Production Management

Subject Code :- HUT1253

BY
ANUPRITA BHOSALE
MANUFACTURING
SYSTEMS

PRODUCTION MANAGEMENT
2
COMPONENTS OF
MANUFACTURING SYSTEM

1. Production Machines

2. Material handling systems

3. Computer systems

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4. Human workers
3
1. PRODUCTION MACHINES
In terms of worker participation, the machines can be
classified as
(1) Manually operated
Manually operated machines are controlled or supervised
by a human worker. The machine provides the power for
the operation and the worker provides the control.
(2) Semi-automated
A semi-automated machine performs a portion of the
work cycle under some form of program control, and a

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worker tends to the machine for the remainder of the
cycle.
(3) Fully automated
capability to operate with no human attention for periods
of time longer than one work cycle. Although a worker’s
attention is not required during each cycle.
4
2. MATERIAL HANDLING
SYSTEM
Functions of material handling
system
1. Loading work units at each station
2. Positioning the work units at each
station
3. Unloading the work units from the
station

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4. Transporting work units between
the stations
5. Temporary storage functions 5
Two types of Routing
(a) Fixed routing
(b) Variable routing

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6
COMMON MATERIAL TRANSPORT
EQUIPMENT IN FIXED ROUTING

Powered roller conveyor

Belt conveyor

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Walking beam transfer equipment

Drag chain conveyor Overhead trolley conveyor

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COMMON MATERIAL TRANSPORT
EQUIPMENT IN VARIABLE ROUTING

Automated guided vehicle system Power-and-free overhead conveyor

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Monorail system
8
3. COMPUTER CONTROL
SYSTEM
• Communicate instructions to workers
• Download part programs
• Control material handling system
• Schedule production
• Diagnose failures
• Monitor safety

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• Quality control
• Manage operations
9
4. HUMAN RESOURCES

Direct labor

Semi automated systems

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Fully automated systems

10
TYPES OF MANUFACTURING
SYSTEMS
Various factors that distinguish different
types of manufacturing systems are

1. Types of operations performed,

2. Number of workstations and system

layout,

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3. Level of automation, and

4. System flexibility
11
1. TYPES OF OPERATIONS
PERFORMED
Parameters of the product that affect the
operations performed in the manufacturing
system are
1. Processing operations

2. Assembly operations to join individual parts

into assembled entities

3. Type of material processed

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4. Size and weight of the part or product

5. Part geometry

6. Part or product complexity 12

2. NUMBER OF WORKSTATIONS AND
SYSTEM LAYOUT
Factor Single-Station System (n = 1) Multi-Station System (n > 1)

Workload Limited to the capacity of a single Capacity increases with the number of
Capacity station workstations
Production Slower, as all work is performed Higher, due to task division and
Rate by one station specialization
All tasks performed at a single
Work Tasks divided into simpler segments
station, leading to higher
Complexity across multiple stations
complexity
Lower, as one workstation Higher, as stations specialize in specific
Efficiency
handles all tasks tasks
System Less complex, fewer stations, and More complex with increased number

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Complexity simpler logistics of stations and coordination

Management
Easier to manage with fewer More challenging, as more stations,
&
stations workers, and machines are involved
Maintenance
Workstation More complex layout options (fixed or
Layout
Single layout, usually simple
variable routing) 13
3. LEVEL OF AUTOMATION
Level of Automation in Manufacturing Systems
Inversely correlated with the manning level (Mi) at each
workstation
Manning Level (Mi): Proportion of time a worker
spends at a station
Mi = 1: One worker required continuously
Mi < 1: Worker tends multiple automated
machines (e.g., Mi = 0.25 for 4 machines)
Mi > 1: Multiple workers at the station
(e.g., Mi = 2 or 3)
Average Manning Level (M)
wu = Number of utility workers

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wi = Number of workers at each
specific station
n= Total number of workstations
in the system
w= Total number of workers
assigned to the system 14
3. LEVEL OF AUTOMATION
Types of Workstations Based on Automation Level

1. Manned Workstations:
- Manual or semi-automated machines
- Requires a worker at each cycle, but one worker may
operate multiple machines

2. Automated Workstations:
-Fully automated machines
-No worker required for every cycle, but periodic
attention needed
(e.g., maintenance, loading/unloading)

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3. Hybrid Systems
Some stations are manned, while others are fully automated
known as partially automated systems
15
3. LEVEL OF AUTOMATION
Example:

Number of workstations (n) = 4

Number of utility workers (wu) = 2
Workers at each workstation:
Station 1: 1 worker (w = 1)
Station 2: 2 workers (w = 2)
Station 3: 1 worker (w = 1)
Station 4: 3 workers (w = 3)
Calculate Average Manning level

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16
4. MANUFACTURING FLEXIBILITY
Flexibility in Manufacturing Systems:
The ability to adapt to changes in operating conditions and
variations in parts/products.

