Manfacturing process

8/3/2019 Manfacturing process

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Manufacturing SystemsManufacturing Systemshttp://www.amiestudy.com


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Manufacturing SystemsManufacturing Systems

Comprises of Inputs, Transformation

Process and Output

http://www.amiestudy.com


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Process and OutputInput Men, Materials,MachinesDrawings,, Instructions, Paper Work etc


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Trans Process- Planning, Control, Storage,Procure, Insp,Assembly, Instructions etc.


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Output- Goods, Services, Parts,

Paperwork, Served Customers etc.


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Output- Goods, Services, Parts,

Paperwork, Served Customers etc.*


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Factors InfluencingFactors Influencing --Mfg SystemMfg System


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Volume of Production


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Repetitiveness


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RepetitivenessPlant Capacity


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Flexibility


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FlexibilityLead Time


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Efficiency


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EfficiencyEnvironment


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EfficiencyEnvironment

*


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Type of ProductionType of Production

Intermittent Continuous

Batch

Mass/Flow Process

Project Jobbing

S l i f Mf SS l i f Mf S


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Selection of Mfg SystemSelection of Mfg System

S l i f Mf SS l i f Mf S


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Variety

S l i f Mf SS l ti f Mf S t


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Variety

Jobbing

S l ti f Mf S tS l ti f Mfg S t


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Variety

Jobbing

Batch

S l ti f Mf S tS l ti f Mfg S t


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Variety

Jobbing

Batch

Mass

S l ti f Mfg S tSelection of Mfg System


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Variety

Jobbing

Batch

MassContinuous



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Variety

Jobbing

Batch

MassContinuous

Qty



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Quantity



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Quantity

Jobbing



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Quantity

Jobbing Batch



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Quantity

Jobbing Batch Mass



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Quantity

Jobbing Batch Mass

Continuous



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Quantity

Jobbing Batch Mass

Continuous

Cost



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Quantity

Jobbing Batch Mass

Continuous

Cost

Growth



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Quantity

JobbingBatch

Mass

Continuous

Cost

GrowthIntro



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Quantity

JobbingBatch

Mass

Continuous

Cost

GrowthIntro

Maturity

Jobbing Type ManufacturingJobbing Type Manu acturing


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g yp gg yp gSystemSystem



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Small Requirements



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Small Requirements

Discontinuous flow, imbalance



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Small RequirementsDiscontinuous flow, imbalanceDisproportionate Manufacturing Cycle



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General Purpose Machines, Process layout



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General Purpose Machines, Process layoutSkilled Labour



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Skilled supervisor



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SystemSystemSmall RequirementsDiscontinuous flow, imbalanceDisproportionate Manufacturing Cycle


Skilled supervisorHigher WIP



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SystemSystemSmall RequirementsDiscontinuous flow, imbalanceDisproportionate Manufacturing CycleGeneral Purpose Machines, Process layoutSkilled Labour


PPC . Limited functions



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SystemSystemSmall RequirementsDiscontinuous flow, imbalanceDisproportionate Manufacturing CycleGeneral Purpose Machines, Process layoutSkilled Labour


PPC . Limited functions* Shi s, Cranes, Furnaces,Boilers, E ui ment

Projects Type Mfg SystemProjects Type Mfg System


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Definite Beginning and End



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Definite Beginning and EndNon Uniform requirement of resources,



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Projects Type Mfg Systemj yp g y

Definite Beginning and EndNon Uniform requirement of resources,Transferable Teams. Loc A to B



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ojects ype g Systej yp g y

Definite Beginning and EndNon Uniform requirement of resources,Transferable Teams. Loc A to BDifferent Agencies, Specialized tasks,



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j yp g yj yp g y

Definite Beginning and EndNon Uniform requirement of resources,Transferable Teams. Loc A to BDifferent Agencies, Specialized tasks,Typical layout- all operations .. Place same



