ManufacturingSystems&

SingleStationManufacturing
Lecture2

ManufacturingSystemsinProduction
S stem
System

Manufacturing System Defined

ManufacturingSystemDefined
Acollectionofintegratedequipmentandhuman
co ect o o teg ated equ p e t a d u a
resources,whosefunctionistoperformoneor
moreprocessingand/orassemblyoperationson
astartingrawmaterial,part,orsetofparts
l
f
Equipment includes
Productionmachinesandtools
Materialhandlingandworkpositioningdevices
Computersystems
Computer systems

Humanresourcesarerequiredeitherfulltimeor
periodically to keep the system running
periodicallytokeepthesystemrunning

Examples of Manufacturing Systems

ExamplesofManufacturingSystems

Singlestationcells
Machineclusters
h
l
Manualassemblylines
Automatedtransferlines
Automated assembly systems
Automatedassemblysystems
Machinecells(cellularmanufacturing)
Flexiblemanufacturingsystems
l ibl
f
i

Componentsofa
Man fact rin S stem
ManufacturingSystem
1. Production
1
Productionmachines
machines
2. Materialhandlingsystem
3 Computersystemtocoordinateand/or
3.
C
di
d/
controltheprecedingcomponents
4. Humanworkerstooperateandmanagethe
system

ProductionMachines
Invirtuallyallmodernmanufacturingsystems,
mostoftheactualprocessingorassemblywork
isaccomplishedbymachinesorwiththeaidof
tools
Classificationofproductionmachines:
Cl ifi i
f
d i
hi
1. Manuallyoperatedmachines arecontrolledor
supervised by a human worker
supervisedbyahumanworker
2. Semiautomatedmachines performaportionofthe
workcycleundersomeformofprogramcontrol,and
aworkertendsthemachinetherestofthecycle
k
d h
h
h
f h
l
3. Fullyautomatedmachines operateforextended
periods of time with no human attention
periodsoftimewithnohumanattention

Manually Operated Machines

Semi Automatic Machines

Fully Automatic Machines

MaterialHandlingSystem
Inmostmanufacturingsystemsthatprocess
p
p
,
orassemblediscretepartsandproducts,the
followingmaterialhandlingfunctionsmustbe
p
provided:
1.
2.
3.
4
4.

Loading workunitsateachstation
Positioning workunitsateachstation
work units at each station
Unloading workunitsateachstation
Transporting workunitsbetweenstationsin
work units between stations in
multistationsystems
5. Temporarystorage
Temporary storage ofworkunits
of work units

WorkTransportBetweenStations
Twogeneralcategoriesofworktransportin
g y
multistationmanufacturingsystems:
1. Fixedrouting

Workunitsalwaysflowthroughthesamesequence
ofworkstations
Mostproductionlinesexemplifythiscategory

2. Variablerouting

Workunitsaremovedthroughavarietyofdifferent
station sequences
stationsequences
Mostjobshopsexemplifythiscategory

(a)FixedRoutingand
(b)
(b)VariableRouting
bl

ComputerControlSystem
Typicalcomputerfunctionsinamanufacturing
yp
p
g
system:
Communicateinstructionstoworkers
Downloadpartprograms
Download part programs tocomputercontrolled
to computer controlled
machines
Control materialhandlingsystem
Schedule production
Failure diagnosiswhenmalfunctions occur
Safety monitoring
Quality control
Operations management

Classificationof
ManufacturingSystems
f
Factors
Factorsthatdefineanddistinguish
that define and distinguish
manufacturingsystems:
1.
1
2.
3
3.
4.
5
5.

