Chapter - 1

Components and classification of

Manufacturing system
Definition
Manufacturing System
 “ Manufacturing system is a collection of integrated
equipments and human resources whose function is to
perform one or more processing and/or assembly
operations on a raw material , part or set of parts”
 A set of operations performed on material which
brings them closer to the desired final form
Cont…
Manufacturing system is the framework with in which
the conversion of input in to output occurs
A manufacturing system can be defined as the
arrangement and operation of machines, tools,
material, people and information to produce a value
added physical, informational or service product
whose success and cost is characterized by measurable
parameters
Cont…
All operation here are concerned with input-
transformation-output process.
 Input: Men, material, machines, drawings etc.
Transformation: Operations, material handling ,
procurement etc.
 Output: The final goods and services.
Thus the combination of operations and activities
mentioned before, employed to create goods or
services is termed as manufacturing systems.
Selection of Manufacturing System:

It must be able to meet the specifications set for the

final product and be cost effective.
The factors affecting the selection :
• Effect of volume
• Capacity of plant
• Flexibility
• Lead time
• Efficiency
• Environment
Examples Of Manufacturing Systems

Single station cells

 Machine clusters
 Manual assembly lines
Automated transfer lines
 Automated assembly systems
 Flexible manufacturing system
Components Of Manufacturing System

Production Machines
 Material handling system
 Computer systems
 Human Resources
Production Machines

In all manufacturing systems, most of the actual

assembly work is accomplished by machines or with
aid of tools
 Classification of manufacturing systems:
1. Manually operated machines which are controlled or
supervised by a human worker.
2. Semi-automated machines perform a portion of work
cycle under some form of program control, and worker
tends the machine the rest.
3. Fully automated machines
Manually Operated Machine
Cont…
Manually operated machines are controlled or
supervised by a human worker.
The machine provides the power for the operation and
the worker provides the control.
The entire work cycle is operator controlled.
Semi-Automated Machine
Cont…
A semi-automated machine performs a portion of the
work cycle under some form of program control, and
A worker tends to the machine for the remainder of the
cycle.
Typical worker tasks include loading and unloading
parts
Fully-Automated Machine
Cont…
Machine operates for extended periods (longer than

one work cycle) without worker attention (periodic

tending may be needed).
Material Handling Systems

The material handling functions in most manufacturing

systems:
1. Loading work units at each station
2. Positioning work units at each station
3. Unloading work units at each station
4. Transporting work units at each station in multi-station
systems
5. Temporary storage of work units
Work transport between stations:
• Fixed Routing
• Variable Routing
Cont…
1. Fixed routing
 Work units always flow through the same sequence of
workstations
 Most production lines exemplify this category
2. Variable routing
Work units are moved through a variety of different
station sequences
 Most job shops exemplify this category
(a) Fixed Routing and
(b) Variable Routing
Computer Control Systems

Typical computer functions in manufacturing systems:

 Communicate instruction to workers( receive processing
or assembly instructions for specific work unit)
 Download part programs
 Control material handling system
 Schedule production
 Failure diagnosis
 Safety monitoring
 Quality control
 Operations management
Human Resources

To operate and manage the system/process

 Required either fulltime or periodically to keep the system
running
 Humans refers to all personnel , operators, vendors
 In context of manufacturing system , human perform some or
all of the value added work that is accomplished on the
parts/products.
 Performing either manual (direct)work on it or by controlling
the machines.
 In fully automated machine, direct labour is still needed.
 For example : loading or unloading parts, changing tools,
resharpening tools etc.
Classification Of Manufacturing Systems

Factors that define and distinguish manufacturing

systems:
• Types of operations performed
• Number of workstations
• System Layout
• Automation and manning level
• Part or product variety
Types Of Manufacturing Systems
Cont…
On Basis of Material Handling and labor:
On Basis of Machinery:
On Basis of Output Produced
Continuous Production System
1. Flow Type
 Output cannot be segregated into different units
 High degree of output
 Output cannot be measured directly
Eg: Power Plant
Cont…
2. Mass Production:
Straight line flow of material
Output visible as identical units.
 Standardized output produced in large quantities.
Problems: Balancing production lines, Machine
maintenance, raw material
Eg: Sugar production
Intermittent Production System

1. Batch Production System:

Variety of products made in small quantities
Various products compete for share of machine
 Outputs are aggregated in form of batches, where
batches can have similar or dissimilar outputs
Problems: Machine-Job allocation problem
Eg: Electrical goods
Cont…
2. Job Order Production System
Does not have its own standard product but accepts
whatever customer orders
Output identifiable in terms of specific job order
 Material flow complex
E.g: Tailor shop
Cont…
3. Project Production System
 It uses resources on different projects
 Product remains fixed and manpower and facilitates
put work on it
 PERT/CPM can be used for planning and control
Part or Product Variety: Flexibility
The degree to which the system is capable of dealing
with variations in the parts or products it produces
Three cases:
1. Single‐model case ‐ all parts or products are identical
2. Batch‐model case ‐ different parts or products are
produced by the system, but they are produced in
batches because changeovers are required
Cont…
3. Mixed‐model case ‐ different parts or products are
produced by the system, but the system can handle the
differences without the need for time‐consuming
changes in setup
 Types of Layout
Product Layout: In this type of layout, only one
product or one type of product is produced in a
given area.
The product must be standardized and
manufactured in large quantities in order to justify
the product layout.