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j yp g yj yp g y


Cost overruns



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j yp g yj yp g y


Cost overrunsManpower problems, not permanent,Psychological detachment, Site work



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j yp g yj yp g y


Cost overrunsManpower problems, not permanent,Psychological detachment, Site work

* Shi s, Locomotives, Roads,Buildin s, Dams

Advantages Job/Project ProductionAdvantages Job/Project Production


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Discontinuous Flow Equipment, Special Products,



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Discontinuous Flow Equipment, Special Products,No Mechanization



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Each Job is Different



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Each Job is DifferentSpecial Training , Division of Labour



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Each Job is DifferentSpecial Training , Division of LabourComplicated Planning/Control



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Each Job is DifferentSpecial Training , Division of LabourComplicated Planning/ControlTime for design



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Each Job is DifferentSpecial Training , Division of LabourComplicated Planning/ControlTime for designGeneral Purpose M/c and Layout



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Advantages Job/Project Productiong j



Unit Quantity



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dva tages Job/ oject oduct og j



Unit Quantity* Maximum WIP

Batch Type ManufacturingBatch Type Manu acturingSystemSystem


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SystemSystem



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SystemSystemShort Runs



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SystemSystemShort RunsSkilled Labour for specific work



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SystemSysteShort RunsSkilled Labour for specific work Skilled Supervisor



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SystemyShort RunsSkilled Labour for specific work Skilled SupervisorLimited Span of Control



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yyShort RunsSkilled Labour for specific work Skilled SupervisorLimited Span of ControlGeneral Purpose Machines



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Manual HandlingLarge WIP



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Manual HandlingLarge WIPQueuesFlexibility



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Manual HandlingLarge WIPQueuesFlexibilityStrong PPC required



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Manual HandlingLarge WIPQueuesFlexibilityStrong PPC required

* Paints, Pharma,Chemicals, Garments,Vehicl

Advantages of Batch ProductionAdvantages of Batch Production


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Most Common Drugs, Cloths,Automat Comp,Forgings,Cast



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Most Common Drugs, Cloths,Automat Comp,Forgings,CastItems Manufactured in Batches



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Intermittent Flow of Material



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Intermittent Flow of MaterialDivision of Labour is Possible



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Intermittent Flow of MaterialDivision of Labour is PossibleTedious Planning/Control



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Less Space, Min Maintenance



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Less Space, Min Maintenance Attention Required on Quality



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Right Quantity



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Right Quantity* WIP can be ad usted

Mass Type ManufacturingMass Type Manu acturingSystemSystem


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Continuous Flow



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Continuous FlowSpecial Machines



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Continuous FlowSpecial MachinesMechanized Handling



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Continuous FlowSpecial MachinesMechanized HandlingLow Skills



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Continuous FlowSpecial MachinesMechanized HandlingLow SkillsShort manufacturing Cycle



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Low WIP



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Low WIPNo QueuesNo Flexibility



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Low WIPNo QueuesNo FlexibilityNo PPC required



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Low WIPNo QueuesNo FlexibilityNo PPC required

* Steel, Pa er,Refiner , Su ar

Advantages of Mass/Flow ProductionAdvantages of Mass/Flow Production


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Smooth Flow Screws, TV sets, Cars, Cycles,



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Smooth Flow Screws, TV sets, Cars, Cycles,Minimum time/unit, Cost/unit



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Minimum Handling


h l


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Minimum HandlingNo Special Training , Division of Labour


S h Fl


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Minimum HandlingNo Special Training , Division of LabourSimple Planning/Control


S h Fl


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Minimum HandlingNo Special Training , Division of LabourSimple Planning/ControlLess Space


S th Fl


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Minimum HandlingNo Special Training , Division of LabourSimple Planning/ControlLess SpaceRight Quality


