MANUFACTURING

SYSTEMS
INTRODUCTION
Manufacturing System
In a factory, manufacturing processes
are assembled together to form a
manufacturing system to produce a
desired set of goods. The manufacturing
system takes specific inputs and
materials, adds value through
processes, transforms the inputs into
products for the customer.
Production System
Services the manufacturing system,
using all the other functional areas of
the plant for information, design,
analysis, and control. These subsystems
are connected to each other to produce
goods or services, or both.
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MANUFACTURING SYSTEMS

The relationship among the elements determines how well the system can
run or be controlled. The control of a system refers to the entire
manufacturing system, not merely the individual processes or equipment.

The entire manufacturing system must be under daily control to enable the
management of material movement, people and processes (scheduling),
inventory levels, product quality, production rates, throughput, and, of
course, cost.

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MANUFACTURING SYSTEMS

It is a sequence of processes and people that actually

produce the desired product(s).
The manufacturing system is defines as the complex
arrangement of physical elements characterized (and
controlled) by measurable parameters. (Black 1991)

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As shown in Figure 2-1, the
production system
services the manufacturing
system, using all other
functional areas of the
plant.

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 Here is a
manufacturing system
Place your screenshot here

with its inputs and

outputs.

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CLASSIFICATION OF
MANUFACTURING
SYSTEMS
Five Manufacturing System Designs
MANUFACTURING SYSTEM DESIGNS

Manufacturing industries vary by the products that they make or

assemble. While almost all factories are different, there are five basic
manufacturing designs (MSDs): four classic (or hybrid combinations
thereof) and one new manufacturing system design that is rapidly gaining
acceptance in almost all of these industries. The classical systems here are
the job shop, the flow shop, the project shop, and the continuous process.
The lean shop is a new kind of system.

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JOB SHOP

The job shop’s distinguishing feature is its functional design. In the job
shop, a variety of products are manufactured, which results in small
manufacturing lot sizes, often one of a kind.

Job shop manufacturing is commonly done to specific customer order, but,

in truth, many job shops produce to fill finished-goods inventories.

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JOB SHOP

Production machines are grouped according the general type of

manufacturing process. The lathes are in one department, drill presses in
another, plastic molding in still another, and so on. The advantage of this
layout is its ability to make a wide variety of products.

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Figure 2-4, depicts the
functionally arranged job
shops.

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Process Planning for the Job Shop

1. Size and shape of the 4. Properties of material being

geometric components of machined (hardness).
the workpiece. 5. Number of pieces to be
2. Tolerances, as applied by produced.
the designer. 6. Machine tools availabe for
3. Material from which the this workpiece.
part is to be made.

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FLOW SHOP

The flow shop has a product-oriented layout composed mainly of flow

lines. When the volume gets very large, especially in assembly line, this is
called mass production.

This kind of system can have (very high) high production rates.

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FLOW SHOP

Specialized equipment, dedicated to the manufacture of a particular

product, is used. The entire plant may be designed exclusively to produce
the particular product or family of products, using special-purpose rather
than general-purpose equipment.

This kind of system can have (very high) high production rates.

The investment in specialized machines and specialized tooling is high.

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FLOW SHOP

Many production skills are transferred from the operator to the machines
so that the manual labor skill level in a flow shop tends to be lower than in
a production job shop.

Items are made to “flow” through a sequence of operations by material-

handling devices (conveyors, moving belts, and transfer devices). The
items move through the operations one at a time. The time spends at each
station or location is fixed or equal (balanced).

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Figure 2-10 shows a layout
of an assembly line or flow
line requiring line balancing.

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PROJECT SHOP

In the typical project shop, a product must remain in a fixed position or

location during manufacturing because of its size and/or weight. The
materials, machines, and people used in fabrication are brought to the site.

Today, large products like locomotives, large machine tools, large aircraft,
and large ships use fixed-position layout. Obviously, fixed-position
fabrication is also used in construction jobs (buildings, bridges, and dams).

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PROJECT SHOP

As with fixed-position layout, the product is large and the construction

equipment and workers must be moved to it. When the job is completed,
the equipment is removed from the construction site.

The project shop invariably has job shop/flow shop elements

manufacturing all the subassemblies and components for the large
complex project and thus has a functionalized production system.

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PROJECT SHOP

The project shop often produces one-of-a-kind products with very low
production rate – from one per day to one per year.

The project shop involves

large stationary assemblies
(projects), where components
are usually fabricated
elsewhere and transported to
the site.

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CONTINUOUS PROCESS

In the continuous process, the project physically flows. Oil refineries,

chemical processing plants, and food-processing operations are examples.

In continuous processes, the products really do flow because they are

liquids, gases, or powders. Continuous processes are the most efficient but
least flexible kinds of manufacturing systems.

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CONTINUOUS PROCESS

They usually have the leanest, simplest production systems because these
manufacturing systems designs are the easiest to control, having the least
work-in-progress (WIP).

However, these manufacturing systems usually involve complex chemical

reactions, and thus a special kind of manufacturing engineer (MfE), called
the chemical engineer (ChE), is usually assigned the task of designing,
building, and running the manufacturing system.

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LEAN MANUFACTURING SYSTEM

The lean shop, employs U-shaped cells or parallel rows to manufacture

components.

The final assembly lines are converted to mixed-model, final assembly so

that the demand for subassemblies and components is leveled, making the
daily demand for components the same every day.

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LEAN MANUFACTURING SYSTEM

In the cells, the machine tools are upgraded to be single-cycle automatics

so parts can be loaded into the machine and the machining cycle started.
The operator moves off to the next machine in the sequence, carrying the
part from the previous process with him, so the lean shop employs
standing, walking multiprocess workers.

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LEAN MANUFACTURING SYSTEM

The system design ensures that the right mix and quantity of parts are
made according to and averaged customer demand.
This system is robust in that is ensures that the right quantity and mix are
made, even though there is variation or disturbance in the manufacturing
process or other operations in the manufacturing system.

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THANKS!

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