Types of Changes and Variations:

-Changes in production schedules (e.g., part mix, quantities, rush
orders, late deliveries).
-Variations in parts/products (e.g., design differences, materials,
new part introductions).

Importance of Flexibility:

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-Flexible manufacturing systems (FMS) are desirable as they help
maintain performance with minimal disruption.
-One key type of flexibility: the ability to produce different part
styles in a mixed-model mode, reducing costly setup changes.
17
4. MANUFACTURING FLEXIBILITY
Key Functions for Mixed-Model Mode:

Identification of Work Units:

- The system must identify different part styles for correct
operations.
- In manual/semiautomatic systems, workers can easily identify; in
automated systems, automatic work unit identification is needed.
Quick Changeover of Operating Instructions:
- In manual systems, workers are cross-trained to perform various
operations for different part styles.
- In automated systems, the correct part program is automatically
loaded once the work unit is identified.

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Quick Changeover of Physical Setup:
- Flexibility requires quick changes in tooling, fixtures, and setup
between different work units.
- Changeover time should be minimal (time taken to swap
completed units for the next). 18
4. MANUFACTURING FLEXIBILITY
Increased Complexity with Flexibility:

Material Handling: Need for systems to handle various part

shapes.

Tools: More tools are required to accommodate different part

variations.

Inspection: Becomes more complex with varied parts.

Logistics: More complicated coordination and supply of

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parts.

Scheduling: More difficult to manage with increased variety

in parts/products.
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CLASSIFICATION OF
MANUFACTURING SYSTEMS

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20
 CLASSIFICATION OF SINGLE
STATION MANUFACTURING CELL

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21
SINGLE STATION MANNED CELL
(ONE WORKER OPERATING A SINGLE MACHINE)

One-Machine/One-Worker Station

Manually Operated Station:

• Worker controls the machine, loads, and unloads the work.

• Example: Engine lathe, drill press, or forge hammer.
• Worker’s attention is needed continuously or for most of
the cycle (e.g., during feed engagement).

Semi-automated Station:

• Machine is controlled by a program (e.g., CNC machine

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tool).
• Worker loads and unloads the machine and changes cutting
tools periodically.
• Worker is required every cycle, but attention may not be
continuous.
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SINGLE STATION MANNED CELL
(ONE WORKER OPERATING A SINGLE MACHINE)

Variations in One-Machine/One-Worker Model

1. Single-Station Manned Cell:

- Worker uses hand tools (e.g., screwdriver, wrench) or
portable powered tools (e.g., handheld drill, soldering iron,
arc welding gun).
- Includes manual inspection tasks at one workstation.

2. Two or More Workers Operating the Same Machine:

- Required when more than one worker is needed for full-
time machine operation or task accomplishment.

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Examples:
Two workers handling heavy forgings in a forge press.
A welder and fitter working together in arc welding.
Multiple workers assembling a large piece of machinery
at one station.
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SINGLE STATION MANNED CELL
(ONE WORKER OPERATING A SINGLE MACHINE)

3. Principal Production Machine with Supporting

Equipment:
-Primary machine with subordinate equipment at
the same station.
Examples:
Drying equipment for plastic molding.
Grinder for trimming plastic moldings at an
injection molding machine.

4. Machine Cluster:

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-When worker’s attention is only needed for a
small portion of the cycle, allowing the worker to
manage multiple machines.
-Machine cluster setup increases efficiency when
the worker is less engaged during part of the cycle. 24
SINGLE STATION MANNED CELL
(ONE WORKER OPERATING A SINGLE MACHINE)

Key Advantages:

1. Quick Implementation

2. Low Capital Investment

3. Ease of Installation and Operation

4. Cost-Effective for Low Production Quantities

5. Versatility in Changeovers

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Dominates job shop and batch production, even used in
high production settings.