Typesofoperations
Types
of operations
Numberofworkstations
System layout
Systemlayout
Automationandmanninglevel
P t
Partorproductvariety
d t
i t

TypesofOperationsPerformed

ProcessingVsassemblyoperations
Type(s)ofmaterialsprocessed
Size andweight ofworkunits
Partorproductcomplexity
p
p
y
Forassembledproducts,numberofcomponents
perproduct
Forindividualparts,numberofdistinctoperations
tocompleteprocessing

Partgeometry
P
Formachinedparts,rotationalvs.nonrotational

NumberofWorkstations
Convenientmeasureofthesizeofthesystem
Letn =numberofworkstations
Individualworkstationscanbeidentifiedby
subscripti,wherei =1,2,...,n

Affectsperformancefactorssuchasworkload
capacity,productionrate,andreliability
Asn increases,thisusuallymeansgreater
h
ll
workloadcapacityandhigherproductionrate
Theremustbeasynergisticeffectthatderives
There must be a synergistic effect that derives
fromn multiplestationsworkingtogethervs.n
singlestations

SystemLayout
Appliesmainlytomultistationsystems
Fixedroutingvs.variablerouting
Fixed routing vs. variable routing
Insystemswithfixedrouting,workstationsare
usually arranged linearly
usuallyarrangedlinearly
Insystemswithvariablerouting,avarietyof
layoutsarepossible
y
p

Systemlayoutisanimportantfactorin
determining the most appropriate type of
determiningthemostappropriatetypeof
materialhandlingsystem

AutomationandManningLevels
Levelofworkstationautomation
Manuallyoperated
Semiautomated
Fullyautomated

ManninglevelMi =proportionoftime
workerisinattendanceatstationi
Mi =1meansthatoneworkermustbeatthe
stationcontinuously
Mi 1indicatesmanualoperations
1 i di t
l
ti
Mi <1usuallydenotessomeformofautomation

PartorProductVariety:
Flexibility
Thedegreetowhichthesystemiscapableof
dealing with variations in the parts or products it
dealingwithvariationsinthepartsorproductsit
produces
Threecases:
Three cases:
1. Singlemodelcase allpartsorproductsareidentical
2. Batchmodelcase differentpartsorproductsare
producedbythesystem,buttheyareproducedin
d d b th
t
b t th
d di
batchesbecausechangeoversarerequired
3. Mixedmodelcase differentpartsorproductsare
producedbythesystem,butthesystemcanhandle
d db h
b h
h dl
thedifferenceswithouttheneedfortimeconsuming
changesinsetup

ThreeCasesofProductVariety
in Manufacturing Systems
inManufacturingSystems

(a) Single-model case, (b) batch model case, and (c) mixedmodel case

EnablersofFlexibility
Identificationofthedifferentworkunits
de t cat o o t e d e e t o u ts
Thesystemmustbeabletoidentifythedifferences
betweenworkunitsinordertoperformthecorrect
processingsequence
i

Quickchangeoverofoperatinginstructions
The
Therequiredworkcycleprogramsmustbereadily
required work cycle programs must be readily
availabletothecontrolunit

Quickchangeoverofthephysicalsetup
Quick changeover of the physical setup
Systemmustbeabletochangeoverthefixturesand
toolsrequiredforthenextworkunitinminimumtime

ManufacturingSystemsforMedium
orHighProductComplexity
Hi h P d t C
l it

ManufacturingSystemsforLow
ProductComplexity
d
l

OverviewofClassificationScheme
Singlestationcells
n =1
1
Manualorautomated

Multistationsystemswithfixedrouting
n >1
Typicalexample:productionline

Multistationsystemswithvariablerouting
y
g
n >1

SingleStationCells
g
n =1
Twocategories:
Two categories:
1. Mannedworkstations manuallyoperatedorsemi
automatedproductionmachine(M
p
( =1))
2. Fullyautomated machine(M <1)

Mostwidelyusedmanufacturingsystem
reasons:
Easiestandleastexpensivetoimplement
Mostadaptable,adjustable,andflexiblesystem
d
bl dj
bl
d fl ibl
Canbeconvertedtoautomatedstationifdemand
for part or product justifies
forpartorproductjustifies

