CHAPTER 1.

Modern Manufacturing Approaches

and Technologies

 Automation – use automated equipment rather than worker

 Material handling technologies – sequence of activity was involved in manufacturing
 Manufacturing systems - integration and coordination of multiple automated or
manual workstations
 Flexible manufacturing –low-volume/high-mix product categories was competed
 Quality programs – high quality will achieve with today’s customer
 CIM – expend the view of design, production, and logistics
 Lean production – less resources + more work

Production System Defined

An assortment of individuals, gear, and systems composed to achieve the assembling tasks of
an organization

1. Facilities -plant and equipment at the facility and the way the system is set up.

2. Manufacturing support systems – total procedures used by company management

production and technical and logistical solutions problem ordering ingredients,
moving on factory and make sure the product is up to quality standard

The Production System

PRODUCTION SYSTEM = manufacturing support system + factory equipment

Production System Facilities

Facilities include factories, production machines and tools, material handling equipment,
inspection controlling computer devices and systems production process
 Plant layout - the way the equipment is physically arranged at the factory
 Manufacturing system - a group of logical devices and factory workers

Manufacturing Systems
 Handheld system - a worker who performs one or more tasks without the aid of power
tools, but sometimes uses hand tools
 Machine Workers System - workers working with machine tools
 Automated systems - processes performed by machines without direct human
involvement

Manufacturing Support Systems

 Business functions - sales and marketing, order entry, cost accounting, customer
billing
 Product design - research and development, design engineering, prototype shop
 Manufacturing planning - process planning, production planning, MRP, capacity
planning
 Manufacturing control - shop floor control, inventory control, quality control

Automation in Production Systems

Two categories of automation in production systems:

1. Production system automation in factories

2. Computerized production support systems

 The two categories overlap due to production support systems are linked at the factory
production system
- Computer Integrated Manufacturing (CIM)
Automated Manufacturing Systems

 Automated machine tools

 Transfer lines
 Automated assembly systems
 Industrial robots that perform processing or assembly operations
 Automated material handling and storage systems to integrate manufacturing
operations
 Automatic inspection systems for quality control

Automated Manufacturing Systems

Fixed Automation
A production system in which the order the processing (or assembly) operation is determined
by device configuration.
Typical functions:

 Suitable for large production

 High initial investment in specially developed equipment
 High production
 Relatively inflexible in terms of accommodating large quantities of products

Programmable Automation
Production system with possibilities change the order of operations to suit it
different product configurations

Typical functions:
 High investment in multipurpose equipment
 Lower production rate than fixed automation
 Flexibility in dealing with variations and changes product configuration
 Best suited for series production
 The physical and programming settings for the components must be changed between
jobs (many)
Flexible Automation
Extensible programmable automation that allows the system to switch from one job to
another without wasting time between jobs

Typical functions:
 High investment for specially developed systems
 Sustainable production of variable product mixes
 Production rate is average
 The flexibility to handle a wide variety of products

Computerized Manufacturing Support Systems

The purpose of production support automation

System:
 Reduction in manual and office work on product design, production planning and
control business function
 Integrating Computer Aided Design (CAD) and automated production (CAM) in
CAD / CAM
 CIM covers CAD / CAM and business functions company

Reasons for Automating

1) Increased labor productivity
2) Reduce labor costs
3) Reducing the effects of labor shortages
4) Reduce or eliminate manual routines and office work
5) Increased work safety
6) Product quality improvement
7) Reduce production time
8) To achieve what cannot be done manually
9) To avoid high costs of non-automation
Automation Principles and Strategies

The USA Principle

1) Understand the process
 Input / output analysis
 Value chain analysis
 Graphic engineering and mathematical modeling
2) Simplify the process
 Reduce unnecessary steps and movements
3) Automate the process

 Ten strategies for automation and production Systems

 Migration automation strategy

Ten Strategies for Automation and Process Improvement

 Specialties of operation
 Combined operation
 Simultaneous operation
 Operations integration
 Increased flexibility
 Better material handling and storage
 Check online
 Process control and optimization
 Control of plant operations
 Computer integrated production
Automation Migration Strategy For Introduction of New Products
Stage 1 - manual production
 Single station manned cells work independently of each other
 Advantage: quick setup, cheap tool

Stage 2 - automatic production

 Automatic cell works with one station any
 When demand increases, automation can be guaranteed

Stage 3 - Automated Integrated Production

 Multi-station system with serial operation and automatic transfer of work items between
stations