MANUFACTURING

SYSTEMS

• 13.1 Components of a Manufacturing System 358
13.2 Types of Manufacturing Systems 363
SINGLE-STATION MANUFACTURING CELLS 370
14.1 Single-Station Manned Cells 371
14.2 Single-Station Automated Cells 372
14.3 Applications of Single-Station Cells 383
14.4 Analysis of Single-Station Cells 385
Chapter 15 MULTI-STATION MANUFACTURING SYSTEMS:
MANUAL ASSEMBLY LINES 396
15.1 Fundamentals of Manual Assembly Lines 398
15.2 Analysis of Single-Model Assembly Lines 404
15.3 Line Balancing Algorithms 411
15.4 Workstation Details 417
15.5 Other Considerations in Assembly Line Design 419
15.6 Alternative Assembly Systems 422
APPENDIX 15A: Batch-Model and Mixed-Model Lines 432
Chapter 16 MULTI-STATION MANUFACTURING SYSTEMS:
AUTOMATED PRODUCTION LINES 447
16.1 Fundamentals of Automated Production Lines 448
16.2 Applications of Automated Production Lines 457
16.3 Analysis of Transfer Lines 460
APPENDIX 16A: Transfer Lines with Internal Storage 470
Chapter 17 AUTOMATED ASSEMBLY SYSTEMS 479
17.1 Fundamentals of Automated Assembly Systems 480
17.2 Analysis of Automated Assembly Systems 486
Chapter 18 GROUP TECHNOLOGY AND CELLULAR
MANUFACTURING 504
18.1 Part Families and Machine Groups 506
18.2 Cellular Manufacturing 513
18.3 Applications of Group Technology 518
18.4 Analysis of Cellular Manufacturing 520
APPENDIX 18A: Opitz Parts Classification and Coding System
531
Chapter 19 MULTI-STATION MANUFACTURING
SYSTEMS: AUTOMATED FOR FLEXIBILITY 534
19.1 Manufacturing Flexibility Defined 536
19.2 Components of an FMS 541
19.3 Analysis of Flexible Manufacturing Systems 547
19.4 Alternative Approaches to Flexible Manufacturing 56
COMPONENTS OF A MANUFACTURING SYSTEM

• (1) production machines plus tools, fixtures, and other related hardware,
• (2) a material handling and/or work-positioning system,
• (3) a computer system to coordinate and/or control the preceding components,
• (4) human workers to operate and manage the system
Production Machines

• the machines can be classified as

• (1) manually operated,
• (2) semiautomated,
• (3) fully automated.
Material Handling System

• Loading, Positioning, and

Unloading.
• Work Transport between Stations.
• Pallet Fixtures and Work Carriers
in Transport Systems.
Computer Control System

• • Communicate instructions to workers. In manually operated workstations that perform different tasks on
different work units, operators must receive processing or
assembly instructions for each specific work unit.
• Download part programs. The computer sends these instructions to computercontrolled workstations.
• Control material handling system. This function coordinates the activities of the material handling system
with those of the workstations.
• Schedule production. Some production scheduling functions may be accomplished at
the site of the manufacturing system.
• Diagnose failures. This involves diagnosing equipment malfunctions, preparing preventive maintenance
schedules, and maintaining the spare parts inventory.
• Monitor safety. This function ensures that the system does not operate in an unsafe
manner. The goal of safety monitoring is to protect both the human workers and the
equipment comprising the system.
• Quality control. The purpose of this control function is to detect and reject defective
work units produced by the system.
• Manage operations. This consists of managing the overall operations of the manufacturing system, either
directly (by supervisory computer control) or indirectly (by
preparing the necessary reports for management personnel).
TYPES OF MANUFACTURING SYSTEMS

• The factors are used to classify including:

• (1) types of operations performed,
• (2) number of workstations and system layout,
• (3) level of automation,
• (4) system flexibility.

• From these factors, a general classification of manufacturing systems is derived

Types of Operations

• One distinction is between (1) processing operations on individual work units and
(2) assembly operations to join individual parts into assembled entities.

