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

• 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
• Work to man an not man to work Comunication
• 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
fix Layout

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