Manufacturing Systems

N. Sinha and S. Mukhopadhyay

Department of Mechanical Engineering
IIT Kanpur
Email: nsinha
 Information About the Course
Schedule: Tuesday, Thursday and Friday (8:00-8:50 AM)
Venue: L-19

Tentative weightage of marks

Quiz (2-3) 20%
Mid Semester Exam 35%
End Semester Exam 40%
Class Participation 5%

Assignments: Will be provided but no need to submit.

Attendance Rules: Will be recorded.
Academic Dishonesty: ZERO Tolerance → “F” Grade
 Definition
A system in which raw materials are processed from one form
into another, known as a product, gaining a higher or added
value in the process and thus creating wealth in the form of a
profit.

An integrated combination of processes, machine systems,

people, organizational structures, information flows, control
systems and computers whose purpose is to achieve economic
product manufacture and internationally competitive
performance.
*Contents in this file taken from various sources for instruction purpose only.
 Inputs and Outputs
✓ The system does not have an
influence or control over all the
inputs, for example, social
pressures.
✓ This means that the system must
be flexible enough to deal with
input variations.
✓ It must also be able to cope with
the rapid changes in technology
and the market, particularly as
product life cycles become
increasingly shorter.

▪ The main output of the manufacturing system can be classified as either

consumer products or producer products.
▪ In some instances, the output of one manufacturing system is the input of
another. Thus, there may be considerable interaction between systems.
Common Characteristics of a Manufacturing System
1. All systems will have specific
business objectives to meet in the
most cost-effective manner.

2. All systems consist of an

integrated set of sub-systems,
usually based on functions, which
have to be linked according to the
material processing.

3. All systems must have some

means of controlling the sub-
systems and the overall system.

4. To operate properly, all systems

need a flow of information and a
decision-making process.
Developing a Manufacturing Strategy
 Developing a Manufacturing Strategy
❖ The manufacturing strategy can be defined as a long range plan to use the
resources of the manufacturing system to support the business strategy
and in turn meet the business objectives.
❖ This in turn requires a number of decisions to be made to allow the
formulation of the manufacturing strategy.

✓ Capacity decisions: what has to be made, what will be used to make it and
when and how will this be achieved?
✓ Process decisions: deciding which type of system should be employed..
✓ Facility decisions: the layout of plant at a factory level, and the assigning of
specific products to specific plants at an organizational level.
✓ Make or buy decisions: important as it will influence the capacity, facilities
and process decisions.
✓ Infrastructure decisions: it will consider the production planning and control
system, the quality assurance system and the organizational structure.
✓ Human resource decision: two main decisions are identifying the functions
and organizational structure required and the reward system, that is, pay,
bonuses, etc.
Manufacturing Organizational Structure
 Typical Sub-functions in Manufacturing
✓ Production planning with responsibility for producing manufacturing
plans such as the master production schedule (MPS) and the materials
requirements plan (MRP).
✓ Quality assurance whose job it is to ensure that products are being made to
the required specification.
✓ Plant maintenance with the responsibility of ensuring that all equipment and
machinery is maintained at an appropriate level for its use.
✓ Industrial engineering whose responsibilities include the determination of
work methods and standards, plant layouts and cost estimates.
✓ Manufacturing engineering whose responsibilities includes manufacturing
systems development, process development, process evaluation and process
planning.
✓ Production/materials control who coordinate the flow of materials and work
through the manufacturing plant (work-in-progress). Stores will usually be
included in this function.
✓ Production whose responsibility it is to physically make the product.
 Categories of Manufacturing System
Manufacturing System

Discrete parts manufacturing Continuous process manufacturing

Cellular manufacturing

Project manufacture Batch manufacture

Jobbing shop manufacture Flow/mass manufacture

Categories of Manufacturing System
Categories of Manufacturing System
 Processing Strategies
Manufacturing Characteristics Competitive Priorities
Strategy
Make-to-stock (MTS) Hold finished goods in stock Low cost, consistent
for immediate delivery (low quality, fast delivery
variety products, e.g. steel plant) speed. (Costly when high
product variety)
Make-to-order (MTO) Make products to customer High degree of
specifications in low volumes customization (longer
(specialized medical delivery time)
equipments)
Assemble-to-order Customize products from High variety, fast
(ATO) relatively few assemblies and delivery. Benefits from
components (Dell, paint Risk-Pooling.
industry)
Processing Strategies
Processing Strategies
 Plant Layout

✓ Plant facility systems design: considers the structural systems, heating,

ventilation and air conditioning (HVAC) and general services, that is, water,
electricity, lighting, etc.
✓ Plant layout design: considers equipment and machinery within the
production area, all production related areas and often personnel areas within
the facility.
✓ Material handling systems design: considers the materials, personnel and
equipment handling systems required to support production.
 Plant Layout
Plant layout is about the physical arrangements of departments,
workgroups within departments, workstations, machines and stock-
holding points within a manufacturing facility.

These are also sometimes referred to as economic activity centres or

work centres.

Plant Layout

Process Layout Hybrid Layout

Product Layout Fixed Position Layout

Process Layout
Product Layout
Fixed Position Layout
 Hybrid Layout
Many organizations have process layouts to manufacture component
parts that are unique to a single product and produced in low volumes,
but employ a product layout to manufacture high-volume common
parts and for assembly.
 Manufacturing Engineering
Manufacturing engineering is generally responsible for all phases of
product manufacture, with the exception of product design.

There are four specific areas of responsibility for manufacturing

engineering:
✓ Manufacturing systems development: incorporates the likes of work
measurement, plant layout and materials handling.
✓ Process development: involves the evaluation, application and
implementation of appropriate new technologies.
✓ Process evaluation: this involves determining the capabilities of the
machines, tools and staff to allow appropriate types of work to be allocated
to each work centre. This may be carried out in conjunction with quality
engineering, particularly if capability studies are required.
✓ Process planning: this is traditionally considered to be the main role of
manufacturing engineering and entails planning the manufacture of the
product.
 Tentative Topics
Project management, Forecasting, Inventory control,
CAD/Geometric modeling, Concurrent engineering, Computer
aided process planning, Material handling and storage systems,
Material requirements planning (MRP), Job sequencing and
scheduling, Just in time (JIT), Group technology (GT), Break-
even analysis, Quality control, Flexible manufacturing systems
(FMS).
Reference Books
1. Systems approach to compter-integrated design and
manufacturing, Nanua Singh, Wiley India.
2. Introduction to Operations and Supply Chain Management,
Cecil Bozarth, Pearson India.
3. Automation, production systems and compter-integrated
manufacturing, M.P. Groover, Eastern Economy Edition.
Applications of Same Tools
27
Humanitarian Relief Supply Chain
Humanitarian Relief Supply Chain

Suppliers
Affected
Regions

Central Distribution Local Storage

Centers

Govt. Agencies
Affected
Regions

Central Distribution
Centers Local Storage

Affected
Donors Regions
30
India – Agriculture/Food
 Food Supply Chain

Share in Global Production

• Tea – 28% (Global Rank = 1)
• Rice – 22% (Global Rank = 2)
• Sugarcane – 21% (Global Rank = 2)
• Pulses – 21% (Global Rank = 1)
• Cattle – 20% (Global Rank = 1)
• Milk – 16% (Global Rank = 1)

Source: Cygnus Report, India Food Processing Sector, 2005

32
 Food Supply Chain
Customers,
Retailers

Farmers Commission Agents/

Wholesalers

Traders