Ch 1 Introduction

Sections:
1. Production Systems
2. Automation in Production Systems
3. Manual Labor in Production Systems
4. Automation Principles and Strategies
5. Organization of the Book

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 Manufacturing

Manufacturing manus (hand) + factus (make)

made by hand

Small shops Factories

Handicraft techniques Machines
Workers see the entire product Specialization

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 The Realities of Modern
Manufacturing
▪ Globalization - Once underdeveloped countries (e.g.,
China, India, Mexico) are becoming major players in
manufacturing
▪ International outsourcing - Parts and products once made
in the United States by American companies are now
being made offshore (overseas) or near-shore (in Mexico
and Central America)
▪ Local outsourcing - Use of suppliers within the U.S. to
provide parts and services

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 More Realities of Modern
Manufacturing
▪ Contract manufacturing - Companies that specialize in
manufacturing entire products, not just parts, under
contract to other companies
▪ Trend toward the service sector in the U.S. economy
▪ Quality expectations - Customers, both consumer and
corporate, demand products of the highest quality
▪ Need for operational efficiency - U.S. manufacturers must
be efficient in their operations to overcome the labor cost
advantage of international competitors

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 Modern Manufacturing Approaches
and Technologies
▪ Automation - automated equipment instead of labor
(reduces labor cost, decreases production cycle times,
increases product quality and consistency)
▪ Material handling technologies - manufacturing usually
involves a sequence of activities; material handling
provides transportation, storage and tracking of
materials through the plant
▪ Manufacturing systems - integration and coordination
of multiple automated or manual workstations through
material handling technologies

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 Modern Manufacturing Approaches
and Technologies
▪ Flexible manufacturing - to compete in the
low-volume/high-mix product categories
▪ Quality programs - to achieve the high quality expected
by today's customers
▪ Computer Integrated Manufacturing (CIM) - to integrate
design, production, and logistics
▪ Lean production - more work with fewer resources

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 Production System Defined

“A collection of people, equipment, and procedures

organized to accomplish the manufacturing operations of
a company”
Two categories:
▪ Facilities – the factory and equipment in the facility and
the way the facility is organized (plant layout)
▪ Manufacturing support systems – the set of procedures
used by a company to manage production and to solve
technical and logistics problems in ordering materials,
moving work through the factory, and ensuring that
products meet quality standards
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 The Production System

Fig. 1.1

White collar

Blue collar

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 Production System Facilities

Facilities include the factory, production machines and

tooling, material handling equipment, inspection
equipment, and computer systems that control the
manufacturing operations
▪ Plant layout – the way the equipment is physically
arranged in the factory
▪ Manufacturing systems – logical groupings of equipment
and workers in the factory
▪ Production line
▪ Stand-alone workstation and worker

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 Manufacturing Systems
Three categories in terms of the human participation in
the processes performed by the manufacturing system:
1. Manual work systems - a worker performing one or
more tasks without the aid of powered tools, but
sometimes using hand tools
2. Worker-machine systems - a worker operating
powered equipment
3. Automated systems - a process performed by a
machine without direct participation of a human

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 Manual Work System (Fig. 1.2.a)

A manual work system consists of one or more workers

performing one or more tasks without the aid of powered
tools.

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 Worker-Machine System (Fig. 1.2.b)

A human worker operates a powered machine, such as a

machine tool or other production machine.

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 Automated System (Fig. 1.2.c)

An automated system is one in which a process is performed

by a machine without the direct participation of a human
worker.

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 Automated System

▪ A semi-automated machine performs a portion of the work

cycle under some form of program control, and a human
worker tends to the machine for the remainder of the
cycle, by unloading and loading it, or performing some
other task each cycle.
▪ A fully automated machine has the capacity to operate for
extended periods of time with no human attention.

