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Part I OVERVIEW OF MANUFACTURING

Chapters:2. Manufacturing Operations3. Manufacturing Models and Metrics

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Ch 2 Manufacturing Operations

Sections:1. Manufacturing Industries and Products2. Manufacturing Operations3. Production Facilities4. Product/Production Relationships5. Lean Production

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Manufacturing Defined -Technological Definition

““Application of physical and chemical processes to Application of physical and chemical processes to alter the geometry, properties, and/or appearance of alter the geometry, properties, and/or appearance of a given starting material to make parts or productsa given starting material to make parts or products””Manufacturing also includes the joining of multiple parts to make assembled productsAccomplished by a combination of machinery, tools, power, and manual labor.Almost always carried out as a sequence of operations

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Manufacturing Defined -Technological Definition

Fig. 2.1.a

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Manufacturing Defined -Economic Definition

““Transformation of materials into items of greater value Transformation of materials into items of greater value by means of one or more processing and/or assembly by means of one or more processing and/or assembly operationsoperations””Manufacturing adds value to the materialExamples:

Converting iron ore to steel adds valueTransforming sand into glass adds valueRefining petroleum into plastic adds value

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Manufacturing Defined -Economic Definition

Fig. 2.1.b

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Classification of Industries

1. Primary industries – cultivate and exploit natural resources

Examples: agriculture, mining2. Secondary industries – convert output of primary

industries into productsExamples: manufacturing, power generation, construction

3. Tertiary industries – service sectorExamples: banking, education, government, legal services, retail trade, transportation

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Manufacturing Industries

ISIC CodeFood, beverages, tobacco 31Textiles, apparel, leather and fur products 32Wood and wood products, cork 33Paper, printing, publishing, bookbinding 34Chemicals, coal, petroleum and their products 35Ceramics, glass, mineral products 36Basic metals, e.g., steel, aluminum 37Fabricated products, e.g., cars, machines, etc. 38Other products, e.g., jewelry, toys 39

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More Industry Classifications

Process industries, e.g., chemicals, petroleum, basic metals, foods and beverages, power generation

Continuous productionBatch production

Discrete product (and part) industries, e.g., cars, aircraft, appliances, machinery, and their component parts

Continuous productionBatch production

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Process Industries and Discrete Manufacturing Industries

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Manufacturing Operations

There are certain basic activities that must be carried out in a factory to convert raw materials into finished productsFor discrete products:1. Processing and assembly operations2. Material handling3. Inspection and testing4. Coordination and controlA processing operation transforms a work material from one state ofcompletion to a more advanced state using energy to alter its shape,properties or appearance to add value to the material.

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Fig. 2.3

Classification of manufacturing processes

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Processing Operations

Shaping operations1. Solidification processes2. Particulate processing3. Deformation processes4. Material removal processesProperty-enhancing operations (heat treatments)Surface processing operations

Cleaning and surface treatmentsCoating and thin-film deposition

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Assembly Operations

Joining processesWeldingBrazing and solderingAdhesive bonding

Mechanical assemblyThreaded fasteners (e.g., bolts and nuts, screws)Rivets Interference fits (e.g., press fitting, shrink fits)Other

An assembly operation joins two or more components to createa new entity which is called an assembly, subassembly, etc.

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Other Factory Operations

Material handling and storageInspection and testingCoordination and control

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Material Handling

“A “A meansmeans of of movingmoving andand storingstoring materialsmaterials betweenbetween processingprocessingandand//oror assemblyassembly operationsoperations””

Material transportVehicles, e.g., forklift trucks, AGVs, monorailsConveyorsHoists and cranes

Storage systemsUnitizing equipmentAutomatic identification and data capture (AIDC)

Bar codesRFIDOther AIDC equipment

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Time Spent in Material Handling

Fig. 2.4

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Inspection and Testing

Inspection – examination of the product and its components to determine whether they conform to design specifications

Inspection for variables - measuringInspection of attributes – gaging

Testing – observing the product (or part, material, subassembly) during actual operation or under conditions that might occur during operation

