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Manufacturing Systems

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Manufacturing Systems
Comprises of – Inputs, Transformation Process and Output

Manufacturing Systems
Comprises of – Inputs, Transformation Process and Output Input – Men, Materials,Machines Drawings,, Instructions, Paper Work etc

Manufacturing Systems
Comprises of – Inputs, Transformation Process and Output Input – Men, Materials,Machines Drawings,, Instructions, Paper Work etc Trans Process- Planning, Control, Storage, Procure, Insp,Assembly, Instructions etc.

Manufacturing Systems
Comprises of – Inputs, Transformation Process and Output Input – Men, Materials,Machines Drawings,, Instructions, Paper Work etc Trans Process- Planning, Control, Storage, Procure, Insp,Assembly, Instructions etc. Output- Goods, Services, Parts, Paperwork, Served Customers etc.

Manufacturing Systems
Comprises of – Inputs, Transformation Process and Output Input – Men, Materials,Machines Drawings,, Instructions, Paper Work etc Trans Process- Planning, Control, Storage, Procure, Insp,Assembly, Instructions etc. Output- Goods, Services, Parts, Paperwork, Served Customers etc. *

Factors Influencing -Mfg System

Factors Influencing -Mfg System
Volume of Production

Factors Influencing -Mfg System
Volume of Production Repetitiveness

Factors Influencing -Mfg System
Volume of Production Repetitiveness Plant Capacity

Factors Influencing -Mfg System
Volume of Production Repetitiveness Plant Capacity Flexibility

Factors Influencing -Mfg System
Volume of Production Repetitiveness Plant Capacity Flexibility Lead Time

Factors Influencing -Mfg System
Volume of Production Repetitiveness Plant Capacity Flexibility Lead Time Efficiency

Factors Influencing -Mfg System
Volume of Production Repetitiveness Plant Capacity Flexibility Lead Time Efficiency Environment

Factors Influencing -Mfg System
Volume of Production Repetitiveness Plant Capacity Flexibility Lead Time Efficiency Environment *

Type of Production
Intermittent Continuous

Mass/Flow

Process

Project

Jobbing

Batch

Selection of Mfg System

Selection of Mfg System

Variety

Selection of Mfg System

Jobbing

Variety

Selection of Mfg System

Batch Jobbing

Variety

Selection of Mfg System
Mass Batch Jobbing

Variety

Selection of Mfg System
Continuous Mass Batch Jobbing

Variety

Selection of Mfg System
Continuous Mass Batch Qty Jobbing

Variety

Selection of Mfg System

Selection of Mfg System

Quantity

Selection of Mfg System
Jobbing

Quantity

Selection of Mfg System
Jobbing Batch

Quantity

Selection of Mfg System
Jobbing Batch Mass

Quantity

Selection of Mfg System
Jobbing Batch Mass Continuous

Quantity

Selection of Mfg System
Jobbing Batch Mass Continuous Cost

Quantity

Selection of Mfg System
Jobbing Batch Mass Continuous Cost

Growth

Quantity

Selection of Mfg System
Jobbing Batch Mass Continuous Cost

Growth Intro

Quantity

Selection of Mfg System
Jobbing Batch Mass Continuous Cost

Maturity Growth Intro

Quantity

Jobbing Type Manufacturing System

Jobbing Type Manufacturing System
Small Requirements

Jobbing Type Manufacturing System
Small Requirements Discontinuous flow, imbalance

Jobbing Type Manufacturing System
Small Requirements Discontinuous flow, imbalance Disproportionate Manufacturing Cycle

Jobbing Type Manufacturing System
Small Requirements Discontinuous flow, imbalance Disproportionate Manufacturing Cycle General Purpose Machines, Process layout

Jobbing Type Manufacturing System
Small Requirements Discontinuous flow, imbalance Disproportionate Manufacturing Cycle General Purpose Machines, Process layout Skilled Labour

Jobbing Type Manufacturing System
Small Requirements Discontinuous flow, imbalance Disproportionate Manufacturing Cycle General Purpose Machines, Process layout Skilled Labour Skilled supervisor