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SINGLE STATION AUTOMATED CELL
(AUTOMATED WORKSTATION WITH WORKER OVERSIGHT)

Key Feature of Single-Station Automated Cell

Unattended Operation:
Capable of operating unattended for extended
periods.

Factors enabling Unattended Operation

1. Identical Work Units (No product variety):

Systems designed to produce identical parts or

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products.

2. Soft Product Variety (Different work units):

Systems designed to handle varying products or
work units. 26
SINGLE STATION AUTOMATED CELL
(AUTOMATED WORKSTATION WITH WORKER OVERSIGHT)
Factors enabling Unattended Operation for Identical
Work Units

Programmed Cycle

Part-Storage System

Automatic Transfer of Work Parts

Periodic Worker Attention

Built-In Safeguards

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Safeguards to protect against:
Unsafe operating conditions for workers.
Self-destructive system behavior.
Damage to work units.
May include high process/equipment reliability, error detection, and
recovery capabilities. 27
SINGLE STATION AUTOMATED CELL
(AUTOMATED WORKSTATION WITH WORKER OVERSIGHT)
Factors enabling Unattended Operation for
Different Work Units

Work Identification System:

•Distinguishes between different starting work units.
•Ensures the correct processing sequence for each part or product style.
•Necessary if identical work units undergo different processing
operations.

Program Downloading Capability:

•Allows transfer of the correct machine cycle program for the identified
part or product style.

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•Assumes that programs for all part styles are pre-prepared and stored
in the machine control unit or accessible to it.

Quick Setup Changeover Capability:

•Ensures work-holding devices and tools for each part are available on
demand for quick changeovers. 28
SINGLE STATION AUTOMATED CELL
(AUTOMATED WORKSTATION WITH WORKER OVERSIGHT)

CNC Machining Centers and Related Machine Tools

Three-Axis Machining Centers

Vertical Machining Center (VMC)
Horizontal Machining Center (HMC)

Four-Axis and Five-Axis Machining Centers

Four-Axis Machine:
Five-Axis Machine:

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29
SINGLE STATION AUTOMATED CELL
(AUTOMATED WORKSTATION WITH WORKER OVERSIGHT)
CNC Machining Centers and Related Machine Tools

1. Machining centers

Three-Axis Machining Centers

Vertical Machining Center (VMC):
-Spindle is oriented vertically relative to the worktable.
-Used for machining the top surface of parts.
-Common applications: cavities in molds, pockets in flat parts (e.g.,
aircraft components).

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Horizontal Machining Center (HMC):
-Spindle is oriented horizontally relative to the worktable.
-Best suited for machining complex cube-shaped parts.
-Common applications: machinery components.
-Advantage: Machining chips fall away due to gravity, unlike VMC
where chips must be brushed or blown away. 30
SINGLE STATION AUTOMATED CELL
(AUTOMATED WORKSTATION WITH WORKER OVERSIGHT)

CNC Machining Centers and Related Machine Tools

Four-Axis and Five-Axis Machining Centers

Four-Axis Machine:
-Has x-, y-, z-axes (same as three-axis machine) plus a fourth
axis (a-axis).
-The a-axis provides rotational control about the x-axis,
allowing the spindle to be oriented at various angles.
-Range of a-axis: typically -90° (vertical) to 0° (horizontal).
Five-Axis Machine:
-Includes x-, y-, z-axes, a-axis, and b-axis.
-The b-axis provides rotational control about the y-axis.

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-The combination of a- and b-axes allows for more complex
tool spindle orientations.
-Tool spindle can be positioned in a hemispherical work
envelope, enabling greater geometric complexity for parts.
-Increased flexibility for machining complex parts. 31
SINGLE STATION AUTOMATED CELL
(AUTOMATED WORKSTATION WITH WORKER OVERSIGHT)

CNC Machining Centers and Related Machine Tools

2. Turning center

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32
SINGLE STATION AUTOMATED CELL
(AUTOMATED WORKSTATION WITH WORKER OVERSIGHT)

CNC Machining Centers and Related Machine Tools

3. Multitasking Machines

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33
SINGLE STATION AUTOMATED CELL
(AUTOMATED WORKSTATION WITH WORKER OVERSIGHT)

ANALYSIS OF SINGLE-STATION CELLS

1. How many single stations are required to satisfy

production requirements?

