Production Systems - Facilities & Manufacturing Support Systems
Summary
TLDRThis tutorial introduces the foundational concepts of production systems, facilities, and manufacturing support systems, essential for industrial automation and computer-integrated manufacturing. It explains the evolution from manual to automated production, detailing the components of production systems, including facilities and support systems. The tutorial also covers manual, work-aided machine, and automated systems, emphasizing their roles in modern manufacturing. It outlines the functions of manufacturing support systems, including business, product design, planning, and control, which are crucial for efficient production operations.
Takeaways
- 📚 The term 'manufacturing' originates from Latin words 'manus' (hand) and 'facere' (to make), reflecting early production methods.
- 🏭 A production system encompasses people, equipment, and procedures to carry out a company's manufacturing operations.
- 🔩 Facilities are a key component of production systems, including physical structures, equipment layout, and the factory environment.
- 🛠️ Manufacturing support systems involve procedures for managing production, addressing technical and logistical challenges, and ensuring quality standards.
- 👷♂️ Direct labor in production systems includes both blue-collar workers operating facilities and white-collar workers managing support systems.
- 🔄 Production systems have evolved from manual work to work-aided machine systems and fully automated systems.
- 🤖 Automation in production systems is characterized by machines performing processes with minimal or no human intervention.
- 🔍 Manufacturing planning involves process planning, scheduling, material requirements planning, and capacity planning to ensure efficient production.
- 📈 Manufacturing control includes shop floor control, inventory control, and quality control to manage and monitor the physical production operations.
- 📊 Quality control involves inspection, data collection, and problem-solving to maintain product quality as per design specifications.
Q & A
What is the origin of the word 'manufacturing'?
-The word 'manufacturing' is derived from two Latin words 'manus' meaning hand and 'facere' meaning to make, implying that the term originally referred to items made by hand.
What are the two major components of a production system?
-A production system consists of two major components: facilities and manufacturing support systems. Facilities include the physical aspects like equipment and factory layout, while manufacturing support systems encompass the procedures for managing production.
What does the term 'facilities' in production systems refer to?
-In the context of production systems, 'facilities' refers to the physical infrastructure, including the factory, production machines, tooling, material handling equipment, inspection equipment, and computer systems that control the manufacturing operations.
How are manufacturing systems categorized based on human participation?
-Manufacturing systems are categorized into three basic types based on human participation: manual work systems, work-a-machine systems, and automated systems. Manual work systems involve workers using hand tools, work-a-machine systems involve human workers operating powered equipment, and automated systems perform processes without direct human participation.
What is the difference between semi-automated and fully automated systems?
-Semi-automated machines perform a portion of the work cycle under program control, requiring human intervention for the remainder of the cycle. Fully automated machines can operate for extended periods without human attention, with a worker only occasionally tending to the machine.
What are the four functions of manufacturing support systems?
-The four functions of manufacturing support systems are business functions, product design, manufacturing planning, and manufacturing control. These functions involve activities such as sales and marketing, design engineering, process planning, scheduling, and quality control.
Why are manufacturing support systems essential for efficient production?
-Manufacturing support systems are essential for efficient production as they plan and control the progress of products through the factory, manage production orders, and ensure product quality meets the specified standards.
What role do business functions play in the manufacturing process?
-Business functions serve as the primary means of communication between the company and the customer. They include sales, marketing, sales forecasting, order entry, and customer billing, and are the starting and ending points of the information processing sequence in manufacturing.
How does product design fit into the manufacturing process?
-Product design is a critical part of the manufacturing process where the product is developed and designed, either based on customer specifications or as a proprietary product by the manufacturer. This phase involves research and development, design engineering, and prototyping.
What is the purpose of manufacturing planning in production systems?
-Manufacturing planning involves process planning, master scheduling, material requirements planning, and capacity planning. Its purpose is to translate the authorization to produce a product into a feasible production plan, ensuring that all necessary materials, components, and resources are available when needed.
Can you explain the role of manufacturing control in production systems?
-Manufacturing control is responsible for managing and controlling the physical operations in the factory to implement the manufacturing plans. It includes shop floor control, inventory control, and quality control, ensuring that products are processed, assembled, and inspected according to the planned schedule and quality standards.
