Scribd
Upload
73 views4 pages

Manufacturing System Study Guide - Week 2

The document discusses manufacturing system architectures and operational parameters. It defines hard and soft product variety, with hard having greater product differences and soft having many common components. Lean production aims to eliminate waste and reduce costs by identifying and removing non-value added activities. The document also calculates the number of production operations, floorspace, and workers needed for a new factory producing 100 product models based on processing steps and assembly times. It describes cellular, fixed-position, process, and product layouts along with example industries for each. Finally, it defines job shop, batch production, cellular manufacturing, and mass production with example industries for each type of production.

Uploaded by

Raynathan Prajnadi
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
73 views4 pages

Manufacturing System Study Guide - Week 2

The document discusses manufacturing system architectures and operational parameters. It defines hard and soft product variety, with hard having greater product differences and soft having many common components. Lean production aims to eliminate waste and reduce costs by identifying and removing non-value added activities. The document also calculates the number of production operations, floorspace, and workers needed for a new factory producing 100 product models based on processing steps and assembly times. It describes cellular, fixed-position, process, and product layouts along with example industries for each. Finally, it defines job shop, batch production, cellular manufacturing, and mass production with example industries for each type of production.

Uploaded by

Raynathan Prajnadi
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
You are on page 1/ 4

Raynathan Prajnadi

02411940000096
Manufacturing System A

2
ARCHITECTURE AND OPERATIONAL PARAMETERS OF
MANUFACTURING SYSTEM

Please answer the following questions and include the references.


1. What is the difference between hard product variety and soft product variety?
2. What is lean production?
3. The SISMAN Company is planning to introduce a new product line and will build a new
factory to produce the parts and assembly the final products for the product line. The new
product line will include 100 different models. Annual production of each model is expected
to be 1000 units. Each product will be assembled of 600 components. All processing of parts
and assembly of products will be accomplished in one factory. There are an average of 10
processing steps required to produce each component, and each processing step takes 30
sec. (includes an allowance for setup time and part handling). Each final unit of product
takes 3.0 hrs to assemble. All processing operations are performed at work cells that each
includes a production machine and a human worker. Products are assembled on single
workstations consisting of two workers each. If each work cell and each workstation require
200 ft2, and the factory operates one shift (2000 hr/yr), determine:
(a) how many production operations,
(b) how much floorspace, and
(c) how many workers will be required in the plant.
4. Different types of production are associated with how much variety and quantity does the
facility have to manufacture. It also uses different types of facility layout, such as cellular
layout, fixed-position layout, process layout, and product layout. Please explain what those
layouts are, give an illustration of each layout, and what type of industries that incorporates
each type of layout.
5. Explain your understanding on the different types of production, such as Job shop, Batch
production, Cellular manufacturing and Mass production with example of industries that use
them.

Contact Person: #188 #191


Raynathan Prajnadi
02411940000096
Manufacturing System A

1. The difference between hard product variety and soft product variety are:
 For hard product variety, products vary greatly, few common parts in the assembly, the conversion
process can be very complicated, and meet the specific needs of customers, a high variety of
operations leads to higher unit costs.
 For soft product variety, subtle differences between products, many common components in an
assembly, the conversion process is clearly defined and requires a standardized process, a low
variety of changes in the conversion process leads to lower unit costs.
2. Lean production is a method that uses internal and external customer pull systems to guide products
(materials, work-in-process, output in the process) and information, and carry out continuous
improvement at the root. Thereby identifying and eliminating waste or non-value-added activities in order
to pursue excellence in manufacturing. Lean production aims to increase the added value of work by
eliminating waste and reducing unnecessary work, reducing costs, improving quality, and shortening
delivery time.
3. A. 100 model x 1000 pcs/model x 600 component x 10 steps
= 600.000.000 production operations

B. - Workcell
5.000.000 hr/yr : 2000 hr/yr
= 2500 workers

2500 workcell x 200ft2


= 500.000 ft2

- Workstation
300.000 hr/yr : 2000 hr/yr
=150 workers

150 workers : 2
= 75 workstation
So,
75 workstation x 200 ft2
= 15.000 ft2
Total = 515.000 ft2

C. - Workcell
5.000.000 hr/yr : 2000 hr/yr= 2500 workers

- Workstation
300.000 hr/yr : 2000 hr/yr
=150 workers
Total = 2650 workers

4. A cellular layout is a manufacturing process system in which the order of equipment and workstations is
more efficient (where the processes, inventory, and materials), and also minimize transportation and
waiting time.
Raynathan Prajnadi
02411940000096
Manufacturing System A

The fixed position layout works by keeping the product components in place while moving the production
equipment (such as equipment, tools, machines, and workers) to the material location.

The process layout is a typical layout used in mass production. At the same time, the quantity
Manufacturing requires mass production of individual parts on a single machine. Automobile is an example
of this process layout.

The product layout is a layout in which the workstation is placed in a single long line or a series of linked
line segments. Jobs are usually transferred between driven conveyor stations. An example of product
layout implementation is the production of automobiles and household appliances.

5.
- Jobshop is a type of production equipment, usually related to equipment with a quantity range of 1-
100 units/year, which will produce a small number of specialized and customized projects. Ex :
customization of watch
- Batch production refers to the situation where it is difficult to choose multiple products, so that a
batch of products can only be produced in batches. Ex : bakery that produce doughnuts
- Cellular manufacturing is the result of thinking about analysis and breaking down the process into
simple components that are easy to analyze and reorganize. Ex : u-shape car parts assembly
- Mass production is a production process used for mass-produced products with few model variations.
Ex : Car manufacturing
References

Čiarnienė, R., Vienažindienė, M. 2012. Economics and management - Lean manufacturing: theory and
practice. Vol. 17 No. 2. Kaunas University of Technology, Lithuania.
Raynathan Prajnadi
02411940000096
Manufacturing System A
Groover, M. 2016. Automation, production systems, and computer-integrated manufacturing. 4th ed. New
York City: Pearson Education.
Sundar, R. ,Balaji, Kumar. 2014. Procedia Engineering. Elsevier

You might also like