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Outline
Components of a Manufacturing System A Classification Scheme for Manufacturing Systems 1 Overview of the Classification Scheme
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Chapter 4
Outline
Components of a Manufacturing System Production Machines Material Handling System Computer Control System Human Resources A Classification Scheme for Manufacturing Systems Type of Operations Performed Numbers of Workstations System Layout Automation & Manning Levels Part or Product Variety Overview of the Classification Scheme Single Station Cell Multi-Station Systems with Fixed Routing Multi-Station Systems with Variable Routing
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Human resources
are required either full-time or periodically to keep the system running
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Manual assembly lines Human workers perform assembly tasks as the product is moved along the line, usually by mechanized conveyor.
Automated transfer lines Series of automated workstations that perform processing operations such as machining.
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Production machines and workstations laid out in a U-shaped configuration. Produce parts / products that are similar but not identical. Machine cells (cellular manufacturing)
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Highly automated machine cell that produces part / product families. Flexible manufacturing systems
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1. Production Machines
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In virtually all modern manufacturing systems, most of the actual processing or assembly work is accomplished by machines or with the aid of tools. Machines can be classified as: Manually operated Semi-automated Fully automated
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1. Production Machines
Manually Operated: control or supervised by a human worker. machine provides the power for the operation and the worker provides the control. worker must be at machine continuously. i.e. lathes, milling machines, drill presses. Semi-Automated: performs a portion of the work cycle under some from of program control, and human worker tends to the machine for the remainder of the cycle, by loading and unloading it or performing some other task each cycle. i.e. CNC lathe controlled. Fully Automated: operates for extended periods of time with no human attention (attention is required not during each cycle but maybe required periodically after certain no. of cycles- i.e. to load raw materials). i.e. injection molding machines.
Chapter 4
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1. Production Machines
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In manufacturing systems, term workstation is used to refer to a loc some well-defined task/operation is lished by an automated machine, a worker-and-machine combination, or a worker using hand tools and/or portable power tools
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Work transport - moving parts between workstations in a multi-station system 3 Can be accomplished either manually or using equipment : 2 general categories:
Fixed routing: Work units always flow through the same sequence of workstations. It means that works units are identical or similar enough that the processing sequence is identical. Most production lines exemplify this category. Variable routing: Work units are transported through a variety of different station sequences. It means that the manufacturing system is processing or assembling ts. Most job shops exemplify this category.
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4. Human Resources
Direct labor
Perform some or all of the value-added work that is accomplished on the parts or products. They directly add to the value of the work unit by performing manual work on it or by controlling the machines that perform the work.
Indirect Labor
Manage/support manufacturing systems, even for fully automated manufacturing systems i.e. computer programmers, computer operators, maintenance & repair personnel, etc.
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Manufacturing systems are distinguished by the types of operations they perform (Processing versus assembly operations) 1 At the highest level, the distinction is between:
Processing operations on individual work units Assembly operations to combine individual processing and assembled entities
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Part geometry
2. Number of workstations
Convenient measure of the size of the system
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Let n = number of workstations Individual workstations can be identified by subscript i, where i = 1, 2, ..., n
Affects performance factors such as workload capacity, production rate, and reliability
= As n increases, this usually means greater workload capacity and higher production rate There must be a synergistic effect that derives from n multiple stations working together vs. n single stations
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3. System Layout
The way the system is laid out. 1 Applies mainly to multi-station systems Fixed routing vs. variable routing
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In systems with fixed routing, workstations are usually arranged linearly 3 In systems with variable routing, a variety of layouts are possible
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System layout is an important factor in determining the most appropriate type of material handling system
3. System Layout
Number of Workstations and System Layout
No. of workstations is a key fac tor in this classification scheme (applicable to both processing or assembly operations) Single station - the simplest case, consisting of one workstation (n=1), usually including a production machine that can be manually operated, semiautomated, or fully automated. Multiple stations with variable routing. Consist 2 or more stations (n>1) that are designed and arranged to accommodate the processing or assembly of different part or product styles. Multiple stations with fixed routing. This system has 2 or more workstations (n>1), which are laid out as a production line.
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M = average manning level for the system Wu = no. of utility workers assigned to the system Wi = no. of workers assigned specifically to the station i, for i=1,2,...,n W = total no. of workers assigned to the system n=number of workstations
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Manual or automated
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Two categories: Manned workstations - manually operated or semi-automated production machine (M = 1) Fully automated machine (M < 1) Most widely used manufacturing system - reasons: Easiest and least expensive to implement Most adaptable, adjustable, and flexible system Can be converted to automated station if demand for part or product justifies
Common example = production line - a series of workstations laid out so that the part or product moves through each station, and a portion of the total work content is performed at each station Conditions favoring the use of production lines: =
Quantity of work units is high Work units are similar or identical, so similar operations are required in the same sequence Total work content can be divided into separate tasks of approximately equal duration
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Defined as a group of workstations organized to achieve some special purpose, such as: Production of a family of parts requiring similar (but not identical) processing operations Assembly of a family of products requiring similar (but not identical) assembly operations Production of a complete set of components used to assemble one unit of a final product Typical case in cellular manufacturing
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