TOPIC 1

INTRODUCTION TO
MANUFACTURING SYSTEM
What Is Manufacturing?
Example 1.1
Incandescent Light Bulbs
• Components of a common incandescent light bulb

Copyright © 2010 Pearson Education South Asia Pte Ltd

What Is Manufacturing?
Example 1.1
Incandescent Light Bulbs
• Manufacturing steps in making an incandescent light
bulb

Copyright © 2010 Pearson Education South Asia Pte Ltd

What Is Manufacturing?
Introduction
INTRODUCTION
History of civilization is the history of making things now
known as MANUFACTURING (MFG).

It is important

Technologically Economically Historically

•Applying •Creating •Better

science to give material wealth weapons led to
society it for nations. conquer the
reads. neighbors.
Introduction
MANUFACTURING & PRODUCTION
The word PRODUCTION appeared in 1483 in English
derived from PROCEDURE (Latin; Lead Forward)
The word MANUFACTURE appeared in 1622, stemming
from MANU FACTUS (Latin; Made by hand)
Introduction
MANUFACTURING
Originally, it meant making by hands
Today it means: Conversion of a design into a finished
product
Design

In 1983, International Management

Material
conference on & Marketing
product
selection

production research
Manufacturing as “ a
series of inter-related
activities and operations Quality
Planning
Assurance
involving :
Producing
Introduction
PRODUCTION
•Transformation of raw materials into products by a series
of energy applications, each of which affects well defined
changes in physicals/chemical characteristics of material.
•Making something new either tangible (products) or
intangible (services)

IMPORTANCE
Provides for basic means of human
1 existence
Its history spans over
several thousand years
and is spread over 2 Creates wealth for nations and

following THREE
Steps towards “human happiness and
important features: 3 world peace”
Introduction

National Academy of Engineering/Sciences in

Washington DC (USA) declared following subjects
necessary for US economic growth and national
security:

*SCIENCE *TECHNOLOGY *MANUFACTURING

Introduction
FLOW OF
•Conversion of raw •Flow of Material
MATERIAL material into involves
products
MANUFACTURING
PROCESS

FLOW OF • Planning & •Flow of

INFORMAT control of Information
ION production
FLOWS IN involves
MANUFACTURING TECHNOLOGY
MANAGEMENT
FLOW OF •Producing in cost- •Flow of Cost
COST effective manner
involves
FINANCIAL
MANAGEMENT
Introduction
FLOWS IN MANUFACTURING:

PLANNING

IF

MF
RAW MANUFACTURING
PRODUCTS
MATERIAL MF PROCESS

IF

CONTROL
 Introduction
Manufacturing Costs and Global Competition
• Manufacturing cost is about 40% of its selling price
• Total cost of manufacturing a product consists of:
1. Materials
2. Tooling
3. Fixed Costs
4. Capital
5. Labour

Copyright © 2010 Pearson Education South Asia Pte Ltd

 Manufacturing System
MANUFACTURING SYSTEM
Process Model :
 Manufacturing System
CLASSIFICATION OF VARIOUS INDUSTRIES
[A] BASED ON TYPE OF PRODUCTS:
1. PRIMARY : Cultivating/exploiting natural resources
- nature oriented industry (mining & agriculture)
2. SECONDARY: Converts outputs of primary industry into useful
goods (automobiles , steel production)
3. TERTIARY: Represents service sector of economy/ offer a
service (banking, retailing)

[B] BASED ON QUANTITY OF PRODUCTION:

1. HANDICRAFT / COTTAGE /ARTISAN TYPE : Village level(handmade)
2. JOB-LOT /JOB SHOP TYPE: 10- 500 Units/year-Lot type
3. MODERATE TYPE : 2500-100,000 products/year-Batch type
4. MASS PRODUCTION TYPE: More than 100,000 parts/year- For discrete
type e.g Car industries
5. Or CONTINUOS TYPE : For non-discrete products e.g Oil, Coal
Manufacturing System
TYPE OF MANUFACTURING [B]

MASS PRODUCTION

BATCH PRODUCTION

JOB-LOT PRODUCTION

FEATURES: 1) MARKET DEMAND 2) INVESTMENT

3) MAN POWER 4) MACHINES & EQUIPT.
5) DELIVERY TIME
Manufacturing System
CHARACTERISTICS OF MASS, BATCH & JOB
LOT MANUFACTURING SYSTEM
HIGH

•MASS
(continuous)

•BATCH
Moderate
LOW •JOB-LOT

LOW HIGH
Manufacturing System
CLASSIFICATION OF BASIC MANUFACTURING
Mass-production :
1) produced continuously or intermittently at high volume for
considerable period of time
2) >100,000 parts per year
3) Industry sales volume is well established
4) Production rates are independent of individual orders
5) Machines usually incapable of performing operation on other
work
6) Common example: bottle caps, pencils, automobile, nuts, bolts
and washers
Manufacturing System
Moderate production:
1) produced in relatively large quantities, but the output may be
variable and more dependent on sales order
2) The machines likely will be multipurpose one
3) The parts produced may vary from 2500 to 100,000 per year
depending on complexity
Example of industry are more descriptive: printing of books,
aircraft compasses and radio transmitters
Manufacturing System
Job-lot production :
1) More flexible and their production is usually limited to lots
closely attuned to sales orders or expected sales
2) Production equipment is multipurpose
3) Employees may be more highly skilled, Performing various
tasks depending on part or assembly being made
4) Lot sizes customarily from 10 to 500 parts per lot, Quantity
depend on demand and order
Example, oil field valves, special meters or antique
automobile

Mass, moderate and job-lot production require different

equipment and systems . The specification of the equipment
identifies what it is and what it can do
Manufacturing System
Goals in manufacturing
1. View manufacturing activities not as individual
2. Meet all design requirements, product specifications
3. Build quality into the product
4. Economical and environmentally friendly (green)
manufacturing methods
5. Evaluate advances in materials, production methods, and
computer integration
6. Adopt flexible production methods
7. Achieving higher levels of productivity
8. Continuous improvement of a company’s products
Manufacturing System
Concurrent Engineering (CE)
• Any iterations will require a
smaller effort and less wasted
time would occur
• Also called simultaneous engineering
• From the earliest stages of product design and
engineering, all are simultaneous

A philosophy that promotes interactive design and

manufacturing effort
To developed product and process simultaneously,
thus optimizing company resources and reducing
time to market cycle
Manufacturing System
Concurrent Engineering (CE).. cont

General CE phases/ Event for a new project:

Phase • Technology and Concept Development

1
• Product and Process Development and
Phase Prototype validation
2
• Process Validation and Product Design
Phase confirmation
3

Phase • Production and Continues Improvement

4
Ph.-1 Technology and concept development:

a Definition of customer requirement

implementation.

b Assessment of primary alternatives

processes.

c Development of required resources.

d Preparation of product plan.

Ph.-2 Product and Process Development
and Prototype validation -CE Function:
This is the phase in which the CE team will

a Product improvement for assembly and

mfg
b Development the mfg and assembly
processes

c Establish baseline process technology

d Establish program goals and risk-reduction
plans freezing
Generally other project elements are addressed in this phase such as financial business plans, product
concept demonstration, freezing of engineering content, and final project approval.
Ph.-3 Process Validation and Product Design
Confirmation :

This is the execution phase where

a The Production process and methods

are finalized

b Simulation and pilot runs are conducted

to test critical steps

c Machine and equipment are validated

for production readiness, quality and
performance
Ph.-4 Production and continuous improvement :

- This face is the Acceleration of production

floor into “ Full rated capacity”. This means:
Attaining high product quality at the lowest
costs.