2. How many machines should be assigned to a

worker in a machine cluster?

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34
SINGLE STATION AUTOMATED CELL
(AUTOMATED WORKSTATION WITH WORKER OVERSIGHT)

1. How many single stations are required to satisfy

production requirements?
The problem is to determine the number of cells or
workstations needed to produce a given quantity of work
units within a specified time period.

n = number of cells or workstations;

WL = workload to be accomplished during the period of
interest, hr/period; and

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AT = available time on one cell in the same period,
hr/period/cell.

35
SINGLE STATION AUTOMATED CELL
(AUTOMATED WORKSTATION WITH WORKER OVERSIGHT)
Workload is defined as the total hours required to produce
a given quantity of work units scheduled during the period
of interest.
It is figured as the quantity of work units to be produced
during the period multiplied by the time required for each
work unit.

WL = QTc

WL = workload scheduled for the period, hr of work/hr or

hr of work/wk, etc.;

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Q = quantity to be produced during the period, pc/hr or
pc/wk, etc.;
Tc = cycle time required per piece, hr/pc.

36
SINGLE STATION AUTOMATED CELL
(AUTOMATED WORKSTATION WITH WORKER OVERSIGHT)

If the workload includes multiple parts or product styles that

can all be produced on the same type of workstation, then

where ,
Qj = quantity of part or product style j produced during the
period, pc;

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Tcj = cycle time of part or product style j, hr/pc;

The summation includes all of the parts or products to be

made during the period.
37
SINGLE STATION AUTOMATED CELL
(AUTOMATED WORKSTATION WITH WORKER OVERSIGHT)

Additional factors that add to the workload include setup

time and fraction defect rate.

Let TTsu = total setup time for all part styles included in the
workload to be accomplished.
In most situations,

where ,

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Tsuj = setup time for part or product style j produced
during the period, hr.

38
SINGLE STATION AUTOMATED CELL
(AUTOMATED WORKSTATION WITH WORKER OVERSIGHT)
Defect rate is the fraction of parts produced that are
defective.

where
Qj = quantity of good units made in the process;
Qoj = original or starting quantity;
qj = fraction defect rate.

combined effect of setup time and fraction defect rate can

be accounted for in the following workload equation:

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39
SINGLE STATION AUTOMATED CELL
(AUTOMATED WORKSTATION WITH WORKER OVERSIGHT)
Available time is the amount of time during the period of
interest that one work cell can devote to satisfying the
workload requirement.
AT = HpA

Where,
AT = available time per cell, hr/cell;
Hp = actual hours during the period, hr/cell;
A = availability

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40
SINGLE STATION AUTOMATED CELL
(AUTOMATED WORKSTATION WITH WORKER OVERSIGHT)
Numerical

A total of 900 parts must be produced in the lathe section

of the machine shop during a particular 40-hr week. The
parts are of 20 different styles, and each style is produced in
its own batch. Average batch quantity is 45 parts. Each batch
requires a setup and the average setup time is 2.5 hr. The
average machine cycle time to produce a shaft is 10 min.
Availability on the lathe is 100%. How many lathes are
required during the week?

PRODUCTION MANAGEMENT
41
SINGLE STATION AUTOMATED CELL
(AUTOMATED WORKSTATION WITH WORKER OVERSIGHT)

Numerical

A total of 900 parts must be produced in the lathe section

of the machine shop during a particular 40-hr week. The
parts are identical. How many lathes will be needed to
produce the 900 parts, given that each machine must be set
up at the beginning of the week? Each setup takes 2.5 hr.
Availability on the lathes is 100% and The average machine
cycle time to produce a shaft is 10 min.

PRODUCTION MANAGEMENT
42
SINGLE STATION AUTOMATED CELL
(AUTOMATED WORKSTATION WITH WORKER OVERSIGHT)

Numerical

Suppose that in Example 1 the anticipated availability of the

lathes is 100% during setup and 92% during the production
run. The fraction defect rate for lathe work of this type is
5%. Other data from Example 1 are applicable. How many
lathes are required during the week, given this additional
information?

