Manufacturing technology

1. MANUFACTURING TECHNOLOGY II
Mr L. chidzuu
077273332
libertychidzuum@gmail.com

2. Manufacturing - Technology
 A process by which labour, energy, material and
equipment are brought together to produce a
product having a greater value than the sum of
materials put in.
 the use of science in industry, engineering, etc., to
invent useful things or to solve problems
 a machine, piece of equipment, method, etc., that
is created by technology

3. Advanced Manufacturing
Traditional
Manufacturing
(20th century)
raw materials
from nature
parts
finished
products
Fabrication Assembly
Advanced
Manufacturing
(21th century)
raw materials
from nature
parts finished
products
Fabrication Assembly
Material
Design
synthetic
materials
Bundling
Integrated
solutions
services
software
continuous
Recycling
recovered
materials

4. What is advanced manufacturing?
1. It is process of converting raw material into complex products
using advanced machines through the application of advancements in
science in manufacturing processes and product design
2. It is the application of advanced technologies and processes at any
stage of the value chain
a. technologies refers to productive equipment and knowledge
b. processes also includes managerial practices (e.g., lean, supply
chain management, e-commerce etc.)
3. In a nut shell building advanced manufacturing is
a. Relative to where an economies’ productive capacity are at
b. Is simply about process and technology upgrading

6. Purely mechanical machines - Anything that uses mechanical energy
only. (e.g., watches, bicycles, egg beater)
Electro-mechanical machines- Mechanical machines that use
electrical sources of energy for propulsion and control purposes (e.g.,
lawn mower, electrical car, aircraft)
Chemo-mechanical machines - Mechanical machines which use
chemical sources of energy?? - control is more important than
propulsion??
Electro-chemical machines - Batteries, solar panels, CDs etc.
Electro-magnetic machines - Computers, TVs (thank you Solymar),
computer chips.
Bio-chemical machines - Enzymes e.g., yeast and
Biological machines - Bacteria, your body cells, yeast
Chemical machines - Pharmaceuticals
what is a machine?

7. What is advanced Manufacturing
Technology?
 AMT is a group of integrated hardware and software
based technologies which if properly implemented,
monitored and evaluated will lead to improving the
efficiency and effectiveness of the firm in
manufacturing a product or providing a service
(Baldwin, 2000).

8. A growing number of organizations are now adopting AMT to
cope with recent phenomenon in today’s competitive
environment such as;
 Shortened product life cycle
 Demand for high quality products
 Need for lower operating costs
 Need for improved manufacturing efficiency
 Reality of global competition
 Awareness of environmental issues

9. Types of advanced manufacturing technologies

10. Benefits of AMT
 Improved return on investment
 Reduced unit costs
 Enhanced competitive advantage
 Increased flexibility
 Improved product quality
 Quick response to customer demands

11. Benefits of AMT
 Decreased lead time
 Reduced delivery time
 Reduced set up costs
 Reduced set up time
 Reduced transportation costs
 Reduced investment in stock
 Reduction in batch sizes
 Improved quality
 Improved reliability
 Improved dependability

12. Role of AMT
 Provides the basis that enables firms to exploit
competitive advantages forested by technology.
 In mass production, firms are expected to gain
competitive edge through the ability to provide a wide
range of products.
 AMT improves the firm’s ability to cope with
environmental uncertainty.
 Small batch producers can enhance their process
efficiencies while maintaining or improving product
flexibility

13. Adopting AMT
 Not all firms adopt AMT because the costs associated
with their adaptation.
 Adaptation occurs when the benefits from adapting
the new technologies overweighs the costs of
implementation.
 In industrialized countries, the costs of labour is
very high and they have opted for AMT.
 Companies must strive to have the competitive
advantage of low cost production.

