Module 1Lecture 3 Overview of Manufacturing .pdf

Industrial automation

1. MT308 Industrial Automation
Mechatronics Engineering Department
Faculty of Engineering
Sana’a University
Dr. Khalil A. Al-Hatab

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Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition,by Mikell P. Groover. 2
Module 1 -Lecture 3: Overview of
Manufacturing
Sections:
❑Manufacturing Industries and Products
❑Manufacturing Operations
❑Production Facilities
❑Product/Production Relationships
❑Production Performance Metrics
❑Manufacturing Costs

3. Machinery
Tools
Power
Labor
Starting Completed part
Material
Waste
As a technological process
Manufacturing
▪TechnologicalDefinition:Applicationofphysical
andchemicalprocessestoalterthegeometry,
properties,and/orappearanceofagivenstarting
materialtomakepartsorproducts.
❑Manufacturingalsoincludesthejoiningofmultiple
partstomakeassembledproducts.
❑Accomplishedbyacombinationofmachinery,tools,
power,andmanuallabor.
❑Almostalwayscarriedoutasasequenceof
operations.
▪EconomicDefinition:Transformationofmaterials
intoitemsofgreatervaluebymeansofoneormore
processingand/orassemblyoperations.
❑Manufacturingaddsvaluetothematerial
❑Examples:
➢Convertingironoretosteeladdsvalue
➢Transformingsandintoglassaddsvalue
➢Refiningpetroleumintoplasticaddsvalue
3
Mfg. Process
As an economic process
Value Added
Starting materiaMaterial in Processing Completed part

Mfg. Process

4. Classification of Industries
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1.Primaryindustries–cultivateandexploitnaturalresources
–Examples:agriculture,mining
2.Secondaryindustries–convertoutputofprimaryindustriesintoproducts
–Examples:manufacturing,powergeneration,construction
3.Tertiaryindustries–servicesector
–Examples:banking,education,government,legalservices,retailtrade,
transportation

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:isacollectionofpeople,equipment,andprocedurestoperform
themanufacturingoperation.Itclassifyintotwocategories:
Mfg. support system
Factory
Equipment
Layout
The set of procedures
used by the company
to manage production
,such as product
design.
Proceduresusedtomanage
productionandtosolvelogistics
&technicalprob.
Theequipmentinfactoryandthewaytheequipmentis
organized.Itincludesmachines,tooling,materialhandling
equipment,inspectionequipment,comp.&plantlayout.

6. Facilities
Manual
work system
Worker
machine
Automated
Using
unpowered
hand tool
Using power
equipment
Automated facility
branches out-to:
Semi-automated
machines and fully
automated machines

7. 7
Functions of
Manufacturing
support system
Business
function
Product design
Manufacturing
planning
Manufacturing
planning control
Communicating with customer
Either provided by customer or in
house if it’s proprietary
Scheduling, Capacity planning and,
process planning
Shop floor
control
Inventory
control
Quality control
Product progress
Balancing too little and
too much inventory
Product quality meets
standard

8. Manufacturing Operations
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❑Therearecertainbasicactivitiesthatmustbecarried
outinafactorytoconvertrawmaterialsintofinished
products
❑For discrete products:
1.Processingandassemblyoperations
2.Materialhandling
3.Inspectionandtesting
4.Coordinationandcontrol

9. Classification of Manufacturing
Processes
9
• Shaping operations
1.Solidification processes
2.Particulate processing
3.Deformation processes
4.Material removal processes
5.Additive manufacturing (a.k.a. rapid prototyping)
• Property-enhancing operations (heat treatments)
• Surface processing operations
– Cleaning and surface treatments
– Coating and thin-film deposition
• Joining processes
–Welding
–Brazing and soldering
–Adhesive bonding
•Mechanical assembly
–Threaded fasteners (e.g., bolts and nuts, screws)
–Rivets
–Interference fits (e.g., press fitting, shrink fits)
–Other
•Material handling and storage
•Inspection and testing
•Coordination and control

10. Material Handling and Storage
10
•Material transport:
–Vehicles, e.g., forklift trucks, AGVs, monorails
–Conveyors
–Hoists and cranes
•Storage systems
•Automatic identification and data capture(AIDC):
–Bar codes
–RFID
–Other AIDC

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▪Time Spent by a Part in a Typical Metal Machining Batch Factory

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Inspection and Testing
❑Inspection–examinationoftheproductanditscomponentsto
determinewhethertheyconformtodesignspecifications:
–Inspectionforvariables–measuring
–Inspectionforattributes–gaging
❑Testing–observingtheproduct(orpart,material,subassembly)
duringactualoperationorunderconditionsthatmightoccur
duringoperation.

