Manufacturing

Systems
MANUFACTURING SYSTEMS

Manufacturing Process is defined as:

A means of transforming material from one form to another

The process can be divided into number of classes:

 Material Removal
 Material Forming
 Material Joining
 Casting, Forging
 Assembly

System is defined as:

A number of entities (processes) acting together as a whole

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MANUFACTURING SYSTEMS
Manufacturing system can be defined as follows:

A series of value-adding manufacturing processes to convert

raw materials into more useful forms and eventually into
finished products

Manufacturing system is a collection of integrated equipment

and human resources, whose function is to perform one or
more processing and/or assembly operations on a starting
raw material, part, or set of parts.

3
MANUFACTURING SYSTEMS
Systems can have following components:

Hardware: Machines, tooling, fixtures, material handling equipment,

raw material etc.

Software: Computer programs, data, procedures

Embedded systems: microcontrollers, PLCs, built-in software like

firmware, mechanical / electrical components

and

Human Workers

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MANUFACTURING SYSTEMS

Production Machines:
The machines can be classified as (1) manually operated, (2) semi-
automated (3) fully automated.

1. Manually operated machines are directed or supervised by a human

worker. The machine provides the power for the operation and the
worker provides the control.

Conventional machine tools (e.g. lathes, milling machines, drill

presses) fit into this category.

The worker must be at the machine continuously.

5
MANUFACTURING SYSTEMS
2. Semi-automated machine performs a portion of the work cycle under
some form of program control, and a human worker tends to the
machine for the remainder of the cycle, by loading and unloading it or
performing some other task each cycle.

An example is a CNC lathe controlled for most of the work cycle by the
part program, but requiring a worker to unload the finished part and
load the next workpiece at the end of the part program/work cycle.

6
MANUFACTURING SYSTEMS
3. Fully automated machine can operate for extended periods of time
(longer than one work cycle) with no human attention. A worker is not
required to be present during each cycle.

The worker may need to tend the machine every tenth cycle or every
hundredth cycle.

An example of this type of operation is found in many injection molding

plants, where the molding machines run on automatic cycle and the
collection bin need is to replaced with an empty bin after extended
periods of time by the operator / sometimes by the robot or intelligent
material handling mechanisms.

Workstation: A location in the factory where some well-defined task or

operation is accomplished by an automated machine, a worker and
machine combination.

A system with multiple stations is called a production / assembly line or

machine cell or other name depending on its configuration and
function. 7
 MANUFACTURING SYSTEMS
CLASSIFICATION
Manufacturing systems can be classified into different categories:

1) Type of Operation: Processing vs. Assembly Operation

2) Number of Workstations and Systems Layout: Variable vs.
Fixed Routing
3) Machine Layout: Fixed Position, Functional, Cellular and Flow
4) Level of Automation: Manual, Semi-automatic or Fully-
automatic
5) Part / Product Variety: Flexibility and Capability
6) Material Flow: Project, Job Shop, Batch, Flow (discrete/
continuous)
7) Market: MTS, MTO, CTO and ETO

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1. TYPES OF OPERATION
 Processing operations on individual work units
 Assembly operations to combine individual parts into
assembled entities

Additional parameters of the product that play a role in

determining the design of the manufacturing system include: type
of material processed, size and weight of the part or product, and
part geometry.

For example. machined parts can be classified according to part

geometry as rotational or non-rotational.

Rotational parts are cylindrical or disk-shaped and require turning

and related rotational operations.

Non rotational (also called prismatic) parts are rectangular or

cube-like and require milling and related machining operations to
shape them. 9
2. NUMBER OF WORKSTATIONS AND
SYSTEMS LAYOUT
The number of workstations exerts a strong influence on the
performance of the manufacturing system in terms of production
capacity, productivity, cost per unit, and maintainability.

As the number of stations increases, the amount of work that can

be accomplished by the system increases. This translates into a
higher production rate as compared with a single workstation's
output.

More stations means that the system is more complex and

therefore more difficult to manage and maintain. The system
consists of more workers, more machines, and more parts being
handled. The logistics and coordination of the system becomes
more complex while maintenance problems occur more
frequently.
10
2. NUMBER OF WORKSTATIONS AND
SYSTEMS LAYOUT
Workstation layouts organized for variable routing can have
a variety of possible configurations, while layouts organized
for fixed routing are usually arranged linearly, as in a
production line.

The layout of stations is an important factor in determining

the most appropriate material handling system.

Following classification scheme (next slide) is applicable to

manufacturing systems that perform either processing or
assembly operations.

11
2. NUMBER OF WORKSTATIONS AND
SYSTEMS LAYOUT
Type I - Single station: This is the simplest case, consisting
of one workstation (n = I), usually including a production
machine that can be manually operated, semi-automated, or
fully automated.

Type II - Multiple stations with variable routing: This

manufacturing system consists of two or more stations (n >
1) that are designed and arranged to accommodate the
processing or assembly of different part or product styles.

