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Manufacturing Processes-Lecture 1

This document discusses various topics related to manufacturing processes and systems. It defines manufacturing as the transformation of materials into valuable products through processes like design, production, and marketing. The document outlines challenges in manufacturing like changing market conditions, global competition, and the need for mass customization. It also discusses types of manufacturing systems like process layout, linear layout, and cellular/group technology layouts. Lastly, it covers concepts like just-in-time manufacturing and flexible systems.

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Oscar Sotomayor
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38 views16 pages

Manufacturing Processes-Lecture 1

This document discusses various topics related to manufacturing processes and systems. It defines manufacturing as the transformation of materials into valuable products through processes like design, production, and marketing. The document outlines challenges in manufacturing like changing market conditions, global competition, and the need for mass customization. It also discusses types of manufacturing systems like process layout, linear layout, and cellular/group technology layouts. Lastly, it covers concepts like just-in-time manufacturing and flexible systems.

Uploaded by

Oscar Sotomayor
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Manufacturing Processes

Oscar E. Sotomayor - EPN


TOPICS
• Definition of manufacturing
• Types of manufacturing systems
• Cellular Manufacturing Systems – Issues in Design
• Production Flow Analysis
• Quantitative Algorithms for Cellular Manufacturing and Systems
• Operator Allocation and Planning Issues
• Just in time Manufacturing
• Flexible Manufacturing - Designs Issues and Algorithms
• Synchronous Manufacturing
The Products
• Discrete products vs. Continuous products
What is Manufacturing?
• Derived from the Latin manu factus, meaning “made by hand”
• Concerned with making products – Include design manufacturing and
marketing
• Transformation of materials in valuable products
Apple: Simply Better Products

The economic success of most firms depends on their ability to


identify the needs of customers and quickly create products that
meet these needs.
Manufacturing Overview - Challenges
• Changing market conditions
• Rate of change is faster
• Global competition
• Need to be proactive not reactive
• Increased customer focus (mass
production to mass
customization)
New Customer
• Availability
• Price
• Quality
• Variety
• Wants to buy frequently
• Absolutely impatient customer
• Wants more value for money
Why manufacturing is important?
Events in history
• Industrial Revolution and James Watt - 1765
• E. Whitney – Interchangable parts. – 1765 to 1825

• Adan Smith
• The Wealth of Nations – Gross Domestic Product – 1776
• Andrew Carnegie
• Steel Industry with a large stable output
• Concept of cost control to increase profits
Other events
• Henry Ford The war
• Speed of manufacturing Computers – cost and information control
Comunication
• Work to man an not man to work
• Moving assembly line
• Did not concentrate on variety
Requirements of Manufacturing
• Make an increasing mariety of products, on shorter lead times with
smaller runs and flawless quality
• Improve ROI by automating and introducing new technology in
process and materials so that Price can be reduced to meet local land
foreing competition
• Mechanize but keep schedules flexible, inventories low, capital cost
minimal and work forcé contented.
Some laws in manufacturing
• 1.- WIP (work in progress) = Production Rate * Throughput time
• 2.- Matter is conserved
in inventory out

• 3.- Larger the scope, less reliable is the systems (more machines, more chances to
fail)
• 4.- Objects decay (performance of machines decay)
• 5.- Complexity of systems grow exponentially (we assume linear relationship –
wrong)
• 6.- Technology advances (Decay of systems create new systems with better
performance)
Some laws in manufacturing
• 7.- Systems components behave randomly (non reliable machines,
non infinite buffers)
• 8.- Limits of human rationality (limited by linear thinking)
• 9.- Combining, Simplifying and Eliminating can save time, money and
effort (led – CMS, JIT, Kanban, etc)
Different Types of Manufacturing Systems

Line Layout
Process Improvement

PROCESS LAYOUT LINEAR LAYOUT

CELLULAR LAYOUT

GROUP TECHNOLOGY = CELLULAR MANUFACTURING


Reorganizing machines, grouping of parts to families ownership and
responsibilities
Process Improvement
• Japanese management systems – JIT, Waste elimination, inventory
reduction
• Produce what customers wants

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