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IB-CIM Lecture 2
IB-CIM Lecture 2
Type of Production
Function in Manufacturing
Organization and Information Processing in Manufacturing
Production Concepts and Mathematical Models
WHAT IS MANUFACTURING
Technologic. Economic.
MANUFACTURING DEFINED AS A TECHNOLOGICAL
Example
iron are is converted into steel
sand is transformed into glass
petroleumis refined into plastic
plastic is molded into the complex geometry of a patio chair
MANUFACTURING INDUSTRIES AND
PRODUCTS
PRODUCTS
Manufactured Products
Primary industries cultivate and exploit natural resources, such as agriculture and
mining.
Secondary industries take the outputs of the primary industries and convert them into
consumer and capital goods.
Manufacturing is the principal activity in this category, but construction and power
utilities are also included.
consumer capital
goods goods
Final products made by the manufacturing industries can be divided into two major
classes: consumer goods and capital goods.
MANUFACTURED PRODUCTS
Consumer goods
Are products purchased directly by consumers, such as cars, personal computers,
TVs, tires, and tennis rackets.
MANUFACTURED PRODUCTS
Capital goods
Are those purchased by companies to produce goods and/or provide services.
Examples :aircraft, computers, communication equipment, medical apparatus,
trucks and buses, railroad locomotives, machine tools, and construction equipment.
PRODUCTION QUANTITY AND PRODUCT
VARIETY
The quantity of products made by a factory has an important influence on the way its
people, facilities, and procedures are organized.
Annual production quantities can be classified into three ranges:
There is an inverse correlation between product variety and production quantity in terms of factory
operations.
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OTHER FACTORY OPERATIONS
• Job Production
• Batch production
Ship building
dam construction
bridge building
book printing
CHARACTERISTICS OF
JOB PRODUCTION
• 1. A large number of general purpose machines are required.
• 2. A large number of workers conversant with different jobs will have to be employed.
• 3. There can be some variations in production.
• 4. Some flexibility in financing is required because of variations in work load.
• 5. A large inventory of materials, parts and tools will be required.
• 6. The machines and equipment setting will have to be adjusted and readjusted to the
manufacturing requirements.
• 7. The movement of materials through the process is intermittent.
LIMITATIONS OF
JOB PRODUCTION
1. The economies of large scale production may not be attained because production is done in
short-runs.
3. One operation is carried out on whole batch and then is passed on to the next operation and so
on.
5. It is generally chosen where trade is seasonal or there is a need to produce great variety of
goods.
MASS OR FLOW PRODUCTION
This method involves a continuous production of standardized products on a large scale.
Under this method, production remains continuous in anticipation of future demand.
Standardization is the basis of mass production. Standardized products are produced under this
method by using standardized materials and equipment. There is a continuous or uninterrupted
flow of production obtained by arranging the machines in a proper sequence of operations.
Process layout is best suited method for mass production units.
MASS OR FLOW PRODUCTION
Flow production is the manufacture of a product by a series of operations, each article going
on to a succeeding operation as soon as possible. The manufacturing process is broken into
separate operations.
MASS OR FLOW PRODUCTION
The product completed at one operation is automatically passed on to the next till its
completion. There is no time gap between the work done at one process and the starting at the
next. The flow of production is continuous and progressive.
CHARACTERISTICS OF
MASS OR FLOW PRODUCTION
1. The units flow from one operation point to another throughout the whole process.
2. There will be one type of machine for each process.
3. The products, tools, materials and methods are standardised.
4. Production is done in anticipation of demand.
5. Production volume is usually high.
6. Machine set ups remain unchanged for a considerable long period.
7. Any fault in flow of production is immediately corrected otherwise it will stop the whole
production process.
SUITABILITY OF
MASS OR FLOW PRODUCTION
1. There must be continuity in demand for the product.
2. The products, materials and equipments must be standardised because the flow of line is
inflexible.
