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
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 (Q ) low 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
Medium Production Quantities (Q ) med 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
High Production (Q ) high 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
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