PRODUCTION SYSTEMS

DEFINITION
MANUFACTURING PROCESS
Application of physical and chemical process to alter the geometry properties
and/or appearance of a given started material to make parts or products. This
definition includes assembly process.
PRODUCTION SYSTEM
A production system is a collection of people, equipment and procedures
organized to perform the manufacturing operations of a company.

MANUFACTURING SYSTEM
A manufacturing system is a collection of integrated equipment designed for
some special mission, such as machining a defined part family or assembling
certain product. Include people.

LEVELS IN PRODUCTION SYSTEM

Facilities
Manufacturing support systems

FACILITIES

Factory
Production machines
Tooling
Material handling equipment
Inspection equipment
Computer system
Plant layout

MANUFACTURING SUPPORT SYSTEMS

Procedures or process needed to manage the production operations
Involve a cycle of information processing

Figure 1.3

Functions:
1. Business functions communication with the customer
Marketing
Forecasting
Order entry
Cost accounting
Customer billing
2. Product design
Research and development
Design engineering
Prototype shop
3. Manufacturing planning
Process planning. Operation sequence
Master scheduling Planning. MPS. Listing of product to be make
Material Requirement planning. MRP. Raw material and purchasing
parts.
Capacity resource planning. CRP

4. Manufacturing control
Shop floor control
Inventory control
Quality control

MANUFACTURING SYSTEM CATEGORIES

In terms of human participation in the process,
1. Manual work system
One or more workers performing one or more tasks with the aid of hand
tools.
Hand tools: Is a small tool that is manually operated by the strength and
skill of the human user.
2. Worker-machine system
A human worker operates powered equipment
3. Automated system
The process is performed by a machine without the direct participation of a
human
worker

Requirement:

Program of instructions and control system

AUTOMATIZATION IN PRODUCTION SYSTEMS

1- Automation of manufacturing system
2- Computerization of manufacturing support systems

Automated Manufacturing System

The process is performed by a machine without the direct participation of a
human worker
Basic types:
1- Programmable automation
2- Flexible automation
3- Fixed automation

Programmable automation
The equipment are designed with the capability to change the sequence of
operation to accommodate different product configuration
Features:
1234-

High investment in general purpose equipment

batch production
Low production rates
Certain flexibility to change product configuration

Example
CNC machine tools with manual part charge lost time

Flexible automation
Is an extension of programmable automation.
1234-

High investment in custom-engineered equipment

Continuous production of variable mixture product
Medium production rates
Flexibility to deal with product design variation. Virtually no time lost for
changeover

Example
Machining operation with automated part charge

Fixed automation
System in which the sequence of processing operation is fixed by the equipment
configuration
1- High initial investment for custom-engineered equipment
2- High production rates
3- Relative inflexibility of the equipment to accommodate product variety
Example
Machining lines transfers
Automated assembly machines assembly lines

Figure 1.5

AUTOMATION PRINCIPLES AND STRATEGIES

USA Principles
1- Understand the existing process
2- Simplify de process
3- Automated the process

Strategies
1- Specialization de operation
2- Combined operations
3- Simultaneous operation
4- Integration of operation
5- Increase of flexibility
6- Improve material handling and storage
7- On line inspection
8- Process control and optimization
9- Plant operation control
10-Computer integrated manufacturing (CIM)

MIGRATION
1- Manual production
2- Automated production
3- Automated integrated production