Production Systems

 Facilities – Factory, equipments, layout

 Manufacturing Support Systems – Logistics,

business functions

 Layout
◦ Fixed Position layout
◦ Process layout
◦ Cellular layout
◦ Product layout
 Definition of CIM:
CIM is the integration of total manufacturing
enterprise by using integrated systems and data
communication coupled with new managerial
philosophies that improve organizational and
personnel efficiency.

Department of Mechanical Engineering NIE 3

 Model of Manufacturing:

1. Factory Physical Activities

2. Information Processing Activities

Department of Mechanical Engineering NIE 4

 Factory Physical Activities:
Operations that come direct in contact with the
product during manufacturing
1. Processing
2. Assembly
3. Material Handling and Storage
4. Inspection and Test

Department of Mechanical Engineering NIE 5

 1.Processing
 Basic Process- Casting, Molding, Forming etc.,
 Secondary Process- Turning, Milling, Drilling etc.,
 Operations to enhance physical properties
Heat–treatment, Pre-shrinking, Coating etc.,
 Finishing operations- Painting, Coating, Lapping
Honing etc.,

Department of Mechanical Engineering NIE 6

 Manufacturing Process model

2. Assembly operations
Assembly and joining process.
Mechanical fastening–Screws, nuts, rivets bolts etc.,
Joining process-soldering, welding, brazing etc.,
Department of Mechanical Engineering NIE 7
 3. Material Handling and Storage
Moving and storing material between the
processing and assembly operations.
4. Inspection and Testing
Inspection is used to determine weather the
manufactured products meets the established
design standards and specification
Testing is concerned with the functional
specification of the final product.
Department of Mechanical Engineering NIE 8
 Information Processing Activities

 Business functions
Product Design
Manufacturing Planning
Manufacturing control

Department of Mechanical Engineering NIE 9

 1.Business functions
Sales, marketing, forecasting, order entry, cost
accounting, servicing, order to manufacture etc.,

2.Product Design
1. Proprietary Product
2. Customer oriented Product

Department of Mechanical Engineering NIE 10

 3. Manufacturing Planning

Process Planning – Route sheets, Master schedule,

MRP, Capacity Planning

4.Manufacturing Control

Shop floor control, Quality control, Inventory

control,

Department of Mechanical Engineering NIE 11

 AUTOMATION
Automation is technology concerned with application of Mechanical,
Electronic and Computer-based systems to operate and control the
production process.
The term automated factory implies where the raw materials enter at
one end and finished product comes out at the other end with all
associated activities from planning to dispatch, are automated with
minimum or no manual intervention.
Automation includes
1.Automatic Machine tools to process parts.
2. Automatic assembly machines.
3.Industrial Robots.
4.Automatic material handling and storage systems.
5.Automatic inspection systems for quality control.
6.Feed back control and computer process control.
7.Computer systems for planning, data collection and decision
making to support manufacturing activities.
TYPES OF AUTOMATION
 High Stand-alone
NC machines
and Variety of

Flexible
Medium manufacturing
systems
Flexibility

Low Transfer
lines
parts

Low Medium High

Production Volume

Application characteristics of flexible manufacturing systems.

P FIXED AUTOMATION
R HIGH
O

FL
EX
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PR

IBI
U

OD

LIT
C

UC
T

Y
T
I

IV I
O

TY
MEDUIM FLEXIBLE
N
AUTOMATION
V
O
L
U LOW PROGRAMMABLE AUTOMATION
M
E

LOW MEDUIM HIGH

PRODUCT VARIETY
Types of Automation: Automated production systems can be
classified into the following three types.

1.Fixed Automation: Is a system in which the sequence of processing

operations is fixed by the equipment configuration.. The operations
in the sequence are usually simple. It is the integration and co-
ordination of many such operations into one piece of equipment that
makes the system complex.
Typical Features:

1.High initial investment for custom engineered equipment.

2.High production rates.
3.Relatively inflexible in accommodating product changes.
4.Low cost per piece.

