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MANUFACTURING

MANUFACTURING. (Lecture 4). Cycle of Manufacturing. Manufacturing spans a large sequence of interrelated phases It involves research, development, design, production, quality control, selling and servicing of a product Research & Development

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MANUFACTURING

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  1. MANUFACTURING (Lecture 4)

  2. Cycle of Manufacturing • Manufacturing spans a large sequence of interrelated phases • It involves research, development, design, production, quality control, selling and servicing of a product • Research & Development • Research is an activity that looks at brand new ideas • Development uses research to create new products • Market research – the current and recent trends in the market • Look for a suitable material • Recommend some choices of material to be chosen • Keep on looking for the methods that could improve the comfort level, productivity of the current products • Productivity is the ratio of the overall outputs to the inputs of a company

  3. Cycle of Manufacturing • Design • Decide the material, the size, color, and the shape etc. • Assembly of a part in the forthcoming product is important in design • Prototype – a handmade test model of the product • Plans for the steps of manufacturing the new product – computer-aided design (CAD) • The plans are later used by the production department • Production • Production department is responsible for actually making the company’s product • Schedule is a timed plan of activities • Purchasing department has to procure the required type of raw material or parts • The suppliers have to deliver the material according to production schedule

  4. Cycle of Manufacturing • Quality Control • Quality control – making sure that the products are all alike or uniform and according to the standards defined by the customer • A standard is a system used for comparison – helps your customers see the quality and performance easily • The process starts from incoming quality control – inspecting the raw materials • Inspections are carried out at the end of assembly lines of different parts • The final step is the inspection of the end-product • Many companies check the quality control used by their suppliers • A supplier gets their new products (prototypes) approved by the representative engineers of their customers before going onto large scale production • After passing the test and being approved, a supplier receives a Supplier Certification Award • Several groups – American National Standards Institute (ANSI), American Society for Testing and Materials (ASTM), Society of Automobile Engineers (SAE) • Measurement systems – MKS System (meters and centimeters), FPS System (feet and inches)

  5. Cycle of Manufacturing • Safety • Safety means freedom from injury or any danger of injury • Colorful and eye-catching signs are posted in a factory • Occupational Safety and Health Administration (OSHA) establish safety rules • National Institute of Occupational Safety and Health (NIOSH) approve protection equipment such as hard hats and safety glasses • Environmental Protection Agency (EPA) restricts hazardous materials thrown into air or water, mostly from chemical plants • Sales & Marketing • Marketing – finding buyers for a company’s product • A company may sell its products to wholesalers or dealers • Wholesaler – a company that purchases large amounts from a manufacturer and then sells smaller amounts to retailers • Retailer – a company, or store, that sells products to consumers, e.g. Panda, Wal-Mart

  6. Cycle of Manufacturing • Servicing • After-sale-services – products that need maintenance or that have been broken • Warranty – terms under which a company repairs or replaces a defective product • The product becomes either a throwaway or a repairable product after the warranty period • The company has its own repair shop or some dealers are responsible for this task

  7. Manufacturing Approaches • Craftspeople, for centuries, make things on their own – carpenters, shoemakers and glassblowers etc • People used to run their own trade at their homes with a small setup • This methodology of manufacturing is known as crafts approach • Custom-made items are often made through crafts approach, e.g. an exotic sports car or products for handicapped people. • Factory system came into being during industrial revolution – people working under one roof • Activities of workers could be tightly supervised (tasks assigned, output accurately measured and time attendance checked etc) • Factory system has advanced a lot since its birth • Factory system gave way to mass production and assembly line production • Assembly line – each worker does one step and passes the item on for the next step • Assembly line products are standardized and interchangeable

  8. Manufacturing Approaches

  9. Manufacturing Approaches • Factory system brought many changes to the society: • standard of living of the people living in industrialized nations improved • unions were formed to protect the rights of workers • child labor laws were passed • the number and importance of schools and day-care-centers increased

  10. Contemporary Trends • Automation is the process of controlling machines through computers • A set of instructions called a program – program control • Sensors provide feedback to make modifications in these programs – feedback control • A sensor is a device that gathers information about its environment • Automation has introduced concepts like robotics, CNC, CAD, CAM and CIM. • Robotics – technology that deals with the use of industrial robots • An industrial robot has one mechanical arm and is controlled by a computer • Robots do jobs that are hazardous, boring, or unpleasant for people • They can be easily reprogrammed to do other tasks • Uses of robotics – spray painting, welding and pick-and-place jobs etc. • CNC – computerized numerical control – machine tools operating through commands from a computer

  11. Contemporary Trends • CAD – computer aided design – designing and planning activities related to a part • CAM – computer-aided manufacturing – programming computers to operate all the machinery • CIM – computer-integrated manufacturing – all the computers in the company are linked together, or integrated • Uses of CIM • design and production departments can communicate instantly • purchasing department can tell their suppliers when to deliver production materials • marketing department can plan when to start selling products • management can direct the entire company from one location. • Other trends in the modern industry – JIT and Flexible Manufacturing • JIT – no storage cost, the raw material arrive at the factory only when it is required • Flexible Manufacturing – using the same set of machines and assembly lines for different models – small batches

  12. Contemporary Trends Cutting a T-shaped profile from a block of steel, using a CNC wire-cut machine

  13. Plant Assembly Fabrication Raw Material or Parts Finished Products Storage Storage Storage Planning & Control • Modern manufacturing industry consists of fabrication and assembly • A plant has to • purchase raw material or parts • convert them into specific components • assemble the components into the several products • Different products could contain several common components A Typical Manufacturing Plant

  14. Planning & Control • The information-subsystems that play a vital role in the smooth running of the company are • Demand forecasting • Operations planning • Inventory planning and control • Operations scheduling • Dispatching • Demand Forecasting • history and the current trends • sales data reflects its effectiveness • Operations Planning • development engineers look for a better manufacturing sequence • the input comes from standard operation times, setup times • machines and other facilities are grouped for a proper assembly-line operation

  15. Planning & Control • Inventory Planning & Control • includes parts, raw materials, assemblies, supplies etc. • depicts the order quantities; reorder points, safety stocks of raw materials, and manufacturing batch sizes • Operations Scheduling • a detailed operation sequence for individual activities • start and stop times for all operations • schedule conflicts on production facilities are resolved here • Dispatching • responsible for initializing production • releases work orders to production operations at the appropriate time

  16. Operations Scheduling • It is the heart of entire planning and control systems • Compromises must be made between economic batch sizes, due dates, resource constraints, manpower leveling, and facility utilization • Program evaluation review technique (PERT) charts are used for scheduling activities. It is a powerful tool • PERT chart tell a manager • list of operations necessary to finish a project • time needed for each operation • critical activities – activities that consume the largest part of project-completion-time • Critical path – a sequence of critical activities • Using PERT chart is also named as critical path method (CPM)

  17. Operations Scheduling • Critical Path Method (CPM) D, 5 5 5 2 2 G, 5 A, 6 C, 3 J, 1 F, 4 8 8 1 E, 3 7 1 7 4 4 B, 2 I, 2 H, 3 3 3 6 6 Network Diagram for CPM A→D→G 6+5+5 = 16 Critical A→C→F 6+3+4 = 13 A→E→H→I 6+3+3+2 = 14 B*→H→I 3*+3+2 = 8 Critical Path Analysis Activities in a Manufacturing System

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