Manufacturing Systems 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

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

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 Lathe Department Milling DepartmentDrilling Department Grinding DepartmentPainting Department Receiving and Shipping Assembly LL LL L L L L MMM GGGG DDDD DDDD P P AAA

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 IN OUT

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

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

Manufacturing System Design Control Raw Materials Assembly Processed based layout

Manufacturing System Design Control Design of work cell Raw Materials Assembly

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

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

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

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 Load/Unload

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

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 Manufacturing System Design Control

Capacity Lead Strategy Capacity expanded in anticipation of demand Expect to gain customers from competitors Demand Capacity Quantity Time

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

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

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