manufacturing systems
DESCRIPTION
Manufacturing Systems. Manufacturing System Design & Control. Manufacturing System Design & Control. Facility Layout and Work Flow Arrangement within a factory of: Machines Departments Workstations Storage areas Aisles and common areas - PowerPoint PPT PresentationTRANSCRIPT
Manufacturing Systems
Manufacturing System Design & Control
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 Department Drilling Department
Grinding Department Painting Department
Receiving and ShippingAssembly
L L
L L
L
L
L
L
M M M
G G G G
D D D D
D D D D
P
P
A A A
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
4 6
5
1
2
11
9
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1210
3
Raw Materials
Assembly
Processed based layout
Manufacturing System Design Control
Design of work cell
4
6
51
211
98
7
1210
3
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 StationUnload StationPallet
Manufacturing System Design Control
Closed Loop FMS:
•Larger variety of parts
•Parts can follow different paths
•Parts can skip stations
Closed Loop FMS
Pallet
UnloadLoad
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
Manufacturing System Design Control
Capacity Lead Strategy
•Capacity expanded in anticipation of demand
•Expect to gain customers from competitors
Demand
Capacity
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an
tity
Time
Manufacturing System Design Control
Capacity Lag Strategy
•Capacity increased after increased in demand
•Common where competition is weak
Demand
Capacity
Time
Qu
an
tity
Manufacturing System Design Control
Average Strategy Lag
•Capacity expanded to coincide with average expected demand
Demand
Capacity
Qu
an
tity
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