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Emerging Trends

Emerging Trends . Major Revolutions in Manufacturing. 1776, Adam Smith “The Wealth of Nations” 1910, Henry Ford and Mass Manufacturing. 1980, The Toyota Production System. Lean Manufacturing. Supply Chain Management. The Gestation of TPS Eiji Toyoda visit to Henry Ford’s factory in 1950.

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Emerging Trends

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  1. Emerging Trends

  2. Major Revolutions in Manufacturing • 1776, Adam Smith “The Wealth of Nations” • 1910, Henry Ford and Mass Manufacturing. • 1980, The Toyota Production System. • Lean Manufacturing. • Supply Chain Management.

  3. The Gestation of TPS • EijiToyoda visit to Henry Ford’s factory in 1950. • The SMED (Single-digit in Minutes Exchange of Die) program at the stamping plant. • Deming’s quality movement in Japan. • The Engineers: TaiichiOhno and Shigeo Shingo Main Features of TPS Greater Product Variety Fast Response (Flexibility) Demand Management The SMED Program. • Gradual Elimination of Waste. • Continuous Improvement (Kaizen), Root-Cause Analysis (5-whys?) and Fool-proofing (Poka-Yoke). Cross-Trained Workers. • Just-In-Time Production • Kanban, Jidoka

  4. Supplier Relationships • Long-term, steady relationships with a few suppliers. • Negotiation based on a long term commitment to productivity and quality improvement. What’s in it for a supplier? • A Stable Manufacturing Environment. Supplier can plan his production 2) Leaner Processes. Cost/Flexibility/Quality 3) Less of Marketing efforts Case of General Motors Saturn Brakes

  5. Computer-Aided Design • Computer-Aided Design (CAD) is product design using computer graphic technology. • increases productivity of designers • creates a database for manufacturing information on product specifications • benefits such as lower product development costs and a greatly shortened design cycle. CAD enables designers to layout and develop work on screen, print it out and save it for future editing, saving time on their drawings CAD is the use of computer systems to assist in the creation, modification, analysis, or optimization of a design.[1] CAD software is used to increase the productivity of the designer, improve the quality of design, improve communications through documentation, and to create a database for manufacturing.[2] CAD output is often in the form of electronic files for print, machining, or other manufacturing operations.

  6. CAM --Robotics • Computer-aided manufacturing (CAM) commonly refers to the use of numerical control (NC) computer software applications to create detailed instructions (G-code) that drive computer numerical control (CNC) machine tools for manufacturing parts. Manufacturers in a variety of industries depend on the capabilities of CAM to produce high-quality parts. • A broader definition of CAM can include the use of computer applications to define a manufacturing plan for t -Tooling design, NC programming, -machine tool simulation -The plan is then executed in a production environment, such as direct numerical control (DNC), tool management, CNC machining.

  7. ERP • ERP is the effective planning of all resources in the organisation • Enterprise Resource Planning(ERP) is a software driven business management system which integrates all facets of the business, including planning, manufacturing, sales and marketing. • Links financial, manufacturing, human resources, distribution & order management into a tightly integrated single system with shared data & visibility across the business

  8. Why Go For ERP 1) Integration and discipline in the organization. 2) Streamlining of business operations 3) Breaks down departmental barriers 4) Good MIS and monitoring: Information is available to the concerned people at the place/time etc for better decision making 5) Optimizes inventory: It determines how many of an item are needed and when, in order to meet the master schedule. ERP thus helps the manager to procure the component as it is needed thereby avoiding excess inventory costs 6) Realistic commitments: Realistic delivery promise can enhance customer satisfaction. With the use of ERP, production can give marketing timely information about the likely delivery times to prospective customers. Potential new orders can be added to the system to calculate how the revised total load can be met with the existing capacity.

  9. Why Go For ERP 7) Increases Efficiency- ERP provides close coordination with various work centers. Consequently, production proceeds with fewer unplanned interruptions with focus on having all components at appropriately scheduled times. 8) Use Of common databases and platform: Solves the problem of data integrity and redundancy. Saves dual entries and speeds up information processing: No duplication of work

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