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Production Operations Production Operations ManagementManagement

Process Technology &Layout

U. Akinc

Process Technology &Layout

U. Akinc

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Various TechnologiesVarious Technologies

Information TechnologyInformation Technology

Product TechnologyProduct Technology

Process TechnologyProcess Technology

Information TechnologyInformation Technology

Product TechnologyProduct Technology

Process TechnologyProcess Technology

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Reasons for TechnologyReasons for Technology

Improved Product and Service QualityImproved Product and Service Quality Lower CostLower Cost Increased Responsiveness to MarketIncreased Responsiveness to Market Increased Responsiveness to CustomerIncreased Responsiveness to Customer SafetySafety

Improved Product and Service QualityImproved Product and Service Quality Lower CostLower Cost Increased Responsiveness to MarketIncreased Responsiveness to Market Increased Responsiveness to CustomerIncreased Responsiveness to Customer SafetySafety

Some of the competitive priorities Some of the competitive priorities

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Barriers to Implementation of Barriers to Implementation of TechnologyTechnology

Difficulty in Financial JustificationDifficulty in Financial Justification

Lack of Understanding by ManagementLack of Understanding by Management

Concern for the Impact of Technology on Concern for the Impact of Technology on the Human Resourcesthe Human Resources

Difficulty in Financial JustificationDifficulty in Financial Justification

Lack of Understanding by ManagementLack of Understanding by Management

Concern for the Impact of Technology on Concern for the Impact of Technology on the Human Resourcesthe Human Resources

traditional ROI based capital budgeting can’t consider non-financial benefitstraditional ROI based capital budgeting can’t consider non-financial benefits

Resistance to change, having to learn “another way” of doing thingsResistance to change, having to learn “another way” of doing things

Fear of loss of jobs due to automationFear of loss of jobs due to automation

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Information and Information and Communication TechnologiesCommunication Technologies

Electronic Data InterchangeElectronic Data Interchange Bar Coding (UPC)Bar Coding (UPC) Electronic PagersElectronic Pagers Cellular TelephonesCellular Telephones Internet/e-MailInternet/e-Mail IntranetIntranet

Electronic Data InterchangeElectronic Data Interchange Bar Coding (UPC)Bar Coding (UPC) Electronic PagersElectronic Pagers Cellular TelephonesCellular Telephones Internet/e-MailInternet/e-Mail IntranetIntranet

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Bar Code TechnologyBar Code Technology Speeds Data EntrySpeeds Data Entry

Increases Data AccuracyIncreases Data Accuracy

Reduces Material Handling LaborReduces Material Handling Labor

Easily Monitors Labor EfficiencyEasily Monitors Labor Efficiency

Speeds Data EntrySpeeds Data Entry

Increases Data AccuracyIncreases Data Accuracy

Reduces Material Handling LaborReduces Material Handling Labor

Easily Monitors Labor EfficiencyEasily Monitors Labor Efficiency

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Process TechnologyProcess Technology

Technology: Manual, Automated or Mental Processes that are Used to Transform Inputs Into Products and Services

Advanced Manufacturing Technology or Automation: Substitution of Machines for Human Physical and mental work.

Key to usage of automation: Repeatability

Technology: Manual, Automated or Mental Processes that are Used to Transform Inputs Into Products and Services

Advanced Manufacturing Technology or Automation: Substitution of Machines for Human Physical and mental work.

Key to usage of automation: RepeatabilityA task that is performed in large number of repetitions is more apt to be automatedA task that is performed in large number of repetitions is more apt to be automated

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Automation and Operations FocusAutomation and Operations Focus

Product Focus:

High Volume Standard Products imply High Degree of Repeatability

Automation is natural Process Focus:

Low Volumes of a wide variety of product and services imply limited repeatability

Automation is more challenging

Product Focus:

High Volume Standard Products imply High Degree of Repeatability

Automation is natural Process Focus:

Low Volumes of a wide variety of product and services imply limited repeatability

