Lecture 01_Introduction to Manufacturing

8/13/2019 Lecture 01_Introduction to Manufacturing

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LECTURE 1

INTRODUCTION TO MANUFACTURING

MOHD RUZI HARUNLecturer

Department Of Automotive

Faculty Ofmechanical Engineering

Universiti Teknikal Malaysia Melaka


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INTRODUCTION TO MANUFACTURING 1

What is MANUFACTURING?

the process of converting raw materials into products.

The word manufacturing is derived from the Latin manu factus, meaning madeby hand.

the conversion of stuff into things (by DeGarmon, 1998).

processing or making a product from raw materials, especially as a large scale

Operation using machinery (by Collin English Dictionary, 1998).

economic term for making goods and services available to satisfy customer

- (by T.Black, 1991).


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2INTRODUCTION TO MANUFACTURING

In modern context, manufacturing can be defined as:

- the making of products from raw materials using various processes,

equipments, operations and manpower according to a detailed plan.

- During processing, the raw material undergoes changes to allow it to become

a part of a product(s).

- Once processed, it should have worth in the market or a value.

- Therefore, it encompasses:

- The design of the product.

- The selection of raw materials.- The sequence of processes through which the product will be manufactured.

- Word production is often interchangeably with word manufacturing.


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Manufacturing can be defined two ways:1) Technology manufacturing is the application of physical and chemical

processes to alter the geometry, properties, and/or appearance of a given

starting material to make parts or products.

Manufacturing also includes the assembly of multiple parts to make products.

2) Economic manufacturing is the transformation of materials into items of

greater value by means one or more processing involve. Therefore,

manufacturing is added value to the material.

The processes to accomplish manufacturing involve a combination ofmachinery, tools, power, and manual labor.

- Added value by changing the materials shape or properties or by

combining it with other materials that have been similarly altered.


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Two ways models to define manufacturing:

1)As a technical process

Manufacturing

Process

Raw materials

Product

Profit

M

achinery

To

oling

Power

La

bor


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2)As an economic process.

Manufacturing

Process

Value

added

Starting

material

Material in

processing

Processed

material


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Manufacturing activities must be responsive to several demands and trends:

A product must fully meet design requirements and specifications.

Manufactured environmental friendly and economical method.

Quality is built in each manufacturing stage.

Production methods must be flexible to respond to changing market demands, types of products,production rates and delivery time required.

New development in technology and managerial activities must constantly evaluated.

Manufacturing activities can be modeled to study the effect of factors on product qualityand cost.

Organization must strive for higher quality and productivity.


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Industries can be classified as:


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Types of industries1) Primary industry

- Those that cultivate and exploit natural resources; eg: agriculture, mining.

2) Secondary industry

- Take the outputs of the primary industries and convert them into consumer and

capital goods.

3) Tertiary industry- Constitute with service sector of the economy.


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PRIMARYINDUSTRY Agriculture

Forestry

Fishing

Livestock Quarries

Mining

Petroleum

SECON

DARYINDUSTRY Aerospace

Automotive

Beverages

Building materials Chemicals

Computers

Consumer appliances

Electronics

Equipment

Food processing

Glass, ceramic

Paper

Pharmaceuticals

Plastics (shaping)

Textiles

Tire and rubber

Wood and furniture

TERTIARYINDUSTRY Banking

Communications

Education

Entertainment Financial services

Health and medical

Government

Hotel

Insurance

Restaurant

Retail trade Tourism

Transportation

Real estate


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1) Project 1 to 10 units.

2) Job shop 10 to 100 units.

3) Batch 100 to 10,000 units.

4) Mass Above 10,000 units.

Production quantity: number of unit produced annually of a particular product

type.

Product variety: different product designs or types that are produced in the plant.

[Low production]

[Medium production]

[High production]


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Low

Medium

High

Productvarie

ty

Product quantity


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Project

Job shop

Mass

Product variety

Pr

oductvolume

1 to 10 units

10 to 100 units

100 to 10,000 units

Above 10,000 units


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TYPE OF MANUFACTURING OPERATIONS

- Product position remains stationary during the manufacturing process size,

weight, location of the product.

- Materials, people, machinery are brought to the product or product site.

- Example: bridge, building construction, aircraft, ships, locomotive.

- Based on customer specifications.


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- Low volume and production quantities called lot sizes with high product variety.

- Satisfies a market for nonstandard or unique product.

- Layout different machines with similar functional or processing capabilities

are grouped together as department.

- Require high skill levels labor to operate a variety of equipments.

- Example: space vehicles, reactor vessels, turbines, aircraft components.

- A short duration activities to provide custom goods.


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- Batch production produce or process any product in groups which is called

batches.

- Can produce a variety of products opposed to a continuous productionprocess, or a one time production.

- Example: Similar standard items made periodically in batches: bakery, paint,

hand tools.

- Same facilities used to manufacture all the different items.

- Useful for industries that makes seasonal items/products for which it is

difficult to forecast the demand.

- Layout of machine functional layout (based on its function to be performed

from section to another section).


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Advantages

- Reduce initial capital outlay due to a single production line can be used to

several products machines can be used more effectively, materials can be

bought in bulk, workers can specialize in that task.

Disadvantages- Requires very careful production planning & control next batches; when, types.

- When switching to another batches takes time (down time) can cause

loss of output (low yield).

- Resulted WIP or create inventory/stock increases costs such as inventory

cost, cost because of damage to stock.


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The example production line (shown below) is that of an engineering company, manufacturing small steel products such as

hinges and locks. They manufacture batches of five hundred at a time. The workers are unskilled and semi skilled. As each taskis completed the item being manufactured is passed down the production line to the next worker, until it is complete.


