Chapter3

ManufacturingSystemsUnit1IntroductiontoManufacturingSystemsUnit2AdvancedManufacturingSystemsUnit3ManufacturingSupportSystemsUnit1Introductionto

ManufacturingSystemsTheDefinitionofManufacturingSystemComponentsofManufacturingSystem

ClassificationsofManufacturingSystems

Definitionof

ManufacturingSystem

Wedefinea

manufacturingsystemtobeacollectionofintegratedequipmentandhumanresources,whosefunctionistoperformoneormoreprocessingand/orassemblyoperationsonastartingrawmaterial,part,orsetofparts.

Definitionof

ManufacturingSystem

Theintegratedequipmentincludesproductionmachinesandtools,materialhandlingandworkpositioningdevices,andcomputersystems.Humanresourcesarerequiredeitherfulltimeorperiodicallytokeepthesystemrunning.

Componentsof

aManufacturingSystemProductionmachinesMaterialtransportSystemsComputerControlSystemHumanResourcesProductionmachinesManuallyoperatedproductionmachinesSemi-automatedproductionmachinesFullyautomatedproductionmachinesMaterialtransportSystemThreefunctions:(1)Loading--involvesmovingtheworkunitsintotheproductionmachineorprocessingequipmentfromasourceinsidethestation.

(2)Positioning--providesfortheparttobeinaknownlocationandorientationrelativetotheworkheadortoolingthatperformstheoperation.

MaterialtransportSystem(3)Unloading--Whentheproductionoperationhasbeencompleted,theworkunitmustbeunloaded,thatis,removedfromtheproductionmachineandeitherplacedinacontainerattheworkstationorpreparedfortransporttothenextworkstationintheprocessingsequence.ComputerControlSystemCommunicateinstructionstoworkersDownloadpartprogramstocomputer-controlledmachines

MaterialhandlingsystemcontrolScheduleproductionFailurediagnosisSafetymonitoringQualitycontrolOperationsmanagementHumanResourcesHumanperformsomeorallofthevalue-addedworkthatisaccomplishedonthepartsorproducts.

Classificationof

ManufacturingSystemType1:SingleStationsType2:Multi-StationCellsType3:ProductionLinesClassificationof

ManufacturingSystemType1:SingleStationsApplicationsofsingleworkstationsarewidespread.①mannedworkstationsinwhichaworkermustbeinattendanceeithercontinuouslyorforaportionofeachworkcycle,and②automatedstations,inwhichperiodicattentionisrequiredlessfrequentlythaneverycycle.Ineithercase,thesesystemsareusedforprocessingaswellasforassemblyoperations,andtheirapplicationsincludesinglemodel,batchmodel,andmixedmodelproduction.Classificationof

ManufacturingSystemType1:SingleStationsReasonsforthepopularityofthesinglemodelworkstationinclude:①itistheeasiestandleastexpensivemanufacturingmethodtoimplement,especiallythemannedversion;②itisthemostadaptable,adjustable,andflexiblemanufacturingsystem;and③amannedsingleworkstationcanbeconvertedtoanautomatedstationifdemandforthepartsorproductsmadeinthestationjustifiesthisconversion.Classificationof

ManufacturingSystemType2:Multi-StationCellsAmultiplestationsystemwithvariableroutingisagroupofworkstationsorganizedtoachievesomespecialpurpose.Itistypicallyintendedforproductionquantitiesinthemediumrange(annualproduction=100~10000partsorproducts),althoughitsapplicationssometimesextendbeyondtheseboundaries.Classificationof

ManufacturingSystemType3:ProductionLinesAmulti-stationmanufacturingsystemwithfixedroutingisaproductionline.Aproductionlineconsistsofaseriesofworkstationslaidoutsothatthepartorproductmovesfromonestationtothenext,aportionofthetotalworkisperformedonitateachstation.Productionlinesaregenerallyassociatedwithmassproduction(10000~1000000partsorproductsperyear).Tendencyof

ManufacturingSystemThemodernmanufacturingsystem—acomplexarrangementthatengineers,manufactures,andmarketsproductsforadiversepopulacewhosewantsandneedsaresubjecttofrequentchange—bearslittlesimilaritytoitsearlypredecessor.Tendencyof