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 Manufacturing Support Systems
“People and procedures by which a company manages its production
Operations”
▪ Design the process and equipment
▪ Plan and control the production orders
▪ Satisfy product quality requirements

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 Manufacturing Support Systems
Involves a cycle of information-processing activities that consists of
four functions:
• Business functions – principal means of communicating with
customer
The production order will be in one of the following forms:
1. an order to manufacture an item to the customer’s
specifications
2. a customer order to buy manufacturer’s product
3. an internal company order based on a forecast of future
demand

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 Manufacturing Support Systems
• Product design - research and development, design engineering,
prototype shop
• Manufacturing planning – the information and documentation that
constitute the product design flows into the manufacturing
planning function
• Process planning: consists of determining the sequence of
individual processing and assembly operations needed to
produce the part
• Master Production Schedule (MPS) is a listing of the products
to be made, the dates on which they are to be delivered, and
the quantities of each
• Materials Requirement Planning (MRP): planning of individual
components and subassemblies that make up each product
• Capacity planning is concerned with manpower and machine
resources
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 Manufacturing Support Systems
• Manufacturing control – concerned with managing and controlling
the physical operations in the factory to implement the
manufacturing plans
• Shop floor control deals with the problem of controlling the
progress of the product as it is being processed, assembled,
moved, and inspected in the factory
• Inventory control attempts to strike a proper balance between
the risk of too little inventory (with possible stock-out of
materials) and the carrying cost of too much inventory, i.e.
what to order and when to order
• Quality control ensures that the quality of product and its
components meet the standards specified by the product
designer

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 Information Processing Cycle in
Manufacturing Support Systems
Fig. 1.3

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 Automation in Production Systems

Two categories of automation in the production system:

1. Automation of manufacturing systems in the
factory
2. Computerization of the manufacturing support
systems
▪ The two categories overlap because manufacturing
support systems are connected to the factory
manufacturing systems
▪ Computer-Integrated Manufacturing (CIM)

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 Computer Integrated Manufacturing

Fig. 1.4 Opportunities for automation and computerization in

a production system

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 Automated Manufacturing Systems
▪ processing
▪ assembly
▪ inspection
▪ material handling
They are called automated because they perform their
operations with a reduced level of human
participation compared with the corresponding
process (sometimes virtually no human participation)

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 Automated Manufacturing Systems
Examples:
▪ Automated machine tools
▪ Transfer lines
▪ Automated assembly systems
▪ Industrial robots that perform processing or
assembly operations
▪ Automated material handling and storage systems to
integrate manufacturing operations
▪ Automatic inspection systems for quality control

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 Automated Manufacturing Systems

Three basic types:

1. Fixed automation
2. Programmable automation
3. Flexible automation

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 Fixed Automation
“A manufacturing system in which the sequence of
processing (or assembly) operations is fixed by the
equipment configuration”
Typical features:
▪ Suited to high production quantities
▪ High initial investment for custom-engineered equipment
▪ High production rates
▪ Relatively inflexible in accommodating product variety

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 Fixed Automation
The economic justification for fixed automation is found in
products that are produced in very large quantities
▪ Transfer lines
▪ Automated assembly lines

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 Programmable Automation

“A manufacturing system designed with the capability

to change the sequence of operations to
accommodate different product configurations”
Typical features:
▪ High investment in general purpose equipment
▪ Lower production rates than fixed automation
▪ Flexibility to deal with variations and changes in
product configuration
▪ Most suitable for batch production
▪ Physical setup and part program must be changed
between jobs (batches)

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 Programmable Automation

The operation sequence is controlled by a program,

which is a set of instructions coded so that they can
be read and interpreted by the system.
New programs can be prepared and entered into
equipment to produce new products.
▪ Numerically controlled (NC) machine tools
▪ Industrial robots
▪ Programmable logic controllers

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 Flexible Automation
“An extension of programmable automation in which the
system is capable of changing over from one job to the
next with no lost time between jobs”
Typical features:
▪ High investment for custom-engineered system
▪ Continuous production of variable mixes of products
▪ Medium production rates
▪ Flexibility to deal with soft product variety

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 Product Variety and Production
Quantity for Three Automation Types
Fig. 1.5

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 Computerized Manufacturing Support
Systems
Objectives of automating the manufacturing support systems:
▪ To reduce the amount of manual and clerical effort in product
design, manufacturing planning and control, and the business
functions
▪ Integrates computer-aided design (CAD) and computer-aided
manufacturing (CAM) in CAD/CAM
▪ CIM includes CAD/CAM and the business functions of the firm
The term CIM denoted the pervasive use of computer systems
to design the products, plan the production, control the
operations, and perform the various information-processing
functions needed in a manufacturing firm.