• Additional parameters of the product that affect the operations performed in the
manufacturing system are the following:
• Type of material processed. Different engineering materials require different
types
of processes.
• Size and weight of the part or product. Larger and heavier work units require bigger
equipment with greater power capacity.
• Part geometry. Machined parts can be classified as rotational or non-rotational.
• Part or product complexity.
Number of Workstations and System Layout

• The number of workstations is a key factor that differentiates manufacturing system types.
single-station cells (n = 1) or multi-station systems (n > 1).

• As the number of stations increases, the amount of work that can be accomplished
by the system increases.
Level of Automation

• the manning level of

a workstation, symbolized Mi, which is the proportion of time that a worker spends
at the station

• If Mi = 1 for station i, it means that one worker must be at the station

continuously. If one worker tends four automatic machines, then Mi = 0.25 for each
of the four machines, assuming each machine requires the same amount of attention

• On sections of automobile and truck final assembly lines, many stations are occupied
by multiple workers, in which case Mi = 2 or 3 or more.
Manufacturing Flexibility
• One important type of flexibility is the
capacity to produce different part or product styles in a mixed-model mode rather than in
batches, which involve costly setup changeovers between styles.

• In order to operate in a mixed-model mode, a manufacturing system must be able to

perform the following functions every work cycle:
• Identification of different work units. Different part or product styles require different operations. The
manufacturing system must identify the work unit in order to
perform the correct operations
• • Quick changeover of operating instructions. The instructions, or part program in the
case of computer-controlled production machines, must correspond to the correct
operation for the given part. In the case of a manually operated system, this generally means workers who (1) are cross-trained in the
variety of operations needed to
process or assemble the different work unit styles and (2) know which operations to
perform on each work unit style. In semiautomatic and fully automated systems, it
means that the required part program is readily available to the controller once the
work unit has been identified.
• Quick changeover of physical setup. Flexibility in manufacturing means that the different work units are not produced in batches. To
enable different work unit styles
to be produced with no time lost between one unit and the next, the flexible manufacturing system must be capable of making any
necessary changes in fixturing and
tooling in a very short time (the changeover time should correspond approximately
to the time required to exchange the completed work unit for the next unit to be
processed).
Classification of manufacturing

systems
Single-Station Manufacturing Cells
SINGLE-STATION MANNED CELLS

• The single-station manned cell, the standard model for which is one machine tended by
one worker, is probably the most widely used production method today
• There are many reasons for its widespread adoption.
• It requires the shortest amount of time to implement. The user company can quickly
launch production of a new part or product using one or more manual workstations,
while it plans and designs a more automated production method.
• It usually requires the least capital investment among alternative manufacturing
systems.
• Technologically, it is the easiest system to install and operate, and its maintenance
requirements are usually minimal.
• For many situations, particularly for low quantities of production, it results in the
lowest cost per unit produced.
• In general, it is the most versatile manufacturing system with regard to changeovers
from one part or product style to the next.
SINGLE-STATION AUTOMATED CELLS

• The single-station automated cell consists of a fully automated machine capable of unattended operation for a
time period longer than one machine cycle.

• Advantages of this system include the following:

• Labor cost is reduced compared to the single-station manned cell.
• Among automated manufacturing systems, the single-station automated cell is the
easiest and least expensive system to implement.
• Production rates are usually higher than for a comparable manned machine.
• It often represents the first step toward implementing an integrated multi-station
automated system.
APPLICATIO
NS OF
SINGLE-
STATION

CELLS
ANALYSIS OF SINGLE-STATION CELLS

• Number of Workstations Required

• Machine Clusters
Number of Workstations Required
• AT = HpA
• where AT = available time per cell, hr/cell; Hp = actual hours during the period, hr/cell;
and A = availability. Equations (14.6) and (14.7) become the numerator and denominator in Equation (14.5)
to solve for the number of cells (production machines) to satisfy
workload requirements. The following examples illustrate two different setup situations.
Machine Clusters

• When a semiautomatic machine in a single-station cell does not require the continuous
attention of a worker during its work cycle, an opportunity exists to assign more than one
machine to the worker. The workstation still requires operator attention every cycle. However, the manning
level of the workstation can be reduced from M = 1 to M 6 1. This
kind of machine organization is sometimes referred to as a “machine cell,” but the term
machine cluster is used in this book.