Economic justification is found in products with very high demand

rates and Volumes. The high initial cost of the equipment can be
spread over a very large number units, thus making the unit cost
attractive compared to alternative methods of production.
2. Programmable Automation: is used when the volume of production
is relatively low and varieties of products to be produced is high. The
production equipment is designed with the capability to change the
sequence of operation to accommodate different product
configurations. The operations sequence is controlled by program,
which is a set of instructions coded so that the system can read and
interpret them. New programs can be prepared and entered into the
equipment to produce new product.
Typical Features:
1.High investment in general purpose equipment.
2.Low production rates relative to fixed automation.
3.Flexibility to deal with changes in product configuration.
4.Most suitable for batch production.
5.Wide family of parts.
6.No change in hardware.
7.Higher cost per piece.
Examples include CNC machine tools and Industrial Robots.
3. Flexible Automation: Is an extension of programmable automation.
A flexible automated system is one that is capable of producing a
variety of products with virtually no time lost for changeovers from
one product to the next. There is no production time is lost while
reprogramming the system and altering the physical setup (tooling,
fixtures, m/c settings). Consequently the system can produce various
combinations and schedules of products instead of requiring they be
made in separate batches.
Typical Features:
1.High investment for a custom engineered system.
2.Continuous production of variable mixtures of products.
3.Medium production rates.
4.Flexibility to deal with product design variations.
Flexible automation differ from programmable automation in that –
1.The capacity to change part programs with no loss of production
time.
2.The capability to change over the physical setup, again with no loss
of production time.
These features allow the automated production to continue
production with out downtime between batches that is characteristic
of programmable automation.
Changing the part programs is generally accomplished by preparing
the programs off-line on a computer system and electronically
transmitting the programs to the automated production system.
Therefore the time required to do the programming for the next job
does not interrupt production on the current job. [Advances in
computer systems technology are largely responsible for this
programming capability in flexible automation.]
Changing the physical setup between parts is accomplished by
making the change over off-line and then moving it into place
simultaneously as next part comes into position for processing. [The
use of pallet fixtures that hold the parts and transfer into position at
the workplace is one way of implementing this approach.]
Examples are flexible manufacturing systems for performing
machining operations.
 Periodic Automated
Worker System
Examples:
 Automated machine tools
 Transfer lines
Transformation
 Automated assembly systems Process
 Industrial robots
 Automated material handling and storage

systems
 Automatic inspection systems for quality

control
 Reasons for Automating
1.To Increase production rate & labor Productivity.
2.To reduce Cost of Labour – Cost of labour increasing – Substitute Machines
for human labour – high rate of output – use of automation results in lower cost /
unit of product.

3.To mitigate the effects of Labour shortages.

4.To Reduce routine manual & clerical tasks – social level of working
5.To improve worker Safety – transfer operator to supervisory role.
Occupational safety and Health Act (OSHA)
6.To save cost of raw materials – need greater efficiency
7.To Improve product quality – reduction in fraction defect rate
8.To Reduce manufacturing lead time - Reduction of Work-in-process
inventory.
9.To accomplish Processes that cannot be done manually
10.To avoid High cost of not automating.
Functions of Production control
FUNCTIONS CAN BE DIVIDED INTO THREE PHASES:

I. PLANNING PHASE – A. PRIOR PLANNING PHASE

B. ACTION PLANNING PHASE

II. ACTION PHASE

III.FOLLOW UP PHASE – A. PROGRESS REPORTING

B. CORRECTIVE ACTION
GENERAL FUNCTION PHASE FORMAL TERMINOLOGY
ESTIMATION OF FUTURE WORK FORECASTING

PLANNING PHASE
PRIOR
PREPARATION OF WORK AUTHORIZATION ORDER WRITING

PREPARATION OF SPECIFICATIONS PRODUCT DESIGN

PLANNING
PREPARATION OF WORK DETAIL PLAN PROCESS PLANNING AND
ROUTING
DETERMINATION OF REQIREMENTS AND MATERIAL CONRTOL
CONTROL OF MATERIALS
ACTION
DETERMINATION OF REQIREMENTS AND TOOL CONTROL
CONTROL OF TOOLS
PLANNING
DETERMINATION OF REQIREMENTS AND LOADING
CONTROL OF EQUIPMENTS AND MANPOWER

FOLLOW UP PHASE
DETERMANATION OF WHEN THE WORK IS TO BE SCHEDULING
DONE
STARTING THE WORK ACTION PHASE DISPATCHING

COLLECTING THE DATA DATA PROCESSING

PROGRESS
INTERPRETING THE DATA DATA PROCESSING
REPORTING
MAKING CURRENT WORK CORRECTIONS EXPEDITING
CORRECTIVE
MAKING PLAN CORRECTIONS ACTION REPLANNING
 Integrated systems of functions in factories that are
production, marketing, order, design, production
control, inventory control, quality control,
inspection, shipping, through communication and
producing technology
COMPUTER INTEGRATED MANUFACTURING:

Definitions:

The term CIM has been coined to denote the common use of
computers to design the products, plan the production, control the
operations and perform the various business related functions
needed in manufacturing firm.

CIM is an mixture of Computer Aided Design[CAD] and Computer

Aided Manufacturing [CAM], Flexible Manufacturing System [FMS],
tooling and quality support systems, in-process gauging and
automated final inspection, automated storage and retrieval
systems and material handling and operation control with in a
business information system.

