Part IV

MANUFACTURING SYSTEMS
Chapters:
13. Introduction to Manufacturing Systems
14. Single-Station Manufacturing Cells
15.
Manual
Assembly
Lines
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18. Cellular Manufacturing
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19.
Flexible Manufacturing
Systems
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Manufacturing Systems in the

Production System

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Ch 13 Introduction to
Manufacturing Systems
Sections:
1. Components of a Manufacturing System
2. A Classification Scheme for Manufacturing Systems
3. Overview of the Classification System
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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
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Materialexist.
handling and work positioning devices
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Computer
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Human resources are required either full-time or
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periodically
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the system
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Examples of Manufacturing Systems

Single-station cells
Machine clusters
Manual assembly lines
Automated transfer lines
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Automated assembly systems
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Machine
(cellular manufacturing)
currentlycells
exist.
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manufacturing
systems
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Components of a
Manufacturing System
1. Production machines
2. Material handling system
3. Computer system to coordinate and/or control the
preceding components
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and manage
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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
operatedInc.,
machines
are controlled
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work
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by a
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3. Fully automated
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Manually Operated Machine

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Semi-Automated Machine

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Fully-Automated Machine

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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
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3. Unloading
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station
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without
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5. Temporary
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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
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Work
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Most job shops exemplify this category
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(a) Fixed Routing and

(b) Variable Routing

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Computer Control System

Typical computer functions in a manufacturing system:
Communicate instructions to workers (receive processing or
assembly instructions for the specific work unit)
Download part programs to computer-controlled machines
Control material handling system
Schedule
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Qualitywithout
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Classification of
Manufacturing Systems
Factors that define and distinguish manufacturing
systems:
1. Types of operations performed
2. Number of workstations
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4. Automation and manning level
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5. Partofor
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Types of Operations Performed

Processing operations on work units versus assembly operations to
combine individual parts into assembled entities
Type(s) of materials processed
Size and weight of work units
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Pearson
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For individual
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processing
No portion
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anyPart
geometry
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For machined
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non-rotational
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Number of Workstations
Convenient measure of the size of the system
Let n = number of workstations
Individual workstations can be identified by subscript i,
where i = 1, 2,...,n
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There must be a synergistic effect that derives from n
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multiple
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System Layout
Applies mainly to multi-station systems
Fixed routing vs. variable routing
In systems with fixed routing, workstations are usually
arranged linearly
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In systems with variable routing, a variety of layouts are
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Automation and Manning Levels

Level of workstation automation
Manually operated
Semi-automated
Fully automated
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Mi 1 indicates
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Mi < 1 Production
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Part or Product Variety:

Flexibility
The degree to which the system is capable of dealing with variations
in the parts or products it produces
Three cases:
1. Single-model case - all parts or products are identical (sufficient
demand/fixed automation)
2. Batch-model
case - different
parts or
products
are NJ.
produced
by
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3. Mixed-model case - different parts or products are produced by
No portion
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the system, but the system can handle the differences without
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Three Cases of Product Variety

in Manufacturing Systems

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Enablers of Flexibility
Identification of the different work units
The system must be able to identify the differences
between work units in order to perform the correct
processing sequence
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System must be able to change over the fixtures and
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tools required
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Manufacturing Systems for Medium or

High Product Complexity

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Manufacturing Systems for Low

Product Complexity

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Overview of Classification Scheme

Single-station cells
n=1
Manual or automated
Multi-station systems with fixed routing
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n>1
reserved. This material is protected under all copyright laws as
Typical example:
production line
theycurrently
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routing
portion of thissystems
material with
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Single-Station Cells
n=1
Two categories:
1. Manned workstations - manually operated or semiautomated production machine (M = 1)
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Most widely
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system
- reasons:
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Easiest and least expensive to implement
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Mostwithout
adaptable,
adjustable,
andfrom
flexible
system For
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the publisher.
Can be
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Multi-Station Systems
with Fixed Routing
n>1
Common example = production line - a series of
workstations laid out so that the part or product moves
through each station, and a portion of the total work
content is performed at each station
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Quantity of work units is high
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Work units are similar or identical, so similar operations
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are required in the same sequence
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Total work
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Multi-Station Systems
with Variable Routing
n>1
Defined as a group of workstations organized to achieve
some special purpose, such as:
Production of a family of parts requiring similar (but not
processing
operations
2008identical)
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Assembly
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Production
of a complete
of components
usedortoby
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assemble
one
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final
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Typical case in cellular manufacturing
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