Manufacturing Systems Analysis

(MF-630)
Course Instructor
Dr. Kashif Ishfaq
 Introduction

What is Manufacturing:
• Manufacturing is the application of physical and chemical processes to alter
the geometry, properties, and/or appearance of a given starting material to
make parts or products.
• Manufacturing also includes assembly of multiple parts to make products.
• The processes to accomplish manufacturing involve a combination of:
– Machinery
– Tools
– Power
– Manual labor
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Manufacturing Industries:

• Industries can be classified as:

– Primary industries

– Secondary industries

– Tertiary industries (service)

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Primary industries:

• Those that cultivate and use natural resources.

– Agriculture

– Forestry

– Fishing

– Livestock

– Quarries

– Mining

– Petroleum
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Secondary industries:
• Secondary industries take the outputs of the primary industries and convert
them into consumer and capital goods.
– Aerospace Apparel Automotive
– Basic metals Beverages Building materials
– Chemicals Computers Construction
– Consumer appliances Electronics Equipment
– Fabricated metals Food processing Glass, Ceramics
– Heavy machinery Paper Petroleum refining
– Pharmaceuticals Plastics (shaping) Power utilities
– Publishing Textiles Tire and rubber
– Wood and furniture
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Tertiary industries:

• It constitutes the service sector of the economy.

– Banking Communications Education

– Entertainment Financial services Government

– Health and medical Hotel Information

– Insurance Legal Real estate

– Repair and maintenance Restaurant

– Retail trade Tourism Transportation

– Wholesale trade
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Manufactured products:
• Consumer goods
• These are the products purchased directly by consumers such as:
– Cars Personal computers
– TVs Tennis rackets
– Shoes Fans, etc.

• Capital goods
• These are the products purchased by other companies to produce goods and supply
services, such as:
– Aircraft Mainframe computers
– Railroad equipment Machine tools
– Construction equipment, etc.
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Discrete items/products:

• These are the individual parts and assembled products, such as:
– Cell phone Plastic chairs

– Computer mouse Washing machine

– Crank shaft Connecting rod

– Electric iron Wrench, etc.

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Continuous items/products:

• Products that are in bulk form and cannot be counted separately, such as:
– Cement Sugar

– Chemicals Beverages

– Paints Fertilizers

– Sheet metal coil Plastic raw material (powder and granular form), etc.
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Production quantity:

• Production quantity refers to the number of units of a given part or product produced annually
by the plant.

• The quantity of products made by a factory has an important influence on the way its people,
facilities, and procedures are organized.

• Annual production quantities can be classified into three ranges:

– Low production quantities

• 1 to 100 units per year

– Medium production quantities

• 100 to 10,000 units per year

– High production quantities

• 10,000 to Millions of units per year

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Product variety:
• Product variety refers to the different product designs or types that are produced in a
plant.
• Different products have different shapes and sizes and styles.
• They perform different functions.
• They are sometimes intended for different markets.
• Some have more components than others.
• When the number of product types made in a factory is high, this indicates high product
variety.
• There is an inverse correlation between product variety and production quantity.
• When product variety is high, production quantity tends to be low; and vice versa.
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Hard product variety:

• When 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 is hard.

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Soft product variety:

• When there are only small differences between products.

• There is a high proportion of common parts among assembled products.

• The difference between car models made on same production line tends to be soft.

• The variety between different product categories tends to be hard; the variety
between different models within the same product category tends to be soft.
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Production systems:

• They are used to manufacture products and the parts assembled into those
products.

• The production system is the collection of people, equipment, and

procedures organized to accomplish the manufacturing operations of a
company.

• Production systems can be divided into two categories:

1. Production system facilities

2. Manufacturing support systems

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Production system facilities:

– Factory

– Production machines and tooling

– Material handling equipment

– Inspection equipment, and

– The computer systems that control the manufacturing operations.

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Low quantity production:

• Production facility associated with this type of production quantity is job
shop.

• Job shop makes low quantities of specialized and customized products.

• The products are typically complex, such as space capsules, aircrafts, and
special machinery.

• Customer orders for these kinds of items are often special, and repeat
orders may never occur.

• Equipment in job shop is general purpose and labor force is highly skilled.
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• A job shop must be designed for maximum flexibility to deal with wide
part and product variations (hard product variety).

• If the product is large and heavy, difficult to move in factory, it remains in a

single location, at least during its final assembly.

