Manufacturing System - A2

8/14/2019 Manufacturing System - A2

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Prepared by Group A2:

2. Izham Hazizi3. Nor Shahril

4. Md Fairul

5. Ahmad Fauzie

Types of ManufacturingSystem

Classifying components of

manufacturing system


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Introduction

Manufacturing System plays very important role in daily

manufacturing operation. The objective is to have efficient control

of the organizational structure in order to produce high quality

products at lower prices within a shorter period of time.

Companies that having a good manufacturing system normallycan execute their operation very well as they become more

productive and to make more efficient use of resources.

Manufacturing information systems, material handling,

computer-integrated manufacturing (CIM), and production planningcontrol are just some of the areas that have help companies

improving their understanding and awareness in the manufacturing

and service sectors in order to stand in the very competitive

industry.


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Component in Manufacturing System

Manufacturing system can be elaborated as system whichhaving the combination of integrated equipments and humanresource, whose give a guideline for material processing.

A Manufacturing system consist of several components, whichcan be listed as below;

Production Machines

Material Handling System

A integrated computer system to control components

Human Resource/ worker to operate and manage the system


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MANUFACTURING

SYSTEM

PRODUCTION MACHINESMATERIAL HANDLING

SYSTEM

COMPUTER SYSTEM HUMAN RESOURCES

Component in Manufacturing System


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Production Machines

In any manufacturing systems, almost all the operation orassembly work was help by the machines or with the aid of thetools.

All this machine will be help to achieve high productivity andalso shortercycle time.

There are many type of production machine and thiscombination of production machine in one production floor canbe called as a workstation.

There are 3 type of production machines as below and all thiswas based on the complexity and how advance the tool:

Manually operated

Semi-automated Fully automated


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Manually Operated Machine

Manually operated machines are controlled/operatedorsupervisedby worker/operator(human resource).

This manually operated machines provides thepowerforoperation and the worker provides the control.

Some example of the machine that fall into this category was aconventionalmachine that was normally found in small andmedium industry such as milling machine and drill pressesmachine.

All this type of machine need the worker to operate is as thismachine do not have any program to control or to perform thetask.

In a modern age factory some example of this type of machinesuch as metrology, where this machine will help to ease the jobbut need an operator to operate the machine.


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Manually Operated Machine

Machine

WorkerManuallyoperated

Load Unload

Work cycle

Worker controlled

The operator must be at the machines continuously to engagethe feed, position the tool, load and unload work parts andperform other task related to the operation.


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Semi Automated Machine

Semiautomated machines can perform a task without anyoperator attend to the tool. By using software/hardware control

machine able to operate without any assistant for one cycle of

task.

An example of machine that fit into this category is CNC

machine orotherprogrammable production machine that underthe tool control for one work cycle. But this type of machine

requires a operator to unload the finished part and load the next

part at the end or beginning of each cycle.

In these cases, the worker must attend to the machine every

cycle but doesnt need to be continuously present during thecycle.


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With this, one operator can attend/operate more than onemachine at one time as only extra time required for each

machine to make sure it continuously running with high

productivity.

Program controlled

Work cycle

Worker controlled


Worker

Load Unload

Program

Control


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Fully Automated Machine

Fully automatedmachines was a machines that capable tooperate automatically with no human attention forperiods of

time that are longer than one work cycle.

Although a worker attention is not required during each cycle,

some form of machine tending may be needed periodically

Time to time operator might be need to attend the toolperiodically to add in new material.Also some error on the

machine that require operator to solve the error before tool can

start running again.

Normally this type of machine will be link withAMHSsystem

too.


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Work cycle

Program controlled


Worker

Load Unload

Program

ControlPeriodic

attention

Most of the advance or high tech factory will have this type ofmachine. This type of machine will help to reduce cycle time andalso to reduce labor cost.

This fully automated machine also can reduce the number ofproduct scrap or reject due to less human involvement in the cycletime.


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Workstation

Combination of machines in one workplace are normally call asworkstation.

In this workstation, some specific task or operation was

performed with combination of this 3 type of machines.

A complete manufacturing system may consist of one or more

workstations. A manufacturing system, with multiple workstation is called

production line, assembly line, machine cellor other name

depending on its configuration and function.


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Material Handling System can be defined as an aspect ofmaterials management relating specifically to the physicaltransfer of materials.

The movement of materials (raw materials, scrap, semi-finishedand finished) to, through and from productive processes; inwarehouses and storage; and in receiving and shipping areas

The work machines which normally semiautomated or fullyautomated machines are connected by a material handlingsystem to optimize parts flow and the central control computerwhich controls material movements and machine flow.