Jobbing Type Manufacturing System
Small Requirements Discontinuous flow, imbalance Disproportionate Manufacturing Cycle General Purpose Machines, Process layout Skilled Labour Skilled supervisor Higher WIP

Jobbing Type Manufacturing System
Small Requirements Discontinuous flow, imbalance Disproportionate Manufacturing Cycle General Purpose Machines, Process layout Skilled Labour Skilled supervisor Higher WIP PPC …. Limited functions

Jobbing Type Manufacturing System
Small Requirements Discontinuous flow, imbalance Disproportionate Manufacturing Cycle General Purpose Machines, Process layout Skilled Labour Skilled supervisor Higher WIP PPC …. Limited functions * Ships, Cranes, Furnaces,Boilers, Equipment

Projects Type Mfg System

Projects Type Mfg System
Definite Beginning and End

Projects Type Mfg System
Definite Beginning and End Non Uniform requirement of resources,

Projects Type Mfg System
Definite Beginning and End Non Uniform requirement of resources, Transferable Teams…. Loc A to B

Projects Type Mfg System
Definite Beginning and End Non Uniform requirement of resources, Transferable Teams…. Loc A to B Different Agencies, Specialized tasks,

Projects Type Mfg System
Definite Beginning and End Non Uniform requirement of resources, Transferable Teams…. Loc A to B Different Agencies, Specialized tasks, Typical layout- all operations .. Place same

Projects Type Mfg System
Definite Beginning and End Non Uniform requirement of resources, Transferable Teams…. Loc A to B Different Agencies, Specialized tasks, Typical layout- all operations .. Place same Cost overruns

Projects Type Mfg System
Definite Beginning and End Non Uniform requirement of resources, Transferable Teams…. Loc A to B Different Agencies, Specialized tasks, Typical layout- all operations .. Place same Cost overruns Manpower problems, not permanent, Psychological detachment, Site work

Projects Type Mfg System
Definite Beginning and End Non Uniform requirement of resources, Transferable Teams…. Loc A to B Different Agencies, Specialized tasks, Typical layout- all operations .. Place same Cost overruns Manpower problems, not permanent, Psychological detachment, Site work * Ships, Locomotives, Roads,Buildings, Dams

Advantages Job/Project Production

Advantages Job/Project Production
Discontinuous Flow –
Equipment, Special Products,

Advantages Job/Project Production
Discontinuous Flow – No Mechanization
Equipment, Special Products,

Advantages Job/Project Production
Discontinuous Flow – No Mechanization Each Job is Different
Equipment, Special Products,

Advantages Job/Project Production
Discontinuous Flow – Equipment, Special Products, No Mechanization Each Job is Different Special Training , Division of Labour

Advantages Job/Project Production
Discontinuous Flow – Equipment, Special Products, No Mechanization Each Job is Different Special Training , Division of Labour Complicated Planning/Control

Advantages Job/Project Production
Discontinuous Flow – Equipment, Special Products, No Mechanization Each Job is Different Special Training , Division of Labour Complicated Planning/Control Time for design

Advantages Job/Project Production
Discontinuous Flow – Equipment, Special Products, No Mechanization Each Job is Different Special Training , Division of Labour Complicated Planning/Control Time for design General Purpose M/c and Layout

Advantages Job/Project Production
Discontinuous Flow – Equipment, Special Products, No Mechanization Each Job is Different Special Training , Division of Labour Complicated Planning/Control Time for design General Purpose M/c and Layout Unit Quantity

Advantages Job/Project Production
Discontinuous Flow – Equipment, Special Products, No Mechanization Each Job is Different Special Training , Division of Labour Complicated Planning/Control Time for design General Purpose M/c and Layout Unit Quantity * Maximum WIP

Batch Type Manufacturing System

Batch Type Manufacturing System
Short Runs

Batch Type Manufacturing System
Short Runs Skilled Labour for specific work

Batch Type Manufacturing System
Short Runs Skilled Labour for specific work Skilled Supervisor

Batch Type Manufacturing System
Short Runs Skilled Labour for specific work Skilled Supervisor Limited Span of Control

