7 WASTE

1. Overproduction: Producing more than is needed. Any resources expended unnecessarily are
considered waste, and producing product when it is not needed is a common waste in manufacturing. This
can occur due to poor production planning and control, or it may result from improper incentive systems
that reward overproduction.
2. Inventory: All idle resources are wasteful, and inventory is one of the most common. Raw materials,
WIP and Finished Goods inventories require significant capital investments, but add no value to the
product. Some may argue that having product on hand so it can ship immediately adds value to the
customer. Short lead times add value, but holding inventory does not. The goal of lean is to achieve the
value desired, such as short lead times, without any waste, such as high inventory levels.
3. Wait Time: Whenever materials, people or machines are sitting idle. Waiting occurs when queues
are built within processes, or when the time required for workers or machines to conduct a value added
process is out of sync with each other. In these situations, one of the resources is waiting, and waste is
occurring. Ideally, every resource would be put to productive use 100% of the time it is required. Any
time a resource spends idle represents lost capacity and productivity, and increases lead time to the
customer.
4. Transportation: Material movement that does not move the product to the customer. The
definitions of waste and value vary within the lean community. There are some who consider all
transportation costs as waste. Others consider some transportation as value added since a product is more
valuable to a customer once it is delivered to the customer. Regardless of the view on transportation,
minimizing transport costs is a goal of lean.
5. Processing: Excessive processing includes any activity that provides no additional value to a
product or service. Often, excessive processing occurs when an individual processing operation can be
combined with other processes or can be eliminated all together. For example, packaging processes do
not add any value to a product.
6. Motion: Any movement, of people, machines or materials that does not add value to a product. The
elimination of motion was one the major drivers that led to the development of cellular manufacturing
techniques. With these techniques, production is completed in a small work cell combining multiple
operations with little to no movement between each operation, and without excess motion expended by
the worker.
7. Defects: Poor quality drives up costs both in wasted materials and labor. Lean manufacturing draws
heavily on total quality techniques and seeks to ensure every activity delivers value. Defects disrupt this
process, causing materials and labor to be lost. More recently, reducing waste and eliminating defects
have taken a major step forward with the development of six sigma techniques. Six sigma tools
compliment the lean framework, and many practitioners describe the combination as Lean Six Sigma.





JIT
Objective: Reduce movement of people & material
Movement is waste
JIT requires
Work cells for product families
Moveable or changeable machines
Short distances
Little space for inventory
Delivery directly to work areas
Objective: Eliminate inventory
JIT requires
Small lot sizes
Low setup time
Containers for fixed number of parts

MRP
The major objectives of an MRP system are to simultaneously:
Ensure the availability of materials, components, and products for planned production and
for customer delivery,
2. Maintain the lowest possible level of inventory,
3. Plan manufacturing activities, delivery schedules, and purchasing activities

DIFFERENCE MRP & JIT
JIT and MRP are completely unlike, but are complementary concepts used in material planning and
control. MRP stands for Manufacturing Resource Planning, while JIT is Just in Time. MRP is a resource
and planning tool that is forward-thinking, and time-phased. The philosophy of JIT, on the other hand, is
based on the riddance of waste. One important feature of JIT is known as kanbas, which is a method of
performance based on restoring used material that has no forward visibility.
While operating a manufacturing business, it is possible to operate only with MRP, but the case isnt the
same with JIT, because it does allow for forward planning, which is a vital planning requirement
when running a manufacturing operation. There is a need to ensure that materials which cannot be
replaced by kanbas, can be availed when needed. This makes MRP a tool that gives more control, while
JIT increases the value of your processes.


Summary:
1 JIT is Just in Time, while MRP refers to Manufacturing Resource Planning.
2 MRP is a resource planning system that focuses on the future, and is time phased, while JIT does not provide
for forward-thinking.
3 The JIT system is a dynamically linked system, that is better applied for short lead times, while MRP is not
linked, and is better suited for long lead times.
4 Whereas the JIT system enhances the value of processes, MRP will give you more control.




AUTOMATIC STORAGE SYSTEM

different type automatic storage
1. Unit load AS/RS: is used to store and retrieve loads that are palletized or stored in standard-size
containers.
2. Mini-load AS/RS: is designed to handle small loads such as individual parts, tools, and supplies.
The system is suitable for use where there is a limit on the amount of space that can be utilized
and where the volume is too low for a full-scale unit load system and tool high for a manual
system.
3 Person-on-board AS/RS: allows storage of items in less than unit load quantities.
4. Deep-lane AS/RS: is another variation on the unit load system. The items are stored in
multi-deep storage with up to 10 items per row rather than single or double deep. This leads to
a high density of stored items.