14. Adopting AMT
Many countries are reluctant to install these
technologies because;
 There are difficulties in implementing the expensive,
complex systems
 AMT requires different support infrastructure
 Insufficient internal skills

15. Obstacles on the implementation of
AMT
 Lack of necessary funding
 Lack of in house technical expertise
 Failure of top management to grasp the benefits of
AMT
 Inadequate planning or lack of vision
 Inadequate cost justification methods

16. Disadvantages of implementing AMT
 Costs of related equipment acquisition
 Costs of related software development
 Increased maintenance expenses
 Difficulties arise because new
technologies and innovation need higher
skill levels

17. Automated
Production Lines

18. Learning Objectives
 Define the concept of automated production lines
 Specify the components of automated production
 Outline the system configurations used in
automated production
 Explain the types of transfer mechanism that may
be used for workpart transfer

19. Automated Production Systems
 An automated production is an intergration of
workstations and work handling systems that are
automated and transfers parts from one station to
the next, normally there is automatic control which
controls movement of work parts
 Manufacturing Technology 2 CUPE
302Haskell_Manufacturing_Systems_Design_and_An
alytics_-_Virtual_Production_Line(480p).mp4

21. Automated Manufacturing Systems
Examples:
 Automated machine tools
 Transfer lines
 Automated assembly systems
 Industrial robots that perform processing or assembly operations
 Automated material handling and storage systems to integrate
manufacturing operations
 Automatic inspection systems for quality control

22. Automated Manufacturing Systems
Three basic types:
1. Fixed automation
2. Programmable automation
3. Flexible automation

23. Fixed Automation
A manufacturing system in which the sequence of processing (or
assembly) operations is fixed by the equipment configuration
Typical features:
 Suited to high production quantities
 High initial investment for custom-engineered equipment
 High production rates
 Relatively inflexible in accommodating product variety

24. General Configuration of APL

25. Programmable Automation
A manufacturing system designed with the capability to change
the sequence of operations to accommodate different product
configurations
Typical features:
 High investment in general purpose equipment
 Lower production rates than fixed automation
 Flexibility to deal with variations and changes in product configuration
 Most suitable for batch production
 Physical setup and part program must be changed between jobs
(batches)

26. Flexible Automation
An extension of programmable automation in which the
system is capable of changing over from one job to the
next with no lost time between jobs
Typical features:
 High investment for custom-engineered system
 Continuous production of variable mixes of products
 Medium production rates
 Flexibility to deal with soft product variety

27. Product Variety and Production
Quantity for Three Automation Types
Fig. 1.5

28. Computerized Manufacturing Support
Systems
Objectives of automating the manufacturing support
systems:
 To reduce the amount of manual and clerical effort in
product design, manufacturing planning and control, and
the business functions
 Integrates computer-aided design (CAD) and computer-aided
manufacturing (CAM) in CAD/CAM
 CIM includes CAD/CAM and the business functions of the
firm

29. Reasons for Automating
1. To increase labour productivity
2. To reduce labour cost
3. To mitigate the effects of labor shortages
4. To reduce or remove routine manual and clerical tasks
5. To improve worker safety
6. To improve product quality
7. To reduce manufacturing lead time
8. To accomplish what cannot be done manually
9. To avoid the high cost of not automating

30. Manual Labor in Production Systems
Is there a place for manual labor in the modern
production system?
 Answer: YES
 Two aspects:
1. Manual labor in factory operations
2. Labor in manufacturing support systems

31. Manual Labor in Factory Operations
The long term trend is toward greater use of automated systems
to substitute for manual labor
 When is manual labor justified?
 Some countries have very low labor rates and automation
cannot be justified
 Task is too technologically difficult to automate
 Short product life cycle
 Customized product requires human flexibility
 To cope with ups and downs in demand
 To reduce risk of product failure

32. Labor in Manufacturing Support Systems
 Product designers who bring creativity to the design task
 Manufacturing engineers who
 Design the production equipment and tooling
 And plan the production methods and routings
 Equipment maintenance
 Programming and computer operation
 Engineering project work
 Plant management