Batch Type Manufacturing System
Short Runs Skilled Labour for specific work Skilled Supervisor Limited Span of Control General Purpose Machines

Batch Type Manufacturing System
Short Runs Skilled Labour for specific work Skilled Supervisor Limited Span of Control General Purpose Machines Manual Handling…………………Large WIP

Batch Type Manufacturing System
Short Runs Skilled Labour for specific work Skilled Supervisor Limited Span of Control General Purpose Machines Manual Handling…………………Large WIP Queues………………………Flexibility

Batch Type Manufacturing System
Short Runs Skilled Labour for specific work Skilled Supervisor Limited Span of Control General Purpose Machines Manual Handling…………………Large WIP Queues………………………Flexibility Strong PPC required

Batch Type Manufacturing System
Short Runs Skilled Labour for specific work Skilled Supervisor Limited Span of Control General Purpose Machines Manual Handling…………………Large WIP Queues………………………Flexibility Strong PPC required * Paints, Pharma,Chemicals, Garments,Vehicl

Advantages of Batch Production

Advantages of Batch Production
Most Common –Drugs, Cloths,Automat Comp,Forgings,Cast

Advantages of Batch Production
Most Common –Drugs, Cloths,Automat Comp,Forgings,Cast Items Manufactured in Batches

Advantages of Batch Production
Most Common –Drugs, Cloths,Automat Comp,Forgings,Cast Items Manufactured in Batches Intermittent Flow of Material

Advantages of Batch Production
Most Common –Drugs, Cloths,Automat Comp,Forgings,Cast Items Manufactured in Batches Intermittent Flow of Material Division of Labour is Possible

Advantages of Batch Production
Most Common –Drugs, Cloths,Automat Comp,Forgings,Cast Items Manufactured in Batches Intermittent Flow of Material Division of Labour is Possible Tedious Planning/Control

Advantages of Batch Production
Most Common –Drugs, Cloths,Automat Comp,Forgings,Cast Items Manufactured in Batches Intermittent Flow of Material Division of Labour is Possible Tedious Planning/Control Less Space, Min Maintenance

Advantages of Batch Production
Most Common –Drugs, Cloths,Automat Comp,Forgings,Cast Items Manufactured in Batches Intermittent Flow of Material Division of Labour is Possible Tedious Planning/Control Less Space, Min Maintenance Attention Required on Quality

Advantages of Batch Production
Most Common –Drugs, Cloths,Automat Comp,Forgings,Cast Items Manufactured in Batches Intermittent Flow of Material Division of Labour is Possible Tedious Planning/Control Less Space, Min Maintenance Attention Required on Quality Right Quantity

Advantages of Batch Production
Most Common –Drugs, Cloths,Automat Comp,Forgings,Cast Items Manufactured in Batches Intermittent Flow of Material Division of Labour is Possible Tedious Planning/Control Less Space, Min Maintenance Attention Required on Quality Right Quantity * WIP can be adjusted

Mass Type Manufacturing System

Mass Type Manufacturing System
Continuous Flow

Mass Type Manufacturing System
Continuous Flow Special Machines

Mass Type Manufacturing System
Continuous Flow Special Machines Mechanized Handling

Mass Type Manufacturing System
Continuous Flow Special Machines Mechanized Handling Low Skills

Mass Type Manufacturing System
Continuous Flow Special Machines Mechanized Handling Low Skills Short manufacturing Cycle

Mass Type Manufacturing System
Continuous Flow Special Machines Mechanized Handling Low Skills Short manufacturing Cycle Low WIP

Mass Type Manufacturing System
Continuous Flow Special Machines Mechanized Handling Low Skills Short manufacturing Cycle Low WIP No Queues………………………No Flexibility

Mass Type Manufacturing System
Continuous Flow Special Machines Mechanized Handling Low Skills Short manufacturing Cycle Low WIP No Queues………………………No Flexibility No PPC required

Mass Type Manufacturing System
Continuous Flow Special Machines Mechanized Handling Low Skills Short manufacturing Cycle Low WIP No Queues………………………No Flexibility No PPC required * Steel, Paper,Refinery, Sugar