• A machine cluster is defined here as a collection of

two or more machines producing parts or products with identical cycle times and serviced
(usually loaded and unloaded) by one worker.
• Several conditions must be satisfied in order to organize a collection of machines
into a machine cluster:
• (1) the semiautomatic machine cycle is long relative to the service portion of the cycle that requires the
worker’s attention;
• (2) the semiautomatic cycle time is the same for all machines;
• (3) the machines that the worker would service are located in close enough proximity to allow time to walk
between them; and
• (4) the work rules of the plant permit a worker to service more than one machine.
Multi-Station Manufacturing Systems: Manual Assembly Lines

• Most manufactured consumer products are assembled. Each product consists of multiple
components joined together by various assembly processes. These kinds of products are usually made on a
manual assembly line. Factors favoring the use of manual assembly lines
include the following:
• Demand for the product is high or medium
• The products made on the line are identical or similar
• The total work required to assemble the product can be divided into small work
elements
• It is technologically impossible or economically infeasible to automate the assembly
operations.
FUNDAMENTALS OF MANUAL ASSEMBLY LINES

• Assembly Workstations

• Work Transport Systems

Line Pacing
Coping with Product Variety
15.1.1 Assembly Workstations
Work Transport Systems

• Manual Methods of Work Transport

• Mechanized Work Transport

Line Pacing

• A manual assembly line operates at a certain cycle time that is established to achieve the
required production rate of the line.

• Manual assembly lines can be designed with three alternative levels of pacing:
(1) rigid pacing, (2) pacing with margin, and (3) no pacing.
15.1.4 Coping with Product Variety

• Three types of assembly line can be distinguished: (1) single model,

(2) batch model, and (3) mixed model.
15.2 ANALYSIS OF SINGLE-MODEL ASSEMBLY LINES (Bài tập nhóm)
• 15.2.1 Cycle Time and Workload Analysis
15.3 Line Balancing Algorithms (báo cáo nhóm)
Multi-Station Manufacturing Systems: Automated Production Lines

Their application is therefore appropriate only under the following

conditions:
• High demand, requiring high production quantities
• Stable product design, because frequent design changes are difficult to accommodate
on an automated production line
• Long product life, at least several years in most cases
• Multiple operations performed on the product during its manufacture.

When the application satisfies these conditions, automated production lines provide the
following advantages:
• Low amount of direct labor
• Low product cost, because the cost of fixed equipment is spread over many units
• High production rate
• Minimal work-in-progress and manufacturing lead time
• Minimal use of factory floor space.
 • 16.1.1 Work Part Transport
FUNDAMENTALS
OF AUTOMATED • 16.1.2 Storage Buffers

PRODUCTION • 16.1.3 Control of the Production Line

LINES
16.3 ANALYSIS OF TRANSFER LINES (Báo cáo nhóm)
Automated Assembly Systems

Automated assembly technology should be considered when the following conditions exist:
• High product demand. Automated assembly systems should be considered for products made in millions of
units (or close to this range).
• Stable product design. In general, any change in the product design means a change
in workstation tooling and possibly the sequence of assembly operations. Such
changes can be very costly.
• A limited number of components in the assembly. Riley [11] recommends a maximum of around a dozen parts.
• The product is designed for automated assembly. In Chapter 24, the product design
factors that allow for automated assembly are explored
17.2 ANALYSIS OF AUTOMATED ASSEMBLY SYSTEMS (Báo cáo nhóm)
18.4 Analysis of Cellular Manufacturing (Báo cáo nhóm)
19.3 Analysis of Flexible Manufacturing Systems (Báo cáo nhóm)