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Manufacturing Systems

Manufacturing Systems. Production Strategy Classification Based on:- customer lead time - max time taken between placing an order and delivery Manufacturing lead time - max time between receipt of an order and delivery of the product

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Manufacturing Systems

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  1. Manufacturing Systems

  2. Production Strategy Classification • Based on:- • customer lead time - max time taken between placing an order and delivery • Manufacturing lead time - max time between receipt of an order and delivery of the product • Need to match manufacturing lead time with customer lead time • Four strategies used to match these lead times: Manufacturing Systems

  3. Engineer to Order (ETO) • New product, complex product, unique designs produced in single units (examples - construction) • Very common in Project type manufacture • Long manufacturing lead times Manufacturing Systems

  4. Make to Order (MTO) • Existing designs with proven production processes • Unpredictable demand(examples - special spec computer) • Assemble to Order (ATO) • customer lead time less than manufacturing lead time • forecasts of product mixes certain or response to customer orders Manufacturing Systems

  5. Make to stock (MTS): • customer lead time less than manufacturing lead time - stock the products so the the manufacturing lead time is minimized • product has few options but good demand Manufacturing Systems

  6. Product Development Cycle • starts from MARKET RESEARCH, to REVIEWS, DESIGN ENGINEERING, PRODUCTION ENGINEERING, MANUFACTURING, CUSTOMER USE • Can be a new product or existing product changes • New Product: • Form, fit and function; • order winning criteria • CONCURRENT ENGINEERING Manufacturing Systems

  7. Existing product: • activity can start from any where Enterprise Organization • CIM implementation affects all facets of the enterprise • Various sections of the enterprise are: • sales and marketing - provide useful information required in pricing, product design, suppliers, e.t.c Manufacturing Systems

  8. Finance and management - coporate goals, financial functions, long-term plans • Product/process definition - design, conceptualization, materials, documentation (CAD/CAD/CAE) • Manufacturing planning and control -interface between engineering and shop floor - MPS , MRP, PAC, Capacity planning • Shop floor - processes, material movement, floor control - AUTOMATION • Support organization Manufacturing Systems

  9. Overview of Product Design and Production Engineering Manufacturing Systems

  10. Considerations: • product design - critical design steps • software for drawing, analysis, modeling, simulations, testing and design • Concurrent engineering • design for quality Manufacturing Systems

  11. Product Design • need for automating design process in CIM • generates the initial product data and drawings • Functional automation - islands of design automation; • potentially productive but has negative enterprise related effects • Single Enterprise database with a single image of all product information - ENTERPRISE DATA INTEGRATION • Communications:- • LAN - supports inter-departmental design activities • WAN - will link enterprises and their contractors/suppliers Manufacturing Systems

  12. Organization Model • Design team - • product design • analysis • materials selection • documentation (both design and production) • Production engineering • production standards(labor, process, quality) • Integrated Product and Production design Manufacturing Systems

  13. Design Process • Form, Fit and Function • Form - desired shape, style and character • Fit - relates more to market functions • Function - performance, reliability, maintanability • Conceptualization: • Typical - similar to previous designs - repetitive design • Atypical - product need that is totally new - concept approach • (Discuss some examples) Manufacturing Systems

  14. Synthesis: • material specification • initial additions of geometric features to the conceptualized design • dimensional details • DFA and DFM (DFMA) • Analysis: • analytical techniques such as Mass property analysis or Finite element methods Manufacturing Systems

  15. Evaluation • checks design against all requirements, form, fit, dimensions, etc • match manufacturing and assembly requirements • Rapid prototyping • Documentation • detailed drawings and assembly drawings • details of materials and parts • BOM • Product electronic data files Manufacturing Systems

  16. Concurrent Engineering • design and production design considered together Manufacturing Systems

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