Type III - Multiple stations with fixed routing: This system

has two or more workstations (n > 1), which are laid out as a
production line.
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3. MACHINE LAYOUT
There are four fundamentally different ways of arranging
workstations/machines within a factory:

Fixed Material: In this case, the plant moves around a

fixed product under manufacture. This is typically
employed for large products (e.g. ship building or civil
engineering projects).

Functional: Similar machines are grouped together.

Group Technology or (Cellular): Machines are arranged to

manufacture product families. (e.g. brake lining
manufacture).

Flow: In this case, the production facilities are designed to

manufacture specific products in large quantities. 13
(e.g. car production).
3. MACHINE LAYOUT
Which is more efficient?

14
3. MACHINE LAYOUT

 Answer – it could be any of them!

 The design of the production space can

influence:

 Output levels
 Efficiency
 Cost levels
 Quality assurance procedures

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4. LEVEL OF AUTOMATION

Following types of manufacturing systems can be classified

in terms of automation:

I M - Single-station manned cell: The basic case is one

machine and one worker. The machine is manually operated
or semi-automated and the worker must be in continuous
attendance at the machine.

I A - Single-station automated cell: This is a fully automated

machine capable of unattended operation for extended
periods of time (longer than one machine cycle). A worker
must periodically load and unload the machine or otherwise
service it.

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4. LEVEL OF AUTOMATION
II M - Multi-station manual system with variable routing:
This has multiple stations that are manually operated or
semi-automated. Work transport between stations is either
manual or mechanized.

II A - Multi-station automated system with variable routing:

This is the same as the previous system, except the
stations are fully automated. Work transport is also fully
automated.

II H - Multi-station hybrid system with variable routing: This

manufacturing system contains both manned and
automated stations. Work transport is manual, automated,
or a mixture (hybrid).

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4. LEVEL OF AUTOMATION
III M - Multi-station manual system with fixed routing: This
manufacturing system consists of two or more stations with
one or more workers at each station. The operations are
sequential, thus necessitating a fixed routing, usually laid out
as a production line. Work transport between stations is
either manual or mechanized.

III A - Multi-station automated system with fixed routing: This

system consists of two or more automated stations arranged
as a production line or similar configuration. Work transport
is fully automated.

III H - Multi-station hybrid system with fixed routing. This

system includes both manned and automated stations. Work
transport is manual, automated, or a mixture (hybrid).
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4. LEVEL OF AUTOMATION

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5. PART / PRODUCT VARIETY

A manufacturing system can be classified according to the

capability of dealing with variations in the parts or products it
produces.

Examples of possible variations:

 variations in type and/or color of plastic molded parts in

injection molding process
 variations in the size of printed circuit boards handled by a
component placement machine
 variations in geometry of machined parts
 variations in parts and options in an assembled product on a
final assembly line

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5. PART / PRODUCT VARIETY
Three types of manufacturing systems according to their capacity to deal
with product variety are:

Hard product variety is when the products differ substantially. In an

assembled product, hard variety is characterized by a low proportion of
common parts among the products; in many cases, there are no
common parts. The difference between a car and a truck, a bulb and
energy saver, deep freezer and fridge are few examples of hard-product
variety.

Soft product variety is when there are only small differences between
products. such as the differences between car models made on the
same production line. There is a high proportion of common parts
among assembled products whose variety is soft. Bulbs of different
21
sizes or fridge with different colours.
5. PART / PRODUCT VARIETY

Hard product and soft product varieties are sometimes

differentiated in terms of design parameters.

Hard product variety depicts two products with

substantial design differences—for example, the
difference between a car and a TV; a bulb and fan or a
fridge and a bottle.

Soft product variety, on the other hand, depicts two

products with substantial commonality across
designs—for example, the commonality between a car
and a truck

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5. PART / PRODUCT VARIETY

Single model: All parts or products made by the manufacturing

system are identical. There are no variations. In this case, demand
for the item must be sufficient to justify dedication of the system to
production of that item for an extended period of time, perhaps
several years. Equipment associated with the system is specialized
and designed for highest possible efficiency.

Batch model: Different parts or products are made by the system,

but they are made in batches because a changeover in physical
setup and/or equipment programming is required between models.
Changeover of the manufacturing system is required because the
differences in part or product style are significant enough that the
system cannot cope unless changes in tooling/jigz/fixtures and
programming are made. (feasible for hard product variety)

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5. PART / PRODUCT VARIETY
Mixed model: Different parts or products are made by the
manufacturing system, but the system is able to handle these
differences without the need for a changeover in setup and/or
program. This means that the mixture of different styles can be
produced continuously rather than in batches.

(feasible for soft product variety)

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6. MATERIAL FLOW STRUCTURES
A manufacturing system can be classified according to the
material flow between workstations.

