Materials + Machine Time + Labor = Manufactured GoodsMaterials + Machine Time + Labor = Manufactured Goods

STRATGIEG AND DESIGNE OF MANUFACTURING SYSTEM

Manufacturing Systems Custom

Manufacturing Continuous

Manufacturing Intermittent

Manufacturing Flexible

Manufacturing Just-In-Time

Manufacturing

Custom Manufacturing

Continuous Manufacturing

Intermittent Manufacturing

Flexible Manufacturing

Just-In-Time Manufacturing

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

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

Continuous Manufacturing Special purpose machines are used to

produce large quantities of products Products have limited variationsUniform parts flow from station to

station Semiskilled workers operate the

stations Examples – automobiles, household

appliances, furniture, paper, and lumber

Special purpose machines are used to produce large quantities of products

Products have limited variationsUniform parts flow from station to

station Semiskilled workers operate the

stations Examples – automobiles, household

appliances, furniture, paper, and lumber

Intermittent Manufacturing Used when continuous manufacturing is not practical

Producing products in lotsAll of the parts are processed through the station together

Often referred to as job-lot manufacturing

Used when continuous manufacturing is not practical

Producing products in lotsAll of the parts are processed through the station together

Often referred to as job-lot manufacturing

Flexible Manufacturing Use of special tools and machines Computer-controlled machines allow

production run to be smallReduced set-up time Increased quality control with the use of the

computerLots as small as one product can be

produced at the cost of continuous manufacturing

Use of special tools and machines Computer-controlled machines allow

production run to be smallReduced set-up time Increased quality control with the use of the

computerLots as small as one product can be

produced at the cost of continuous manufacturing

Just-In-Time Manufacturing Computer-based monitoring system Developed in JapanJIT stresses effective use of resourcesFocus 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

Computer-based monitoring system Developed in JapanJIT stresses effective use of resourcesFocus 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

1. Which answer choice defines custom manufacturing?

A. Special purpose machines are used to produces a large number of goods as parts move from one station to the next

B. Computer controlled machines are used to produce lots as small as one product but at the cost of continuous manufacturing

C. Raw materials arrive JIT for production, parts are produced JIT to be assembled, and products are produced JIT to meet the customer delivery orders

D. Producing products in lots E. Oldest form of manufacturing that is used to

produce a smaller number of goods

2. Which answer choice defines continuous manufacturing?

A. Special purpose machines are used to produces a large number of goods as parts move from one station to the next

B. Computer controlled machines are used to produce lots as small as one product but at the cost of continuous manufacturing

C. Raw materials arrive JIT for production, parts are produced JIT to be assembled, and products are produced JIT to meet the customer delivery orders

D. Producing products in lots E. Oldest form of manufacturing that is used to

produce a smaller number of goods

3. Which answer choice defines intermittent manufacturing?

A. Special purpose machines are used to produces a large number of goods as parts move from one station to the next

B. Computer controlled machines are used to produce lots as small as one product but at the cost of continuous manufacturing

C. Raw materials arrive JIT for production, parts are produced JIT to be assembled, and products are produced JIT to meet the customer delivery orders

D. Producing products in lots E. Oldest form of manufacturing that is used to

produce a smaller number of goods

4. Which answer choice defines flexible manufacturing?

A. Special purpose machines are used to produces a large number of goods as parts move from one station to the next

B. Computer controlled machines are used to produce lots as small as one product but at the cost of continuous manufacturing

C. Raw materials arrive JIT for production, parts are produced JIT to be assembled, and products are produced JIT to meet the customer delivery orders

D. Producing products in lots E. Oldest form of manufacturing that is used to

produce a smaller number of goods

5. Which answer choice defines just-in-time manufacturing?

A. Special purpose machines are used to produces a large number of goods as parts move from one station to the next

B. Computer controlled machines are used to produce lots as small as one product but at the cost of continuous manufacturing

C. Raw materials arrive JIT for production, parts are produced JIT to be assembled, and products are produced JIT to meet the customer delivery orders

D. Producing products in lots E. Oldest form of manufacturing that is used to

produce a smaller number of goods

6. Is an automobile custom or continuous manufacturing?

A. Continuous Manufacturing B. Custom Manufacturing

7. Is a space shuttle custom or continuous manufacturing?

A. Continuous Manufacturing B. Custom Manufacturing

8. Is a household appliance custom or continuous manufacturing?

A. Continuous Manufacturing B. Custom Manufacturing

 •    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……

HOW TO CHOOSE BETWEEN THEM

COMPONENTS OF MANUFACTURING SYSTEM

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?

A Closer LookA Closer Look

Application of FMS

Metal-cutting machiningMetal formingAssemblyJoining-welding (arc , spot), glueingSurface treatmentInspectionTesting

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

Advantages of using FMSTo reduce set up and queue timesImprove efficiencyReduce time for product completionUtilize human workers betterImprove product routingProduce a variety of Items under one roofImprove product qualityServe a variety of vendors simultaneouslyProduce more product more quickly

FMS ExampleThrough 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

Illustration example of a FMS

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

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.