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MANUFACTURING
SYSTEMS
Manufacturing Operations Management
Progress so far
Time
Station
Lot sizing
principles
Cost
EOQ-based
Lot sizing
principles
PROCESS
UNDERSTANDING
Drilling Machine
Casting
Forging
LAYOUT
UNDERSTANDING
DM
TM
TM
TM
TM
VMM
DM
DM
VMM
BM
BM
TM
DM
BM
TM
VMM
VMM
TM
DM
DM
BM
TM
HIGH
VOLUME
TRANSFER
LINE
SPECIAL
SYSTEM
FLEXIBLE
MANUFACTURING
SYSTEM
MANUFACTURING
Cells
STD. AND GEN.
MACHINERY
LOW
HIGH
VARIETY
Product Family
Similar design
attributes (shape),
dissimilar
manufacturing
attributes
Similar
manufacturing
routings, dissimilar
designs
Also dishes in restaurants.
Linking
Process?
Process
Planning
Machine
Routings
etc
Manufacturing
Group Technology
Examining Opitz Code:
2nd Digit
main shape
Rotational
3rd Digit
rotational
machining
5th Digit
4th Digit
additional
plane surface holes teeth &
matching
forming
External
shape
element
Internal
shape
element
Machining
of plane
surfaces
Other holes
and teeth
Main shape
Rotational
machining
Machining
of plane
surfaces
Other holes
teeth and
forming
Main bore
& rotational
machining
Machining
of plane
surfaces
Other holes
teeth and
forming
5
6
7
8
9
Special
Main shape
Main shape
Special
Supplimentary
code
Digit
6 7 8 9
Dimensions
Material
Original shape of raw materials
Accuracy
FORM CODE
Non-rotational
Positions
with a
digit
1st Digit
part class
This Form
code is the
Opitz Code
Solution on this
shaft- like part
TM
DM
BM
TM
VMM
VMM
TM
DM
DM
BM
TM
Product families
Part family a
group of
machines
People,
Incentives,
Justification
standardization
30% Report reduction in new shop drawings
20% Report reduction in floor space
45% Report reduced scrap
80% Report reduced production and quality costs
69% Report reduced set-up time (cost)
FORMING PART
FAMILIES
FORMING CELLS
Assigning part families to machines
Clustering Techniques
We cluster Machines to build cells:
Cells lead to Flow Mathematics
Cells contain all equipment needed to produce a part family
Cells allow development of Multi-functional workers
Cells hold work teams responsible for production and quality They
Empower the workers
Empowered to set internal schedules
Empowered to assign tasks
Empowered to train and rotate jobs
Etc, etc, etc
Before
Clustering
After
Clustering
Example
Part Number
X
Machine ID
A
1
1
1
D
E
Step 1:
Part Numbers
B. Wt:
25
24
23
22
21
20
Machine ID
B
C
1
1
1
1
D. Equiv
Rank
23+21 = 10
24+23 = 24
25+22=36
24+23+21
= 26
25+22+20=
37
Step 3:
Part Number
Machine ID
B. WT.
24
23
22
21
20
D. Equiv
24+23
= 24
22+21=
6
22+21+
20=7
24+23=
24
22+20=
5
24=16
Rank
Great
Cluster
Result!
Back at Step 1:
Part Number
B Wt:
25
24
23
22
21
20
Machine ID
D. Eqv
Rank
25+24+
23=56
25+24=
48
22+21+
20 = 7
22+21=6
22+20=5
2.
3.
4.
5.
For each row of the machine/part matrix (M/P/M) read the pattern
of cell entries as a binary word. Rank the rows by decreasing
binary value. Equal values stay in same order.
Ask if newly ranked rows in the matrix are the same as previous
order? Yes (STOP) No (continue)
Re-form the M/P/M with rows in new descending order. Now rank
the columns by decreasing binary word weight. Columns of equal
weight are left where they are
Are current column weights the same as current column order?
Yes (STOP), No (continue)
Re-form the matrix column order per rank order (highest to left)
and return to #1.
P1
[aij] =
P2
P3
P4
P5
P6
M1
M2
M3
M4
M5
M6
M7
1
1
1
1
1
1
1
1
1
1
Issues in Clustering:
R/O clustering oscillations indicating need of machine
Performance Measures
Cost Based
Time Based
38
MCT
Price
On-time
Delivery
39
o Order
o Forecast
40
41
42
Consider an Example
Operation 1: 15 days
Intermediate WIP: 100 units (consumption 5 per day)
Operation 2: 25 days
44
Data Collection
Historical data
o Purchase orders
o Part usage rates
o Part receipts
o Operations chart
o FGI quantities
o Components of replenishment lead time
45
through production
o Quoting process
o Raw material procurement
46
(c) Debjit Roy, Logistics Management