HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION

FACULTY OF ELECTRICAL AND ELECTRONIC ENGINEERING

Hệ thống sản xuất tích hợp (FMS and CIM)

Lecturer: Dr. Trần Mạnh Sơn

Department of Automatic Control
Email: sontm@hcmute.edu.vn
0919 197 139

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 Rules in Class

 Attend at least 80% of class hours

 Complete all home-works, assignments (If any), and Mid-term

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 Assessment

 Assignment (50%)
 Mid-term 1, Mid-term 2
 Final Exam (50%)
 Writen exam

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 Textbook and References

[1] Hệ thống sản xuất tích hợp, Đặng Thiện Ngôn, Lê Chí Cương
[2] Automation Production System, and Computer Integrated Manufacturing, Mikell

P. Groover, 2015
 Software:
 Factory IO
 SolidWorks

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 Content of this course

 Chapter 1: Introduction
 Chapter 2: Life Cycle of Product
 Chapter 3: Overview of Manufacturing
 Chapter 4: Elements of CIM
 Chapter 5: Automatic Identification and Data Capture
 Chapter 6: Quality Control Systems
 Chapter 7: Just-in-Time Manufacturing, Lean Manufacturing

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 Overview of Manufacturing

Chapter 3: Overview of Manufacturing

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 Content of Chapter 3

 3.1 Concepts
 3.2 Product/production relationships
 3.3 Manufacturing performance

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 Concepts

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 Concepts

Manufacturing: the application of physical and/or chemical processes to alter the

geometry, properties, and/or appearance of a given starting material to make parts or
products

Technological process Economic process

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 Concepts

 Manufacturing Industries: enterprises and organizations that produce, supply goods,

and service
Manufacturing Industries

Primary Industries: Cultivate/exploit

natural resources (Agriculture, Mining)

Secondary Industries: Produce

products
Tertiary industries : Services (Bank,
Education, Entertainment..)

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 Concepts

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 Concepts

 Continuous production: the output of the product is uninterrupted

Process Industry Discrete Manufacturing Industry

 Batch production: when the materials are processed in finite amounts or quantities

Process Industry Discrete Manufacturing Industry

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 Concepts

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 Concepts

 Manufacturing Operations: convert raw materials into finished products

Manufacturing
Operations

processing operation Assembly operation

Uses energy to alter a

work part’s shape, Two or more separate
physical properties, or parts are joined to form
appearance to add a new entity
value to the material

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 Product/production relationships

 Production quantity: refers to the number of units of a given part or product produced
annually by the plant
 Product variety: refers to the different product designs or types that are produced in a
plant

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 Product/production relationships

 Layout in manufactory:
Product product
remains in a single
location during its
entire fabrication.
Products include
ships, aircraft, railway
locomotives, and
heavy machinery.

Fixed position layout

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 Product/production relationships

 Layout in manufactory:
Equipment is arranged
according to function or type
Ex. The lathes are in one
department, the milling
machines are in another
department
Material handling is required
to move parts between
departments
Process layout Inventory tends to be high

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 Product/production relationships

 Layout in manufactory:
Groups of similar parts or
products can be made on the
same equipment without
significant lost time for
changeovers

Cellular layout
 Workstations are arranged into
one long line/ into a series of
connected line segments.
 Assembly line: cars and
household appliances, main
boards.
Product layout
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 Product/production relationships

 Quantity-based manufacturing classification:

 Low Production (Job Shop): Low quantity range of 1–100 units/ year
• Specialized and customized products
• Products are typically complex, such as experimental aircraft and special
machinery

 Medium Production: medium quantity range (100–10,000 units annually). Batch

production
 High Production: high quantity range (10,000 to millions of units per year) (Mass
Production)

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 Product/production relationships

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 Manufacturing Performance

 Cycle time analysis: The cycle time Tc is the time that one work unit1 spends being
processed or assembled

