Ch 1 Introduction

Sections:
1. Production Systems
2. Automation in Production Systems
3. Manual Labor in Production Systems
4. Automation Principles and Strategies
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The Realities of Modern

Manufacturing
Globalization - Once underdeveloped countries (e.g.,
China, India, Mexico) are becoming major players in
manufacturing
International outsourcing - Parts and products once made
in the United States by American companies are now
being made offshore (overseas) or near-shore (in Mexico
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Local
outsourcing
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parts
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More Realities of Modern

Manufacturing
Contract manufacturing - Companies that specialize in
manufacturing entire products, not just parts, under
contract to other companies
Trend toward the service sector in the U.S. economy
Quality expectations - Customers, both consumer and
corporate,
products
of the
highest
quality
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Modern Manufacturing Approaches

and Technologies
Automation - automated equipment instead of labor
Material handling technologies - because
manufacturing usually involves a sequence of activities
Manufacturing systems - integration and coordination
of multiple automated or manual workstations
Flexible manufacturing - to compete in the low2008
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Quality programs
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Production System Defined

A collection of people, equipment, and procedures
organized to accomplish the manufacturing
operations of a company
Two categories:
Facilities the factory and equipment in the facility
the way
the facility
organized
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The Production System

Fig. 1.1

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Production System Facilities

Facilities include the factory, production machines and
tooling, material handling equipment, inspection
equipment, and computer systems that control the
manufacturing operations
Plant layout the way the equipment is physically
arranged
the factory
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Manufacturing
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logical
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equipment
and workers in the factory
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Production
line may be reproduced, in any form or by
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Stand-alone workstation and worker
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Manufacturing Systems
Three categories in terms of the human participation in
the processes performed by the manufacturing system:
1. Manual work systems - a worker performing one or
more tasks without the aid of powered tools, but
sometimes using hand tools
2. Worker-machine
- a Saddle
workerRiver,
operating
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Automated
they3.currently
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machine
participation
human
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Manual Work System

Fig. 1.2 (a)

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Worker-Machine System
Fig. 1.2 (b)

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Automated System
Fig. 1.2. (c)

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Manufacturing Support Systems

Involves a cycle of information-processing activities that
consists of four functions:
1. Business functions - sales and marketing, order entry,
cost accounting, customer billing
2. Product design - research and development, design
prototype
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Information Processing Cycle in

Manufacturing Support Systems
Fig. 1.3

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Automation in Production Systems

Two categories of automation in the production system:
1. Automation of manufacturing systems in the
factory
2. Computerization of the manufacturing support
systems
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Computer Integrated Manufacturing

Fig. 1.4

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Automated Manufacturing Systems

Examples:
Automated machine tools
Transfer lines
Automated assembly systems
Industrial robots that perform processing or
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Automated
material
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integrate
manufacturing operations
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Automatic inspection systems for quality control
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Automated Manufacturing Systems

Three basic types:
1. Fixed automation
2. Programmable automation
3. Flexible automation
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Fixed Automation
A manufacturing system in which the sequence of
processing (or assembly) operations is fixed by the
equipment configuration
Typical features:
Suited to high production quantities
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High production
rates
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Relatively inflexible in accommodating product variety
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Programmable Automation
A manufacturing system designed with the capability
to change the sequence of operations to
accommodate different product configurations
Typical features:
High investment in general purpose equipment
Lower
production
rates
fixed
automation
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Most suitable
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Flexible Automation
An extension of programmable automation in which the
system is capable of changing over from one job to the
next with no lost time between jobs
Typical features:
High investment for custom-engineered system
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Product Variety and Production

Quantity for Three Automation Types
Fig. 1.5

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Computerized Manufacturing Support

Systems
Objectives of automating the manufacturing support
systems:
To reduce the amount of manual and clerical effort in
product design, manufacturing planning and control, and
the business functions
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Reasons for Automating

1. To increase labor productivity
2. To reduce labor cost
3. To mitigate the effects of labor shortages
4. To reduce or remove routine manual and clerical tasks
5. To improve worker safety
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To accomplish
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9. To avoid the high cost of not automating
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Manual Labor in Production Systems

Is there a place for manual labor in the modern
production system?
Answer: YES
Two aspects:
1. Manual labor in factory operations
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2. Labor in manufacturing support systems
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Manual Labor in Factory Operations

The long term trend is toward greater use of
automated systems to substitute for manual labor
When is manual labor justified?
Some countries have very low labor rates and
automation cannot be justified
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Labor in Manufacturing Support

Systems
Product designers who bring creativity to the design task
Manufacturing engineers who
Design the production equipment and tooling
And plan the production methods and routings
Equipment maintenance
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andiscomputer
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Automation Principles and Strategies

1. The USA Principle
2. Ten Strategies for Automation and Process Improvement
3. Automation Migration Strategy

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U.S.A Principle
1. Understand the existing process
Input/output analysis
Value chain analysis
Charting techniques and mathematical modeling
2. Simplify the process
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3. Automate the process
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Ten
automation
and production
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may
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migration
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Ten Strategies for Automation and

Process Improvement
1. Specialization of operations
2. Combined operations
3. Simultaneous operations
4. Integration of operations
5. Increased flexibility
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6. Improved material handling and storage
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they
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optimization
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Computer-integrated
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Automation Migration Strategy

For Introduction of New Products
1. Phase 1 Manual production
Single-station manned cells working independently
Advantages: quick to set up, low-cost tooling
2. Phase 2 Automated production
Single-station automated cells operating
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Automated
integrated
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Multi-station
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system in
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Automation
Migration
Strategy

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Organization of the Book

1. Overview of Manufacturing
2. Automation and Control Technologies
3. Material Handling and Identification Technologies
4. Manufacturing Systems
5. Quality Control in Manufacturing Systems
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Systems
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Organization of the Book

Fig.1.7

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