ManufacturingSystemThreeofthemostimportantofthesearewidespreadandinexpensivetransportationsystems,communicationsystemsthatprovidereal-timeinteractionbetweenpeopleinalmostanypartoftheworld,andcomputersthatassistinthedesign,control,andanalysisofcomplexactivities.Unit2Advanced

ManufacturingSystemsGroupTechnology(GT)

FlexibleManufacturingSystems(FMS)

ComputerIntegratedManufacturingSystems(CIMS)LeanProduction(LP)AgileManufacturing(AM)E-ManufacturingGroupTechnology(GT)TwoMajorTasks:(1)Identifyingthepartfamilies(2)RearrangingproductionmachinesintomachinecellsBenefitsofGroupTechnology

Promotesstandardization

MaterialhandlingisreducedProcessplanningandproductionschedulingaresimplified

SetuptimesarereducedWork-in-processisreducedWorkersatisfactionimproves

HigherqualityworkisaccomplishedFlexibleManufacturing

Systems(FMS)ContentofFMS:(1)Processequipment

(2)Materialhandlingequipment

(3)Acommunicationsystem

(4)Acomputercontrolsystem

AdvantagesofFMS(1)Increasedproductivity(2)Shorterpreparationtimefornewproducts(3)Reductionofinventorypartsintheplant(4)Savingoflaborcost

(5)Improvesproductquality(6)Attractingskilledpeopletomanufacturing(7)Improvedoperator’ssafetyComputerIntegrated

ManufacturingSystems(CIMS)ActivitiesofCIMS:(1)Identifyinganeedforaproduct(2)Designingaproducttomeettheneeds

(3)Obtainingtherawmaterialsneededtoproducetheproduct(4)Applyingappropriateprocessestotransformtherawmaterialsintofinishedproducts

(5)Transportingproductstothemarket(6)MaintainingtheproductstoendureproperperformanceinthefieldBenefitsofCIMS(1)Productqualityincreases

(2)Leadtimesarereduced

(3)Directlaborcostsarereduced

(4)Productdevelopmenttimesarereduced

(5)Inventoriesarereduced

(6)Overallproductivityincreases

(7)DesignqualityincreasedLeanProduction(LP)TenRulesofLP:(1)Eliminatewaste;

(2)Minimizeinventory;

(3)Maximizeflow;(4)Pullproductionfromcustomerdemand;(5)Meetcustomerrequirements;

LeanProduction(LP)TenRulesofLP:(6)Doitrightthefirsttime;

(7)Empowerworkers;(8)Designforrapidchangeover;

(9)Partnerwithsuppliers;(10)Createacultureofcontinuousimprovement.AgileManufacturing(AM)

AMisaNewManufacturingStrategy

AMisaProductionModeofthe21stCentury

E-Manufacturing

WhatisE-Manufacturing?

WhatistheFutureofE-Manufacturing?E-Manufacturing

WhatisE-Manufacturing?E-manufacturingcanbemostcogentlyandgenerallydescribedastheapplicationoftheInternettomanufacturing.E-manufacturingisnotthesamethingasproductionautomation,itisperfectlycomplementarytotheideaofproductionautomation—anadditionalstrategyandapproachthatcanturbochargethevalueproducedbytheapplicationoftechnologytothefactory.E-Manufacturing

WhatisE-Manufacturing?E-businessore-commerceisdefinedmostcogentlyandaccuratelyastheapplicationoftheInternettobusiness.E-ManufacturingWhatistheFutureofE-Manufacturing?Arealisticprojectionofthefutureofe-manufacturingwouldsimultaneouslytakeintoaccounttheveryrealpoweroftheinnovationsembodiedinthee-manufacturingparadigm,whilealsonotingthefundamentaldifficultiesofchanginganymanufacturingculture.Unit3Manufacturing

SupportSystemsCAD(Computer-AidedDesign)CAM(Computer-AidedManufacturing)CAPP(Computer-AidedProcessPlanning)CAE(Computer-AidedEngineering)Unit3Manufacturing