PRODUCTION MANAGEMENT
43
SINGLE STATION AUTOMATED CELL
(AUTOMATED WORKSTATION WITH WORKER OVERSIGHT)

Machine Cluster

In a machine cluster, multiple machines can be managed

by a single worker instead of one worker per machine. This
setup is possible when the machine's cycle time (how long it
runs on its own) is long enough that the worker only needs
to step in occasionally to provide service (like loading or
unloading). The goal is to assign more machines to a single
worker to improve efficiency without overwhelming the
worker.

PRODUCTION MANAGEMENT
44
SINGLE STATION AUTOMATED CELL
(AUTOMATED WORKSTATION WITH WORKER OVERSIGHT)

Machine Cluster

Key Conditions for Machine Clusters:

• The machine should have a long cycle time (the time it

runs on its own)

• All machines in the cluster should have the same cycle

time.

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• The machines should be close enough together that the
worker can move between them quickly.

45
SINGLE STATION AUTOMATED CELL
(AUTOMATED WORKSTATION WITH WORKER OVERSIGHT)
Machine Cluster

Tm = Machine’s time to complete its cycle without worker

involvement (machine cycle time).

Ts = Time the worker spends servicing each machine (like

loading/unloading).

Tr = Time it takes the worker to move from one machine to

another (repositioning time).

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Tc = Total cycle time for the machine (Tm + Ts).
worker's total servicing time= (Ts + Tr)

For n number machines = n (Ts + Tr)

46
SINGLE STATION AUTOMATED CELL
(AUTOMATED WORKSTATION WITH WORKER OVERSIGHT)

Machine Cluster

For the system to be perfectly balanced in terms of worker

time and machine cycle time,

n(Ts + Tr) = Tm + Ts

The number of machines that should be assigned to one

worker is given by:

PRODUCTION MANAGEMENT
47
SINGLE STATION AUTOMATED CELL
(AUTOMATED WORKSTATION WITH WORKER OVERSIGHT)

Machine Cluster

A machine shop has many CNC lathes that operate on a

semiautomatic cycle under part program control. A
significant number of these machines produce the same part,
with a machine cycle time = 2.75 min. One worker is
required to perform unloading and loading of parts at the
end of each cycle. This takes 25 sec. Determine how many
machines one worker can service if it takes of 20 sec to
walk between the machines and no machine idle time is

PRODUCTION MANAGEMENT
allowed.

48
SINGLE STATION AUTOMATED CELL
(AUTOMATED WORKSTATION WITH WORKER OVERSIGHT)

Machine Cluster

The CNC grinding section has a large number of machines

devoted to grinding shafts for the automotive industry. The
grinding cycle takes 4.2 min and produces one [Link] the
end of each cycle, an operator must be present to unload
and load parts, which takes 35 sec.
(a) Determine how many grinding machines the worker can
service if it takes 20 sec to walk between the machines
and no machine idle time is allowed.

PRODUCTION MANAGEMENT
(b) How many seconds during the work cycle is the worker
idle?

49
 MULTI-STATION MANUFACTURING
SYSTEMS: MANUAL ASSEMBLY LINES
Why manual assembly lines are so productive

1. Specialization of labor
2. Interchangeable parts
3. Work flow principle
4. Line pacing

PRODUCTION MANAGEMENT
Configuration of a manual assembly line
50
 MULTI-STATION MANUFACTURING
SYSTEMS: MANUAL ASSEMBLY LINES

FUNDAMENTALS OF MANUAL ASSEMBLY LINES

1. Assembly Workstations

2. Work Transport Systems

3. Line Pacing

4. Coping with Product Variety

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51
 MULTI-STATION MANUFACTURING
SYSTEMS: MANUAL ASSEMBLY LINES
FUNDAMENTALS OF MANUAL ASSEMBLY LINES
1. Assembly Workstations

Workstation
A designated location on a manual assembly line where work elements
are performed by workers.

Tools and Equipment:

Includes necessary hand or powered tools for the tasks at that station.