Outlines
🏭 Introduction to Production Systems
This paragraph introduces the concept of production systems in the context of industrial automation and manufacturing. It explains that the term 'manufacturing' comes from Latin words meaning 'made by hand', reflecting the historical roots of production. The paragraph outlines the evolution of production systems from manual labor to modern, automated processes. It defines a production system as a collection of people, equipment, and procedures organized to perform manufacturing operations. The two major components of a production system are facilities, which include the physical aspects of production like equipment and factory layout, and manufacturing support systems, which encompass procedures for managing production and solving logistical and technical issues. The paragraph also discusses the role of people in production systems, distinguishing between direct labor (blue-collar workers) and professional staff (white-collar workers).
🔧 Manufacturing Systems and Automation
This section delves into the specifics of manufacturing systems, highlighting three types: manual work systems, work machine systems, and automated systems. Manual work systems involve workers using hand tools for tasks without power tools. Work machine systems combine human workers with powered equipment, leveraging their respective strengths. Examples include machinists operating lathes and industrial robots working alongside human operators. Automated systems are characterized by processes performed by machines without direct human participation, governed by programmed instructions and control systems. The paragraph further explains the concepts of semi-automated and fully automated machines, with semi-automated machines requiring human intervention for part of the work cycle, and fully automated machines operating independently for extended periods. It also touches on the role of workers in automated processes, who may be needed to monitor operations and perform maintenance.
📈 Manufacturing Support Systems and Their Functions
The final paragraph focuses on manufacturing support systems, which are crucial for the efficient operation of production facilities. These systems encompass a range of activities including business functions, product design, manufacturing planning, and manufacturing control. Business functions involve customer interaction through sales, marketing, order entry, and billing. Product design is initiated by customer requirements or internal forecasts and may involve research and development, design engineering, and prototyping. Manufacturing planning involves process planning, scheduling, material requirements planning, and capacity planning to ensure the production process is feasible and resources are available. Manufacturing control deals with managing factory operations to implement plans, including shop floor control, inventory control, and quality control. This involves monitoring product progress, balancing inventory levels, and ensuring product quality meets standards through inspection and problem-solving approaches like statistical process control and Six Sigma.
Mindmap
Keywords
💡Manufacturing
💡Production Systems
💡Facilities
💡Manufacturing Support Systems
💡Automation
💡Manual Work Systems
💡Work-Machine Systems
💡Automated Systems
💡Business Functions
💡Product Design
💡Manufacturing Planning
Highlights
Introduction to the course on industrial automation, computer integrated manufacturing, and materials handling.
The etymology of 'manufacturing' and its historical context dating back to 1567.
Definition of a production system as a collection of people, equipment, and procedures for manufacturing operations.
Components of a production system: facilities and manufacturing support systems.
Facilities include the physical aspects of production such as equipment, layout, and factory location.
Manufacturing support systems encompass procedures for managing production and solving technical and logistics issues.
Role of people in production systems, including direct labor and professional staff.
Differentiation between manual work systems, work machine systems, and automated systems.
Characteristics and examples of manual work systems, emphasizing the use of hand tools and manual material handling.
Work machine systems where human workers operate powered equipment alongside machines.
Automated systems perform processes without direct human participation, utilizing programmed instructions and control systems.
Levels of automation: semi-automated and fully automated systems, with examples from injection molding plants.
Manufacturing support systems' role in organizing a company for efficient production operations.
Business functions as the primary means of customer communication and their place in the information processing sequence.
Product design process, including customer-provided designs and proprietary product development by the manufacturer.
Manufacturing planning activities such as process planning, master scheduling, material requirements planning, and capacity planning.
Manufacturing control functions like shop floor control, inventory control, and quality control to manage factory operations.
Quality control's focus on ensuring product quality through inspection, data collection, and problem-solving approaches like SPC and Six Sigma.
Upcoming discussion on automation in production systems in the next video.