Advantages of Mass/Flow Production

Advantages of Mass/Flow Production
Smooth Flow –
Screws, TV sets, Cars, Cycles,

Advantages of Mass/Flow Production
Smooth Flow – Screws, TV sets, Cars, Cycles, Minimum time/unit, Cost/unit

Advantages of Mass/Flow Production
Smooth Flow – Screws, TV sets, Cars, Cycles, Minimum time/unit, Cost/unit Minimum Handling

Advantages of Mass/Flow Production
Smooth Flow – Screws, TV sets, Cars, Cycles, Minimum time/unit, Cost/unit Minimum Handling No Special Training , Division of Labour

Advantages of Mass/Flow Production
Smooth Flow – Screws, TV sets, Cars, Cycles, Minimum time/unit, Cost/unit Minimum Handling No Special Training , Division of Labour Simple Planning/Control

Advantages of Mass/Flow Production
Smooth Flow – Screws, TV sets, Cars, Cycles, Minimum time/unit, Cost/unit Minimum Handling No Special Training , Division of Labour Simple Planning/Control Less Space

Advantages of Mass/Flow Production
Smooth Flow – Screws, TV sets, Cars, Cycles, Minimum time/unit, Cost/unit Minimum Handling No Special Training , Division of Labour Simple Planning/Control Less Space Right Quality

Advantages of Mass/Flow Production
Smooth Flow – Screws, TV sets, Cars, Cycles, Minimum time/unit, Cost/unit Minimum Handling No Special Training , Division of Labour Simple Planning/Control Less Space Right Quality Right Quantity

Advantages of Mass/Flow Production
Smooth Flow – Screws, TV sets, Cars, Cycles, Minimum time/unit, Cost/unit Minimum Handling No Special Training , Division of Labour Simple Planning/Control Less Space Right Quality Right Quantity * Minimum WIP

Disadvantages of Mass Production

Disadvantages of Mass Production
Stoppage ..Breakdown

Disadvantages of Mass Production
Stoppage ..Breakdown Complicated Maintenance

Disadvantages of Mass Production
Stoppage ..Breakdown Complicated Maintenance Change in Product Difficult

Disadvantages of Mass Production
Stoppage ..Breakdown Complicated Maintenance Change in Product Difficult Change in Layout Difficult

Disadvantages of Mass Production
Stoppage ..Breakdown Complicated Maintenance Change in Product Difficult Change in Layout Difficult System speed = Slowest m/c Speed

Disadvantages of Mass Production
Stoppage ..Breakdown Complicated Maintenance Change in Product Difficult Change in Layout Difficult System speed = Slowest m/c Speed Special Supervision Skills

Disadvantages of Mass Production
Stoppage ..Breakdown Complicated Maintenance Change in Product Difficult Change in Layout Difficult System speed = Slowest m/c Speed Special Supervision Skills High Investment

Disadvantages of Mass Production
Stoppage ..Breakdown Complicated Maintenance Change in Product Difficult Change in Layout Difficult System speed = Slowest m/c Speed Special Supervision Skills High Investment Special Machines

Disadvantages of Mass Production
Stoppage ..Breakdown Complicated Maintenance Change in Product Difficult Change in Layout Difficult System speed = Slowest m/c Speed Special Supervision Skills High Investment Special Machines * Problem with WIP

Analysis of Production System

Analysis of Production System
Factor Items
Equipment

Jobbing Standard Standard
M/c Groups

Batch Standard Standard
M/c Groups

Mass Designed Layout Arranged

Process Plant Outside Designed
Continuous

Building Layout Flow Cost/time WIP Handling
Supervisor
Sales/Design

Nil High High Standard Tech Tech

Continuous Nil Moderate Small medium Small Standard Special Specialized
Tech,Special

Specialized

Special

Least Nil Nil Co-ordin. Special

Selection.. Comparison 1
Size..Quantity Capital Investment Mfg Cost Tech (Op) Skills Orgn Structure Flexibility Job Security Type Small Lowest Highest High Medium Medium Medium High Medium Partly Low Batch Large Large Lowest Low High No High ? Mass/Pr