S th Fl S TV C C l


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Right Quantity


Smooth Flow S TV C C l


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Right Quantity* Minimum WIP

Disadvantages of Mass ProductionDisadvantages of Mass Production


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Stoppage Breakdown


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Stoppage ..Breakdown


Stoppage Breakdown


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Stoppage ..BreakdownComplicated Maintenance


Stoppage Breakdown


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Change in Product Difficult


Stoppage Breakdown


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Change in Product DifficultChange in Layout Difficult


Stoppage Breakdown


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Change in Product DifficultChange in Layout DifficultSystem speed = Slowest m/c Speed


Stoppage Breakdown


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Change in Product DifficultChange in Layout DifficultSystem speed = Slowest m/c SpeedSpecial Supervision Skills


Stoppage Breakdown


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Change in Product DifficultChange in Layout DifficultSystem speed = Slowest m/c SpeedSpecial Supervision SkillsHigh Investment




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Special Machines




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Special Machines* Problem with WIP


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Analysis of Production SystemAnalysis of Production System


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Analysis of Production SystemAnalysis of Production System

ItemsProcessMassBatchJobbingFactor


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SpecialSpecialTech,SpecialTechSales/DesignCo-ordin.SpecializedSpecializedTechSupervisor NilSpecialStandardStandardHandling NilSmallmediumHighWIP

LeastSmallModerateHighCost/timeContinuousContinuous Nil NilFlow

DesignedArrangedM/c GroupsM/c GroupsLayoutOutsideLayoutStandardStandardBuildingPlantDesignedStandardStandardEquipment

Items

Selection.. Comparison 1Selection.. Comparison 1

L gM diL tC it lLargeMediumSmallSize..Quantity


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High ?LowLowJob Security

NoPartly YesFlexibility

Specific Versatile VersatileOrgn Structure

HighMediumMediumSupervisory Skill

LowHighHighTech (Op) Skills

LowestMediumHighestMfg Cost

LargeMediumLowestCapitalInvestment

Mass/PrBatchJob/ProjType


LargeMediumSmallSize..Quantity


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HighLowLowNew TechnologyGoodModeratePoorEfficiency

MinModerateMaximumLead time

MinMediumGoodPPC Involvement

LowMediumHigh Variable Cost

HighestMediumMinimumFixed Cost

GoodMediumLowestRepeatability

Mass/PrBatchJob/ProjType


ConsistenMedium??Quality


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NoPartly YesSwitchoverNoPartly Yes Variety of JobsFullMediumOptimumM/c Utilization

UnchangedFlexibleFlexiblePlant Layout

t

MassBatchJobType

Functions of Production Engineer Functions of Production Engineer


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Establish Correct way of Process thru Study


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Eliminate Unnecessary Operations




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Prepare Drawing of All fixtures required




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Prepare Drawing of All fixtures requiredTime,Method Studies




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Establish Process with Mutual Consent




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Establish Process with Mutual ConsentEstimate Correct Cost




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Train for Effective Performance




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Train for Effective Performance

* Updated on Modern Development, Methods

Process FormulationProcess Formulation


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Define Problem


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Define ProblemD fi Eff i


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Define Effectiveness


Define ProblemD fi Eff ti


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Construct Model e= f ( x,y)


Define ProblemD fi Eff ti


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Construct Model e= f ( x,y)Search Alternatives .. List


Define ProblemDefine Effectiveness


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Analysis of alternatives .. Procons




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Analysis of alternatives .. ProconsEvaluation of Alternatives




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Analysis of alternatives .. ProconsEvaluation of Alternatives

* Decide Optimum Solution

Production System AnalysisProduction System Analysis


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Linear Programming


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Linear ProgrammingWaiting List Model