Purpose


Other function of AGV

Navigation & Guidance allows the vehicle to follow a predetermined route which is optimized for the
material flow pattern of a given application
Routing is the vehicles ability to make decisions along the guidance path in order to select optimum
routes to specific destinations
Traffic Management is a system or vehicle ability to avoid collisions with other vehicles while at the
same time maximizing vehicle flow and therefore load movement throughout the system.
Load Transfer is the pickup and delivery method for an AGVS system, which may be simple or
integrated with other subsystems.
System Management is the method of system control used to dictate system operation.


Difference CNC and DNC

main difference is tht CNC has a computer dedicated to operate and control only 1 machine. Whereas DNC has a
computer which operates and control more than 1 machine.
Direct numerical control(DNC) is a manufacturing system in which a number of NC machines are controlled by
a computer through direct connection at a time.and computer numerical control (CNC) is the numericalcontrol
system in which a dedicated computer is built into the control to perform basic and advanced NC(numirical
control) functions..


Difference token ring, token bus, CSMACD

Token ring
A single electronic token moves around the ring from one computer to the next. If a computer does not have
information to transmit, it simply passes the token on to the next workstation. If a computer wishes to transmit
and receives an empty token, it attaches data to the token. The token then proceeds around the ring until it comes
to the computer for which the data is meant. At this point, the data is captured by the receiving computer.

Token bus
This is a combination of the concepts of token rings and the Ethernet bus.
There are 2 routing modes for the token. When carrying a message, the token goes directly from source to
destination. When the token is empty, it makes the complete loop, following the chain, while looking for new
messages to send.

Csmacd
Suppose two devices want to put a message on the Ethernet at the same time. The answer is that the
messages will actually collide. A protocol called CSMA/CD (carrier sense multiple access with
collision detection) handles this problem.
When message collide, both of the sending devices are notified by the CSMA/CD, which jams the
entire network so that all devices will stop transmitting. After waiting an appropriate time, device
transceivers can again attempt to transmit messages.

Speed
Protocol Cable Speed Topology
Ethernet
Twisted Pair,
Coaxial, Fiber
10 Mbps Linear Bus, Star, Tree
Fast
Ethernet
Twisted
Pair,
Fiber
100 Mbps
Star
LocalTalk
Twisted
Pair
.23 Mbps
Linear Bus or Star
Token
Ring
Twisted
Pair
4 Mbps -
16 Mbps
Star-Wired Ring
FDDI Fiber 100 Mbps
Dual ring
ATM
Twisted
Pair,
Fiber
155-2488
Mbps
Linear Bus, Star, Tree


Topology type

1 Ring
All individual user stations are connected in a continuous ring. This message is forwarded from one station to the
next until it reaches its assigned destination. If any station fails, the entire network will shut down.
2 bus
All stations have independent access. This system is reliable and easier than the other two to service.
3 linear bus
A linear bus topology consists of a main run of cable with a terminator at each end. All nodes (file server,
workstations, and peripherals) are connected to the linear cable.
Advantages of a Linear Bus Topology
Easy to connect a computer or peripheral to a linear bus.
Requires less cable length than a star topology.

Disadvantages of a Linear Bus Topology
Entire network shuts down if there is a break in the main cable.
Terminators are required at both ends of the backbone cable.
Difficult to identify the problem if the entire network shuts down.
Not meant to be used as a stand-alone solution in a large building.

4 tree
Tree topologies integrate multiple star topologies together onto a bus. In its simplest form, only hub devices
connect directly to the tree bus, and each hub functions as the "root" of a tree of devices. This bus/star hybrid
approach supports future expandability of the network much better than a bus (limited in the number of devices
due to the broadcast traffic it generates) or a star (limited by the number of hub connection points) alone.
5 star
The central control/station is called a server because its network role is to make the
interconnection between the various robots, NC machines & automation devices that need to
communicate.
Suitable for situations that are not subject to frequent configuration changes. All message pass
through a central station.
This is not a popular type of LAN for CIM. Telephone systems in office buildings usually have this
type of topology.