Ch 13: Introduction to Manufacturing

Systems
Learning Objectives:
By the end of the lecture the student should be able to:
† Explain what manufacturing system is?
† Outline major phases in the history of manufacturing.
† Outline and explain components/activities (and their
relationships) of production and manufacturing systems.
† Classify and explain manufacturing systems depending on its
characteristics/complexity.
† Highlight the challenges/complexity of manufacturing systems.
† Briefly explain what agile/lean manufacturing is?
† Briefly explain what data-rich manufacturing is?

NOTE: Materials used to create this presentation were supplied from:

Lecture notes designed by 2008 Pearson Education Inc. Third Edition by Professor Mikell P. Groover
Lecture notes designed by Professor Darek Ceglarek, University of Wisconsin – Madison.
Manufacturing: An Introduction
† What is manufacturing?
Manufacturing (or Production): The process of converting raw
materials into products that have value in the marketplace.
„ manufacturing concerns about making cars, airplanes, stoves,
shoes, toys, TVs, mobile phones, and etc.
„ manufacturing engineering is the study of how to make maximal
amount of desirable products with minimal production cost, and
minimal time.
„ manufacturing is the backbone of modern society and creates the
wealth of a nation

† The types of manufacturing

„ Continuous: gasoline, steel, plastic film, …
„ Discrete: car, airplane, computer, furniture, ...
Brief History of Manufacturing
„ Discovery and invention of materials and processes to make things
† Neolithic period (8000-3000 B.C)
„ Woodworking, polishing of stone, firing of clay pottery, metallurgy (copper, gold, silver and
tin)
† Bronze Age (3500-1500 B.C)
„ Work with iron, quenching, tempering (heat treatment of steel)
† Iron Age (starting 1000 B.C)
„ New properties of steel
„ Development of systems of production
† First Industrial Revolution (1760-1830) in England
„ Watt’s steam engine
„ Machining operations (boring, milling, turning, drilling, etc.)
„ Eli Whithey: interchangeable parts
„ Adam Smith: division of labor
† Second Industrial Revolution (1865-1900)
„ Railroads
„ Fredrick Taylor, Frank and Lilian Gilbreath: scientific management (motion study, time
study, standardization, data collection, record keeping, cost accounting, etc.)
„ Henry Ford: assembly line (mass production
„ Henry Gantt: process planning (Gantt chart)
„ Electrification
† Modern Manufacturing Systems (I&ME 471)
The change of characteristics of
manufacturing
Modern Production System
Functional Components of Modern
Production System
 Manufacturing in the Product Life Cycle
Field warranty service
Quality
Market control
analysis,
Production
R&D
system
Process
design Prototyping
GD&T
Statistic
Process
Engineering Product Control (SPC)
Modeling design Manufacturing
GD&T

Rapid
Prototyping
Computer
Aided
Manufacturing
Computer (CAM)
Aided Design
(CAD) Topics and related classes
Manufacturing System Activities
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
Production Machines
† In virtually all modern manufacturing systems, most of
the actual processing or assembly work is accomplished
by machines or with the aid of tools
† Classification of production machines:
1. Manually operated machines are controlled or supervised
by a human worker
2. Semi-automated machines perform a portion of the work
cycle under some form of program control, and a worker
tends the machine the rest of the cycle
3. Fully automated machines operate for extended periods of
time with no human attention
Work Transport Between Stations
† Two general categories of work transport in multi-station
manufacturing systems:
1. Fixed routing
† Work units always flow through the same sequence of
workstations
† Most production lines exemplify this category
2. Variable routing
† Work units are moved through a variety of different
station sequences
† Most job shops exemplify this category
a) Fixed routing; b) Variable Routing
Material Handling System
In most manufacturing systems that process or
assemble discrete parts and products, the following
material handling functions must be provided:
1. Loading work units at each station
2. Positioning work units at each station
3. Unloading work units at each station
4. Transporting work units between stations in multi-
station systems
5. Temporary storage of work units
Example:
Multistage Manufacturing System
Product Process Quality
Manufacturing Market
Design Design Inspection

Taguchi method, 1980’s SPC Techniques,

Shewhart, 1932

Process/product In-process sensing Quality Inspection

information information information

Integration of
Design & Manufacturing

• Product/process design determines process performance

• Information integration is a critical area in developing such methodologies
Classification of
Manufacturing Systems
† Factors that define and distinguish manufacturing
systems:
1. Types of operations
2. Number of workstations
3. System layout
4. Automation and manning level
5. Part or product variety
Manufacturing Systems for Medium or
High Product Complexity
Manufacturing Systems for Low
Product Complexity
Manufacturing Challenges
† Rapid changing market
† Fast development of new technology
„ Example: nano-engineering, bio-engineering
† Competition
† A “use brain” generation, not willing to learn the trade
which requires hand skills

To Survive
(1) Lower cost
(2) High quality
(3) Faster product development cycle
 Complexity in Manufacturing Systems
Design Examples of Manufacturing Systems Process Control

• New product 10 7 • Aircraft has over 100K

Spaceship
realization time Missile
distinctly oriented
48->36->24->18 surfaces to be aligned
Complexity (Number of Parts)
months 10 6
Personal Aircraft
Computer
Color Video
Camera Computer
10 5

• 3 billion opportunities
• Shorter lead time VCR Automobile for error per day per
10 4
(6mo->4mo->..) Motorcycle factory
Bicycle Color TV
10 3
Radio Microwave
Ovens
Telephone • To have less than
Answering
• Reduce/avoid # of 10 2 machine 100 defects/day
Electronic Calculators
mfg. system failures => process control
Antennas Nagayama & Funk, 1985 has error rate<
10 1
10 1 10 2 10 3 10 4 10 5 10 6 1/30 ppm
Market Size (M$)
Current Direction:
Lean/Agile Manufacturing
Future Direction:
Data-rich Manufacturing Environment