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Coordination and Control

Regulation of the individual processing and assembly operations

Process controlQuality control

Management of plant level activitiesProduction planning and controlQuality control

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Production Facilities

A manufacturing company attempts to organize its facilities in the most efficient way to serve the particular mission of the plantCertain types of plants are recognized as the most appropriate way to organize for a given type of manufacturingThe most appropriate type depends on:

Types of products madeProduction quantityProduct variety

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Production Quantity

Number of units of a given part or product produced annually by the plantThree quantity ranges:1. Low production – 1 to 100 units2. Medium production – 100 to 10,000 units3. High production – 10,000 to millions of units

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Product Variety

““Refers to the number of different product or part Refers to the number of different product or part designs or types produced in the plantdesigns or types produced in the plant””Inverse relationship between production quantity and product variety in factory operationsProduct variety is more complicated than a number

Hard product variety – products differ greatlyFew common components in an assembly

Soft product variety – small differences between products

Many common components in an assembly

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Product Variety vs. Production Quantity

Fig. 2.5

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Low Production Quantity

Job shopJob shop – makes low quantities of specialized and customized productsAlso includes production of components for these productsProducts are typically complex (e.g., specialized machinery, prototypes, space capsules)Equipment is general purposePlant layouts:

Fixed positionProcess layout

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Fixed-Position Layout

Fig. 2.6 (a)

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Process Layout

Fig. 2.6 (b)

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Medium Production Quantities

1.1. Batch productionBatch production – A batch of a given product is produced, and then the facility is changed over to produce another product

Changeover takes time – setup timeTypical layout – process layoutHard product variety

2.2. Cellular manufacturingCellular manufacturing – A mixture of products is made without significant changeover time between products

Typical layout – cellular layoutSoft product variety

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Cellular Layout

Fig. 2.6 (c)

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High Production (mass production)

1.1. Quantity productionQuantity production – Equipment is dedicated to the manufacture of one product

Standard machines tooled for high production (e.g., stamping presses, molding machines)Typical layout – process layout

2.2. Flow line productionFlow line production – Multiple workstations arranged in sequence

Product requires multiple processing or assembly stepsProduct layout is most common

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Product Layout

Fig. 2.6 (d)

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Relationships between Plant Layout and Type of Production Facility

Fig. 2.7

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Product/Production Relationships

Total number of product units = Qf =Product variety

Hard product variety = differences between productsSoft product variety = differences between models of products

Product and part complexityProduct complexity np = number of parts in productPart complexity no = number of operations per part

∑=

P

jjQ

1

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Factory Operations Model

Simplified for purposes of conceptualization:Total number of product units Qf = PQTotal number of parts produced npf = PQnp

Total number of operations nof = PQnpno

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Limitations and Capabilities of a Manufacturing Plant

Manufacturing capabilityManufacturing capability - the technical and physical limitations of a manufacturing firm and each of its plantsThree dimensions of manufacturing capability:1. Technological processing capability - the available set

of manufacturing processes2. Physical size and weight of product3. Production capacity (plant capacity) – max production

quantity that can be made in a given time underassumed operating conditions

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Lean Production

““Operating the factory with the minimum possible Operating the factory with the minimum possible resources and yet maximizing the amount of work resources and yet maximizing the amount of work accomplishedaccomplished””Resources include workers, equipment, time, space, materialsAlso implies completing products in the minimum possible time and achieving a very high quality level to completely satisfy the customerIn short, lean production means doing more with less, and doing it better

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Lean Production and Manufacturing Activities

Manufacturing activities can be divided into three categories:1. Value-adding activities - contribute real value to the work

unit2. Auxiliary activities - support the value-adding activities but

do not contribute value to the product3. Wasteful activities - do not add value nor do they support

the value adding activitiesIf not performed, there would be no adverse effect on the product “ELIMINATE !”

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Programs Associated with Lean Production

Just-in-time delivery of partsWorker involvementContinuous improvementReduced setup timesStop the process when something is wrongError preventionTotal productive maintenance