Workstation Types:

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Standing Workstations
Sitting Workstations

Work Flow:
Workers perform tasks as the product moves along (standing) or in a
stationary position (sitting). 52
 MULTI-STATION MANUFACTURING
SYSTEMS: MANUAL ASSEMBLY LINES
FUNDAMENTALS OF MANUAL ASSEMBLY LINES

2. Work Transport Systems

Manual Mechanized
Methods Work Transport
of Work
Transport - continuous transport system
- Synchronous transport
-Starving - Asynchronous transport
-Blocking

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53
 MULTI-STATION MANUFACTURING
SYSTEMS: MANUAL ASSEMBLY LINES
Velocity–distance diagram and physical layout

PRODUCTION MANAGEMENT
(a) continuous transport, (b) synchronous transport, and (c) asynchronous
transport
54
 MULTI-STATION MANUFACTURING
SYSTEMS: MANUAL ASSEMBLY LINES
3. Line Pacing
Levels of Pacing in Manual Assembly Lines
• Rigid Pacing
-Implemented by synchronous work transport systems.
-Workers must complete tasks within a fixed time cycle.
Drawbacks:
-Physically and emotionally stressful for workers over long shifts.
-If the task is incomplete within the cycle time, the work unit exits incomplete,
potentially affecting downstream work.
• Pacing with Margin
Workers are allowed more time than the cycle time, providing flexibility for
task variations or issues.

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Achieved by:
-Allowing queues of work units between stations (asynchronous transport
system).
-Designing stations where workers have more time than the cycle time (longer
station length).
-Allowing workers to move past station boundaries (upstream or downstream
allowances). 55
 MULTI-STATION MANUFACTURING
SYSTEMS: MANUAL ASSEMBLY LINES

3. Line Pacing

• No Pacing
-No time limit to complete tasks at stations.
Can occur when:
-Manual work transport allows workers to control timing.
-Work units can be removed from the conveyor.
-Asynchronous conveyor allows workers to release work units when ready.

PRODUCTION MANAGEMENT
56
 MULTI-STATION MANUFACTURING
SYSTEMS: MANUAL ASSEMBLY LINES
FUNDAMENTALS OF MANUAL ASSEMBLY LINES

4. Coping with Product Variety

Three types of assembly line can be distinguished:

(1) single model,
(2) batch model,
(3) mixed model

PRODUCTION MANAGEMENT
57
 MULTI-STATION MANUFACTURING
SYSTEMS:
AUTOMATED PRODUCTION LINES
FUNDAMENTALS OF AUTOMATED PRODUCTION
LINES
1. Work Part Transport
Depending on the geometry of the work part
-palletized transfer line
-free transfer line

Depending on the System Configurations

(1) in-line
(2) segmented in-line

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(3) Rotary

Depending on the transport mechanisms

(1) linear transport systems
(2) rotary indexing mechanisms 58
 59

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 MULTI-STATION MANUFACTURING
SYSTEMS:
AUTOMATED PRODUCTION LINES

Rotary indexing mechanisms

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Geneva mechanism with six slots

60
 MULTI-STATION MANUFACTURING
SYSTEMS:
AUTOMATED PRODUCTION LINES
Geneva mechanism with six slots
where
θ = angle of rotation of worktable during indexing
(degrees of rotation)
ns = number of equally spaced slots in the Geneva.
The angle of driver rotation during indexing = 2θ

Given the rotational speed of the driver, total cycle time is

PRODUCTION MANAGEMENT
where Tc = cycle time, min
N = rotational speed of driver, rev/min

61
 MULTI-STATION MANUFACTURING
SYSTEMS:
AUTOMATED PRODUCTION LINES
Of the total cycle time, the dwell time, or available service time
per cycle, is given by

Tr = indexing time, min

PRODUCTION MANAGEMENT
A rotary worktable is driven by a Geneva mechanism with six
slots, The driver rotates at 30 rev/min. Determine the cycle time,
available processing time, and the lost time each cycle to index
the table.
62
 MULTI-STATION MANUFACTURING
SYSTEMS:
AUTOMATED PRODUCTION LINES
FUNDAMENTALS OF AUTOMATED PRODUCTION
LINES

2. Storage buffers
Temporary storage locations between workstations in automated
production lines.

Key Functions:
• Minimize Breakdown Impact

PRODUCTION MANAGEMENT
• Parts Bank
• Store Output
• Accommodate Process Delays
• Smooth Cycle Time

63
 MULTI-STATION MANUFACTURING
SYSTEMS:
AUTOMATED PRODUCTION LINES
FUNDAMENTALS OF AUTOMATED PRODUCTION
LINES

2. Storage buffers

Storage Buffers in Different Systems

• More easily integrated in in-line transfer machines than
rotary indexing machines.

