Outline

2.008
1. Manufacturing Systems
2. Types of Plant Layouts
Manufacturing Systems
3. Production Rates
4. Design and Operations

2.008 - Spring 2004 2

Manufacture What is mfg systems?

Market Conceptual Design for
Research Design Manufacture

Unit
Unit
Manufacturing
Manufacturing
Processes
Processes
Assemblyand
Assembly and
Joining
Joining •Machining
•Injection molding
•Welding •Casting
Factory,
•Bolting •Stamping
Systems &
•Bonding •Chemical Vapor
Enterprise
•Soldering Deposition

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How Man, Machine, and

Time spectrum of Typical Activities in a
Manufacturing Organization
Material Spend Time in the
Factory
Seconds Period Activity
108 Decade People Materials Machines
Plant design, Machine Selection,
107 Year System Simulation Valu e - Value -
Value -
adde d adde d
106 Month Process design: CAD adde d
Catalogs
Week Select manufacturing methods

105 Day
Factory Operation
104 Ship – Receive
Hour Transport Inventory
103
Waste Waste Waste
102
Minute Part handling
101 Load/Unload “Waste”: waiting for materials, “Waste”: transportation, storage, “Waste”: unnecessary
Assembly watching machine running, inspection and rework movement of machine, setup
1 Second producing defects, looking for time, machine breakdown,
Machine control tools, fixing machine unproductive maintenance,
.1
CNC – DNC breakdowns, producing producing defective products,
.01 Adaptive control unnecessary items, etc. producing products when not
Intelligent machines needed, etc.
.001 Millisecond
Process control
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 Types of Plant Layout

Disruptions/Variation

(Random Events)
• Job Shop

• Machine failure • Project Shop

• Set-up change • Flow Line
• Operator absence • Transfer Line
• Starvation/Blockage • Cellular System
• Demand change
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Job Shop Project Shop

Raw Material
Machines/Resoues

Machines/Resources
A A D D are brought to and

A B
are grouped according
removed from

A A D D A B
to the process they
stationary part as

perform
D D required Raw
C C material/
Ready part
C C

C C D
D
C D
Ready part

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Flow Line and Transfer Line Cellular System

Raw Material Raw Material

Machines/Resources
Machines/Resources B A C B C D E
are grouped
are grouped in lines
according to the D E F G
according to the A D B
processes required
processes sequence
G for part families
of part(s) D F
A B

F F D F

Ready part
Ready part

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2
 Production Rates
Production Quantity and Plant Layout
• Case I:
Pro ject Shop
– One machine
– Everything works
Job Shop

C ellular System
M

Flow L i ne
1
Production rate =
1 10 100 1,000 10,000 100,000 Operation time
Quantity

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Production Rates (cont’d) Production Rates (cont’d)

• Case II: • Case III:
– One machine – Many machines
– Machine breaks down (disruption) – No machine breaks down
– Everything else works – No buffers
M
M1 M2 Mi Mk
MTTF MTTF
Efficiency = =
MTTF + MTTR MTTR
(utilization)

Efficiency
Production rate =
Operation time

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Production Rates (cont’d) Production Rates (cont’d)

• Case IV: • Case V:
– Many machines (same operation time) – Many machines (same operation time)
– No machine breaks down – Machine breaks down
– No buffers – No buffers

M1 M2 Mi Mk M1 M2 Mi Mk

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 Production Rates (cont’d)

Production Rates (cont’d)
• Case VI:
– Many machines and buffers in between • Production rate increases if:
– Machine breaks down – Increase the rate of the slowest machine
– Reduce the disruptions
M1 B1 M2 B2 M3 Mk-1 B k-1 Mk – Introduce “buffers”
– Introduce in-process control

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Disruptions
(Random Events) Waiting

• Machine failure • Underutilization

• Set-up change
• Idleness
• Operator absence
• Inventory
• Starvation/Blockage

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Cycle Time and Lead Time

Inventory/Work-in-Process (WIP)
Order Order

• It costs money
Supplier Plant Customer
• It gets damaged
Supply Supply
• It becomes obsolete
• It shrinks Takt time =
Daily available time
Daily average demand
• It increases lead time
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4
 Cycle Time Cycle Time (cont’d)
“Cycle Time” • Example:
• The time a part spends in the system Operation time = 1, One-piece operation

M1 M2 M3 M4 M5

Little’s Law: L = λw Production rate = 1

L: average inventory Cycle time = 5
λ: average production rate Inventory = 5
w: average cycle time

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Cycle Time Cycle Time

Batch Production One-Piece Production

1. 2. Op1 Op2 Op3

Op1 Op2 Op3

Operation time: 3 minutes

Operation time = 3 minutes
Batch (Lot) size: 1000
Cycle time = 1,000*3 + 2*3 = 3,006 minutes
Cycle time = 1,000*3 + 1,000*3 + 1,000*3 = 9,000min

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Cycle Time and Lead Time

Order Order
Systems Design and Operation

Supplier Plant Customer • Cycle time < Lead time

Supply Supply
• Lumpiness

Takt time =
Daily available time • Information contents
Daily average demand

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5
 Lumpy Demand Typical Design Guidelines
Wrench A Wrench B Wrench C Wrench D • Leveling
D 1 1 1 1 1 1
P 5 5
D
P 15
6 6 6
15
6 6 6
15
D
P 10
3 3 3 3
10
3 3 D
P 25
7 7 7 7
25
7 7
• Balancing
• Single-piece flow
Forging X Forging Y • Low materials handling
D 20 0 15 0 0 20
• Low setup time
D 35 0 0 35 0 0
P 25 25 25 P 50 50

• Smaller lot size

Steel Z • Low WIP
D 75 0 25 50 0 25
• Faster feedback
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Plant Operations

• Push (MRP, ERP, etc.) vs. Pull (JIT)

• Batch vs. One-piece

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