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- Also known as flow production, repetitive flow production, series production.

- Machinery (eg: robots, machine press) that is needed to set up the mass

production line is so expensive.

- Involved fewer labor cost and a faster rate of production.

- Producing goods in large quantities at low cost per unit and produce in a short

period of time.

- Plant and equipments are arranged in a flow line layout.

- Operation is done base on specific product and thus make the production

control easily.

- Work piece is transfer automatically from one machine to another.

- Example: light bulbs, refrigerator, tv.


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Lean Production and Agile Manufacturing

- A systematic approach to identifying and eliminating waste in manufacturing

process through continuous improvement by following the product at thedemand of the customer.

- Related to a word less: less time, inventory space, people, developing the

product, minimize the cost.

- It is all about speed and getting it right at the first time.


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Benefits of Lean Manufacturing

- Overhead operating costs reduces by 30%.

- Sales ($) per employee 10 times higher.

- Profits 4 times.

- Lead time cut by 50% to 90%.

- Process queues cut by 70%.

Principle of Lean Manufacturing

- Voice of the customer.

- Continuous improvement.

- Recognize & eliminating waste of:- Over production.

- Inventory.

- Defects (Non-zero defect rates).


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- Waiting time.

- Peoples talents, & motivations.

- Motion.

- Transportation.


Principle of Lean Manufacturing (cont)


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- Agile manufacturing is a term applied to an organization that has created the

processes, tools, and training to enable it to response quickly to customer needs andmarket changes while still controlling costs and quality.

- The implementation of the principles of lean production on a broad scale.


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Concurrent engineering (CE) is a philosophy that promotes interactive design

and manufacturing efforts to develop product and process simultaneously,

thus optimizing the use of company resources and reducing time to market

cycles. It has four general phases which are:

Technology and concept development.

Product and process development and prototype validation

Process validation and product confirmation.

Production and continuous improvement.



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- Parts can be grouped and then produced by classifying them into families.

- This can be done according to similarities in:

i) design.ii) manufacturing process to produce the part.

- Also known as families of parts.

- Parts will pass through a similar sequence of manufacturing operations and will be

processed on the same machine tools.

- Example of GT: Cylindrical parts they may look almost the same, but it has difference

in the materials, tolerances, and surface finishes and thus causing them to be madeon different machine tools.

- The set-up of an automated machine only requires small changes between the

individual batches and some of the individual set-up times will be drastically reduced.

- Having different machine in one section, so that each parts is completed in that

particular section.


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- It tends to simplify and break the whole system into small, autonomous units.


- Raw materials, parts & components are delivered to the manufacturer just in

time to be used, parts & components are produced JIT to be made into

subassemblies & assemblies, and products are finished JIT to be delivered to

the customer.

- JIT is also known as pull system


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Benefit s/Advantages of JIT

- Low inventory carrying cost.

- Fast detection of defects in the production or the delivery of supplies and, hence,

low scrap loss.

- Reduced inspection and reworking of parts.

- High quality products made at low cost.

- Reduction of :

60% to 80% in inventory.

Up to 90% in rejection rates.

90% in lead times.

50% in scrap & rework.

20% to 40% in product cost.


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Benefit s/Advantages of JIT (cont)Increases:

- 30% to 50% in labor productivity.


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KANBAN SYSTEM

- Integrated with the implementation of JIT concept.

- Kanban means visible record.

- Originally consisted of two types of cards:

i) Production card: authorizes the production of one container or cart of identical,specified parts at a workstation.

ii) Conveyance/move card: authorizes the transfer of one container or cart of parts

from that particular w/station to the w/station where the parts will be used.


The cards contain information on:

i) Type of parts.

ii) Location where issued.

iii) Part number.

iv) Number of items in container.


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1) FIXED POSITION LAYOUT- Involved with huge parts; eg: construction of aeroplane, bridge, buildings.

- All resources such as manpower, raw materials, tools, machinery and etc will be

brought to the product.

- Involve with longer lead time.


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2) FUNCTIONAL (PROCESS) LAYOUT- Plant grouped according to type of process.

- Specialization of skills.

- Higher machine utilization.

- Queues of work.

- Longer lead times.

- Flexibility of operation.

- Low volume and high variety of manufacturing.


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L

FUNCTIONAL (PROCESS) LAYOUT

L

L L

M M

M M

G G

G G


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- Plant arrangement to facilitate material processing in the same order.

- Machines and equipment are positioned along a flow line.

- Product passes from workstation to another workstation along the flow line.

- Suitable for mass production system.

- Several flow lines may come together to feed the final assembly line.

- Need to categorize operations to ensure equal processing time at all work stations

(line balancing).

- High level of machine and manpower utilization.


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L L M DProduct A

L M M D

Product B

L G GProduct C

M W G DProduct D

FLOW LINE (PRODUCT) LAYOUT


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Advantages


- Reduced work handling leads to short cycle time/piece.

- Less WIP.

- Simple planning and control.

- Reduced labor skill.

- Good space utilization.

Disadvantages

- Limited flexibility.

- Machine breakdown causes major problem.

- High setting up cost.- Uses expensive special purpose machine.


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- Plant divided into groups or cells in a small unit (individual cell), consisting of one to

several workstations.

- A w/station can contains either one machine (known as a single machine cell), or

several machines (known as a group machine cell) with each machine performing a

different operation on the part.

- Cells can process a complete family of parts need to form families of products.

- The flow among the equipment in the cells can vary depending on the composition of

parts within the part family.

- Good example for the implementation of the concept of group technology.

- The machines at w/stations can be modified, retooled, and regroup for different

product lines within the same family of parts.

Lecture 01_Introduction to Manufacturing

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