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 Some of the Advantages of Product Layout
are:
 lower total material handling cost,
 lower total production time,
 less work in process,
 greater incentive for groups of workers to raise level of
performance,
 less floor area required per unit of production and
 greater simplicity of production control, fewer control records
needed and lower accounting cost.

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 Product Layout is Used When:
 one or few standard products are to be produced,
 large volume of production of each item over a considerable time
is needed,
 minimum of inspection is required during sequence of operations,
 minimum of very heavy equipment or equipment requiring special
facilities are needed,
 materials and products permit bulk or continuous handling of
mechanical means and
 one machine is always used for one purpose.

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 Process Layout
Process Layout: Similar equipment and similar
operations are grouped together in the process or
functional layout. It is particularly useful where low
volume is required.

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 Some of the Advantages of Process Layout
are:
 less duplication of equipment, hence lower investment cost,
 greater flexibility of production,
 better and more efficient supervision,
 greater incentive for individual workers to raise level of
performance,
 better control of complicated or precision processes,
 easier to handle breakdowns of equipment by transferring work
to another machine or station.

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 Process Layout is Used when
 many types or styles of products are on special order ,

 relatively low volume of production on individual items is needed,

 many inspections are required during a sequence of operations,

 high proportion of very heavy equipment or equipment requiring

special treatment exist,
 materials or products become too large or too heavy to permit bulk or
continuous flow and
 one machine is used for different operations.

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 Fixed-Position Layout
 Fixed-Position Layout: In this type of layout, the material
or major component remains in a fixed location, and tools,
machinery, men as well as other pieces of material are
brought to this location.
 Typical examples are ship building, construction industries,
aircraft building and bench work exercises. This type of
layout is not frequently used in industrial enterprises. For
this reason we are not going to look into its advantage and
disadvantages.

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 a) IN PARALLEL

a) IN SERIES

a) COMBINED

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Examples of Machine Arrangements
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 Material Handling Defined
“The movement, storage, protection and control of
materials throughout the manufacturing and distribution
process including their consumption and disposal”
(The Material Handling Industry of America)
Estimated to represent 20-25% of total manufacturing
labor cost in US
The proportion varies depending on type of production and
degree of automation
 Material Handling
Handling of materials must be performed
Safely
Efficiently
At low cost
In a timely manner
Accurately (the right materials in the right quantities to
the right locations)
And without damage to the materials
 Design Considerations
in Material Handling
Material characteristics
Flow rate, routing, and scheduling
Plant layout
Unit load principle
 Material Characteristics

Material characteristics affect type of transport and storage

equipment required
Solid, liquid or gas
Size
Weight
Shape - long, flat, bulky
Condition - hot, cold, wet, dirty
Risk of damage - fragile, brittle, sturdy
Safety risk - explosive, flammable, toxic, corrosive
 Flow Rate, Routing, and Scheduling

Flow rate - amount of material moved per unit time

Examples: pieces/hr, pallet loads/hr, tons/hr
Whether the material must be moved in individual units, as
batches, or continuously (pipe line)
Routing - pick-up and drop-off locations, move distances,
routing variations, conditions along the route (surface,
traffic, elevation)
Scheduling - timing of each delivery
Prompt delivery when required
Use of buffer stocks to mitigate against late deliveries
 Plant Layout
Material handling equipment considerations must be
included in the plant layout design problem
Correlation between layout type and material handling
equipment:
Plant layout type Material handling equipment
Fixed-position Cranes, hoists, industrial trucks
Process Hand trucks, forklift trucks, AGVs
Product Conveyors for product flow
Trucks to deliver parts to stations
 Unit Load Principle (unitizing)
In general, the unit load should be as large as practical for
the material handling system that will move and store it
A unit load is the mass that is to be moved or otherwise
handled at one time
Reasons for using unit loads in material handling:
Multiple items handled simultaneously
Required number of trips is reduced
Loading/unloading times are reduced
Product damage is decreased
 Unit Load Containers

(a) Wooden pallet, (b) pallet box, (c) tote box