MultiStationSystems
withFixedRouting
i h Fi d R i
n >1
Commonexample=productionline aseriesof
workstationslaidoutsothatthepartorproduct
moves through each station and a portion of the
movesthrougheachstation,andaportionofthe
totalworkcontentisperformedateachstation
Conditionsfavoringtheuseofproductionlines:
Conditions favoring the use of production lines:
Quantityofworkunitsishigh
Workunitsaresimilaroridentical,sosimilar
operationsarerequiredinthesamesequence
ti
i d i th
Totalworkcontentcanbedividedintoseparatetasks
ofapproximatelyequalduration

MultiStationSystems
with Variable Routing
withVariableRouting
n >1
Definedasagroupofworkstationsorganized
D fi d
f
k i
i d
toachievesomespecialpurpose,suchas:
Productionofafamilyofpartsrequiringsimilar
P d ti
f f il f
t
ii
i il
(butnotidentical)processingoperations
Assemblyofafamilyofproductsrequiringsimilar
Assembly of a family of products requiring similar
(butnotidentical)assemblyoperations
Productionofacompletesetofcomponents
p
p
used
toassembleoneunitofafinalproduct

Typicalcaseincellularmanufacturing

SingleStationManufacturing
Cells

Classificationof
Si l S i M
SingleStationManufacturingCells
f
i C ll

SingleStationManufacturingCells
Mostcommonmanufacturingsystemin
industry
Operationisindependentofotherstations
Performeitherprocessingorassembly
operations
Canbedesignedfor:
Singlemodelproduction
Batchproduction
Mixedmodelproduction
p

SingleStationMannedCell
Oneworkertendingoneproductionmachine
(most common model)
(mostcommonmodel)
Mostwidelyusedproductionmethod,
especiall in job shop and batch prod ction
especiallyinjobshopandbatchproduction
Reasonsforpopularity:
Shortesttimetoimplement
Requiresleastcapitalinvestment
Easiesttoinstallandoperate
Typically,thelowestunitcostforlowproduction
Mostflexibleforproductorpartchangeovers

SingleStationMannedCellExamples
Workeroperatingastandardmachinetool
Workerloads&unloadsparts,operatesmachine
Worker loads & unloads parts operates machine
Machineismanuallyoperated

Workeroperatingsemiautomaticmachine
W k
i
i
i
hi
Workerloads&unloadsparts,startssemi
automaticworkcycle
i
k
l
Workerattentionnotrequiredcontinuously
d i
duringentireworkcycle
ti
k
l

Workerusinghandtoolsorportablepower
toolsatonelocation
l
l
i

Variationsof
Si l S i MannedCell
SingleStation
M
d C ll
Two(ormore)workersrequiredtooperatemachine
Twoworkersrequiredtomanipulateheavyforging
atforgepress
Welderandfitterinarcweldingworkcell
Oneprincipalproductionmachineplussupport
equipment
Dryingequipmentforamanuallyoperated
injectionmoldingmachine
Trimmingshearsatimpressiondieforgehammer
totrimflashfromforgedpart
i fl h f
f
d

SingleStationAutomatedCell
Fullyautomatedproductionmachinecapableof
operatingunattendedforlongerthanoneworkcycle
Workernotrequiredexceptforperiodictending
Reasonswhyitisimportant:
Laborcostisreduced
Easiestandleastexpensiveautomatedsystemto
implement
Productionratesusuallyhigherthanmannedcell
Firststepinimplementinganintegratedmulti
stationautomatedsystem

Enablersfor
Unattended Cell Operation
UnattendedCellOperation
Forsinglemodelandbatchmodelproduction:
Programmedoperationforallstepsinworkcycle
Partsstoragesubsystem
Automaticloading,unloading,andtransfer
betweenpartsstoragesubsystemandmachine
Periodicattentionofworkerforremovalof
finishedworkunits,resupplyofstartingwork
units,andothermachinetending
Builtinsafeguardstoavoidselfdestructive
operationordamagetoworkunits
ti
d
t
k it

Enablersfor
Unattended Cell Operation
UnattendedCellOperation
Formixedmodelproduction:
Alloftheprecedingenablers,plus:
All f th
di
bl
l
Workunitidentification:
Automatic
Automaticidentification(e.g.,barcodes)orsensors
identification (e g bar codes) or sensors
thatrecognizealternativefeaturesofstartingunits
Ifstartingunitsarethesame,workunitidentificationis
unnecessary