5. It should be possible to find time taken at each operation so that flow of work is standardised.
• Production rate Rp
• Production capacity PC
• Utilization U
• Availability A
• Manufacturing lead time MLT
• Work-in-progress WIP
4/
Production rate Rp
• Hourly production rate
• Work units completed/Hr
• Cycle time: Time that one work unit spends being
processed or assembled. It is the time between
when one work unit begins processing and next
unit begins.
• Not all time is productive.
• Cycle time consists of i) actual machining
operation time ii) workpart handling time
iii) tool handling time per workpiece
Operation Cycle Time
where
MLTj = manufacturing lead time for part or product j (min).
Tsuji = setup time for operation i (min) for the product j,
Qj = quantity of part or product in the batch (pc),
Tcji = operation cycle time for operation i (min/pc),
Tnoji = nonoperation time associated with operation i (min), and
i indicates the operation sequence in the processing; i = I, 2,... noj
To simplify and generalize the model,
let us assume that all setup times, operation cycle times, and non
operation times are equal for the noj machines.
Further, let us suppose that the batch quantities of all parts or
products processed through the plant are equal and that they are
all processed through the same number of machines, so that noj =
no , With these simplifications, Eq. becomes:
where
MLT = manufacturing lead time,
no = number of operations,
Tsu = setup time,
Q = batch quantity,
Tc = cycle time per part, and
Tno = non-operation time
• For a job shop in which the batch size is one (Q = 1), Eq.
(1.12) becomes
MLT=no(Tsu+TC+Tno)------------ (1.13)
For mass production, the Q term in Eq. (1.12) is very large
and dominates the other terms.
In the case of quantity type mass production in which a
large number of units are made on a single machine (no
=1). The MLT simply becomes the operation cycle time for
the machine after the setup has been completed and
production begins.
MLT = QxTc ------------1.14
4
For flow line mass production, the entire production line is
set up in advance. Also, the non operation time
between processing steps is simply the transfer time Tr
to move the part or product from one workstation to
the next. The station with the longest operation time
sets the pace for all stations:
MLT =no(Tr +Max To) = noTc --------------1.15
Since , (Tr +Max To) = Tc (1.5)
Since the number of stations is equal to the number of
operations (n = no) Eq. (1.15) can also be stated as
MLT =n(Tr +Max To) = nTc --------------1.16
A certain part is produced in a batch size of 100 units. The batch must be routed
through five operations to complete the processing of the parts. Average
setup time is 3 hr/operation, and average operation time is 6 min . Average
non operation time due to handling, delays, inspections, etc., is 7 hours for
each operation. Determine how many days it will take to complete the batch,
assuming the plant runs one 8-hr shift/day.
Solution:
Given:
Q = 100 units
no = 5
Tsu = 3hr/operation
Tc = 6 min
Tno = 7 hr/operation
The manufacturing lead time is computed from Fq
MLT = no (Tsu + QTc + Tno)
MLT = 5(3 + 100 X 0.1 + 7) = 100 hours
At 8 hr/day. this amounts to L00/8 = 12.5 days
A certain part is routed through six machines in a batch production plant. The
setup and operation times for each machine are given in the table below. The
batch size is 100 and the average non operation time per machine is 12 hours.
Determine (a) manufacturing lead time and (b) production rate for operation 3
Solution:
Given:
Q = 100 units
no = 5
Tsu = 3hr/operation
Tno = 12hr/machine
A certain part is routed through six machines in a production plant. The
operation times for each machine are given in the table below. Suppose the
part is made in very large quantities on a production line in which an
automated work handling system is used to transfer parts between machines.
Transfer time between stations = 15 s. The total time required to set up the
entire line is 150 hours. Assume that the operation times at the individual
machines remain the same. Determine (a) manufacturing lead time for a part
coming off the line.(b) production rate for operation 3. and (c) theoretical
production rate for the entire production line.
Solution:
Given:
a) MLT = no(Tr+MaxTo)
b) Rp3 = 60/Tp ; But Tp = Tc = To
c) Rp = 60/Tp; But Tp = Tc ; But Tc =
Tr+Max To
Work-In-Process