man sys design and control

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ManufacturingSystems

Manufacturing System

Design & Control


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Manufacturing System Design &Control

Facility Layout and Work Flow

Arrangement within a factory of:

Machines

Departments

Workstations

Storage areas

Aisles and common areas

Ensures a smooth flow of work, material, people and

information through the system


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Manufacturing System Design &Control

3 three basic types of layout:Process

Product

Fixed-Position

3 hybrid layouts:

Cellular

Flexible Manufacturing Systems

Mixed-model Assembly Lines


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Manufacturing System Design Control

Process Layout:

Similar activities grouped together in work areasSuitable for low volume or batch production

Flexible

Not very efficient

Storage space large receiving, small shipping

Large aisles for movement of material

Lathe

Department

Milling Department Drilling Department

Grinding Department Painting Department

Receiving and ShippingAssembly

L L

L L

L

L

L

L

M M M

G G G G

D D D D

D D D D

P

P

A A A


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Product Layout:

Arrange activities in sequence of operationLine set up for one product

Specialised machines

Suitable for mass production

More automated than process layouts

EfficientLine flow avoid bottlenecks

Not flexible

IN

OUT


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Fixed Position Layout:

Large projects too big to moveEquipment and parts moved in and out of work area

Highly skilled workers - costly


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Hybrid Layouts:

Try to mix flexibility of process layout with efficiency ofproduct layout

Cellular Layouts:

Machines grouped into cells

Cells process parts with similar features

Work cell resembles a small assembly line (product)

Layout between cells treated as process layout


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4 6

5

1

2

11

9

8

7

1210

3

Raw Materials

Assembly

Processed based layout


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Design of work cell

4

6

51

211

98

7

1210

3

Raw Materials

Assembly


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Flexible Manufacturing Systems:

Automates the entire manufacture of a

product

Very costly

Complex software

Small number of FMS worldwide

Flexible Manufacturing Cell:Smaller version of FMS

One manufacturing process is automated


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Progressive FMS:

All parts follow same progression through the work

stations

Best where group technology can be applied

Progressive FMS

Load StationUnload StationPallet


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Ladder FMS layout:

Parts moved to and from any machine in any

sequence

More flexible than progressive and closed loop

systemsLoad/Unload


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Mixed Model Assembly Lines:

More than one product is processed by the line

Workers trained to work on more than one station

Layout of line changed

Long and short operations arranged to canceleach other

Traditional line

U Shaped Line


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Capacity Management:

Demand for product can fluctuate over time

Capacity < demand - Lose business

Excess capacity: storage cost, labour cost etc.

Capacity planning: match capacity to present andanticipated demand

Capacity Planning

Capacity Lead StrategyCapacity Lag Strategy

Average Capacity Strategy



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Capacity Lead Strategy

Capacity expanded in anticipation of demand

Expect to gain customers from competitors

Demand

Capacity

Quantity

Time


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Capacity Lag Strategy

Capacity increased after increased in demand

Common where competition is weak

Demand

Capacity

Time

Quantity


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Average Strategy Lag

Capacity expanded to coincide with average

expected demand

Demand

Capacity

Quantity

Time


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How much to increase capacity?

100% capacity not efficient

20% cushion is generally used

20% capacity allows for unexpected demand

Negative capacity can be used - Airlines

man sys design and control

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