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 Reasons for Automating

1. To increase labor productivity

2. To reduce labor cost
3. To mitigate the effects of labor shortages
4. To reduce or remove routine manual and clerical tasks
5. To improve worker safety
6. To improve product quality
7. To reduce manufacturing lead time
8. To accomplish what cannot be done manually
9. To avoid the high cost of not automating

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 Manual Labor in Production Systems

Is there a place for manual labor in the modern

production system?
▪ Answer: YES
▪ Two aspects:
1. Manual labor in factory operations
2. Labor in manufacturing support systems

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 Manual Labor in Factory Operations
The long term trend is toward greater use of
automated systems to substitute for manual labor
▪ When is manual labor justified?
▪ Some countries have very low labor rates and
automation cannot be justified
▪ Task is too technologically difficult to automate
▪ Short product life cycle
▪ Customized product requires human flexibility
▪ To cope with ups and downs in demand
▪ To reduce risk of product failure

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 Labor in Manufacturing Support
Systems
▪ Product designers who bring creativity to the design task
▪ Manufacturing engineers who
▪ Design the production equipment and tooling, and
▪ Plan the production methods and routings
▪ Equipment maintenance
▪ Programming and computer operation
▪ Engineering project work
▪ Plant management

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 Automation Principles and Strategies

The preceding discussion leads us to conclude that

automation is not always the right answer for a given
production situation. A certain caution and respect must
be observed in applying automation technologies.
1. The USA Principle
2. Ten Strategies for Automation and Process
Improvement
3. Automation Migration Strategy

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 U.S.A Principle
1. Understand the existing process
▪ Input/output analysis
▪ Value chain analysis
▪ Charting techniques and mathematical modeling
2. Simplify the process
▪ Reduce unnecessary steps and moves
3. Automate the process
▪ Ten strategies for automation and production
systems
▪ Automation migration strategy

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 Ten Strategies for Automation and
Process Improvement
If automation seems a feasible solution to improving
productivity, quality or other measure of performance,
then the following ten strategies provide a road map to
search for these improvements.
1. Specialization of operations: The use of special-purpose
equipment designed to perform one operation with the
greatest possible efficiency.
2. Combined operations: Involves reducing the number of
distinct production machines or workstations through
which the part must be routed. Saves setup, material
handling effort, waiting time, lead time.
3. Simultaneous operations: Reduces total processing time.
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 Ten Strategies for Automation and
Process Improvement
4. Integration of operations: Linking several workstations
together into a single integrated mechanism, using
automated work handling devices to transfer parts
between stations.
5. Increased flexibility: Attempts to achieve maximum
utilization of equipment for job-shop and
medium-volume situations by using the same
equipment for a variety of parts or products (reduce
setup and programming time).
6. Improved material handling and storage: Reduces WIP
and shortens manufacturing lead time.

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 Ten Strategies for Automation and
Process Improvement
7. On-line inspection: Permits corrections to the process as
the product is being made (reduces scrap, improves
quality)
8. Process control and optimization: Control at
process/machine level
9. Plant operations control: Control at plant level
10. Computer-integrated manufacturing: Integration of
factory operations with design and the business
functions.

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 Automation Migration Strategy
For Introduction of New Products
A formalized plan for evolving the manufacturing systems
used to produce new products as demand grows.
1. Phase 1 – Manual production
▪ Single-station manned cells working independently
▪ Advantages: quick to set up, low-cost tooling
2. Phase 2 – Automated production
▪ Single-station automated cells operating
independently
▪ As demand grows and automation can be justified
3. Phase 3 – Automated integrated production
▪ Multi-station system with serial operations and
automated transfer of work units between stations
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Automation
Migration
Strategy
Fig. 1.6

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 Organization of the Book
1. Overview of Manufacturing
2. Automation and Control Technologies
3. Material Handling and Identification Technologies
4. Manufacturing Systems
5. Quality Control in Manufacturing Systems
6. Manufacturing Support Systems

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 Organization of the Book
Fig.1.7

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