Tc = cycle time, min/pc

To = time of the actual processing or assembly operation min/pc
Th = handling time, min/pc
Tt = average tool handling time, min/pc (tool handling time consists of time spent changing
tools when they wear out, time changing from one tool to the next

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 Manufacturing Performance

 Production rate: expressed as an hourly rate, that is, work units completed per hour

Operation Cycle time

Production rate
Type of Production
• Job shop production
• Batch Production
• Mass Production

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 Manufacturing Performance

 Job Shop Production: Quantities less than 100 pcs. If Q=1 (quantity)

Tp = average production time, min/pc

Tsu = setup time to prepare the machine to produce the part, min/pc
Tc = cycle time
 Production Rate:

 Rp = hourly production rate, pc/hr

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 Manufacturing Performance

 Batch Production: (Sequential batch processing, Simultaneous Batch)

Sequential Batch Simultaneous Batch

Batch processing time(Tb- Batch processing time(Tb-
min/batch) min/batch)

Tsu = setup time; Q = batch Tsu = setup time; Tc = cycle time per
quantity, pc/batch; Tc = cycle time work unit, min/cycle.
per work unit, min/cycle.

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 Manufacturing Performance

 Average production time per work unit Tp

 Production Rate:

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 Manufacturing Performance

 Mass production: quantity mass production & flow-line mass production

Quantity Mass Production Flow-line Mass Production
Production rate(Rp) = cycle Production rate(Rp) =cycle rate of the
rate of the machine (Rc). machine (Rc).
Q is very large,

S
S Tc: cycle time of production line. Max To:
maximum of the operation times for all
stations on the line. Tr: time to transfer
work units between stations each cycle.

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 Manufacturing Performance

A batch of parts is produced on a semi-automated production machine. Batch size

is 200 units. Setup requires 55 min. A worker loads and unloads the machine each cycle,
which takes 0.44 min. Machine processing time is 2.86 min/cycle, and tool handling time
is negligible. One part is produced each cycle.
Determine:
(a) Average cycle time,
(b) Time to complete the batch, and
(c) Average production rate
 Solution:
a) = + = 0.44 + 2.86 = 3.3 ⁄

b) = +Q = 55 + 200x3.3 = 11.92hr

c) Rp=16.78pc/hr

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 Manufacturing Performance

 Production capacity:
Maximum rate of output that a production facility (or production line, or group of
machines) is able to produce under a given set of assumed operating conditions
Determine Production Capacity

PC = Production capacity, pc/period; n = number of machines; and Hpc = the number

of hours

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 Manufacturing Performance

Example: Production Capacity

The automatic lathe department has five machines, all devoted to the production of the same
product. The machines operate two 8-hr shifts, 5 days/week, 50 weeks/year. Production rate
of each machine is 15 unit/hr. Determine the weekly production capacity of the automatic
lathe department.
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 Manufacturing Performance

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 Manufacturing Performance

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 Manufacturing Performance

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 Manufacturing Performance

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 Manufacturing Performance

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 Manufacturing Performance

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 Manufacturing Performance

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 Manufacturing Performance

 Utilization: the proportion of time that a productive resource (e.g., a production

machine) is used relative to the time available under the definition of plant capacity

Ui = utilization of machine i
fij = the fraction of time during the available hours that machine i is processing part style j
Overall utilization for the plant:
n n
 f
i 1 j
ij U i
i 1
U 
n n

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 Manufacturing Performance

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 Manufacturing Performance

Workload: 72 hr
For plant capacity: maximum
number of hours (80 hr)

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 Manufacturing Performance

 Adjusting plant Capacity:

 Increase or decrease the number of machines n in the plant
 Increase or decrease the number of shifts per week
 Increase or decrease the number of hours worked per shift
 Increase the production rate Rp by making improvements in methods and/or
processing technology

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 Manufacturing Performance

 Manufacturing-Lead time:

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 Manufacturing Performance

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 Manufacturing Performance

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 Manufacturing Performance

 Work-in-process: the quantity of parts or products currently located in the factory that
either are being processed or are between processing operations

