Course Reflection
AK47
hacker_ch.5.pptxManufacturing Systems
Chapter 5 Hacker
ETSC 101 Chapter 5 Hacker
1
The System
ETSC 101 Chapter 5 Hacker
The flow of things and consumption of resources. Outputs are often the inputs to other systems. Large complicated systems will have many subsystems. The more systems, the more resources consumed, the higher cost.
2
Types of Manufacturing Systems
Job Shop
Flow Shop
Project Shop
Continuous Process
Linked Cell
ETSC 101 Chapter 5 Hacker
This isn’t cookie cutter. Many manufacturing systems will also combine these different types of manufacturing systems to construct a composite manufacturing system. Linked cell is a lot like that.
3
Job Shop
Welding and fabrication
Refurbish/repair
Plasma cutting/CNC machining
Low volume/high variety
ETSC 101 Chapter 5 Hacker
Examples. Job shops will have a lot of different kinds of equipment and will do many different kinds of jobs.
4
Flow Shop
ETSC 101 Chapter 5 Hacker
Simple plastic assemblies
Screw/fasteners
Paper products
High volume/low variety
Project and Continuous Processes
Continuous
Very high production/almost zero flexibility
ETSC 101 Chapter 5 Hacker
Project
Very low production (just one unit)/very high flexibility
A nuclear power plant shows examples of continuous process and project shop manufacturing. Constructing the power plant was an example of a project shop manufacturing system. The processes that the power plant performs on water to produce mechanical, and then electrical energy, is example of continuous process manufacturing, in that the water is constantly flowing, carrying energy, and that energy is being converted into other types of energy continuously.
6
Continuous/Flow Mixed Process
Plastic parts that are extruded or blow molded
Experiences phase change
ETSC 101 Chapter 5 Hacker
Material stocks and other extruded material is an example of a mixed manufacturing system where in the materials liquid state, it is a part of a continuous process, but when it solidifies, it enters a flow line process.
7
Linked Cell
ETSC 101 Chapter 5 Hacker
Linked Cell increased efficiency by localizing a number of manufacturing processes in one area, eliminating movement of the operator performing the operations. This is a manufacturing system type heavily influenced by the growth of automation technology and is often in tandem with a flow line manufacturing system.
8
#1 Goal with Manufacturing Systems
Design and implement manufacturing systems that provide low cost, superior quality, and on-time delivery of the final product.
ETSC 101 Chapter 5 Hacker
Quality (TQM)
Met expectations of customers.
Determine performance of current system.
Improve product design to promote quality.
Improve inputs from suppliers.
Establish Statistical Process Control (SPC) of the manufacturing system.
ETSC 101 Chapter 5 Hacker
Total Quality Management
This means that the definition of quality of a product will change with market change.
10
ETSC 101 Chapter 5 Hacker
There is no need to get into the SPC details. There are entire majors around this topic. In short, every specification has a tolerance. Monitoring how the actual output stays within or without that tolerance can help quality personnel to recognize trends in the output data, which will allow them to predict when the process will go beyond the limits of the tolerance, and then make corrections to get the process producing the output back in “control”.
Quality is an important consideration when looking at any system whether it’s the production of fine art, teaching pedagogy, exercise and fitness plans, counseling methodology, flight take-off preparation, rhetoric analysis, excavation procedure, business model conceptualization. Even when planning a good night of having fun. There are certain things that need to be monitored to ensure a good night is had.
11
Safety & Ergonomics
Not only important for the customer using the end product, but for the personnel making the end product in the manufacturing system.
ETSC 101 Chapter 5 Hacker
We discussed this in regards to the customer, but the personnel making the product also need to be able to make the product in a safe environment. This is guided by the design of the manufacturing system. It is also important for personnel to be comfortable when performing the operations required for processing of the product. Manufacturing systems are therefore designed to fit likely personnel.
Take a CNC milling machine. The operating panel should be located at an appropriate height to prevent slouching of the operator. Carts should also be available to prevent operators from carrying heavy objects across the hazardous manufacturing floor.
12
Mass Production & Automation
Mass Production Goals:
High Productivity
Low Cost
Low Labor
ETSC 101 Chapter 5 Hacker
Automation Outcomes:
Replacement of workers.
Less recurring costs.
Higher degree of accuracy and precision.
No needs for rest with continual power source and proper cooling.
Automation Drawbacks:
High initial fixed costs.
Need for higher qualified technicians.
Higher degree of accuracy and precision.
No needs for rest with continual power source and proper cooling.
13
Effects of Automation
Fewer low skilled jobs
More Higher skilled jobs.
Another way to lower costs, labor, and increase productivity is by outsourcing.
ETSC 101 Chapter 5 Hacker
Many argue that automation is eliminating jobs, but others will say that although lower paying jobs are being eliminated and replaced by automation technology, higher paying jobs are being created to manage and monitor the automation equipment. Though this would seem uneven, it is actually expected for higher productivity to lead to expansion of the company, meaning the creation of even more jobs.
Outsourcing is when a company hires another company to add value to a product development system. This is often done in manufacturing, hiring companies over seas where labor is cheaper.
14
Competing in the Global Market
Lean Manufacturing
Concurrent Engineering
Agile Manufacturing
Because the market and competition is global, manufacturing also is becoming a global enterprise.
This entails…
Flat organizations
Highly compressed life cycles
High volume of virtual development
ETSC 101 Chapter 5 Hacker
Lean manufacturing is making only what you need, keeping resources around only when you need them. Lack of excess.
Concurrent engineering is involving everyone along the product’s life cycle in the development process to plan manufacturing, engineering, marketing, and other critical tasks in different functions from conception to production ramp up.
Agile manufacturing, very similar to agile project management, is using high level team work and fast paced decision making to develop products component by component with continual customer involvement and feedback. This method is useful for developing products at a very fast paced.
All these are used to remain competitive in a rapidly growing global market.
Flat organizations mean that the designer and manufacturers are closely connected and in constant communication about the specifications and constraints of the product. Life cycles are compressed to be less than a year rather than less than a decade. High volume of virtual development allows the number of prototypes to be reduced, and the number of visits from manufacturers to be reduced. The product prototype can be sent via virtual communication and discussed virtually rather than having to be in person to examine the performance of the prototype.
15
Emphasis on Tech. Development or Something Else?
Leadership in creating new technology only pays off when rapidly implemented and embedded in high quality, cost competitive, innovative products that meet customer needs.
ETSC 101 Chapter 5 Hacker
