İMALAT SİSTEMLERİ –

MANUFACTURING
SYSTEMS
 Expectations from Manufacturing
In general, obtain
 Functional-wise“fullfilling the needs”,

 Asthetically “satisfying”,

 Environmentally “safe”,

 Economically “cost suitable”,

 “Highly reliable”

 “High quality'

products and hence increasing lift quality of

humans and society.
 System:

Definition:
An entity
 having defined inputs, outputs and constraints,
 that consists of various phisical elements that are
related to each other in a complex manner,
 which can be characterized using‘measurable
parameters’.
Manufacturing System defined:
“A collection of integrated equipment and human resources, whose
function is to perform one or more processing and/or assembly
operations on a starting raw material, part, or set of parts”
 Equipment includes

 Production machines and tools

 Material handling and work positioning devices

 Computer systems

 Human resources are required either full-time or periodically to

keep the system running

Manufacturing Systems in the
Production System
Üretim Sistemi - İmalat Sistemi İlişkisi

FIGURE 38-1 Classical

production system
showing inclusion of
manufacturing system and
most of the major
functional elements.
Manufacturing
System within
Production
Planning
Classification of Manufacturing
Systems:
With respect to Manufacturing Process
 Job Shop Manufacturing (Sipariş Tipi

İmalat)
 Flow Shop Manufacturing (Akış Tipi İmalat

)
 Project Type Manufacturing (Proje Tipi

İmalat )
Sipariş Tipi Atölye – Job Shop

M1 M4

M3 M6

M2 M5
Akış Tipi Atölye – Flow Shop

M1 M2 M3 MN
 Contraints and Objectives for Job-shop and
Flow-shop Manufacturing:

Sample Contraints Sample Objective

 Machine  In what sequence will

capacity the manufacturing

 Manpower orders processed?
 How will the individual
capacity
 Time machines loaded?
 Space
Project Type Manufacturing
Classification of Manufacturing
Systems -
 With respect to production quantity:
 Discrete (order type) manufacturing – Kesikli
İmalat
 Batch manufacturing – Parti Tipi İmalat
 Continuous (Mass) manufacturing – Sürekli
imalat
Discrete (order type manufacturing)
Kesikli İmalat
 Job shop - Sipariş Tipi Atölye
 High product variability – Geniş
ürün yelpazesi
 Low volume – Düşük hacim
Batch type manufacturing – Parti
Tipi İmalat
 Medium product variability –
Orta seviyede ürün çeşitliliği
 Medium volume- Orta seviyede
hacim

Örn: Otomobil yan sanayii

Continuous Manufacturing:
A. Kitle İmalat Sistemi (Mass Production)
(Üretim ve Montaj Hatları)
 Low product variability
 High volume
Ex: Automotive
industry, Whiteware
industry
Continuous Manufacturing:
B. Flow Type Productiom

- Low product variability

- Petrochemical, food, pharmaceutical industries

 Modern Approaches within
Manufacturin g Systems
 Hücresel İmalat Sistemleri – Grup Teknolojisi
(Cellular Manufacturing-Group Technology)
 Bilgisayarla Bütünleşik Üretim Sistemleri
(Computer Integrated Manufacturing Systems
CIM)
 Esnek İmalat Sistemleri (Flexible Manufacturing
Systems – FMS)
 Yalın Üretim (Lean Production) ve Tam
Zamanında Üretim Sistemleri (Just in Time –
JIT)
Cellular Manufacturing – Group
Technology
Hücresel İmalat – Grup Teknolojisi
 Traditional Layout: process type, where the
machines are grouped with respect to their
similarities
 Group Technology: Machines are grouped to
with respect to product similarities
 Process Layout – Yerleşim Örneği
Area 1 Area 2 Area 3

Assembly Painting Machine Shop

Department Department Department
(1) (2) (3)

40’

Receiving Shipping Testing

Department Department Department
(4) (5) (6)

Figure 9.5 Area 4 Area 5 Area 6

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publishing as Prentice Hall
 Work Cells – İş hücreleri
 Reorganizes people and machines
into groups to focus on single
products or product groups
 Group technology identifies
products that have similar
characteristics for particular cells
 Volume must justify cells
 Cells can be reconfigured as
designs or volume changes
© 2011 Pearson Education, Inc.
publishing as Prentice Hall
 Advantages of Work Cells
1. Reduced work-in-process inventory
2. Less floor space required
3. Reduced raw material and finished goods
inventory
4. Reduced direct labor
5. Heightened sense of employee participation
6. Increased use of equipment and machinery
7. Reduced investment in machinery and
equipment
© 2011 Pearson Education, Inc.
publishing as Prentice Hall
 Requirements of Work Cells

1. Identification of families of products

2. A high level of training, flexibility
and empowerment of employees
3. Being self-contained, with its own
equipment and resources
4. Test (poka-yoke) at each station in
the cell

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publishing as Prentice Hall
 Improving Layouts Using Work
Cells

Current layout - workers in

small closed areas.

Improved layout - cross-trained

workers can assist each other.
May be able to add a third worker
as additional output is needed.

Figure 9.10 (a)

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publishing as Prentice Hall
 Improving Layouts Using Work
Cells

Current layout - straight

lines make it hard to balance Improved layout - in U
tasks because work may not shape, workers have better
be divided evenly access. Four cross-trained
workers were reduced.

U-shaped line may reduce employee movement

and space requirements while enhancing
communication, reducing the number of
workers, and facilitating inspection
Figure 9.10 (b)
© 2011 Pearson Education, Inc.
publishing as Prentice Hall
ESNEK ÜRETİM SİSTEMLERİ (EÜS)
Flexible Manufacturing Systems (FMS)
 Bir Esnek Üretim Sistemi makine ve ilgili
teçhizatın bir grup oluşturulmak için bir araya
getirilmesi olarak tanımlanır. Sistemin üç ana
kısmı vardır:
1-Nümerik kontrollü tezgahlar (NC / CNC
Machines)
2-Otomatik malzeme değiştiricili genel amaçlı
makine merkezi
3-Merkezi bilgisayar kontrol sistemidir.
Esnek İmalat Sistemleri Genel
Özellikleri
Common Features of FMS
Örnek Esnek İmalat Sistemi:
 An example of an FMS for
prismatic aircraft parts
using a wire-guided AGV
for part transfer.
 Computer-Integrated
Manufacturing (CIM)
 Extension of flexible manufacturing
systems
 Backwards to engineering and inventory control
 Forward into warehousing and shipping
 Can also include financial and customer service areas
 Reducing the distinction between low-
volume/high-variety, and high-
volume/low-variety production

© 2011 Pearson Education, Inc.

publishing as Prentice Hall
 Computer-
Integrated
Manufacturing
(CIM)

Figure 7.10
© 2011 Pearson Education, Inc.
publishing as Prentice Hall
 Yalın Üretim - Lean Manufacturing
 Eliminate waste within the time between customer
order and dispatch. More, a philosophy. kısaltan
Traditional manufacturing

customer Waste Dispatch

order

Time
Lean Manufacturing
customer Dispatch
order
Waste

Time (shorter)
Malzeme Akış Planlaması:
Klasik Sistemler ile JIT
karşılaştırması
 Kanban
1. User removes a
standard sized
container
2. Signal is seen by
the producing
department as
authorization to
replenish
Signal marker
on boxes

Part numbers
mark location
Figure 16.8
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publishing as Prentice Hall
 Kanban

Material/Parts Final Finished Customer

Supplier assembly goods order

Work
cell

Kanban
Kanban Kanban

Figure 16.9
© 2011 Pearson Education, Inc.
publishing as Prentice Hall