Computer numerical control

CNC ‫التحكم الرقمي بالحاسوب‬

‫ علي محمد عبد الشاهد‬:‫إعداد الدكتور‬

Ali Mohmed Abdulshahed, BSc, MSc, PhD.

Email: aa_shahed@yahoo.com ‫ مقدمة‬: b01 ‫المحاضرة‬

Email: a.abdulshahed@eng.misuratau.edu.ly
ORCID ID: http://orcid.org/0000-0001-7630-0606
 Manufacturing

Manufacturing can be defined as the application of physical and/or chemical processes to alter the geometry, properties,
and/or appearance of a given starting material to make parts or products. Manufacturing also includes the joining of
multiple parts to make assembled products.

‫إعداد الدكتور علي عبد الشاهد‬

aa_shahed@yahoo.com
 Manufacturing
Production Capacity
EXAMPLE
The automatic lathe department has five machines, all devoted to the production of the same product. The
machines operate two 8-hr shifts, 5 days/week, 50 weeks/year. Production rate of each machine is 15 unit/hr.
Determine the weekly production capacity of the automatic lathe department.

Solution

PC = the production capacity of a given facility

‫إعداد الدكتور علي عبد الشاهد‬

aa_shahed@yahoo.com
 Manufacturing
Production Quantity and Product Variety
EXAMPLE

Suppose a company has designed a new product line and is planning to build a new plant to manufacture this
product line. The new line consists of 100 different product types, and for each product type the company wants to
produce 10,000 units annually. The products average 1,000 components each, and the average number of processing
steps required for each component is 10. All parts will be made in the factory. Each processing step takes an average
of 1 min. Determine (a) how many products, (b) how many parts, and (c) how many production operations will be
required each year, and (d) how many workers will be needed in the plant, if each worker works 8 hr per shift for 250
days/yr (2,000 hr/yr)?

Solution

‫إعداد الدكتور علي عبد الشاهد‬

aa_shahed@yahoo.com
 Manufacturing
a) The total number of units to be produced by the factory annually is given by

b) The total number of parts produced annually is

c) The number of distinct production operations is

d) First consider the total time TT to perform these operations. If each operation takes 1 min (1/60 hr)

If each worker works 2,000 hr/yr, then the total number of workers required is
 Manufacturing
Manufacturing Lead Time MLT

MLT is defined as the total time required to process a given part or product through the plant, including any time
due to delays, parts being moved between operations, time spent in queues, and so on.
Let Tc = the operation cycle time at a given machine, and Tno = the nonoperation time associated with each
operation. Further, suppose that the number of separate operations (machines) through which the work unit
must be routed = no. In batch production, there are Q work units in the batch. A setup is generally required to
prepare each machine for the particular product, which requires a time = Tsu. Given these terms, manufacturing
lead time for a given batch is defined as

EXAMPLE
A certain part is produced in batch sizes of 100 units. The batches must be routed through five operations to
complete the processing of the parts. Average setup time is 3.0 hr/batch, and average operation time is 6.0
min/pc. Average nonoperation time is 7.5 hr for each operation. Determine the manufacturing lead time to
complete one batch, assuming the plant runs 8 hr/ day, 5 days/wk.
Solution

‫إعداد الدكتور علي عبد الشاهد‬

aa_shahed@yahoo.com
 Manufacturing
Manual versus Automated Production
Manufacturing costs can be classified into two major categories: (1) fixed costs and (2) variable costs. A fixed cost is
one that remains constant for any level of production output. Examples include the cost of the factory building and
production equipment, insurance, and property taxes. All of the fixed costs can be expressed as annual amounts.
Expenses such as insurance and property taxes occur naturally as annual costs. Capital investments such as building
and equipment can be converted to their equivalent uniform annual costs using interest rate factors.

A variable cost is one that varies in proportion to production output. As output increases, variable cost increases.
Examples include direct labor, raw materials, and electric power to operate the production equipment. The ideal
concept of variable cost is that it is directly proportional to output level. Adding fixed and variable costs results in
the following total cost equation:

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aa_shahed@yahoo.com
 Manufacturing
Manual versus Automated Production

When comparing automated and manual production methods, it is typical that the fixed cost of the automated
method is high relative to the manual method, and the variable cost of automation is low relative to the manual
method, as pictured in Figure. Consequently, the manual method has a cost advantage in the low quantity range,
while automation has an advantage for high quantities.

Fixed and variable costs as a function of

production output for manual and automated
production methods

‫إعداد الدكتور علي عبد الشاهد‬

aa_shahed@yahoo.com
 Manufacturing
Manual versus Automated Production

EXAMPLE
Two production methods are being compared, one manual and the other automated. The manual method produces
10 pc/hr and requires one worker at $15.00/hr. Fixed cost of the manual method is $5,000/yr. The automated
method produces 25 pc/hr, has a fixed cost of $55,000/yr, and a variable cost of $4.50/hr. Determine the break-even
point for the two methods; that is, determine the annual production quantity at which the two methods have the
same annual cost. Ignore the costs of materials used in the two methods.
Solution

‫إعداد الدكتور علي عبد الشاهد‬

aa_shahed@yahoo.com
 Manufacturing
Manual versus Automated Production

Solution

‫إعداد الدكتور علي عبد الشاهد‬

aa_shahed@yahoo.com