HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION

FACULTY OF ELECTRICAL AND ELECTRONIC ENGINEERING

Hệ thống sản xuất tích hợp (FMS and CIM)

Lecturer: Dr. Trần Mạnh Sơn

Department of Automatic Control
Email: sontm@hcmute.edu.vn
0919 197 139

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 Rules in Class

➢ Attend at least 80% of class hours

➢ Complete all home-works, assignments (If any), and Mid-term

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 Assessment

➢ Assignment (50%)
✓ Mid-term 1, Mid-term 2
➢ Final Exam (50%)
✓ Writen exam

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 Textbook and References

[1] Hệ thống sản xuất tích hợp, Đặng Thiện Ngôn, Lê Chí Cương
[2] Automation Production System, and Computer Integrated Manufacturing, Mikell

P. Groover, 2015
➢ Software:
✓ Factory IO
✓ SolidWorks

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 Content of this course

➢ Chapter 1: Introduction
➢ Chapter 2: Life Cycle of Product
➢ Chapter 3: Overview of Manufacturing
➢ Chapter 4: Elements of CIM
➢ Chapter 5: Automatic Identification and Data Capture
➢ Chapter 6: Quality Control Systems
➢ Chapter 7: Just-in-Time Manufacturing, Lean Manufacturing

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 Overview of Manufacturing

Chapter 3: Overview of Manufacturing

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 Content of Chapter 3

➢ 3.1 Concepts
➢ 3.2 Product/production relationships
➢ 3.3 Manufacturing performance

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 Concepts

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 Concepts

Manufacturing: 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

Technological process Economic process

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 Concepts

✓ Manufacturing Industries: enterprises and organizations that produce, supply goods,

and service

Manufacturing Industries
Primary Industries: Cultivate/exploit
natural resources (Agriculture, Mining)

Secondary Industries: Produce

products
Tertiary industries : Services (Bank,
Education, Entertainment..)

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 Concepts

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 Concepts

✓ Continuous production: the output of the product is uninterrupted

Process Industry Discrete Manufacturing Industry

✓ Batch production: when the materials are processed in finite amounts or quantities

Process Industry Discrete Manufacturing Industry

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 Concepts

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 Concepts

➢ Manufacturing Operations: convert raw materials into finished products

Manufacturing
Operations

processing operation Assembly operation

Uses energy to alter a

work part’s shape, Two or more separate
physical properties, or parts are joined to form
appearance to add a new entity
value to the material

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 Product/production relationships

➢ Production quantity: refers to the number of units of a given part or product produced
annually by the plant
➢ Product variety: refers to the different product designs or types that are produced in a
plant

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 Product/production relationships

➢ Layout in manufactory:
❖Product product
remains in a single
location during its
entire fabrication.
❖Products include
ships, aircraft, railway
locomotives, and
heavy machinery.

Fixed position layout

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 Product/production relationships

➢ Layout in manufactory:
❖Equipment is arranged
according to function or type
❖Ex. The lathes are in one
department, the milling
machines are in another
department
❖Material handling is required
to move parts between
departments
Process layout ❖Inventory tends to be high

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 Product/production relationships

➢ Layout in manufactory:
❖Groups of similar parts or
products can be made on the
same equipment without
significant lost time for
changeovers

Cellular layout
➢ Workstations are arranged into
one long line/ into a series of
connected line segments.
➢ Assembly line: cars and
household appliances, main
boards.
Product layout
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 Product/production relationships

➢ Quantity-based manufacturing classification:

✓ Low Production (Job Shop): Low quantity range of 1–100 units/ year
• Specialized and customized products
• Products are typically complex, such as experimental aircraft and special
machinery

✓ Medium Production: medium quantity range (100–10,000 units annually). Batch

production
✓ High Production: high quantity range (10,000 to millions of units per year) (Mass
Production)

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 Product/production relationships

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 Manufacturing Performance

➢ Cycle time analysis: The cycle time Tc is the time that one work unit1 spends being
processed or assembled

Tc = cycle time, min/pc

To = time of the actual processing or assembly operation min/pc
Th = handling time, min/pc
Tt = average tool handling time, min/pc (tool handling time consists of time spent changing
tools when they wear out, time changing from one tool to the next