Supervisory Skill Medium Yes Low Job/Proj

Versatile Versatile Specific

Selection.. Comparison 2
Size..Quantity Repeatability Fixed Cost Variable Cost PPC Involvement Lead time Efficiency New Technology Type Small Lowest Minimum High Good Poor Low Job/Proj Medium Medium Medium Medium Medium Large Good Highest Low Min

Maximum Moderate Min Moderate Good Low Batch High Mass/Pr

Selection.. Comparison 3
Quality Plant Layout ?? Flexible Medium Flexible Medium Partly Partly Consisten t Unchange d Full No No

M/c Utilization Optimum Variety of Jobs Yes Switchover Yes

Type

Job

Batch

Mass

Functions of Production Engineer

Functions of Production Engineer
Establish Correct way of Process thru Study

Functions of Production Engineer
Establish Correct way of Process thru Study Eliminate Unnecessary Operations

Functions of Production Engineer
Establish Correct way of Process thru Study Eliminate Unnecessary Operations Prepare Drawing of All fixtures required

Functions of Production Engineer
Establish Correct way of Process thru Study Eliminate Unnecessary Operations Prepare Drawing of All fixtures required Time,Method Studies

Functions of Production Engineer
Establish Correct way of Process thru Study Eliminate Unnecessary Operations Prepare Drawing of All fixtures required Time,Method Studies Establish Process with Mutual Consent

Functions of Production Engineer
Establish Correct way of Process thru Study Eliminate Unnecessary Operations Prepare Drawing of All fixtures required Time,Method Studies Establish Process with Mutual Consent Estimate Correct Cost

Functions of Production Engineer
Establish Correct way of Process thru Study Eliminate Unnecessary Operations Prepare Drawing of All fixtures required Time,Method Studies Establish Process with Mutual Consent Estimate Correct Cost Train for Effective Performance

Functions of Production Engineer
Establish Correct way of Process thru Study Eliminate Unnecessary Operations Prepare Drawing of All fixtures required Time,Method Studies Establish Process with Mutual Consent Estimate Correct Cost Train for Effective Performance * Updated on Modern Development, Methods

Process Formulation

Process Formulation
Define Problem

Process Formulation
Define Problem Define Effectiveness

Process Formulation
Define Problem Define Effectiveness Construct Model e= f ( x,y)

Process Formulation
Define Problem Define Effectiveness Construct Model e= f ( x,y) Search Alternatives .. List

Process Formulation
Define Problem Define Effectiveness Construct Model e= f ( x,y) Search Alternatives .. List Analysis of alternatives .. Pro…cons

Process Formulation
Define Problem Define Effectiveness Construct Model e= f ( x,y) Search Alternatives .. List Analysis of alternatives .. Pro…cons Evaluation of Alternatives

Process Formulation
Define Problem Define Effectiveness Construct Model e= f ( x,y) Search Alternatives .. List Analysis of alternatives .. Pro…cons Evaluation of Alternatives * Decide Optimum Solution

Production System Analysis

Production System Analysis
Linear Programming

Production System Analysis
Linear Programming Waiting List Model

Production System Analysis
Linear Programming Waiting List Model Simulation Models

Production System Analysis
Linear Programming Waiting List Model Simulation Models Network Model

Production System Analysis
Linear Programming Waiting List Model Simulation Models Network Model * Statistical Techniques

Manufacturing Processes Classification
Cons Mass Casting Forming Heat Treatm PM Polymer M Removal Machining Grinding Un- Conv M Addition Welding Mech Jointg Adhesive B

Metal Working Process

Manufacturing Processes 1
Casting Forging Extruding Rolling Drawing Squeezing Crushing Piercing Swaging Bending Shearing Spinning Roll Forming Torch Cutting Electroform.. Pwdr Forming Machinery * Profile Cutting

Stretch Forming

Manufacturing Processes 2
Turning Planing Shaping Drilling Boring Reaming Sawing Broaching Milling Grinding Hobbing * Routing

Manufacturing Processes 3
Polishing Belt grinding Tumbling Plating Honing Lapping Super-finishing Spraying Inorganic Coating Parkerizing Anodizing Sheradizing * Galvanizing