The following diagrams explains the Organization and

Information Processing in Manufacturing
MODEL OF MANUFACTURING
(B) Information
processing
Activities
Product Design

Business Manufacturing
Functions Planning

Raw (A)
Factory Finished
Materials
Physical Products
Activities

Manufacturing
Control
 FACTORY OPERATIONS

1. PROCESSING
Raw 2. ASSEMBLY Finished
Materials 3. MATERIAL HANDLING Products
4. INSPECTION AND TEST

RECEIVING SHIPPING

5. CONTROL
 Information Processing
Cycle in a Typical
Product design
Manufacturing Firm
Product Development
Engineering Drawings
Bills of Materials

Business Functions MFG. Planning

Customers
Marketing Process Planning
Sales Master Schedule
Order Entry FACTORY Requirement
Customer Billing OPERATIONS Planning
Capacity Planning

Manufacturing Control
Shop Floor Control
Quality Control
Inventory Control
1) Reducing developing time for new product
2) Reducing transporting time
3) Optimal inventory control
4) Reducing planning time for production
5) Reducing lead time for production
6) Rapid response for customers’ claim
7) Quality improvement
8) Increasing competitive power
1. SPECIALIZATION OF OPERATIONS

2. COMBINED OPERATIONS

3. SIMULTANEOUS OPERATIONS

4. INTEGRATION OF OPERATIONS

5. INCREASED FLEXIBILITY

6. IMPROVED MATERIAL HANDLING AND STORAGE

7. ON-LINE INSPECTION

8. PROCESS CONTROL AND OPTIMIZATION

9. PLANT OPERATIONS CONTROL

10. COMPUTER-INTEGRATED MANUFACTURING

AUTOMATION STRATEGIES

To increase productivity in manufacturing process certain fundamental

strategies are employed.

1. SPECIALIZATION OF OPERATIONS: Involves use of special purpose

equipment designed to perform one operation with greatest possible
efficiency. This is analogous to the concept of labour specialization which
has been employed to improve labour productivity.

2. COMBINED OPERATIONS : Production occurs as a sequence of

operations. Complex parts may require many processing steps. Involves
reducing the number of distinct production machines or workstations
through which the parts must be routed. This is accomplished by
performing more than one operation at a given machine, there by reducing
the number of separate machines needed.

Since each machine typically involves a setup, setup time can be usually
saved as a consequence of this strategy. Material handling effort and non
operation time are also reduced.
3. SIMULTANEOUS OPERATIONS: A logical extension of the combined
operations is to perform at the same time the operations that are combined
at one work station. In effect, two or more processing (assembly)
operations are being performed simultaneously on the same work part,
thus reducing the total processing time.

4. INTEGRATION OF OPERATIONS: Several work stations are linked to form

a single integrated mechanism using automated work handling devices to
transfer parts between stations. This reduces the number of separate
machines through which the product must be scheduled. With more than
one workstation, several parts can be processed simultaneously, there by
increasing the overall output of the system.

5. INCREASED FLEXIBILITY: To achieve maximum utilization of equipment,

the same equipment can be used to manufacture a variety of products by
adopting flexible automation concepts. Primary objectives are to reduce
setup and programming times [for the production machine] which
translates into lower MLT and WIP.

6. IMPROVED MATERIAL HANDLING AND STORAGE: By using automated

material handling and storage system, non-productive time can be
reduced resulting in the reduction of MLT and WIP times.
7. ON-LINE INSPECTION: Inspection is incorporated in the manufacturing
process which permits corrections to the process as the product is made.
This reduces scrap and brings the overall quality of product closer to the
nominal specifications intended by the designer.
This differs from traditional way of inspection since quality of work is
inspected after the process. This means that poor quality product has
already been produced by the time it is inspected.

8. PROCESS CONTROL AND OPTIMIZATION: This includes a wide range of

control schemes intended to operate the individual processes and
associated equipment more efficiently. Individual process times can be
reduced and product quality improved by this strategy.

9. PLANT OPERATIONS CONTROL: In the previous strategy individual

manufacturing processes are controlled, where as this strategy is
concerned with control at the plant level. It attempts to manage and
coordinate the aggregate operations in the plant level more efficiently. This
involves a high level of computer networking within the factory.
10. COMPUTER-INTEGRATED MANUFACTURING: This is one step ahead of
the previous strategy. Here integration of the factory operations with
engineering design and many of the other business functions of the firm.
CIM involves extensive use of computer applications, computer data bases
and computer networking in the company.
 AUTOMATION STRATEGIES

STRATEGY EFFECT
SPECIALIZATION OF OPERATIONS REDUCE To
COMBINED OPERATIONS REDUCE nm ,Th,,Tno
SIMULTANEOUS OPERATIONS REDUCE To,nm ,Th,,Tno
INTEGRATION OF OPERATIONS REDUCE nm ,Th,,Tno
INCREASED FLEXIBILITY REDUCE Tsu, MLT, WIP,
INCREASE U
IMPROVED MATERIAL HANDLING REDUCE Tno, MLT, WIP
AND STORAGE
ON-LINE INSPECTION REDUCE Tno, q
PROCESS CONTROL AND REDUCE To, q
OPTIMIZATION
PLANT OPERATIONS CONTROL REDUCE Tno, MLT
INCREASE U
COMPUTER-INTEGRATED REDUCE MLT, DESIGN TIME,
MANUFACTURING PRODUCTION PLANNING TIME
INCREASE U