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 Manufacturing Performance

➢ Production rate: expressed as an hourly rate, that is, work units completed per hour

Operation Cycle time

Production rate
Type of Production
• Job shop production
• Batch Production
• Mass Production

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 Manufacturing Performance

✓ Job Shop Production: Quantities less than 100 pcs. If Q=1 (quantity)

Tp = average production time, min/pc

Tsu = setup time to prepare the machine to produce the part, min/pc
Tc = cycle time
 Production Rate:

 Rp = hourly production rate, pc/hr

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 Manufacturing Performance

✓ Batch Production: (Sequential batch processing, Simultaneous Batch)

Sequential Batch Simultaneous Batch

Batch processing time(Tb- Batch processing time(Tb-
min/batch) min/batch)

Tsu = setup time; Q = batch Tsu = setup time; Tc = cycle time per
quantity, pc/batch; Tc = cycle time work unit, min/cycle.
per work unit, min/cycle.

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 Manufacturing Performance

 Average production time per work unit Tp

 Production Rate:

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 Manufacturing Performance

✓ Mass production: quantity mass production & flow-line mass production

Quantity Mass Production Flow-line Mass Production

Production rate(Rp) = cycle Production rate(Rp) =cycle rate of the
rate of the machine (Rc). machine (Rc).
Q is very large,

S
S Tc: cycle time of production line. Max To:
maximum of the operation times for all
stations on the line. Tr: time to transfer
work units between stations each cycle.

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 Manufacturing Performance

A batch of parts is produced on a semi-automated production machine. Batch size

is 200 units. Setup requires 55 min. A worker loads and unloads the machine each cycle,
which takes 0.44 min. Machine processing time is 2.86 min/cycle, and tool handling time
is negligible. One part is produced each cycle.
Determine:
(a) Average cycle time,
(b) Time to complete the batch, and
(c) Average production rate
 Solution:
a) 𝑇𝑐 = 𝑇0 + 𝑇ℎ = 0.44 + 2.86 = 3.3𝑚𝑖 𝑛Τ𝑝 𝑐

b) 𝑇b = 𝑇su + Q𝑇c = 55 + 200x3.3 = 11.92hr

c) Rp=16.78pc/hr

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 Manufacturing Performance

✓ Production capacity:
Maximum rate of output that a production facility (or production line, or group of
machines) is able to produce under a given set of assumed operating conditions
Determine Production Capacity

PC = Production capacity, pc/period; n = number of machines; and Hpc = the number

of hours

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 Manufacturing Performance

Example: Production Capacity

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.
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 Manufacturing Performance

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 Manufacturing Performance

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 Manufacturing Performance

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 Manufacturing Performance

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 Manufacturing Performance

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 Manufacturing Performance

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 Manufacturing Performance

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 Manufacturing Performance

✓ Utilization: the proportion of time that a productive resource (e.g., a production

machine) is used relative to the time available under the definition of plant capacity

Ui = utilization of machine i
fij = the fraction of time during the available hours that machine i is processing part style j
Overall utilization for the plant:
n n
 f
i =1
ij U i
U= j
= i =1

n n

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 Manufacturing Performance

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 Manufacturing Performance

Workload: 72 hr
For plant capacity: maximum
number of hours (80 hr)

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 Manufacturing Performance

➢ Adjusting plant Capacity:

✓ Increase or decrease the number of machines n in the plant
✓ Increase or decrease the number of shifts per week
✓ Increase or decrease the number of hours worked per shift
✓ Increase the production rate Rp by making improvements in methods and/or
processing technology

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 Manufacturing Performance

✓ Manufacturing-Lead time:

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 Manufacturing Performance

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 Manufacturing Performance

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 Manufacturing Performance

✓ Work-in-process: the quantity of parts or products currently located in the factory that
either are being processed or are between processing operations

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 Manufacturing Performance

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 Manufacturing Cost

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 Manufacturing Cost

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 Manufacturing Cost

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 Manufacturing Cost

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 Manufacturing Cost

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 Manufacturing Cost

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 Manufacturing Cost

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 Manufacturing Cost

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 Manufacturing Cost

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 Manufacturing Cost

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 Manufacturing Cost

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 Manufacturing Cost

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 Several Examples

Thank You For Your Listening

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