Capabilitytodownloadprogramsforeachwork
unit style (programs prepared in advance)
unitstyle(programspreparedinadvance)
Capabilityforquickchangeoverofphysicalsetup

PartsStorageSubsystemand
Automatic Parts Transfer
AutomaticPartsTransfer
Necessaryconditionsforunattendedoperation
Givenacapacity=np partsinthestoragesubsystem,
thecellcantheoreticallyoperateforatime
UT =npTc
whereUT =unattendedtimeofoperation
Inreality,unattendedtimewillbelessthanUT
becausetheworkerneedstimetounloadfinished
partsandloadrawworkpartsintothestorage
t
dl d
k
t i t th t
subsystem

PartsStorageCapacity
Typicalobjectivesindefiningthedesiredparts
storage capacity np:
storagecapacityn
MakenpTc =afixedtimeintervalthatallowsone
workertotendmultiplemachines
p
MakenpTc =timebetweenscheduledtoolchanges
Maken
Make npTc =onecompleteshift
one complete shift
MakenpTc =oneovernight(lightsoutoperation)

StorageCapacityofOnePart
Example:twopositionautomaticpalletchanger
(APC)
Withnopalletchanger,workcycleelementsof
loading/unloadingandprocessingwouldhavetobe
performedsequentially
f
d
i ll
Tc =Tm +Ts
whereTm =machinetimeandTs =workerservice
time
Withpalletchanger,workcycleelementscanbe
i h ll h
k
l l
b
performedsimultaneously
Tc =Max{T
M {Tm,TTs}+T
} Tr
whereTr =repositioningtimeofpalletchanger

CNCMachiningCenterwithAutomatic
PalletChanger
ll
h
StoresOnePart

StorageCapacitiesGreaterThan
One
Machiningcenters:
Variousdesignsofpartsstorageunitinterfacedto
V i
d i
f
i i
f d
automaticpalletchanger(orotherautomated
transfer mechanism)
transfermechanism)
Turningcenters:
Industrialrobotinterfacewithpartscarousel
p
Plasticmoldingorextrusion:
Hoppercontainssufficientmoldingcompoundfor
unattendedoperation
Sheetmetalstamping:
Startingmaterialissheetmetalcoil

Machining center and automatic pallet changer with pallet holders arranged
radially; parts storage capacity = 5

Machining center and in-line shuttle cart system with pallet holders along its
l
length;
th parts
t storage
t
capacity
it = 16

Machining center with pallets held on indexing table; parts storage capacity = 6

Machining center and parts storage carousel with parts loaded onto pallets;
parts storage capacity = 12

ApplicationsofSingleStation
Manned Cells
MannedCells
CNCmachiningcenterwithworkertoload/unload
CNCturningcenterwithworkertoload/unload
CNC turning center with worker to load/unload
ClusteroftwoCNCturningcenterswithtimesharing
of one worker to load/unload
ofoneworkertoload/unload
Plasticinjectionmoldingonsemiautomaticcycle
with worker to unload molding sprue and runner
withworkertounloadmolding,sprue,andrunner
Oneworkeratelectronicssubassemblyworkstation
inserting components into PCB
insertingcomponentsintoPCB
Stampingpresswithworkerloadingblanksand
unloadingstampingseachcycle
g
p g
y

ApplicationsofSingleStation
AutomatedCells
d ll
CNC
CNCMCwithAPCandpartsstoragesubsystem
MC with APC and parts storage subsystem
CNCTCwithrobotandpartsstoragecarousel
Cluster of ten CNC TCs each with robot and parts
ClusteroftenCNCTCs,eachwithrobotandparts
storagecarousel,andtimesharingofoneworkerto
load/unloadthecarousels
Plasticinjectionmoldingonautomaticcyclewith
robotarmtounloadmolding,sprue,andrunner
Electronicsassemblystationwithautomated
insertionmachineinsertingcomponentsintoPCBs
Stampingpressstampspartsfromlongcoil