Manufacturing Processes 4
Welding Soldering Brazing Sintering Pressing Screw fastening * Adhesive Joining

Hot …. Cold Working

Hot …. Cold Working
Hot Working–> recrystallisation temperature

Hot …. Cold Working
Hot Working–> recrystallisation temperature Aprox 0.6 times Melting Point

Hot …. Cold Working
Hot Working–> recrystallisation temperature Aprox 0.6 times Melting Point Cold Working–< recrystallisation temperature

Hot …. Cold Working
Hot Working–> recrystallisation temperature Aprox 0.6 times Melting Point Cold Working–< recrystallisation temperature Aprox <0.3 melting point

Hot …. Cold Working
Hot Working–> recrystallisation temperature Aprox 0.6 times Melting Point Cold Working–< recrystallisation temperature Aprox <0.3 melting point CW- distorts grain

Hot …. Cold Working
Hot Working–> recrystallisation temperature Aprox 0.6 times Melting Point Cold Working–< recrystallisation temperature Aprox <0.3 melting point CW- distorts grain HW – refines grains

Hot …. Cold Working
Hot Working–> recrystallisation temperature Aprox 0.6 times Melting Point Cold Working–< recrystallisation temperature Aprox <0.3 melting point CW- distorts grain HW – refines grains * Costs involved

Plastic Deformation

Plastic Deformation
It done above re-crystallization temp. It does not produce strain in metal.

Plastic Deformation
It done above re-crystallization temp. It does not produce strain in metal. Aluminum 150 Deg C

Plastic Deformation
It done above re-crystallization temp. It does not produce strain in metal. Aluminum Copper 150 Deg C 200 Deg C

Plastic Deformation
It done above re-crystallization temp. It does not produce strain in metal. Aluminum Copper Gold 150 Deg C 200 Deg C 200 Deg C

Plastic Deformation
It done above re-crystallization temp. It does not produce strain in metal. Aluminum Copper Gold Iron 150 Deg C 200 Deg C 200 Deg C 450 Deg C

Plastic Deformation
It done above re-crystallization temp. It does not produce strain in metal. Aluminum Copper Gold Iron Nickel 150 Deg C 200 Deg C 200 Deg C 450 Deg C 590 Deg C

Plastic Deformation
It done above re-crystallization temp. It does not produce strain in metal. Aluminum Copper Gold Iron Nickel Silver 150 Deg C 200 Deg C 200 Deg C 450 Deg C 590 Deg C 200 Deg C

Plastic Deformation
It done above re-crystallization temp. It does not produce strain in metal. Aluminum Copper Gold Iron Nickel Silver * Zinc, Lead 150 Deg C 200 Deg C 200 Deg C 450 Deg C 590 Deg C 200 Deg C 45 Deg C

Metal Working Variables

Metal Working Variables
Input variables Dependent Output var

Mat Size,Shape,Properties Power required Geometry of Tool, Die Lubrication, Friction Starting Temperature Extent of deformation Speed of deformation Dimensional Accuracy Surface Finish Final Temperature Final Mat Stru/Properties Production Rate

Cold Working Process

Cold Working Process
Advantages Disadvantages

Better Dim Accuracy Good Surface Finish Stress,Fatigue, Wear Properties Improved Easy hardening

Strain Hardening limits defor Required intermediate HT Higher deformation energy>>heavy machinery Reduction in Ductility

Minimum Contamination Residual Stresses Produced

Hot Working Process

Hot Working Process
Advantages Low deformation energy>less power High reduction possible No strain Hardening High Ductility Mat structure can be altered to improve properties Disadvantages Poor surface finish … ..scaling Non uniform mat stress Difficult handling High cost m/c, heating Poor tolerances … thermal expansion

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Thank You ! and Wish You Best of e Life
pradeepvtupe@gmail.com
PT
Facilitator

P Chairman-The Institution of Engineers(I), Maharashtra State Centre, Secretary-Pune Management Association
Chartered Engineer, Marketing, Management Consultant, QMS-

MahaEngineers-Subscribe@yahoogroups.com

Impossible is Untried