Normally the machines can be segregate to 3 parts; loading

unit, positioning unit & unloading unit. Anyhow, transporting work unit between machines to machines

(stations to stations) is also required


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Loading

Unit

Positioning

Unit &

Processing

Unloading

Unit

Machine A

Illustration of Material Handling System


Conveyors, handling robots, automated material handlingsystem (AMHS) are most other automated material handlingsystems fall into this category.


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Machine A

Machine CMachine D

Machine B

Transporting work unit between machines to machines


START

END- FINISHING

GOOD


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Manual WIP trolley

AHMS


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Computer is required to control the automated and semi automated equipment and to participate in the overall

coordination and management of the manufacturing system.

Even in manually computer system is useful to supportproduction, such as a completely manually assembly line.

Computer Control System


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Computer control system divide into:ii. Communicate instructions to workers

communicate to the operator by given complete

instructions. Download part programs to computer

send instructions to computer controlled. i.e CNC machinetools

iv. Material handling system control. Controlling the material handling system to the coordinate

at the workstations.

v. Schedule production accomplished at the site of the manufacturing system.



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i. Failure diagnosis diagnosis equipment malfunctions, preparing preventive

maintenance schedule and maintaining spare parts

inventory.

ii. Safety monitoring to ensure that the system operate in the safe mode and at

the same time to protect workers and the equipment in the

system.

iii. Quality control Functions to detect any possibility reject product from the

production line.

iv.Operations management managing all manufacturing operations whether direct or

indirect.



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exampleexample

Managementcentre

computermanagement

Control room

CD/DVD masteringProduction centre

Stores and Distribution



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Human Resources

Humans refers to allpersonnel, operators, vendors, customersetc.

To operate and manage the system/process

Required eitherfulltime orperiodicallyto keep the system

running

System manufacturingis value added system to produce partsand products

In contextofmanufacturing system, humanperform some or allof the value addedworkthat is accomplishedon theparts/products.


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Human Resources

Performing eithermanual(direct) work on it or by controllingthemachines.

In fully automated machine, direct labour is still needed. For example : loading or unloading parts, changing tools,

resharpening tools etc.

In Automated Manufacturing System, workers also are needed

to support the system.

For example : computer programmers/operators, maintenance and

repair.


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Personnelrelated issues include what is the capability levelofavailable labor, working culture (one shift or two shift), how

many workers need to hire, what is the level of training needed,

whatpolicies to drive a good working environment.

As a conclusion Manufacturing system need all these fourcomponent to make up the system (running the system).

Each component plays an important role in manufacturing

system. If either one of the components is not included, this

systems is not call a manufacturing system.

Human Resources


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Conclusion

Video.mp4

Example of factory that using combination of 4

components of Manufacturing System

With the combination of this 4 manufacturing system components willhelp to improve company competitiveness in the global market.This is essential for company to have good system for in each

components so that the company can satisfy the customer need and keep

growing.


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Reference

Groover, M.P., Automation, Production Systems, and Computer

Integrated Manufacturing. Prentice-Hall Int. 2001

http://www.daifukumalaysia.com/company/mhglossary.php

http://www.technologystudent.com/prddes1/flexbl2.html http://www.nuigalway.ie/staff/david_osullivan/documents/ch13.ppt http://www.his.se/PageFiles/9234/AUB161-L19-handouts.pdf?

epslanguage=sv
http://www.daifukumalaysia.com/company/mhglossary.phphttp://www.technologystudent.com/prddes1/flexbl2.htmlhttp://www.nuigalway.ie/staff/david_osullivan/documents/ch13.ppthttp://www.his.se/PageFiles/9234/AUB161-L19-handouts.pdf?epslanguage=svhttp://www.his.se/PageFiles/9234/AUB161-L19-handouts.pdf?epslanguage=svhttp://www.his.se/PageFiles/9234/AUB161-L19-handouts.pdf?epslanguage=svhttp://www.his.se/PageFiles/9234/AUB161-L19-handouts.pdf?epslanguage=svhttp://www.his.se/PageFiles/9234/AUB161-L19-handouts.pdf?epslanguage=svhttp://www.his.se/PageFiles/9234/AUB161-L19-handouts.pdf?epslanguage=svhttp://www.his.se/PageFiles/9234/AUB161-L19-handouts.pdf?epslanguage=svhttp://www.his.se/PageFiles/9234/AUB161-L19-handouts.pdf?epslanguage=svhttp://www.his.se/PageFiles/9234/AUB161-L19-handouts.pdf?epslanguage=svhttp://www.his.se/PageFiles/9234/AUB161-L19-handouts.pdf?epslanguage=svhttp://www.his.se/PageFiles/9234/AUB161-L19-handouts.pdf?epslanguage=svhttp://www.nuigalway.ie/staff/david_osullivan/documents/ch13.ppthttp://www.technologystudent.com/prddes1/flexbl2.htmlhttp://www.daifukumalaysia.com/company/mhglossary.php

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Manufacturing System - A2