chapter 3 design of production system (1)

7/31/2019 Chapter 3 Design of Production System (1)

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Chapter 3

Design of production

system


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1 Product and service

design


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1.1 Objectives of productand service design To bring new or revised products or services

to the market as quickly as possible

To design products and/or services that havecustomer appeal.

To increase the level of customer satisfaction.

To increase quality To reduce costs


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1.2Design for customers

It is too difficult to fix-up

Too much functions

Too complicated to operation, etc.


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1.3 Design formanufacturing and assembly

(DFMA)


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1.3.1

Objectives To reduce the number of parts and

simplify the product.

To make easy to manufacture andassembly

Reduce the costs


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1.3.2 Principles and methods Standardization

Minimize parts and operation

Modular design Design for ease of jointing and separating

and ease of coupling/uncoupling

Design for one-way assembly, one- way

travel Avoid special fasteners and connectors

CAD--Computed- aided design


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Modular designA form of standardization in whichcomponent parts are subdivided into

modules that are easily replaced orinterchanged.


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Advantages of Modular

design Fewer parts to deal with inventory and in

manufacturing

Reduce training costs and time. More routine purchasing, handing, and

inspection procedures.

Opportunities for long production runs andautomation.

Need for fewer parts and improve quality.


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Disadvantages of Modular

design Designs may be frozen with too many

imperfections remaining.

High cost of design changes increasesresistance to improvements.

Decreased variety results in less

consumer appeal.


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1.4Design for reliability

Reliability is the probability that an itemwill function as planned over a given

time period. It may be calculated asfollows:

(--a constant failure rate)

teR


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1.5 Designing andDeveloping new services


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Three dimensions of service

design The degree of standardization of a

service.

The degree of customer contact indelivering the service.

The mix of physical goods and

intangible services


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Three service-ways Way of Line

Automatic way

Individual way


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2. Process design


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2.1 Types of processing Continuous processing

Intermittent processing

Projects


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Continuous processing Highly specialized system producing

large volumes of one or a few

standardized items. Repetitive manufacturing (Typically,

these products are produced in discrete

units.)


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Intermittent processingSystem that produces lower volumes ofitems or services with a greater variety

of processing requirements Batches / lots

Job shop


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2.2 The contents of the

process design

P 125, Figure 4.3


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2.4 types of process

designs Product-focused

Process-focused

Group technology/

Cellular Manufacturing


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Product-focusedA form of production processing

organization in which productiondepartments are organized according tothe type of product/service beingproduced.

(See Figure 4.4, P.128)


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Process-focusedA form of production in which

production operations are grouped

according to type of processes.

(See Figure 4.5, P.129)


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Group technology/cellular

manufacturing (GT/CM)

Form of production based on a coding

system for parts that allows families ofparts to be assigned to manufacturingcells for production.

(P.130-131)


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3. Production technology

selection NC--numerically controlled machines

Robots

Automated quality control inspection AIS--automated identification systems

Automated production systems:

FMS---Flexible manufacturing systems CAD/CAM

CIMS (see Figure 5.3 P.185)


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Characteristics of factories ofthe future

(P.186)


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4.2 Analyzing retailing andother service location

Table 7.3 (p.260)


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5. Layout

5.1 Objectives of facility layouts

Table 8.1 (p.281)


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5.2 Four basic types of layouts for

manufacturing facilities Process layouts

Product layouts

Cellular manufacturing layouts

Fixed position layout


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5.2.1

Process layouts

Functional layouts, job shop

The layouts are designed toaccommodate variety in productdesigns and processing steps.

A variety of products in relatively smallbatches


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Product layouts They are designed to accommodate

only a few product designs.

The volume is large


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Cellular manufacturing

layouts Machines are grouped into cells, and

the cells function somewhat like a

product layout island within a larger jobshop or process layout.

(Table p.285)


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Hybrid layouts


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5.3 New trends in

manufacturing layout Cellular manufacturing layouts within larger

process layouts

Automated material-handling equipment U-shaped production lines

More open work areas

Smaller and more compact factory layouts Less space provided for storage of inventories


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5.4 Service facility layouts

chapter 3 design of production system (1)

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