Unit 2 Manufacturing Operations

Sections:
1. Manufacturing Industries and Products
2. Manufacturing Operations
3. Production Facilities
4. Product/Production Relationships
5. Lean Production
6. Manufacturing Metrics
 Manufacturing Lead Time
 Rate of Production
 Production Capacity
 Work in Progress
 Design Times
 Utilisation/Availability
 Classification of Industries

1. Primary industries – cultivate and exploit natural

resources
 Examples: agriculture, mining
2. Secondary industries – convert output of primary
industries into products
 Examples: manufacturing, power generation,
construction
3. Tertiary industries – service sector
 Examples: banking, education, government, legal
services, retail trade, transportation
 Manufacturing Industries

ISIC Code
 Food, beverages, tobacco 31
 Textiles, apparel, leather and fur products 32
 Wood and wood products, cork 33
 Paper, printing, publishing, bookbinding 34
 Chemicals, coal, petroleum, & their products 35
 Ceramics, glass, mineral products 36
 Basic metals, e.g., steel, aluminum 37
 Fabricated products, e.g., cars, machines, etc. 38
 Other products, e.g., jewelry, toys 39
 More Industry Classifications

 Process industries, e.g., chemicals, petroleum, basic

metals, foods and beverages, power generation

 Discrete product (and part) industries, e.g., cars, aircraft,

appliances, machinery, and their component parts
 Manufacturing Industry
 Transformation Operations
 Machine Processing
 Assembly
 Adding value*
 Other Operations
Material handling Raw Part or
Inspection and testing Material Transformation Process Product
Coordination and control

Scrap or
Power Waste
Tools
Machines
Labour
 Processing Operations

 Shaping operations
 Solidification processes
 Particulate processing
 Deformation processes
 Material removal processes
 Property-enhancing operations (heat treatments)
 Surface processing operations
 Cleaning and surface treatments
 Coating and thin-film deposition
 Assembly Operations

 Joining processes
 Welding
 Brazing and soldering
 Adhesive bonding
 Mechanical assembly
 Threaded fasteners (e.g., bolts and nuts, screws)
 Rivets
 Interference fits (e.g., press fitting, shrink fits)
 Other
 Material Handling

 Material transport
 Vehicles, e.g., forklift trucks, AGVs, monorails
 Conveyors
 Hoists and cranes
 Storage systems
 Unitizing equipment
 Automatic identification and data capture
 Bar codes
 RFID
 Other AIDC
Time Spent in Material Handling
 Inspection and Testing

Inspection – conformance to design specifications

 Inspection for variables - measuring
 Inspection of attributes – gauging
Testing – observing the product (or part, material,
subassembly) during operation
 Coordination and Control

 Regulation of the individual processing and assembly

operations
 Process control
 Quality control
 Management of plant level activities
 Production planning and control
 Quality control
 Production Facilities and Layout

 Facilities organised in the most efficient way to serve the

particular mission of the plant and depends on:
 Types of products manufactured
 Production quantity
 Product variety
 Production Quantity (Q)

 Number of units of a given part or product produced

annually by the plant
 Three quantity ranges:
1. Low production – 1 to 100 units
2. Medium production – 100 to 10,000 units
3. High production – 10,000 to millions of units
 Product Variety (P)

 Number of different product or part designs or types

 ‘Hard’ product variety – products differ greatly
 Few common components in an assembly
 ‘Soft’ product variety – small differences between
products
 Many common components in an assembly
 Low Production Quantity (Qlow)

Job shop – makes low quantities of specialized and

customized products
 Products are typically complex (e.g., specialized
machinery, prototypes, space capsules)
 Equipment is general purpose
 Plant layouts:
 Fixed position
 Process layout
Fixed-Position Layout
Process Layout
 Medium Production Quantities (Qmed)

1. Batch production – A batch of a given product is

produced, and then the facility is changed over to
produce another product
 Changeover takes time – setup time
 Typical layout – process layout
 Hard product variety
2. Cellular manufacturing – A mixture of products is made
without significant changeover time between products
 Typical layout – cellular layout
 Soft product variety
Cellular Layout
 High Production (Qhigh)

1. Quantity production – Equipment is dedicated to the

manufacture of one product
 Standard machines tooled for high production (e.g.,
stamping presses, molding machines)
 Typical layout – process layout
2. Flow line production – Multiple workstations arranged in
sequence
 Product requires multiple processing or assembly
steps
 Product layout is most common
Product Layout
PQ Relationships

Q
 Product Quantity and Variety

 Let Qj = annual quantity of variety ‘j’

 P = variety of products from ‘1’ to ‘j’ P
 Total number of product units = Qf = Q j
j 1
 Product and Part Complexity

 Product complexity np = number of components in

product
 Part complexity no = number of processing operations
per part
 Factory Operations Model

