1. 8. Features of Manufacturing Industries – Part B
Mr P Mulholland
St Joseph’s High School Crossmaglen

2. Production Scheduling and Production Logistics
Advantages
Flexible and easy to adapt if product or quantity changes.
Minimises work in progress
Minimises the amount of stock held
Raises productivity (the ratio of output to inputs in production; it is a measure of the efficiency of production)

3. Robotics in Production
Read and make notes on Edexcel Textbook p

4. Robotics in Production

5. Material Handling Systems
Read and make notes on Edexcel Textbook p

6. Automated Materials- Handling Systems
Materials handling systems provide transportation and storage of materials, components and assemblies.
Activities start with unloading goods from delivery transport, then passed through to storage, onto machining, assembly, testing, packing and finally loading the finished product onto transport again.
Each stage of the production process requires a different design of handling equipment.
CIM systems enable a range of material-handling systems to operate within the workplace. Fully automated systems ensure materials, components and assemblies are delivered to the production line when required without significant manual intervention.
The downside of implementing this system is the downsizing of the workforce due to increased automation.

7. Automated Storage and Retrieval System
An ASRS is an automated robotic system for sorting, storing and retrieving materials in a warehouse.
Within CIM, a computer controls the transportation of materials and components to the required points. All stocks of materials and components are stored in racking systems.
The system will select the correct component from the rack, retrieve it by means of a crane and place it on a conveyor or onto an automated guide vehicle (AGV) for transportation.
Warehousing and distribution are about moving as much product to market as possible, in the shortest amount of time.

8. Automated Storage and Retrieval System
Interior view of the Automated Storage and Retrieval System (ASRS) located at the Defense Visual Information Center. Motion media and still media from all the military services are stored here. The ASRS is an environmentally controlled, self-contained, state-of-the-art, robotics track guided system. It is four stories high and about half the size of a football field. This low angle view was taken from the rear of the ASRS with the camera mounted on the robot arm. A bar-coded bin full of motion picture film is ready to be driven forward.

9. Automated Storage and Retrieval System
Fully automated 4 aisle bin warehouse for electronic components with Mustang AS/R machines from TGW

10. Automated Storage and Retrieval System
Traditional manual systems have a limited throughput of approximately ten load movements per hour, which is in stark contrast to the average of 40 load movements per hour that are performed by ASRS.
ASRS enables the company to increase throughput and reduce labour costs.
Employees’ technical skills are developed by operating such a system.

11. Automated Guided Vehicle
An AGV is a materials-handling device that is used to move parts between machines or work centres.
They are small, independently powered vehicles that are usually guided by radio frequency wires that are buried in the floor, or use optical sensors in a laser guided navigational system.
They are controlled by receiving instructions either from a central computer or from their own on board computer.
Read Table 3.16 p105.

12. Automated Guided Vehicle

13. Automated Guided Vehicle
The painted body of a new Aston Martin DB9 is worth more than most people pay for their entire car, so the last thing
that the prestige sports car producer wants is damage to the body during handling.
However careful a person is, there is always the risk of human error, so Aston Martin has chosen to install a driverless, automated guided vehicle (AGV) to
perform DB9 body transport duties at its new, purpose-built facility in Gaydon, Warwickshire.

14. Automated Stock Control Just In Time
JIT manufacturing is a system used by companies to reduce costs.
JIT is seen to reduce waste in a company.
JIT manufacturing is related to efficiency.
A product is only manufactured when it is required.
Producing products only when needed means quality and efficiency in manufacturing are improved. This can lead to higher returns for the company.
New stock is only ordered when needed e.g.. when a stock level is reached.
There is no over ordering which reduces storage space and reduces costs.

15. Example of JIT Car Manufacture
Materials are only bought in for use in immediate manufacture.
Process of manufacturing is smooth as the right amount of materials is delivered at the right time to be used in the manufacturing process.
Turnover is rapid.
Money tied up in raw materials and components (stock) is reduced.
Vehicles are usually built to order.
Reduces the problem of producing cars that will not be sold, reducing the risk for the company.

16. Flexible Manufacturing Systems
FMS are manufacturing systems that are set up to allow a company some degree of flexibility to allow it to react and make changes quickly to the manufacturing process.
Changes might be predicted or unpredicted.
Machine Flexibility
System’s ability to change to produce new products
Ability to change order of operations
Routing Flexibility
Ability to use multiple machines
Ability to change such as capacity and capability

17. Advantages Improved productivity Quicker machinery set up times
Lower labour costs
Reduced down time on machines
Production and productivity are increased

18. Quick Response Manufacturing
The main purpose of QRM is to reduce the lead time in all areas of manufacturing.
QRM is seen by the client as responding rapidly in designing and making products customised to their needs.
QRM is seen by the company as a way to improve quality of product and reduce costs.

19. Advanced Manufacturing Technology
AMT describes the significant impact of computers on manufacturing.
Computer technology has led to the development of CAD/CAM, robotics, material handling devices and CIM systems that have increased the accuracy and flexibility of the manufacturing process.
Computer technology features strongly in automation used in modern manufacturing systems.
Computers have allowed automation to become flexible and more effective in applications other than mass production.