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Waiting List Model




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Waiting List Model

Simulation Models




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Waiting List Model

Simulation ModelsNetwork Model




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Waiting List Model

Simulation ModelsNetwork Model

* Statistical Techniques

Manufacturing ProcessesManufacturing Processes --ClassificationClassification

Cons Mass M Removal M Addition


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Cons Mass

Casting

FormingHeat Treatm

PMPolymer

M Removal

MachiningGrindingUn- Conv

WeldingMech Jointg Adhesive B

e ae aWorkingWorking

ProcessProcess


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Manufacturing Processes 1Manufacturing Processes 1

Casting Piercing Torch Cutting


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g

ForgingExtruding

RollingDrawing

SqueezingCrushing

PiercingSwagingBendingShearingSpinningStretch Forming

Roll Forming

Torch Cutting

Electroform..Pwdr Forming

Machinery* Profile Cutting


Turning Broaching


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g

PlaningShaping

DrillingBoring

ReamingSawing

BroachingMillingGrindingHobbing

* Routing


Polishing Spraying


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g

Belt grindingTumbling

PlatingHoning

LappingSuper-finishing

SprayingInorganic CoatingParkerizing

AnodizingSheradizing

* Galvanizing


Welding


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g

SolderingBrazing

SinteringPressing

Screw fastening* Adhesive Joining

Hot . Cold WorkingHot . Cold Working


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Hot . Cold WorkingHot . Cold WorkingHot Working > recrystallisation temperature


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Aprox 0 6 times Melting Point


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Aprox 0.6 times Melting Point




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Cold Working< recrystallisation temperature




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Aprox recrystallisation temperature



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Aprox


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Plastic DeformationPlastic Deformation

It done above re-crystallization temp. Itdoes not produce strain in metal.


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Aluminum 150 Deg C




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Aluminum 150 Deg CCopper 200 Deg C




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Gold 200 Deg C




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Gold 200 Deg CIron 450 Deg C




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Gold 200 Deg CIron 450 Deg CNickel 590 Deg C




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Gold 200 Deg CIron 450 Deg CNickel 590 Deg CSilver 200 Deg C




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Gold 200 Deg CIron 450 Deg CNickel 590 Deg CSilver 200 Deg C

* Zinc, Lead 45 Deg C


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Metal Working VariablesMetal Working Variables


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Metal Working VariablesMetal Working VariablesDependent Output varInput variables


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Production RateSpeed of deformation

Final Mat Stru/PropertiesExtent of deformation

Final TemperatureStarting Temperature

Surface FinishLubrication, Friction

Dimensional AccuracyGeometry of Tool, Die

Power requiredMat Size,Shape,Properties


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Cold Working ProcessCold Working Process


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Cold Working ProcessCold Working ProcessDisadvantages Advantages


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Residual Stresses ProducedMinimum Contamination

Reduction in DuctilityEasy hardening

Higher deformationenergy>>heavy machinery

Stress,Fatigue, WearProperties Improved

Required intermediate HTGood Surface Finish

Strain Hardening limits deforBetter Dim Accuracy


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Hot Working ProcessHot Working Process


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Hot Working ProcessHot Working ProcessDisadvantages Advantages


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Poor tolerances thermal expansion

Mat structure can bealtered to improveproperties

High cost m/c, heatingHigh DuctilityDifficult handlingNo strain HardeningNon uniform mat stressHigh reduction possible

Poor surface finish ..scaling

Low deformationenergy>less power

and Wish You Best of e Life


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[email protected]

PT Chartered Engineer , Marketing, Management Consultant, QMS-Facilitator

P Chairman-The Institution of Engineers(I),

Maharashtra State Centre, Secretary-Pune Management Association

[email protected]

Impossible is UntriedImpossible is UntriedImpossible is UntriedImpossible is Untried

!!

and Wish You Best of e Life


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[email protected]

PT Chartered Engineer , Marketing, Management Consultant, QMS-Facilitator

P Chairman-The Institution of Engineers(I),

Maharashtra State Centre, Secretary-Pune Management Association

[email protected]

Impossible is UntriedImpossible is UntriedImpossible is UntriedImpossible is Untried

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Manfacturing process