Simplified :

 Total number of product units Qf = PQ

 Total number of parts produced npf = PQnp
 Total number of operations nof = PQnpno

where
P = Product variety
Q = Product quantity
np = Number of parts in product
no = Number of operations in product
 Worked Problem
2.2: The ABC Company is planning a new product line and will build a
new plant to manufacture the parts for a new product line. The
product line will include 50 different models. Annual production of
each model is expected to be 1000 units. Each product will be
assembled of 400 components. All processing of parts will be
accomplished in one factory. There are an average of 6 processing
steps required to produce each component, and each processing
step takes 1.0 minute (includes an allowance for setup time and part
handling). All processing operations are performed at workstations,
each of which includes a production machine and a human worker. If
each workstation requires a floor space of 250 m2, and the factory
operates one shift (2000 hr/yr), determine (a) how many production
operations, (b) how much floorspace, and (c) how many workers will
be required in the plant.
 Solution

This problem neglects the effect of assembly time:

(a) nof = PQnpno = 50(1000)(400)(6) = 120,000,000
operations in the factory per year.
(c) Total operation time = (120 x 106 ops)(1min./(60 min./hr))
= 2,000,000 hr/yr.
At 2000 hours/yr per worker, w = = 1000 workers.
(b) Number of workstations n = w = 1000.

Total floorspace = (1000 stations)(250 m2/station) = 250,000

m2
 Manufacturing Capability

 Technological processing capability - the available set

of manufacturing processes
 Physical size and weight of product
 Production capacity (plant capacity) - production
quantity that can be made in a given time
 Lean Production

Operating the factory with the minimum possible resources

and yet maximizing the amount of work accomplished

 Utilisation of Resources - workers, equipment, time,

space, materials
 Minimising time
 Maximising quality (accuracy)
 Minimising cost

 Doing more with less, and doing it better

 Programs Associated with
Lean Production
 Just-in-time delivery of parts
 Worker involvement
 Continuous improvement
 Reduced setup times
 Stop the process when something is wrong
 Error prevention
 Total productive maintenance
 Problem 2.4
 The XYZ Company is planning to introduce a new product line and will build
a new factory to produce the parts and assembly the final products for the
product line. The new product line will include 100 different models. Annual
production of each model is expected to be 1000 units. Each product will be
assembled of 600 components. All processing of parts and assembly of
products will be accomplished in one factory. There are an average of 10
processing steps required to produce each component, and each processing
step takes 30 sec. (includes an allowance for setup time and part handling).
Each final unit of product takes 3.0 hours to assemble. All processing
operations are performed at work cells that each includes a production
machine and a human worker. Products are assembled on single
workstations consisting of two workers each. If each work cell and each
workstation require 200 ft2, and the factory operates one shift (2000 hr/yr),
determine: (a) how many production operations, (b) how much floorspace,
and (c) how many workers will be required in the plant.
 If the company were to operate three shifts (6000 hr/yr) instead of one shift,
determine the answers to (a), (b), and (c).
 Solution
 Solution: (a) Qf = PQ = 100(1000) = 100,000 products/yr
 Number of final assembly operations = 100,000 assy.opns/yr
 Number of processing operations nof = PQnpno = 100(1000)(600)(10) =
600,000,000 proc.opns/yr
 (c) Total processing operation time = (600 x 106 ops)(0.5 min./(60
min./hr)) = 5,000,000 hr/yr.
 Total assembly operation time = (100 x 103 asby ops)(3 hr/product) =
300,000 hr/yr
 Total processing and assembly time = 5,300,000 hr/yr
5,300,000hr / yr
 At 2000 hours/yr per worker, w = 2000hr / wor ker = 2650 workers.
 (b) With 1 worker per workstation for processing operations, n = w =
2500 = 2500 workstations.
 With 2 workers per stations for assembly, n = w/2 = 150/2 = 75
workstations.
 Total floor space A = (2575 stations)(200 ft2/station) = 515,000 ft2
 Solution
 (a) Same total number of processing and assembly operations but
spread over three shifts.
 Number of final assembly operations = 100,000 assy.opns/yr
 Number of processing operations nof = PQnpno = 100(1000)(600)(10) =
600,000,000 proc.opns/yr
 (c) Same total number of workers required but spread over three shifts.
 Total workers w = 2650 workers. Number of workers/shift = w/3 =
883.33  884 workers/shift.
 (b) Number of workers for processing operations = 2500/3 = 833
worker per shift (884 on one shift)
 Number of workers for assembly = 150/3 = 50 workers per shift.
 Number of workstations n = 833 + 50/2 = 858 (859 on one of the
shifts).
 Using the higher number, Total floor space A = (859 stations)(200
ft2/station) = 171,800 ft2