Manufacturing systems design

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Different layouts for various manufacturing systems
3 three basic types of layout:
Process layout
Product layout
Fixed-Position layout

3 hybrid layouts:
Cellular Manufacturing
Flexible Manufacturing Systems
Mixed-model Assembly Lines

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Manufacturing systems design

  1. 1. LEAN MANUFACTURING SYSTEMS Manufacturing System Design By: Kiran Hanjar S 1MS12MIA03 III Sem, IE (M.Tech) Dept. of IEM, MSRIT Department of IEM, MSRIT 1
  2. 2. Factors influencing the system designs in an emerging industrial space  More companies serve global markets by making products for customers worldwide.  As production of a variety of products increases, decreases in lot sizes and quantities result.  Requirements for closer tolerances continue to increase. Requirements demand higher levels of accuracy, precision, and quality.  Product reliability is increasing in response to excessive product liability lawsuits.  The time between an initial design concept and a resulting product continues to shorten due to concurrent or simultaneous engineering.  Ergonomics and worker safety continue to grow in importance as workercompensation costs escalate and humanistic trends continue  Green manufacturing strategies continue to help protect the earth from further pollution Department of IEM, MSRIT 2
  3. 3. Introduction  Facility Layout and Work Flow  Arrangement within a factory of:  Machines  Departments  Workstations  Storage areas  Aisles and common areas  Ensures a smooth flow of work, material, people and information through the system Department of IEM, MSRIT 3
  4. 4. Types of Layouts • 3 three basic types of layout: • Process layout • Product layout • Fixed-Position layout • 3 hybrid layouts: • Cellular Manufacturing • Flexible Manufacturing Systems • Mixed-model Assembly Lines Department of IEM, MSRIT 4
  5. 5. Process Layout • • • • • • Similar activities grouped together in work areas Suitable for low volume or batch production Flexible Not very efficient Storage space – large receiving, small shipping Large aisles for movement of material Drilling Department Milling Department Lathe Department D L L L L L M L M D D D M D D D D Grinding Department G G G Painting Department P G P L L Receiving and Shipping Department of IEM, MSRIT Assembly A A A 5
  6. 6. Product Layout • • • • • • • • Arrange activities in sequence of operation Line set up for one product Specialised machines Suitable for mass production More automated than process layouts Efficient Line flow – avoid bottlenecks IN Not flexible Department of IEM, MSRIT OUT 6
  7. 7. Fixed Position Layout • Large projects too big to move • Equipment and parts moved in and out of work area • Highly skilled workers - costly Department of IEM, MSRIT 7
  8. 8. Hybrid Layouts Try to mix flexibility of process layout with efficiency of product layout Cellular Layouts: • Machines grouped into cells • Cells process parts with similar features • Work cell resembles a small assembly line (product) • Layout between cells treated as process layout Department of IEM, MSRIT 8
  9. 9. Comparison Design of work cell Processed based layout Assembly 4 6 Assembly 7 5 9 4 8 8 1 0 2 2 1 1 0 3 1 2 9 6 1 3 1 1 1 2 1 1 Raw Materials Department of IEM, MSRIT 5 7 Raw Materials 9
  10. 10. Flexible Manufacturing Systems • Automates the entire manufacture of a product • Very costly • Complex software • Small number of FMS worldwide • Flexible Manufacturing Cell: • Smaller version of FMS • One manufacturing process is automated Department of IEM, MSRIT 10
  11. 11. Progressive FMS • Progressive FMS: • All parts follow same progression through the work stations • Best where group technology can be applied Unload Station Department of IEM, MSRIT Load Station Pallet Progressive FMS 11
  12. 12. Closed Loop FMS • Larger variety of parts • Parts can follow different paths • Parts can skip stations Load Unload Pallet Closed Loop FMS Department of IEM, MSRIT 12
  13. 13. Ladder FMS layout • Parts moved to and from any machine in any sequence • More flexible than progressive and closed loop Load/Unload systems Department of IEM, MSRIT 13
  14. 14. Mixed Model Assembly Lines • More than one product is processed by the line • Workers trained to work on more than one station • Layout of line changed • Long and short operations arranged to cancel each other Traditional line Department of IEM, MSRIT U Shaped Line 14
  15. 15. Limitations • • • • • • • System size and complexity inhibit modeling and control, due to implied-time expenditures. Systems are dynamic and unstable. The environment can change the system and vice versa. Relationships may be awkward to express in analytical terms, and interactions may be nonlinear. Thus, well-behaved functions often do not apply. Data or information may be difficult to secure, inaccurate, conflicting, missing, or too abundant to digest. Objectives may be difficult to define, particularly in systems that have an impact on social and political issues. Goals may conflict. The act of observing and trying to control a system changes the behavior of the system. Analysis and control algorithms for systems can be subject to errors of omission and commission. Some errors will be related to breakdowns or delays in feedback elements. Department of IEM, MSRIT 15
  16. 16. THANK YOU Department of IEM, MSRIT 16