20. Flexible Manufacturing System
A FMS system is a form of flexible automation in which several machines are linked together by a material handling system, with all aspects controlled by a central computer.
FMS brings together modern manufacturing technologies such as CNC, robotics, automated material handling etc to form an integrated system.
FMS have powerful computing capacities that give them the ability to control, coordinate equipment, plan production and route materials through the system.
The main advantage of FMS is its high flexibility in managing manufacturing resources in terms of both machines and personnel in order to manufacture a new product.

21. Flexible Manufacturing System
This flexibility allows the system to react quickly to changes in production whether they are predicted or not.
This uses two main features:
Machine flexibility- systems ability to change and make new products or parts.
Routing flexibility- ability to use multiple machines to perform the same operation on a part and be able to cope with large scale change.
Advantages of FMS include:
Increased productivity due to automation
Shorter lead times for new products due to flexibility
Lower labour cost due to automation
improved production quality due to automation
The main disadvantage of FMS is that the setting up takes a lot of planning and is very expensive to initiate.

22. Flexible Manufacturing Cells
As customers demand variety and customisation of products as well as specific quantities delivered at specific times, a lean manufacturer must remain flexible enough to serve its customers needs.
Manufacturing cells allow manufacturers to provide their customers with the right product at the right place at the right time.
This is achieved by grouping similar products together into families that can be processed on the same equipment in the same sequence.
A manufacturing cell is a group of workstations, machines or equipment arranged such that a product can be processed progressively from one workstation to another without having to wait for the batch to be completed and without additional handling between operations.

23. Flexible Manufacturing Cells
Modular production methods provide flexibility as upgrades to processes can be performed relatively quickly and easily by shutting down one cell whilst another simultaneously opens and takes its place.
Entire production line does not have to be disrupted which reduces costs from stoppages and ‘downtime’.
Typically a manufacturing cell involves 3-12 workers and 5-15 workstations in a compact arrangement.
Some cells are fully automated using CAD/CAM.
Materials sit in an initial queue when they enter the cell. Once processing begins, they move directly from process to process, resulting in a very fast throughput.
Read types of manufacturing cells p102.

24. Computer Integrated Manufacture
CIM takes the concept of integration of separate manufacturing technologies developed by FMS a step further by bringing all aspects of a company’s operations, not just those that are involved directly in manufacture.
A CIM system uses computer networks to integrate the processing of production and business information with manufacturing operations to create cooperative and smooth running production lines.
Tasks performed within CIM include:
Design of product using CAD
Planning cost effective work flow
Controlling machines and equipment
Ordering stock, materials and invoicing customers

25. Computer Integrated Manufacture
One of the drawbacks of a CIM system is its dependence on computer data to fully integrate all operations.
The cost of managing data is also a key issue within CIM. If data becomes corrupted it may cause machinery to malfunction.
To prevent this companies often use a product data management system.

26. Product Data Management System
PDM is an information system used to manage the data of a product as it passes from design to manufacture.
The data includes plans, 3D models, CAD drawings, CNC programs as well as all related project data and documents.
PDM manages the data in a way that if information is updated on one database, the effects are highlighted in others.
The focus is on managing and tracking the, change and storage of all information related to the product.

27. Product Data Management System
Example:
The design of a component part may go through many changes during the course of its development, each involving CAD data to change.
When the designer is satisfied with the component the PDM system will notify an analyst that the design is ready for a stress analysis to be performed. When this task is complete the analyst signs it off electronically.
the PDM system will notify a manufacturing engineer that the component is ready for planning of its manufacture and a tool designer that the component design is ready for a tool design.
After these tasks are performed, relevant data is entered onto the system and is signed off by the team. It is then released to be manufactured.
Figure 3.10 p99.

28. Product Data Management System
Advantages of PDM include:
Reduced time to market- data is instantly available to teams and can be reviewed eliminating sign off time.
Improved productivity- changes to product data are tracked and managed automatically. This reduces time to search for documents and design data can be reused.
Improved control- efficient management systems makes sure that current data is being used, with only certain members able to edit data.

29. Enterprise Resource Planning Systems
Fig 3.11 p100.
ERP systems aim to integrate all departments and data across a company onto a single computer system that can serve all the needs of the different departments.
This uses a unified database.
Example
Finance, human resources, manufacturing and warehousing use their own system but ERP combines them all together into a single integrated program so departments can communicate and share information easily.
ERP takes a customer order and provides a road map for automating the different steps along the path to fulfilling it.

30. Enterprise Resource Planning Systems
Example
Customer order is entered into an ERP system
All info to complete the order is accessible, such as: customer credit rating, level of stock in warehouse, delivery schedule.
All info can be seen and updated instantly if necessary.
When the particular department finishes with the order it is automatically routed to the ERP system to the next department.
Any order can be easily tracked and customers should receive their order faster without errors.
ERP systems are expensive to install and costs are incurred during the change over period.
Considerable training is needed for the workforce to be able to use the software effectively and efficiently.
Success depends on the skill and experience of the workforce and ongoing training.

