produced JIT to be assembled, and products are produced JIT to meet the customer delivery orders
Producing products in lots
Oldest form of manufacturing that is used to produce a smaller number of goods

14. 6. Is an automobile custom or continuous manufacturing?
Stop
for
Questions
Continuous Manufacturing
Custom Manufacturing

15. 7. Is a space shuttle custom or continuous manufacturing?
Stop
for
Questions
Continuous Manufacturing
Custom Manufacturing

16. 8. Is a household appliance custom or continuous manufacturing?
Stop
for
Questions
Continuous Manufacturing
Custom Manufacturing

17. HOW TO CHOOSE BETWEEN THEM
 •    How much will it take in both effort and energy for you to be able to obtain, implement and maintain consistency with the manufacturing system you will go with? Which of the systems available will best benefit the type of manufacturing you are planning? 
•    How much will it take in both effort and energy for you to be able to obtain, implement and maintain consistency with the manufacturing system you will go with? 
CONTD……

18. COMPONENTS OF MANUFACTURING SYSTEM

19. CONTD…..
 •   How easy or difficult will it be for the employees, managers and owners to implement and maintain the manufacturing system? 
 •  How much will the manufacturing system cost, and what can you afford to spend? 
  •Will the cost efficiency from the manufacturing system resolve into enough of a saving of cost, to benefit the cost of the program?

20. Flexible Manufacturing System(FMS)
A Closer Look

21. Application of FMS Metal-cutting machining Metal forming Assembly
Joining-welding (arc , spot), glueing
Surface treatment
Inspection
Testing

22. FMS different approaches
The capability of producing different parts without major retooling
A measure of how fast the company converts its process/es from making an old line of products to produce a new product
The ability to change a production schedule, to modify a part, or to handle multiple parts

23. Advantages of using FMS
To reduce set up and queue times
Improve efficiency
Reduce time for product completion
Utilize human workers better
Improve product routing
Produce a variety of Items under one roof
Improve product quality
Serve a variety of vendors simultaneously
Produce more product more quickly

24. FMS Example Body Shop Paint Shop Final Assembly
Through the use of reprogrammable tooling in the body shop, standardized equipment in the paint shop and common build sequence in final assembly, Ford can build multiple models on one or more platforms in one plant.
In the body shop, where the sheet metal comes together to form the vehicle’s body, flexibility means more than 80 percent of the tooling is not specific to one model. It can be reprogrammed to weld a car or a truck or a crossover of similar size.
Body Shop
In the paint shop, flexibility means robotic applicators are programmed to cover various body styles – as they move through the paint booth – with equal precision. This results in minimizing waste and environmental impact while maximizing quality.
Paint Shop
In the final assembly area, flexibility means the build sequence is the same among multiple models on one or more platforms allowing for efficient utilization of people and equipment.
Final Assembly

25. Illustration example of a FMS

26. Disadvantage of using FMS
Limited ability to adapt to changes in product or product mix (ex:machines are of limited capacity and the tooling necessary for products, even of the same family, is not always feasible in a given FMS)
Substantial pre-planning activity
Expensive, costing millions of dollars
Technological problems of exact component positioning and precise timing necessary to process a component
Sophisticated manufacturing systems

27. Development of FMS
Several actions must be decided on before you can have a have a FMS.  These actions include.
Selecting operations needed to make the product.
Putting the operations in a logical order.
Selecting equipment to make the product.
Arranging the equipment for efficient use.
Designing special devices to help build the product.
Developing ways to control product quality.