Production Systems - Facilities & Manufacturing Support Systems

Summary

This 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

00:00

🏭 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).

05:01

🔧 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.

10:03

📈 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.

Keywords

💡Manufacturing

Manufacturing refers to the process of creating goods or products using labor, machinery, tools, and other processes. In the video, manufacturing is discussed as a historical activity that has evolved from manual labor to modern, automated systems. The script mentions that the word 'manufacturing' derives from Latin words meaning 'made by hand,' highlighting its origins in manual production. The video's theme revolves around the transformation of manufacturing through the use of production systems, facilities, and support systems.

💡Production Systems

A production system is a collection of people, equipment, and procedures organized to perform the manufacturing operations of a company. The video explains that production systems are essential in modern manufacturing and consist of facilities and manufacturing support systems. The script emphasizes the importance of these systems in organizing the physical and procedural aspects of manufacturing, such as equipment layout and management procedures.

💡Facilities

Facilities in the context of production systems refer to the physical infrastructure, including equipment, factory layout, and the environment in which the manufacturing processes occur. The video script describes facilities as a major component of production systems, encompassing everything from production machines and tooling to material handling and inspection equipment. The layout and organization of these facilities directly impact the efficiency and effectiveness of the manufacturing operations.

💡Manufacturing Support Systems

Manufacturing support systems are the procedures and processes used by a company to manage production, solve technical and logistics problems, and ensure product quality. These systems include product design and business functions that do not directly contact the product but are crucial for planning and controlling its progress through the factory. The video script discusses how these systems are integral to the operation of production facilities, highlighting their role in activities such as process planning, production planning, and quality control.

💡Automation

Automation is the use of control systems and information technologies to reduce the need for human intervention in the production process. The video script introduces automation as a key aspect of modern production systems, where processes are performed by machines without direct human participation. Automation can range from semi-automated systems that require some human involvement to fully automated systems that operate independently. The video suggests that automation is a significant factor in improving efficiency and reducing labor in manufacturing.

💡Manual Work Systems

Manual work systems are those that involve workers performing tasks without the aid of power tools or machinery. The video script describes manual work systems as consisting of one or more workers using hand tools for tasks such as material handling and assembly. These systems are contrasted with work machine systems and automated systems, highlighting the labor-intensive nature of manual work and its reliance on human skill and effort.

💡Work-Machine Systems

Work-machine systems involve human workers operating powered equipment or machines to perform production tasks. The video script explains that these systems combine the strengths of human workers and machines, with humans handling tasks that require adaptability and decision-making, while machines perform repetitive, precise tasks. Examples from the script include a machinist operating a lathe or a team working with an industrial robot, illustrating the synergy between human and machine in these systems.

💡Automated Systems

Automated systems are processes that are performed by machines without the direct participation of human workers. The video script defines automated systems as those that execute a program of instructions through a control system, requiring power to drive the process. These systems can operate for extended periods without human attention, reducing the need for direct labor. The script mentions that there is often a spectrum between work-machine systems and automated systems, with many work-machine systems incorporating some level of automation.

💡Business Functions

Business functions in the context of manufacturing support systems refer to the activities that facilitate communication with customers and are essential for the company's interaction with the market. The video script includes sales and marketing, sales forecasting, order entry, and customer billing as part of business functions. These functions are crucial for understanding customer needs, capturing orders, and managing the relationship with the customer, which in turn influences the production plans and product design.

💡Product Design

Product design is the process of conceptualizing and planning the creation of a product, which may be to customer specifications or as a proprietary product by the manufacturer. The video script discusses how product design is a critical part of the manufacturing process, involving research and development, design engineering, and prototyping. The design phase is where the product's specifications and features are determined, which then influence the subsequent manufacturing planning and production processes.

💡Manufacturing Planning

Manufacturing planning involves the activities of process planning, master scheduling, material requirements planning, and capacity planning. The video script explains that manufacturing planning is about translating the product design into a feasible production schedule, ensuring that the necessary materials, components, and resources are available when needed. This planning phase is essential for coordinating the various aspects of production to meet customer orders and delivery deadlines.

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