Transcripts
welcome to academic gain tutorials in
this video we are going to generate the
basic concept about production systems
facilities and manufacturing support
systems this video is the first class of
our course on industrial automation
computer integrated manufacturing and
materials handling we will cover all
related topics one by one before
starting if you haven't subscribed to
this channel yet just click on subscribe
and press the bell icon here we come up
with new videos on different subjects to
make the academic studies easier for you
so into the topic the word manufacturing
derives from two Latin words meanness
hand and factors make so that the
combination means made by hand this was
the way manufacturing was accomplished
when the word first appeared in the
English language around 1567 commercial
goods of those times were made by hand
workers had to specialize in their tasks
rather than overseeing the fabrication
of the entire product they were
responsible for only a small part of the
total work slowly but surely the systems
of production were being developed the
systems of production are essential in
modern manufacturing so that's where our
topic comes in production systems a
production system is a collection of
people equipment and procedures
organized to perform the manufacturing
operations of a company it consists of
two major components number one
facilities the physical facilities of
the production system include equipment
the way the equipment is laid out and
the factory in which the equipment is
located and number 2 manufacturing
support systems these are the procedures
used by the company to manage production
and to solve the technical and logistics
problems encountered in ordering
materials moving the work through the
factory and ensuring that products meet
quality standards product design and
certain business functions are included
in the manufacturing support systems in
modern manufacturing operations portions
of the prod
chin system our automated or
computerized in addition production
systems include people people make these
systems work in general
direct labor people blue-collar workers
are responsible for operating the
facilities and professional staff people
white-collar workers are responsible for
the manufacturing support systems now we
will discuss in details about both
facilities and manufacturing support
systems facilities the facilities in the
production system consist of the factory
production machines and tooling material
handling equipment inspection equipment
and computer systems that control the
manufacturing operations facilities also
include the plant layout which is the
way the equipment is physically arranged
in the factory the equipment is usually
organized into manufacturing systems
which are the logical groupings of
equipment and workers that accomplish
the processing and assembly operations
on parts and products made by the
factory manufacturing systems can be
individual work cells consisting of a
single production machine and a worker
assigned to that machine more complex
manufacturing systems consist of
collections of machines and workers for
example a production line the
manufacturing systems come in direct
physical contact with the parts and or
assemblies being made they touch the
product in terms of human participation
in the processes performed by the
manufacturing systems three basic
categories can be distinguished as we
can see in these figures a manual work
systems B work machine systems and C
automated systems manual work systems a
manual work system consists of one or
more workers performing one or more
tasks without the aid of power tools
manual material handling tasks are
common activities in manual work systems
production tasks commonly require the
use of hand tools such as screwdrivers
and hammers when using hand tools a work
holder is often employed to grasp the
work part and position it securely for
processing examples of production
related manual tasks involve
the use of hand tools include a
machinist using a file to round the
edges of a rectangular part that has
just been milled a quality control
inspector using a micrometer to measure
the diameter of a shaft a material
handling worker using a dolly to move
cartons in a warehouse a team of
assembly workers putting together a
piece of machinery using hand tools work
of machine systems in a work a machine
system a human worker operates powered
equipment such as a machine tool or
other production machine this is one of
the most widely used manufacturing
systems work of machine systems include
combinations of one or more workers and
one or more pieces of equipment the
workers and machines are combined to
take advantage of their relative
strengths and attributes which are
listed in this table humans
sense unexpected stimuli develop new
solutions to problems coped with
abstract problems adapt the change
generalize from observations learn from
experience make decisions based on
incomplete data machines perform
repetitive tasks consistently store
large amounts of data retrieve data from
memory reliably perform multiple tasks
simultaneously apply high forces n power
perform simple computations quickly make
routine decisions quickly
examples of worker machine systems
include the following a machinist
operating an engine lathe to fabricate a
part for a product a fitter and an
industrial robot working together in an
arc welding work sell a crew of workers
operating a rolling mill that converts
hot steel slabs into flat plates a
production line in which the products
are moved by mechanized conveyor and the
workers at some of the stations use
power tools to accomplish their
processing or assembly tasks automated
systems an automated system is one in
which a process is performed by a
machine without the direct participation
of a human worker Automation is
introducing a program of instructions
combined with a control system that
executes the instructions
power is required to drive the process
and to operate the program in control
system these terms will be defined more
completely later in this video series
there is not always a clear distinction
between worker machine systems and
automated systems because many work of
machine systems operate with some degree
of automation two levels of automation
can be identified semi automated and
fully automated a semi automated machine
performs a portion of the work cycle
under some form of program control and a
human worker tends to the machine for
the remainder of the cycle by loading
and unloading it or by performing some
other tasks each cycle a fully automated
machine is distinguished from its semi
automated counterpart by its capacity to
operate for an extended period of time
with no human attention extended period
of time means longer than one work cycle
a worker is not required to be present