Project: In a project, the inputs are brought to the project

location as they are needed; there is no material flow in the
process. e.g. building construction, ship building

Job shop: A job shop is a flexible operation that has several

activities through which work can pass. In a job shop, it is not
necessary for all activities to be performed on all products, and
their sequence may be different for different products.
e.g. machine shop with drill, lathe and milling machine but one
product goes on drill and lathe and the other goes on lathe and
drill

25
6. MATERIAL FLOW STRUCTURES

Batch process: where groups of items are made together. Each

batch is finished before starting the next block of goods.
e.g 50 loaves of white bread, after finishing it will start baking 50
loaves of brown bread

Flow process: where identical items are produced on an

assembly line. e.g. cars, canned drinks

Continuous flow process: a continuous flow process has a fixed

momentum and fixed sequence of activities. Rather than being
processed in discrete steps, the product is processed in a
continuous flow. e.g. oil refineries and sugar processing
industries

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7. MEANS OF SERVING THE MARKET
A manufacturing system can be classified according to the
markets it can serve

Make to Stock (MTS): In this case, the customer requires product

with almost no forward notice. Suppliers usually manufactures in
anticipation of demand and maintain stock of finished product.
E.g. stationary, cold drinks, lays chips etc

Configure to Order (CTO/ATO): In this case, customer is prepared

to wait for limited period. Company usually configures
components into saleable products when actual customer order
are received. E.g. car industry, ordering food in a restaurant

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7. MEANS OF SERVING THE MARKET

A manufacturing system can be classified according to the

markets it can serve

Make to Order (MTO): In this case, company does not commit

resources until firm customer order have been received.
E.g. manufacturing of commercial and fighter airplanes

Engineer to Order (ETO): This is similar to MTO except that in

this case, the item to be manufactured is defined by the
customer. E.g. customised Ferrari or Rolls Royce or private
airplane, tailored clothes etc

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Classification of Production Systems

Purpose built equipment

Process Engineering & moulding

focus

Automotive

Product Petrochemicals
focus

Figure 3: Classification of Production Systems (J. Miltenburg ;2007)

Flexible Manufacturing
Systems
Flexible Manufacturing System
Flexible Manufacturing System

3.1
Flexible Manufacturing System

3.1
Flexibility
1. Machine flexibility

Capability of a machine to perform a variety of operations on a

variety of part types and sizes. It depends on changeover, ease of
machine programming, tool storage capacity etc.

2. Routing flexibility

Alternative machines, sequences or resources can be used for

manufacturing a part for changes resulting from equipment
breakdowns, tool breakages, controller failures, etc.

It depends on the similarity of the parts in the mix, similarity and

duplication of workstations etc.

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Flexibility
3. Process flexibility

 Ability to absorb changes in the product line by performing

similar operations.
 The process generalization method which can be used for more
than one product .
 e.g. painting a car is a flexible process which have a generalized
range of car sizes that it can adapt to.

4. Product flexibility

 Ability to change over to a new set of products economically and

quickly in response to markets.
 Different variants in a model but closely related in design
 e.g. Ford producing mini trucks as well as SUVs ; cell phones of
different models
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Flexibility

5. Production flexibility

Ability to produce a range of part styles / products that can be

produced on the systems without adding capital equipment /
investment.

6. Volume flexibility

Ability to economically produce parts in high and low quantities of

production in order to respond unanticipated demand to meet
customer needs. It depends on the level of manual labour
performing production, amount invested in capital equipment,
available inventory etc.

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Flexibility
7. Expansion flexibility

Ease with which the system can be expanded to increase total

production quantities (capacity enhancement). It depends on the
expense of adding the workstations, ease with which layout can be
changed / expanded, type of part handling system used, ease with
which properly trained workers can be added.

37
Types of Flexible Manufacturing Systems

3.1
Types of Flexible Manufacturing Systems

3.1
Types of Flexible Manufacturing Systems
Single machine

3.1

Single Machine Cell

Types of Flexible Manufacturing Systems

3.1

Flexible Manufacturing Cell

Flexible Manufacturing Cell

Types of Flexible Manufacturing Systems

3.1

Flexible Manufacturing System

FMS Components

3.1
Work Stations

3.1
Work Stations

3.1
Material Handling and Storage Systems

3.1
Computer Control Systems

3.1
Human Resources

3.1
FMS Components
FMS Components

A 5 machine FMS for machining at Cincinnati Milacron, OH, USA

Advantages of FMS
 Reduction in manufacturing cost by lowering direct
labor cost and minimizing scrap, re-work, and material
wastage.
 Less skilled labor required.
 Reduced inventory, due to the planning and
programming precision
 Reduction in production lead time permitting
manufacturers to respond more quickly to the
variability of market demand.
 Better process control resulting in consistent quality.
Disadvantages of FMS
 Limited ability to adapt to changes in product or
product mix (e.g., machines are of limited capacity and
the tooling necessary for products, even of the same
family, is not always feasible)
 Expensive, costing millions of dollars
 Technological problems related to component
positioning and precise timing to process a component
to maintain consistent quality
 Sophisticated manufacturing systems
 Types of FMS layouts
1. In-line layout: All parts in the production process follow the
same progression through the machining station.

2. Loop layout: Arranged for the general order of processing for a

larger variety of parts.
• Parts can skip stations for flexibility
• Used for large part sizes
• Best for long process times

3. Ladder layout:
• Parts can be sent to any machine in any sequence

4. Open Field Layout:

• Enables material to move along the machine centers in any
particular order necessary.
 In-line layout

In-line Layout
Loop layout

Loop Layout
 Ladder
layout

Ladder Layout
Open field
layout

Open field Layout