CNCMachiningCenter
Machinetoolcapableofperformingmultiple
operationsthatuserotatingtoolsonaworkpartin
onesetupunderNCcontrol
Typicaloperations:milling,drilling,andrelated
operations
Typicalfeaturestoreducenonproductivetime:
Automatictoolchanger
Automaticworkpartpositioning
Automaticpalletchanger

CNCHorizontalMachiningCenter

CNCTurningCenter
Machinetoolcapableofperformingmultiple
p
g
p
operationsonarotatingworkpartinone
setupunderNCcontrol
Typicaloperations:
Typical operations:
Turningandrelatedoperations,e.g.,contour
turning
turning
Drillingandrelatedoperationsalongworkpart
axisofrotation

CNCTurningCenter

AutomatedStampingPress

Stamping press on automatic cycle producing stampings from sheet metal

coil

CNCMillTurnCenter
Machinetoolcapableofperformingmultiple
p
g p
g
operationseitherwithsinglepointturning
toolsorrotatingcuttersinonesetupunderNC
control
Typicaloperations:
Turning,milling,drillingandrelatedoperations
Turning milling drilling and related operations

Enablingfeature:
Capabilitytocontrolpositionofcaxisinaddition
C bilit t
t l
iti
f
i i dditi
tox andzaxiscontrol(turningcenterislimitedto
xx andz
and zaxis
axiscontrol)
control)

PartwithMillTurnFeatures

Example part with turned

turned, milled
milled, and drilled features

SequenceofOperationsofa
MillTurnCenterforExamplePart

(1) Turn smaller diameter, (2) mill flat with part in

programmed angular positions, four positions for
square cross section; (3) drill hole with part in
programmed
p
g
angular
g
position,
p
, and (4)
( ) cutoff of the
machined piece

AnalysisofSingleStationSystem
y
g
y
WorkLoad:
Theworkloadisthequantityofworkunitsproduced
duringtheperiodofinterestmultipliedbytime(hrs)
required for each unit
requiredforeachunit
WL QTc
WhereWL=workloadscheduled;Q=quantitytobe
Wh
WL
kl d h d l d Q
i
b
producedduringperiod;andTc=cycletimerequired
/piece (hr/pc)
/piece(hr/pc)
Ifworkloadincludesmultiplepartstylesthen
WL Q jTcj
i

Ifn=numberofworkstations&AT=available
timeonstationintheperiod(hr/period)
Then
Then
WL
n

AT

Example:
l
Supposeacertainfacilityproduce800shaftsina
lathesectionduringaparticularweek.Shafts
areidenticalinshapeandrequiressame
machinecycles.Tc =11.5min.determine
numberoflathesifthereare40hoursof
availabletimeoneachlathe.

WL QTc
WL 800 11.5(min) 9200(min) 153.33(hrs )

Time available
a ailable is 40 hrs
hrs= AT
WL
n
AT
153.33
n
3.82 4lathes
40

Several factors complicates the single model like

setup time, availability, utilization, worker
efficiencyy and defect rate

In previous problem suppose setup time is 3

3.5
5 hrs
hrs. how
many lathes are then required?

AT 40 3.5 36.5hrs
h
153.33
n
4.2 5lathes
36.5
Checking for Utilization U

4 .2
U
0.84 84%
5
153 .33

OT 3 .5
40 1 .83 hr
4

This is a total of 4(1.83 hrs) = 7.33 hrs for 4 m/c operators

Including setup time CASE 2; Shaft type = 20 different

i own b
in
batch;
t h A
Average b
batch
t h size
i = 40 parts
t
Batch setup time = 3.5 hrs; Tc = 11.5 min
Computing
g number of machines again
g
for..