during each cycle instead the worker may
need to tend the machine every tenth
cycle or every hundredth cycle an
example of this type of operation is
found in many injection molding plants
where the molding machines run on
automatic cycles but periodically the
molded parts at the machine must be
collected by a worker figure C depicts a
fully automated system the semi
automated system is best portrayed by
figure be in certain fully automated
processes one or more workers are
required to be present to continuously
monitor the operation and make sure that
it performs according to the intended
specifications examples of these kinds
of automated processes include complex
chemical processes oil refineries and
nuclear power plants the workers do not
actively participate in the process
except to make occasional adjustments in
the equipment settings perform periodic
maintenance and spring into action if
something goes wrong manufacturing
support systems to operate the
production facilities efficiently a
company must organize itself to design
the processes and equipment plan and
control the production orders
and satisfy product quality requirements
these functions are accomplished by
manufacturing support systems people and
procedures by which a company manages
its production operations most of these
support systems do not directly contact
the product but they plan and control
its progress through the factory
manufacturing support involves a
sequence of activities as depicted in
this figure the activities consist of
four functions that include much
information flow and data processing one
business functions to product design
three manufacturing planning and for
manufacturing control business functions
the business functions are the principal
means by which the company communicates
with the customer they are therefore the
beginning and the end of the information
processing sequence included in this
category are sales and marketing sales
forecasting order entry and customer
billing the order to produce a product
typically originates from the customer
and proceeds into the company through
the sales department of the firm the
production order will be in one of the
following forms one in order to
manufacture an item to the customers
specifications to a customer order to
buy one or more of the manufacturers
proprietary products or three an
internal company order based on a
forecast of future demand for a
proprietary product product design if
the product is manufactured to customer
design the design has been provided by
the customer and the manufacturers
product design department is not
involved if the product is to be
produced to customer specifications the
manufacturers product design department
may be contracted to do the design work
for the product as well as to
manufacture it if the product is
proprietary the manufacturing firm is
responsible for its development and
design the sequence of events that
initiates a new product design often
originates in the sales department the
direction of information flow is
indicated in this figure the departments
of the firm that are organized to
accomplish product design might include
research and development design
engineering
and perhaps a prototype shop
manufacturing planning the information
and documentation that constitute the
product design flows into the
manufacturing planning function the
information processing activities in
manufacturing planning include process
planning master scheduling material
requirements planning and capacity
planning process planning consists of
determining the sequence of individual
processing and assembly operations
needed to produce the part the
manufacturing engineering department is
responsible for planning the processes
and related technical details such as
tooling manufacturing planning includes
logistics issues commonly known as
production planning the authorization to
produce the product must be translated
into the master production schedule
which is a listing of the products to be
made the dates on which they are to be
delivered and the quantities of each
based on this master schedule the
individual components and sub assemblies
that make up each product must be should
yield raw materials must be purchased or
requisitioned from storage pots must be
ordered from suppliers and all of these
items must be planned so they are
available when needed the computations
for this planning are made by material
requirements planning in addition the
master schedule must not list more
quantities of products than the factory
is capable of producing each month with
its given number of machines and
manpower capacity planning is concerned
with determining the human and equipment
resources of the firm and checking to
make sure that the production plan is
feasible manufacturing control
manufacturing control is concerned with
managing and controlling the physical
operations in the factory to implement
the manufacturing plans the flow of
information is from planning to control
as indicated in this figure information
also flows back and forth between
manufacturing control and the factory
operations included in this function are
shop floor control inventory control and
quality control shop floor control deals
with the problem of monitoring the
progress of the product as it is being
processed assembled moved and inspected
in the factory
shop floor control is concerned with
inventory in the sense that the
materials being processed in the factory
are work in process inventory
thus shop floor control and inventory
control overlap to some extent inventory
control attempts to strike a proper
balance between the risk of too little
inventory with possible stock outs of
materials and the carrying cost of too
much inventory
it deals with such issues as deciding
the right quantities of materials to
order and when to reorder a given item
when stock is low the function of
quality control is to ensure that the
quality of the product and its
components meet the standards specified
by the product designer to accomplish
its mission quality control depends on
inspection activities performed in the
factory at various times during the
manufacture of the product also raw
materials and component parts from
outside sources are sometimes inspected
when they are received and final
inspection and testing of the finished
product is performed to ensure
functional quality and appearance
quality control also includes data
collection and problem-solving
approaches to address process problems
related to quality such as statistical
process control SPC and Six Sigma so we
have learnt about production systems
facilities and manufacturing support
systems in details in the next video we
will discuss in details about automation
in production systems thank you
you
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