Automation is more challenging

Line-Flow = flow-shopLine-Flow = flow-shop

In the form of fixed automation In the form of fixed automation

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Fixed AutomationFixed AutomationAutomation of the processes and transfer

of parts among stations. Characterized by: High set up cost Rigid Capabilities Extreme efficiency

Examples: Assembly Lines Transfer Lines Process industries (e.g., petro-chemicals)

Automation of the processes and transfer of parts among stations. Characterized by:

High set up cost Rigid Capabilities Extreme efficiency

Examples: Assembly Lines Transfer Lines Process industries (e.g., petro-chemicals)

Sometimes referred to as Detroit type automation Sometimes referred to as Detroit type automation

Machines that are linked with automatic materials handlingMachines that are linked with automatic materials handling

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An example of fixed automation: Egg processingAn example of fixed automation: Egg processing

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Flexible AutomationFlexible Automation

Automatic Processes that can be easily changed from one task to another. Characterized by:

Low set up costs A range of capabilities Reasonably Efficient

Example: Job Shop

Automatic Processes that can be easily changed from one task to another. Characterized by:

Low set up costs A range of capabilities Reasonably Efficient

Example: Job Shop

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Group TechnologyGroup TechnologyAnother Attempt to obtain the efficiency of

product focus without giving up the flexibility of process focus

Elements of Group Technology: Part Families based on commonality of

Processing Steps Part Geometry

Manufacturing Cells: Arrangement of Equipment best suited for a family

Another Attempt to obtain the efficiency of product focus without giving up the flexibility of process focus

Elements of Group Technology: Part Families based on commonality of

Processing Steps Part Geometry

Manufacturing Cells: Arrangement of Equipment best suited for a family

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Computer Integrated Computer Integrated Manufacturing(CIM)Manufacturing(CIM)

Integration of total manufacturing enterprise

through the use of integrated systems and

data communications coupled with new

management philosophy that improve

organizational and personnel efficiency.

(SME)

Integration of total manufacturing enterprise

through the use of integrated systems and

data communications coupled with new

management philosophy that improve

organizational and personnel efficiency.

(SME)

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CIMCIM

An Umbrella term to encompass the integration of:

Product Design/Engineering Process Planning /Development Manufacturing Operations Production/Inventory Control

An Umbrella term to encompass the integration of:

Product Design/Engineering Process Planning /Development Manufacturing Operations Production/Inventory Control

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Components of CIMComponents of CIM 1. CAD:Computer Assisted Design: Use of Computers

in interactive engineering drawing, storage and manipulation of existing designs.

2. CAM:Computer Assisted Manufacture: Use of

Computers to program, direct and control manufacturing equipment in the fabrication of parts.

1. CAD:Computer Assisted Design: Use of Computers

in interactive engineering drawing, storage and manipulation of existing designs.

2. CAM:Computer Assisted Manufacture: Use of

Computers to program, direct and control manufacturing equipment in the fabrication of parts.

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Components of CIM Components of CIM (cont’d)(cont’d)

3. CAPPComputer Assisted Process Planning:

Selecting operations, their sequences, tools and material handling systems using interactive computer systems

4. NC MachinesNumerically Controlled Machines:Machines which take their instructions from a

control device that can be programmed and reprogrammed in software

3. CAPPComputer Assisted Process Planning:

Selecting operations, their sequences, tools and material handling systems using interactive computer systems

4. NC MachinesNumerically Controlled Machines:Machines which take their instructions from a

control device that can be programmed and reprogrammed in software

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Components of CIM Components of CIM (cont’d)(cont’d) 5.RoboticsVersatile, programmable devices capable of human

like operations.– Used Mostly in:

Hazardous Repetitive tasks Handling Heavy Parts

– Such as: Spot welding Inspection Circuit board Assembly Spray Painting

5.RoboticsVersatile, programmable devices capable of human

like operations.– Used Mostly in:

