LECTURE 1 INTRODUCTION TO MANUFACTURING MOHD RUZI HARUN Lecturer

Department Of Automotive Faculty Ofmechanical Engineering Universiti Teknikal Malaysia Melaka

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What is MANUFACTURING? the process of converting raw materials into products. The word manufacturing is derived from the Latin manu factus, meaning made by hand.

the conversion of stuff into things (by DeGarmon, 1998).

processing or making a product from raw materials, especially as a large scale Operation using machinery (by Collin English Dictionary, 1998). economic term for making goods and services available to satisfy customer - (by T.Black, 1991).

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In modern context, manufacturing can be defined as:

- the making of products from raw materials using various processes, equipments, operations and manpower according to a detailed plan. - During processing, the raw material undergoes changes to allow it to become a part of a product(s). - Once processed, it should have worth in the market or a value.

- Therefore, it encompasses:
- The design of the product. - The selection of raw materials. - The sequence of processes through which the product will be manufactured. - Word production is often interchangeably with word manufacturing.

INTRODUCTION TO MANUFACTURING Manufacturing can be defined two ways:

1) Technology manufacturing is the application of physical and chemical processes to alter the geometry, properties, and/or appearance of a given starting material to make parts or products. Manufacturing also includes the assembly of multiple parts to make products. The processes to accomplish manufacturing involve a combination of machinery, tools, power, and manual labor. 2) Economic manufacturing is the transformation of materials into items of greater value by means one or more processing involve. Therefore, manufacturing is added value to the material. - Added value by changing the materials shape or properties or by combining it with other materials that have been similarly altered.

INTRODUCTION TO MANUFACTURING Two ways models to define manufacturing: 1) As a technical process

Machinery

Tooling

Power

Labor

Product Raw materials Manufacturing Process Profit

INTRODUCTION TO MANUFACTURING 2) As an economic process.

Manufacturing Process
Value added

Starting material

Material in processing

Processed material

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INTRODUCTION TO MANUFACTURING Manufacturing activities must be responsive to several demands and trends:
A product must fully meet design requirements and specifications. Manufactured environmental friendly and economical method. Quality is built in each manufacturing stage.

Production methods must be flexible to respond to changing market demands, types of products, production rates and delivery time required.

New development in technology and managerial activities must constantly evaluated.

Manufacturing activities can be modeled to study the effect of factors on product quality and cost. Organization must strive for higher quality and productivity.

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Industries can be classified as:

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Types of industries
1) Primary industry - Those that cultivate and exploit natural resources; eg: agriculture, mining. 2) Secondary industry - Take the outputs of the primary industries and convert them into consumer and capital goods. 3) Tertiary industry - Constitute with service sector of the economy.

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SECONDARY INDUSTRY

Agriculture Forestry Fishing Livestock Quarries Mining Petroleum

Aerospace Automotive Beverages Building materials Chemicals Computers Consumer appliances Electronics Equipment Food processing Glass, ceramic Paper Pharmaceuticals Plastics (shaping) Textiles Tire and rubber Wood and furniture

TERTIARY INDUSTRY

PRIMARY INDUSTRY

Banking Communications Education Entertainment Financial services Health and medical Government Hotel Insurance Restaurant Retail trade Tourism Transportation Real estate

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1) Project 1 to 10 units.
2) Job shop 10 to 100 units. 3) Batch 100 to 10,000 units. 4) Mass Above 10,000 units.

[Low production] [Medium production] [High production]

Production quantity: number of unit produced annually of a particular product type.

Product variety: different product designs or types that are produced in the plant.

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Product variety

Low

Medium

High

Product quantity

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Product volume

Above 10,000 units Mass 100 to 10,000 units

10 to 100 units Job shop 1 to 10 units Project

Product variety

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TYPE OF MANUFACTURING OPERATIONS

- Product position remains stationary during the manufacturing process size, weight, location of the product. - Materials, people, machinery are brought to the product or product site. - Based on customer specifications. - Example: bridge, building construction, aircraft, ships, locomotive.

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- Low volume and production quantities called lot sizes with high product variety. - Satisfies a market for nonstandard or unique product. - Layout different machines with similar functional or processing capabilities are grouped together as department. - Require high skill levels labor to operate a variety of equipments. - A short duration activities to provide custom goods. - Example: space vehicles, reactor vessels, turbines, aircraft components.

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- Batch production produce or process any product in groups which is called batches.

- Can produce a variety of products opposed to a continuous production process, or a one time production.
- Useful for industries that makes seasonal items/products for which it is difficult to forecast the demand. - Example: Similar standard items made periodically in batches: bakery, paint, hand tools. - Same facilities used to manufacture all the different items. - Layout of machine functional layout (based on its function to be performed from section to another section).

INTRODUCTION TO MANUFACTURING Advantages - Reduce initial capital outlay due to a single production line can be used to several products machines can be used more effectively, materials can be bought in bulk, workers can specialize in that task. Disadvantages

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- Requires very careful production planning & control next batches; when, types. - When switching to another batches takes time (down time) can cause loss of output (low yield).

- Resulted WIP or create inventory/stock increases costs such as inventory cost, cost because of damage to stock.

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The example production line (shown below) is that of an engineering company, manufacturing small steel products such as hinges and locks. They manufacture batches of five hundred at a time. The workers are unskilled and semi skilled. As each task is completed the item being manufactured is passed down the production line to the next worker, until it is complete.