11 .5
WL 20 (3 .5) 20 ( 40 )
223 .33 hrs
60
223.33
n
5.58 6lathes
l th
40
Available time is
AT = T A U
AT = available time; T = Actual clock time;
A = Availability; U = utilization
it is noted that worker efficiency system is considered in Manual system

Defect rate relationship is also considered here

Q Qo (1 q )
Q quantity
Q=
q
y of g
good units;; Qo= Original
g
or starting
g
units; and q = fraction defect rate
The above equation can be solved for

Q
Qo
(1 q )
Combined effects of workers efficiency and fraction
defect rate (considered in Work Load)

QTc
WL
Ew (1 q )
Ew is worker efficiency

MachineCluster
Amachineclusterisdefinedasacollectionoftwoor
moremachinesproducingpartsorproductswith
identicalcycletimesandisservicedbyoneworker.
Whereasmachinecellconsistsofoneormoremachines
organizedtoproduce
i d
d
f il f
familyofparts/products
/ d
Consideracollectionofsingleworkstation,allproducts
aresameinpartsandoperatingonsamesemi
i
t
d
ti
i
automaticcycletime
Let Tm =machinecycletime
LetT
= machine cycle time
Ts =Servicingtimebyworker
If
IfworkerisalwaysavailablewhenservicingisNEEDEDand
k i l
il bl h
i i i NEEDED d
machineneveridle

Tc =Tm +Ts
Ifmorethanonemachineisassignedtotheworker,a
certainamountoftimewill;belostbecauseof
walkingfromonemachinetothenextcalled
f
repositioningtimeTr.
Ti
Timerequiredforoperatortoserviceonemachineis
i df
t t
i
hi i
Ts +Tr andtimetoservicenmachinesisn(Ts +Tr ).
Forsystemtobebalanced
n(Ts +Tr )=Tm +Ts
Tm Ts
n
Ts Tr

n(Ts +Tr ) cannotbebalancedwithTc of

machine

Scenarios
n1 andn2
Introducing cost factors
Introducingcostfactors
LetCL =laborcostrate
Cm =machinecostrate
hi
t t
Case1:ifn1 =max.integersn,workerwillhave
idletimeandcycletimeofmachinecluster
willbecycletimeofmachinei.e.Tc =Tm +Ts
C

pc

C L
n 1
C
n1

T m T s

Case2:ifn2 =min.integers>n,machinewill
g
,
haveidletimeandcycletimeofmachine
clusterwillbetimeittakesforworkerto
servicen2machineswhichisn(Ts+Tr).

C pc n 2 C L C m n 2 T s T r
Inabsenceofcostdataworkersmusthavesomeidle
time and machine will be utilized 100%
timeandmachinewillbeutilized100%
n1 =max.integers T m T s
Ts Tr

Problem(determiningW/stns)
Astampingplantmustbedesignedtosupplyan
automotiveengineplantwithsheetmetalstampings.
Theplantwilloperateone8hourshiftfor250daysper
yearandmustproduce15,000,000 goodquality
stampings annually Batch size = 10 000 good stampings
stampingsannually.Batchsize=10,000goodstampings
producedperbatch.Scraprate=5%.Onaverageittakes
3.0 sec to produce each stamping when the presses are
3.0sectoproduceeachstampingwhenthepressesare
running.Beforeeachbatch,thepressmustbesetup,
andittakes4hr toaccomplisheachsetup.Pressesare
90%reliableduringproductionand100%reliableduring
setup.Howmanystampingpresseswillberequiredto
accomplishthespecifiedproduction?
li h th
ifi d
d ti ?

Solution

Problem(M/cCluster)
A worker is currently responsible for tending two machines
in a machine cluster. The service time per machine is
0 35 min and the time to walk between machines is 0.15
0.35
0 15
min. The machine automatic cycle time is 1.90 min. If
the worker's hourlyy rate = $
$12/hr
/ and the hourlyy rate for
each machine = $18/hr, determine (a) the current hourly
rate for the cluster, and (b) the current cost per unit of
product, given that two units are produced by each
machine during each machine cycle. (c) What is the %
idle time of the worker? (d) What is the optimum
number of machines that should be used in the machine
cluster, if minimum cost per unit of product is the
decision criterion?

Solution