• In rotary systems, buffers are used:

PRODUCTION MANAGEMENT
-Before the dial-indexing system for raw parts.
-After the dial-indexing machine to collect finished
parts.
-Between adjacent dial-indexing machines.
64
 MULTI-STATION MANUFACTURING
SYSTEMS:
AUTOMATED PRODUCTION LINES
FUNDAMENTALS OF AUTOMATED PRODUCTION LINES

3. Control of the Production Line

a. Control Functions
-Sequence Control
-Safety Monitoring
-Quality Control

b. Line Controllers
-Programmable Logic Controllers (PLCs)

PRODUCTION MANAGEMENT
-Personal Computers (PCs):
-Software Upgrades
-Data Recording
-Diagnostics
-Preventive Maintenance
-User-Friendly Interface
65
 JOB SHOP PRODUCTION

• Small batches of a variety of custom products are made.

• Most of the products produced require a unique set-up and
sequencing of process steps.
• Volume and standardization is low and products are often
one of a kind.

Characteristics of a Job Shop

1. Layout
- similar equipment or functions are grouped together
- The layout is designed to minimize material handling,
cost, and work in process inventories

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- Job shops use general purpose equipment
- Job shops compete on quality, speed of product
delivery, customization, and new product introduction

66
 JOB SHOP PRODUCTION

Characteristics of a Job Shop

2. Employees
- Highly skilled craft employees who can operate several
different classes of machinery.
- These workers are paid higher wages for their skill levels
- The role of management is to bid on jobs and to establish
prices for customer orders.

3. Information
- Information is needed to quote a price, bid on a job, route an order
through the shop, and specify the exact work to be done.
- Information begins with quoting, then a job sheet and blueprint are

PRODUCTION MANAGEMENT
prepared before the job is released to the floor
- While it is often easy to bid on jobs the shop has manufactured
before, new jobs require accurate costing of labor, materials, and
equipment as well as accurate assigning of overhead to the job.

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 JOB SHOP PRODUCTION

Characteristics of a Job Shop

4. Scheduling
- A job is characterized by its route, its processing requirements, and
its priority.
- In a job shop the mix of products is a key issue in deciding how and
when to schedule jobs.
- Jobs may not be completed based on their arrival pattern in order to
minimize costly machine set-ups and change-overs.
- Work may also be scheduled based on the shortest processing time.

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 BATCH PRODUCTION

- Identical or similar items are produced together for

different sized production runs.
- Products to be mass-produced in batches with small to
major
changes to the product.
- Products are made as specified groups or amounts, within
a time frame.
- Under batch system of production the work is divided
into operations and one operation is done at a time. After

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completing the work on one operation it is passed on to
the second operation and so on till the product is
completed.

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 CONTINUOUS FLOW PRODUCTION

- Continuous flow is a Lean method that allows you to

move a single product through every step of your process
instead of grouping work items into batches.
- The method is called this way because it allows you to
continuously send goods to market.
- This provides you with the opportunity to deliver value
more often to your customers.
- Continuous flow is especially useful for reducing
inventory costs and the wait time of your work items.
- Before planning manufacturing to stock, a sales forecast is

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made to estimate the likely demand of the product and a
master schedule is prepared to adjust the sales forecast
based on past orders and level of inventory
- First-in-First-out method is followed in the system.
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 CONTINUOUS FLOW PRODUCTION

Types of Continuous Production

- Mass Production
- Process Production
- Assembly Production

Mass Production
- Standardization of product, process, materials, machine
and uninterrupted flow of materials are the main
characteristics of this system.
- Quality of products tends to be uniform and high due to

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standardization and mechanization

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 CONTINUOUS FLOW PRODUCTION

Types of Continuous Production

- Mass Production
- Process Production
- Assembly Production

Process Production
- This system is used for the manufacture of those items
whose demand is continuous and high. Here, single raw
material can be transformed into different kinds of
products at different stages of the production process

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- On the basis of the nature of production process, flow of
production may be classified into
Analytical process of production and
Synthetic process of production.
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