Hazardous Repetitive tasks Handling Heavy Parts

– Such as: Spot welding Inspection Circuit board Assembly Spray Painting

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Merlin1

A Multi-Axes RobotA Multi-Axes Robot

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Merlin2

A Merlin robot programmed to cut carpet to specified sizesA Merlin robot programmed to cut carpet to specified sizes

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Merlin3

A Merlin Robot spot welding A Merlin Robot spot welding

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Anatomy of a Merlin robot (has three degrees of freedom or axes)

Anatomy of a Merlin robot (has three degrees of freedom or axes)

Bus 241 22Gantry1

Gantry Robots work like “Etch-a-sketch”. Movement is on 3 linear axes (x,y,z) as opposed to rotational as in Merlin. This robot is installing the wind shield on a car

Gantry Robots work like “Etch-a-sketch”. Movement is on 3 linear axes (x,y,z) as opposed to rotational as in Merlin. This robot is installing the wind shield on a car

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Gantry2

Another Gantry robot: cutting clothAnother Gantry robot: cutting cloth

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Components of CIM Components of CIM (cont’d)(cont’d)

6. AGV

Automatically Guided Vehicles 7. AS/RS

Automated Storage and Retrieval Systems

6. AGV

Automatically Guided Vehicles 7. AS/RS

Automated Storage and Retrieval Systems

Please visit the linkPlease visit the link

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Automatically Guided vehicle examples Automatically Guided vehicle examples

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Infrastructure of CIMInfrastructure of CIM

Use of integrated computer software for

Production Scheduling

Inventory Control

Capacity Planning

Shop Floor Control

Use of integrated computer software for

Production Scheduling

Inventory Control

Capacity Planning

Shop Floor Control

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Layout PlanningLayout Planning Selecting location for and transfer routes and Selecting location for and transfer routes and

means among work departmentsmeans among work departments: Traditional typesTraditional types ::

– Functional (Process Focus)Functional (Process Focus)– Line Flow (Product focus)Line Flow (Product focus)– Fixed Position (Project)Fixed Position (Project)

ModernModern– Group TechnologyGroup Technology

Selecting location for and transfer routes and Selecting location for and transfer routes and means among work departmentsmeans among work departments:

Traditional typesTraditional types ::– Functional (Process Focus)Functional (Process Focus)– Line Flow (Product focus)Line Flow (Product focus)– Fixed Position (Project)Fixed Position (Project)

ModernModern– Group TechnologyGroup Technology

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Functional LayoutFunctional Layout

Painting

Packing

Sanding

Turning

Gluing

Cutting Drilling

Planing

Resources are organized into functional departmentsResources are organized into functional departments

Most appropriate for process focusMost appropriate for process focus

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Line Flow LayoutLine Flow Layout

Product flows through processes A-E Product flows through processes A-E in a sequence dictated by the assembly in a sequence dictated by the assembly requirements of the product.requirements of the product.

Product flows through processes A-E Product flows through processes A-E in a sequence dictated by the assembly in a sequence dictated by the assembly requirements of the product.requirements of the product.

A E D B C B

E D

A C E

A B D

B C

Most appropriate for Product FocusMost appropriate for Product Focus

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Cell A

Cell B

Planing

PaintingCell C

Manufacturing Cells in Manufacturing Cells in Group TechnologyGroup TechnologyRefer back to slide number 12: Group Technology. Here the departments are arranged to produce families of similar parts efficiently

Refer back to slide number 12: Group Technology. Here the departments are arranged to produce families of similar parts efficiently

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A Part FamilyA Part Family

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Manufacturing (GT) CellManufacturing (GT) Cell

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Product Product Process Process

MatrixMatrix

LowVolume-Unique

Many Products-

LowVolume

SeveralProducts-

HighVolume

OneProduct-

Very HighVolume

No Flow

Jumbled Flow

Mixed withDominant Flows

Line Flow

Continuousor Automated

Project

Job Shop

Batch

AssemblyLine

Continuous

Process

Product Variety and VolumeProduct Variety and Volume

Iden

tifie

d P

roce

ss

Iden

tifie

d P

roce

ss

Pat

tern

Pat

tern