SupportSystemsCAD(Computer-AidedDesign)Theadvancesmadeoverthelast30yearsintheuseofcomputersformechanicaldesignhaveoccurredatamorerapidpacethanalltheprogressindesignvisualizationthatprecededtheadventofcomputertechnology.Theintroductionof2Ddraftingpackagesrepresentedthefirstwidespreadmigrationofengineerstonewdesigntools,andmanufacturersreadilyembracedthistechnologybecauseoftheproductivitygainsitoffered.Unit3Manufacturing

SupportSystemsCAD(Computer-AidedDesign)Thenextstageintheevolutionofdesigntoolswasthemovefrom2Dto3Ddesignsystems.Thisrepresentedthesecondlargemigrationofengineerstoanewdesignparadigmfrom“computer-aideddrafting”to“computer-aideddesign”.Unit3Manufacturing

SupportSystemsCAM(Computer-AidedManufacturing)TheintroductionofCAMsystemsallowedmanufacturingandtoolingengineerstowritecomputerprogramstocontrolmachinetooloperationssuchasmillingandturning.Thesecomputernumericallycontrolled(CNCorNC)programscontainhundredsorthousandsofsimplecommands,muchlikedrivinginstructions,neededtomovethemachinetoolpreciselyfromonepositiontothenext.Unit3Manufacturing

SupportSystemsCAM(Computer-AidedManufacturing)Withthedevelopmentof3DCADsolidmodelingsystems,theinterimstepofdevelopingcomputercodetocontrol3DCAMmachiningoperationshasbeenautomated.Unit3Manufacturing

SupportSystemsCAPP(Computer-AidedProcessPlanning)ThereismuchinterestbymanufacturingfirmsinautomatingthetaskofprocessplanningusingCAPPsystems.Theshop-trainedpeoplewhoarefamiliarwiththedetailsofmachiningandotherprocessesaregraduallyretiring,andthesepeoplewillbeunavailableinthefuturetodoprocessplanning.Analternativewayofaccomplishingthisfunctionisneeded,andCAPPsystemsareprovidingthisalternative.Unit3Manufacturing

SupportSystemsCAPP(Computer-AidedProcessPlanning)CAPPisusuallyconsideredtobepartofcomputer-aidedmanufacturing(CAM).However,thistendstoimplythatCAMisastand-alonesystem.Infact,asynergyresultthatCAMiscombinedwithcomputer-aideddesigncreatesaCAD/CAMsystem.Insuchasystem,CAPPbecomesthedirectconnectionbetweendesignandmanufacturing.Unit3Manufacturing

SupportSystemsCAE(Computer-AidedEngineering)CAEstandsforcomputer-aidedengineeringandprimarilyencompassestwoengineeringsoftwaretechnologiesthatmanufacturersuseinconjunctionwithCADtoengineer,analyze,andoptimizeproductdesigns.Designanalysisandknowledge-basedengineering(KBE)applicationshelpmanufacturerstorefinedesignconceptsbysimulatingaproduct’sphysicalbehaviorinitsoperatingenvironmentandinfusingthedesigner’sknowledgeandexpertiseintothemanufacturingprocess.Unit3Manufacturing

SupportSystemsCAE(Computer-AidedEngineering)CreatingaCADmodelisonething,butcapturingtheknowledgeordesignintentthatwentintodesigningthemodelandreusingitaspartofmanufacturingrepresentstheessenceofKBEsoftwaretechnology.Designanalysis,alsofrequentlyreferredtoasfiniteelementanalysis(FEA),isasoftwaretechnologyusedtosimulatethephysicalbehaviorofadesignunderspecificconditions.Unit3Manufacturing

SupportSystemsCAE(Computer-AidedEngineering)Themorecommontypesofdesignanalysesthatareperformedincludestructural,thermal,kinematics(motion),electromagnetic,andfluiddynamicsanalyses.Chapter4ServiceSystemsUnit1IntroductiontoServiceSystemsUnit2ServiceQualityUnit1Introductionto

ServiceSystems

DefinitionofServiceClassificationsofServiceCharacteristicsofServiceOperationsUnit1Introductionto

ServiceSystems

DefinitionofServiceAserviceisanactivityorseriesofactivitiesofmoreorlessintangiblenaturethatnormally,butnotnecessarily,takeplaceininteractionsbetweencustomerandserviceemployeesand/orphysicalresourcesorgoodsand/orsy