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Coordination and Control
•Regulationoftheindividualprocessingand
assemblyoperations:
–Processcontrol
–Qualitycontrol
•Managementofplantlevelactivities:
–Productionplanningandcontrol
–Qualitycontrol

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Production Facilities
•Amanufacturingcompanyattemptstoorganizeitsfacilitiesinthemost
efficientwaytoservetheparticularmissionoftheplant.
•Certaintypesofplantsarerecognizedasthemostappropriatewayto
organizeforagiventypeofmanufacturing.
•Themostappropriatetypedependson:
–Typesofproductsmade
–Productionquantity
–Productvariety

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❑Numberofunitsofagivenpartor
productproducedannuallybythe
plant.
•Three quantity ranges:
1.Low production –1 to 100 units
2.Medium production –100 to
10,000 units
3.High production –10,000 to
millions of units
Product Variety
❑Referstothenumberofdifferentproductorpart
designsortypesproducedintheplant.
•Inverserelationshipbetweenproductionquantityand
productvarietyinfactoryoperations.
•Productvarietyismorecomplicatedthananumber:
–Hardproductvariety–productsdiffergreatly
•Fewcommoncomponentsinanassembly
–Softproductvariety–smalldifferencesbetween
products
•Manycommoncomponentsinanassembly
Production Quantity
Production Facilities

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Medium Production Quantities
Job shop –makes low quantities of specialized and
customized products.
•Includes production of components for these
products.
•Products are typically complex (e.g., specialized
machinery, prototypes, space capsules).
•Equipment is general purpose.
•Plant layouts:
–Fixed position
–Process layout
Low Production Quantity
Production Facilities
1.Batch production –A batch of a given product is
produced, and then the facility is changed over
to produce another product
–Changeover takes time –setup time
–Typical layout –process layout
–Hard product variety
2.Cellular manufacturing –A mixture of products
is made without significant changeover time
between products
–Typical layout –cellular layout
–Soft product variety

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High Production
Production Facilities
1.Quantity production –Equipment is dedicated to the manufacture of one product
–Standard machines tooled for high production (e.g., stamping presses, molding
machines)
–Typical layout –process layout
2.Flow line production –Multiple workstations arranged in sequence
–Product requires multiple processing or assembly steps
–Product layout is most common

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Production Performance Metrics
Production Performance Metrics:
1.Cycle time T
c
2.Production rate R
p
3.Availability A
4.Production capacity PC
5.Utilization U
6.Manufacturing lead time MLT
7.Work-in-progress WIP
❑“Asystemofrelatedmeasuresthatfacilitates
thequantificationofsomeparticular
characteristic”
❑Why use metrics?
➢To track performance in successive periods,
➢Tryoutnewtechnologiesandsystemsto
determinetheirmerits,identifytheirproblems,
➢To compare alternative methods, and
➢To make good decisions.

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Production Rate (batch/job shop/flow)
Operation Cycle Time

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23. How to Adjust Plant Capacity
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▪Overtheshortterm:
▪Increaseordecreasenumberworkersw
▪Increaseordecreaseshiftsperweek
▪Increaseordecreasehourspershift(e.g.,overtime)
▪Overtheintermediateandlongterms:
▪Increasenumberofmachinesn
▪IncreaseproductionrateR
pbymethodsimprovementsand/orprocessing
technology

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28. 28

29. Manufacturing Costs
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•Twomajorcategoriesofmanufacturingcosts:
1.Fixedcosts-remainconstantforanyoutputlevel.
2.Variablecosts-varyinproportiontoproductionoutputlevel.
•Addingfixedandvariablecosts:
TC=FC+VC(Q)
where
✓TC=totalcosts
✓FC=fixedcosts(e.g.,building,equipment,taxes)
✓VC=variablecosts(e.g.,labor,materials,utilities)
✓Q=outputlevel.

30. Manufacturing Costs
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•Alternativeclassificationof
manufacturingcosts:
1.Directlabor-wagesand
benefitspaidtoworkers
2.Materials-costsofraw
materials
3.Overhead-alloftheother
expensesassociatedwith
runningthemanufacturing
firm
•Factoryoverhead
•Corporateoverhead

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