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- Also known as flow production, repetitive flow production, series production. - Producing goods in large quantities at low cost per unit and produce in a short period of time. - Machinery (eg: robots, machine press) that is needed to set up the mass production line is so expensive. - Involved fewer labor cost and a faster rate of production. - Plant and equipments are arranged in a flow line layout. - Operation is done base on specific product and thus make the production control easily. - Work piece is transfer automatically from one machine to another.

- Example: light bulbs, refrigerator, tv.

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Lean Production and Agile Manufacturing

- A systematic approach to identifying and eliminating waste in manufacturing process through continuous improvement by following the product at the demand of the customer. - Related to a word less: less time, inventory space, people, developing the product, minimize the cost. - It is all about speed and getting it right at the first time.

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Benefits of Lean Manufacturing - Overhead operating costs reduces by 30%. - Sales ($) per employee 10 times higher. - Profits 4 times. - Lead time cut by 50% to 90%. - Process queues cut by 70%. Principle of Lean Manufacturing

- Voice of the customer.

- Continuous improvement. - Recognize & eliminating waste of: - Over production. - Inventory. - Defects (Non-zero defect rates).

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Principle of Lean Manufacturing (cont) - Waiting time. - Peoples talents, & motivations. - Motion. - Transportation.

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- The implementation of the principles of lean production on a broad scale. - Agile manufacturing is a term applied to an organization that has created the processes, tools, and training to enable it to response quickly to customer needs and market changes while still controlling costs and quality.

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Concurrent engineering (CE) is a philosophy that promotes interactive design

and manufacturing efforts to develop product and process simultaneously, thus optimizing the use of company resources and reducing time to market cycles. It has four general phases which are: Technology and concept development. Product and process development and prototype validation Process validation and product confirmation.

Production and continuous improvement.

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- Also known as families of parts. - Parts can be grouped and then produced by classifying them into families. - This can be done according to similarities in: i) design. ii) manufacturing process to produce the part. - Parts will pass through a similar sequence of manufacturing operations and will be processed on the same machine tools. - Example of GT: Cylindrical parts they may look almost the same, but it has difference in the materials, tolerances, and surface finishes and thus causing them to be made on different machine tools. - The set-up of an automated machine only requires small changes between the individual batches and some of the individual set-up times will be drastically reduced. - Having different machine in one section, so that each parts is completed in that particular section.

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- Raw materials, parts & components are delivered to the manufacturer just in time to be used, parts & components are produced JIT to be made into subassemblies & assemblies, and products are finished JIT to be delivered to the customer.

- JIT is also known as pull system - It tends to simplify and break the whole system into small, autonomous units.

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Benefit s/Advantages of JIT - Low inventory carrying cost. - Fast detection of defects in the production or the delivery of supplies and, hence, low scrap loss. - Reduced inspection and reworking of parts. - High quality products made at low cost. - Reduction of : 20% to 40% in product cost. 60% to 80% in inventory. Up to 90% in rejection rates. 90% in lead times. 50% in scrap & rework.

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Benefit s/Advantages of JIT (cont) Increases:

- 30% to 50% in labor productivity.

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KANBAN SYSTEM
- Integrated with the implementation of JIT concept. - Kanban means visible record. - Originally consisted of two types of cards:

i) Production card: authorizes the production of one container or cart of identical, specified parts at a workstation.
ii) Conveyance/move card: authorizes the transfer of one container or cart of parts from that particular w/station to the w/station where the parts will be used. The cards contain information on: i) Type of parts. ii) Location where issued. iii) Part number. iv) Number of items in container.

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1) FIXED POSITION LAYOUT

- Involved with huge parts; eg: construction of aeroplane, bridge, buildings.
- All resources such as manpower, raw materials, tools, machinery and etc will be brought to the product. - Involve with longer lead time.

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2) FUNCTIONAL (PROCESS) LAYOUT

- Plant grouped according to type of process. - Specialization of skills. - Higher machine utilization. - Queues of work. - Longer lead times. - Flexibility of operation. - Low volume and high variety of manufacturing.

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FUNCTIONAL (PROCESS) LAYOUT

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- Plant arrangement to facilitate material processing in the same order. - Machines and equipment are positioned along a flow line. - Product passes from workstation to another workstation along the flow line.

- Suitable for mass production system.

- Several flow lines may come together to feed the final assembly line. - Need to categorize operations to ensure equal processing time at all work stations (line balancing). - High level of machine and manpower utilization.

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Product A

Product B

Product C

Product D

FLOW LINE (PRODUCT) LAYOUT

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Advantages - Reduced work handling leads to short cycle time/piece. - Less WIP. - Simple planning and control. - Reduced labor skill. - Good space utilization.

Disadvantages
- Limited flexibility. - Machine breakdown causes major problem. - High setting up cost. - Uses expensive special purpose machine.

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- Plant divided into groups or cells in a small unit (individual cell), consisting of one to several workstations. - A w/station can contains either one machine (known as a single machine cell), or several machines (known as a group machine cell) with each machine performing a different operation on the part. - Cells can process a complete family of parts need to form families of products. - The flow among the equipment in the cells can vary depending on the composition of parts within the part family. - Good example for the implementation of the concept of group technology. - The machines at w/stations can be modified, retooled, and regroup for different product lines within the same family of parts.