1 / 33

2.008 Manufacturing Systems

2.008 Manufacturing Systems. Outline. Manufacturing Systems Types of Plant Layouts Production Rates Design and Operations. Market Research. Conceptual Design. Design for Manufacture. Unit Manufacturing Processes. Assembly and Joining. Factory, Systems & Enterprise. Manufacture.

melisande-faure
Download Presentation

2.008 Manufacturing Systems

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. 2.008Manufacturing Systems

  2. Outline • Manufacturing Systems • Types of Plant Layouts • Production Rates • Design and Operations

  3. Market Research Conceptual Design Design for Manufacture Unit Manufacturing Processes Assembly and Joining Factory, Systems & Enterprise Manufacture

  4. What is mfg systems?

  5. Time spectrum of Typical Activities in aManufacturing Organization

  6. Materials People Machines Value-added Value-added Value-added Waste Waste Waste How Man, Machine, and Material Spend Time in the Factory "Waste": waiting for materials, watching machine running, producing defects, looking for tools, fixing machine breakdowns, producing unnecessary items, etc “Waste”: transportation, storage, inspect on and rework "Waste": unnecessary movement of machine, setup time, machine breakdown, unproductive maintenance, producing defective products, producing products when not needed, etc.

  7. Disruptions/Variation(Random Events) • Machine failure • Set-up change • Operator absence • Starvation/Blockage • Demand change

  8. Types of Plant Layout • Job Shop • Project Shop • Flow Line • Transfer Line • Cellular System

  9. Raw Material A A D D A A D D D D C C C C C C Ready part Job Shop Machines/Resources are grouped according to the process they perform

  10. A B A B Raw material/ Ready part D D C D Project Shop Machines/Resources are brought to and removed from stationary part as required

  11. Raw Material B A C A D B D F G F F Ready part Flow Line and Transfer Line Machines/Resources are grouped in lines according to the processes sequence of part(s)

  12. Raw Material B C D E F D E G A B D F Ready part Cellular System Machines/Resources are grouped according to the processes required for part families

  13. Project Shop Job Shop Cellular System Flow Line 1 10 100 1,000 10,000 100,000 Quantity Production Quantity and Plant Layout

  14. M Production Rates • Case I: • One machine • Everything works

  15. M Production Rates (cont’d) • Case II: • One machine • Machine breaks down (disruption) • Everything else works

  16. M1 M2 Mi Mk Production Rates (cont’d) • Case III: • Many machines • No machine breaks down • No buffers

  17. M1 M2 Mi Mk Production Rates (cont’d) • Case IV: • Many machines (same operation time) • No machine breaks down • No buffers

  18. M1 M2 Mi Mk Production Rates (cont’d) • Case V: • Many machines (same operation time) • Machine breaks down • No buffers

  19. M1 B1 M2 B2 Mi Mk-1 Bk-1 Mk Production Rates (cont’d) • Case VI: • Many machines and buffers in between • Machine breaks down

  20. Production Rates (cont’d) • Production rate increases if: • Increase the rate of the slowest machine • Reduce the disruptions • Introduce “buffers” • Introduce in-process control

  21. Disruptions (Random Events) • Machine failure • Set-up change • Operator absence • Starvation/Blockage

  22. Waiting • Underutilization • Idleness • Inventory

  23. Inventory/Work-in-Process (WIP) • It costs money • It gets damaged • It becomes obsolete • It shrinks • It increases lead time

  24. Order Order Supplier Plant Customer Supply Supply Cycle Time and Lead Time

  25. Cycle Time “Cycle Time” ．The time a part spends in the system Little’s Law: L = λw L: average inventory λ: average production rate w: average cycle time

  26. M1 M2 M3 M4 M5 Cycle Time (cont’d) • Example: Operation time = 1, One-piece operation Production rate = 1 Cycle time = 5 Inventory = 5

  27. Op1 Op2 Op3 Cycle Time Batch Production 1. Operation time: 3 minutes Batch (Lot) size: 1000 Cycle time = 1,000*3 + 1,000*3 + 1,000*3 = 9,000min

  28. Op1 Op2 Op3 Cycle Time One-Piece Production 2. Operation time = 3 minutes Cycle time = 1,000*3 + 2*3 = 3,006 minutes

  29. Order Order Supplier Plant Customer Supply Supply Cycle Time and Lead Time

  30. Systems Design and Operation • Cycle time < Lead time • Lumpiness • Information contents

  31. Lumpy Demand Wrench A Wrench B Wrench C Wrench D Forging X Forging Y Steel Z

  32. Typical Design Guidelines • Leveling • Balancing • Single-piece flow • Low materials handling • Low setup time • Smaller lot size • Low WIP • Faster feedback

  33. Plant Operations • Push (MRP, ERP, etc.) vs. Pull (JIT) • Batch vs. One-piece

More Related