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 Manufacturing Performance

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 Manufacturing Cost

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 Manufacturing Cost

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 Manufacturing Cost

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 Manufacturing Cost

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 Manufacturing Cost

All costs are compiled and classified into four categories:

(1) direct labor, (2) material, (3) factory overhead, and (4) corporate
overhead
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 Manufacturing Cost

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 Manufacturing Cost

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 Manufacturing Cost

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 Manufacturing Cost

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 Manufacturing Cost

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 Manufacturing Cost

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 Manufacturing Cost

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 Manufacturing Cost

 Cost of Equipment usage:

The trouble with overhead rates is that they are based on labor cost alone. A machine
operator who runs an old, small engine lather will be costed at the same overhead rate as
an operator running a new automated lathe just purchased for 500.000$. If differences in
rates of different production machines are not recognized, manufacturing costs will not be
accurately measured by the overhead rate structure.
 Divide the cost of a worker running a machine into two components: (1) direct labor
cost and (2) machine cost. Associated with each is an applicaple overhead rate.
 The direct labor cost consists of the wages and benefits paid to operate the machine.
Applicable factory overhead expenses allocated to direct labor cost might include taxes
paid by the employer, certain fringe benefits, and line supervision.
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 Manufacturing Cost

 Cost of Equipment usage:

 The machine annual cost is the initial cost of the machine apportitoned over the life of
the asset at the appropriate rate of return used by the firm.
= ( ⁄ , , )
UAC: equivalent uniform annual cost, $/yr; IC= initial cost of the machine, $; (A/P,I,N) =
capital recovery factor; i = annual interest rate; and N = number of years in the service life
of the equipment.
N
i 1  i 
( A / P, i, N )  N
1  i  1

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 Manufacturing Cost

 Cost of Equipment usage:

The uniform annual cost can be expressed as an hourly rate by dividing the annual
cost by the number of annual hours of equipment use. The machine overhead rate may
include power to drive the machine, floor space, maintenance and repair expenses, and
so on.
Total cost rate for the machine is the sum of labor and machine costs:
= 1+ + 1+

Co = hourly rate to operate the machine, $/hr; CL = direct labor wage rate, $/hr; FOHRL
= factory overhead rate for labor; Cm = machine hourly rate, $/hr; and FOHRm = factory
overhead rate applicable to the machine.
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 Manufacturing Cost

 Cost of Equipment usage:

Example: hourly cost of a machine
The following data are given for a production machine consisting of one worker and
one piece of equipment: direct labor rate = $15.00/r, applicable factory overhead rate on
labor = 60%, capital investment in machine = $100,000, service life of the machine = 4 yr,
rate of return = 10%, salvage value in 4 yr = 0, and applicable factory overhead rate on
machine = 50%. The machine will be operated one 8-hr shift, 250 day/yr. Determine the
appropriate hourly rate for the machine.
Solution:

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 Manufacturing Cost

 Cost of Equipment usage:

Example: hourly cost of a machine

The uniform annual cost for 100.00$ initial cost:

Apply the factory overhead rate for the machine:

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 Manufacturing Cost

 Cost of Equipment usage:

Example: hourly cost of a machine
Total cost rate to operate the machine:
= 24.00 + 23.66 = 47.66 $⁄ℎ

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 Manufacturing Cost

 Cost of a manufactured part

The unit cost of a manufactured part or product is the sum of the production cost, material
cost, and tooling cost.
The unit production cost for each unit operation in the sequence of operations to produce the
part or product is given by: +
Coi: cost rate to perform unit operation i, $/min
Tpi: production time of operation i, min/pc
Cti: cost of any tooling used in operation i, $/pc
The total unit cost of the part is the sum of the costs of all unit operations plus the cost of raw
materials:
= + +

Cpc: cost per piece, $/pc; Cm: cost of starting material, $/pc; no: all unit operations
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 Manufacturing Cost

 Cost of a manufactured part

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 Several Examples

Thank You For Your Listening

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