31. Lean Manufacturing and JIT Systems
A key feature of lean manufacturing is the notion of ‘just in time’.
This means there are no warehouses full of materials, materials arrive when they are needed.
The objective of lean manufacturing is to provide techniques that ensure minimum waste is incurred during production and to produce products only as needed.
QUITE SIMPLY: JIT ensures that the right materials, components and products arrive at the right place, at the right time and in the exact amount. This reduces waste and overstocking, saving space and costs.
Producing the right amount at the right time relies upon accurate analysis and forecasts using the right information at the right time.
If a company is inaccurate with their predictions, such as a rise in demand stocks will be used up quickly. If a supplier fails to deliver production can come to a complete stop.
Copy table 3.14 p101.

32. Pull Tools- Kanban
A lean organisation needs to be tailored so that orders are pulled through the production system. A Kanban system uses cards, or containers as simple visual signal to indicate when to pull materials, components or products through the production system.
Kanban involves production and transportation systems:
Production Kanban includes details of the operations that need to be carried out at the workstation or manufacturing cell
Transportation Kanban only contains details regarding wher the materials, components or products have come from and where they are going to.
The main benefit is it reduces the amount of work in progress and finished goods in stock. Kanban restricts the supplu of materials and components until they are needed, which provides an effective JIT.

33. Perfection Tools- Kaizen
Kaizen is also known as continuous improvement, where small changes are made to the production process resulting in small improvements being made.
It is carried out on a regular basis as the changes made are often low cost and the improvements tend to be small.

34. Quick Response Manufacturing
QRM was developed to give companies a competitive advantage by increasing their operating efficiency.
QRM requires a manufacturer to move from batch production to flow production. This production is triggered by consumer demand and not based on complex demand forecasts.
Operating this system means a manufacturer can respond to fluctuations in the economy and market demand as well as excess stock piling of products which costs money.

35. Quick Response Manufacturing
QRM involves several concepts such as TQM, JIT and manufacturing cells but its main aim is to increase the overall flexibility and responsiveness of the company.
Example
By manufacturing in cells, production teams can be dedicated to specific product lines.
These teams can be quickly and efficiently reallocated if the product mix changes.
This means a manufacturer has increased production flexibility and will be better equipped to meet changing market demands.

36. Quick Response Manufacturing
In an ideal QRM situation the manufacturer would begin production as soon as an order is initiated, suppliers would deliver raw materials directly to the production line, the product would be manufactured and the finished goods would flow directly to the awaiting truck for delivery.
The primary functions of QRM are:
Pull raw materials through the production process strictly according to market demands.
Ensure every order moves through as quickly as possible throughout the entire chain.
Advantages and disadvantages p96.

37. Concurrent Manufacturing
Diagram p96.
In order to remain competitive and cope with pressure from what customers want, manufacturers need to get to the market first with products.
Concurrent manufacturing provides a systematic approach to the integration of design, manufacture and related processes where all life cycle stages of the product are considered simultaneously.
One of the main advantages is that designs are produced ‘right first time’ through the use of different design teams, reducing development time and allows the early release of the product.

38. Concurrent Manufacturing
A concurrent manufacturing system brings together many people such as manufacturing, project management, technical, marketing etc who work with the designers to build a multi-disciplinary team.
These teams work together and can make decisions about the product.
They can make trade offs between:
design features
part manufacturability
assembly requirements
material need
cost and time restraints

39. Concurrent Manufacturing
Differences are dealt with more easily at the early part of the design stage. This makes the design process quicker and more efficient as no re design is needed and manufacture can start earlier.
One of the most important aspects for success will be how well the team works together. Excellent communication is needed.
Computer based systems enable efficient communication between individual members and project teams for product development.
Combining concurrent manufacturing systems, effective management and teamwork ensures the development of a high quality and reliable product with low life-cycle costs in the shortest development time.

40. Concurrent Manufacturing
Early in the development stage designers can use Quality Function Deployment (QFD). A strategy for staying in touch with customer requirements in order to create a more successful product.
Lead time has proved to be an aspect of modern competition.
By decreasing lead time, a company is able to respond rapidly to changes in market trends to incorporate new technologies.
By using concurrent manufacturing systems, lead times can be reduced, creating a market advantage for producing products quickly.

41. Concurrent Manufacturing
QFD is a quality assurance method that factors customer satisfaction into the development of a product before it is manufactured.
Main features of QFD are:
Focus on customer requirements
Use of multi disciplinary teamwork
Use of the ‘House of Quality’ Matrix
The matrix is used to convert customer requirement into priority targets for the product.
Advantages of using QRD in concurrent manufacturing include:
Reduced time to market
Reduction in design modifications
Decreased design and manufacturing costs
Improved product quality
Enhanced customer satisfaction
Factfile on p97.