• Workers and processing equipment are brought to the product, rather than
moving the product to the equipment.
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• This type of layout is called fixed-position layout.

• The individual parts that comprise these large products are often made in
factories that have a process layout.
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• In process layout, the equipment is arranged according to function or type.

• The lathes are in one department, the milling machines are in another
department, and so on.
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Medium quantity production:

• Depending on product variety, two different types of facilities are used.
• When product variety is hard, batch production is used.
• Batch of one product is made, after which the facility is changed over to
produce a batch of next product, and so on.
• The changeover between production runs takes time, called the setup time or
changeover time.
• It is the time to change tooling and to setup and reprogram the machinery.
• It is lost production time, which is a disadvantage of batch production.
• The equipment is usually arranged in a process layout.
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• If the product variety is soft, cellular manufacturing is used.

• Extensive changeover may not be required between one product style and
the next.

• Groups of similar parts are made on the basis of similarities in design

attributes or the manufacturing attributes.

• Processing or assembly of different parts or products is accomplished in

cells consisting of several workstations or machines.
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• Each cell is designed to produce a limited variety of part configurations,

according to the principles of group technology.

• The layout is called cellular layout.

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High quantity production:

• It is also known as mass production.

• The production facility is dedicated to the manufacture of that product.

• Two categories of mass production can be distinguished:

– Quantity production

– Flow line production

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Quantity production:

• It involves mass production of single parts on single piece of equipment.

• The method of production typically involves standard machines such as

stamping press equipped with special tooling e.g. dies and material
handling devices.

• The typical layout used is process layout.

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Flow line production:

• It involves multiple workstations arranged in sequence, and the parts or assemblies
are physically moves through the sequence to complete the product.

• The collection of stations is designed specifically for the product to maximize

efficiency.

• The layout is called product layout, and the workstations are arranged into one long
line, or into a series of connected line segments.
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• The most familiar example of flow line production is the assembly line,
associated with products such as cars and household appliances.
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Manufacturing support systems :

• This is a set of procedures used by the company to manage production and to
solve technical and logistics problems encountered in ordering materials,
moving work through the factory, and ensuring that products meet quality
standards.
• It consists of four functions:
1. Business functions
2. Product design
3. Manufacturing planning
4. Manufacturing control
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Business functions:

• It is the principal mean of communicating with customers.

• Including in this category are:

– Sales and marketing

– Sales forecasting

– Order entry

– Cost accounting

– Customer billing
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Product design:

• Product (customer design) : Design (customer)

• Product (customer specifications) : Design (manufacturer’s design department)

• Product (proprietary) : Design (responsibility of manufacturing firm)

• Design department of the manufacturing firm might include:

– Research and development

– Design engineering

– Drafting

– Prototype shop
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Manufacturing planning:

• It includes followings:
– Process planning

– Master scheduling

– Requirements planning

– Capacity planning
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Process planning:

• It consists of determining the sequence of individual processing and

assembly operations needed to produce the part.

• The manufacturing engineering and industrial engineering departments are

responsible for planning the processes and related technical details.
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Master scheduling:

• The authorization to produce the product must be translated into the master
production schedule.

• Master production schedule is the listing of:

– the products to be made

– when they are to be delivered

– in what quantities

• Months are traditionally used to specify deliveries in master schedule.

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Material requirement planning:

• Based on this schedule, the individual components and subassemblies that
make up each product must be planned.
• Raw materials must be purchased or demanded from storage.
• Purchase parts must be ordered from suppliers.

Capacity planning:
• It is concerned with planning the manpower and machine resources of the
firm.
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Manufacturing control:

• It is concerned with managing and controlling the physical operations in

the factory to implement the manufacturing plans.

• Included in the manufacturing control function are:

– Shop floor control

– Inventory control

– Quality control
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Shop floor control:

• It deals with the problem of monitoring the progress of the product as it is

being processed, assembled, moved, and inspected in the factory.
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Inventory control:

• It attempts to strike a proper balance between:

– the danger of too little inventory and

– carrying costs of too much inventory

• It deals with such issues as deciding the right quantities of materials to

order and when to reorder a given item when stock is low.
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Quality control:
• The mission of quality control is to ensure that the quality of the product
and its components meet the standards specified by the product designer.

• Quality control depends on inspection activities performed in the factory at

various times during the manufacture of the product.

• Raw materials and components parts from outside sources are sometimes
inspected when they are received.

• Final inspection and testing of the finished product is performed to ensure

functional quality and appearance.