IE 484: Integrated Production Systems II

2019-2020
Spring-2020-2
Manufacturing Systems:
Reading assignments:
Transfer Lines: P.448-452 of Chp. 8.1-2 from textbook
FMS: P.453-455 of Chp. 8.3 from textbook
Lean Production: P.458-467 of Chp. 8.5-6 from textbook
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Manufacturing
• Manufacturing - The set of
correlated operations and
activities required to produce a
product,
• Factors affecting the facility
planning process:
• Production volume
• Product variety
• Value of each product
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• Layout and Handling System
affected by
• Product mix and design
• Processing and materials
technology
• Handling, storage, and control
technology
• Production volumes, schedules,
and routings
• Management philosophies
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 Transfer Lines
• Materials flow from one station to next station in a
sequential manner.
• Production rate is governed by the slowest operation Refrigerator door
• High volume applications https://www.youtube.com/watch?v=ArxMgfEBXFw
• High level of automation
• Inventory buffers can be used between workstations to
compensate for some variations between workstations.
• Production systems similar to transfer lines:
• Automated assembly systems for automotive parts
• Chemical process production systems
• Beverage bottling and canning processes
• Heat treatment and surface treatment processes
• Steel fabrication processes
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Transfer lines...
• Disadvantages:
• Very high equipment costs
• Inflexible in the number of products manufactured
• Inflexible layout
• Large deviation in production rates incase of equipment failure.
• Facilities planning for transfer lines is relatively simple
• Processing equipment is arranged according to processing sequence
• Typically, straight line or rectangular flow paths are used

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 Flexible Manufacturing Systems (FMS)
• An FMS is a “reprogrammable” manufacturing
system capable of producing a variety of
products automatically.
• Conventional manufacturing systems have
been marked by one of two distinct features:
• The capability of producing a variety of different
product types, but at a high cost (e.g., job shops).
• The capability of producing large volumes of a
product at a lower cost, but very inflexible in terms
of the product types which can be produced (e.g.,
transfer lines).
• An FMS is designed to provide both of these
features:
• Designed around size of parts processed & average
processing time for parts
• Can process wide variety of items quickly

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Automated Manufacturing Cell
• FMS Components:
• Numerical Control (NC) machine tools
• Tool changers
• Automated material handling system (AMHS)
• Automated guided vehicles (AGV)
• Conveyors
• Automated storage and retrieval systems (AS/RS)
• computer control
• Industrial Robots
• Control Software

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Lean Manufacturing
• A concept whereby all production people work together to eliminate Muda
(waste).
• Defined as any expense that doesn’t help to produce value. We want to do only work that will
add value.
• 8 mudas of lean (Originally 7 wastes identified by Taiichi Ohno):
• Defects (Leads to rework and poor people utilization)
• Overproduction,
• Waiting,
• Neglect of human talent (unused talent) *** NEW***
• Transportation,
• Inventory on hand (Unnecessary amount)
• Motion (Unnecessarly excessive)
• Excess processing (over/extra processing)

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Impact of Lean on Facility designs
• Reduction of inventories:
• Space requirements are reduced.
• Smaller loads are moved and stored.
• Storage requirements are reduced.
• Deliveries to points of use
• Decentralized storage policy is
required to support the multiple
receiving docks.
• The building requires multiple
receiving docks as well as storage
equipments for decentralized
storage.
• Internal deliveries to the point of use
is carried out using MH equipments
for smaller loads and short distances.
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• Quality at the source
• Proper packaging, stacking, and
wrapping procedures for parts and
boxes on pallets or containers.
• Efficient transportation, handling and
storage of parts.
• A production system that allow the
worker to perform his operation
without time pressure
• Better communication, line
balancing and multifunctional
workers
• U-shaped lines are used to promote
better communication among
workers.
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U-shaped flow lines
• Helps to implement the concept
of group technology
• Scalable
• By increasing or decreasing the
number of operators
• Flexible
• By making machines movable so
that the machines can be re-laid
out to minimize part
transportation time & operater
walking time.
• Quick setup

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Balancing U-Shaped Lines

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