Documents and technical data

2thpart
The manufacturing ranges
Manufacturing Ranges
Parts to
produce

Drawing of
definition
Ranking
Study of forms
pieces By group technology
Inventory of
means

Nombre de pièces
to be done
 Manufacturing Ranges
Number of pieces
to be done

Great Averages Small series Production

series in series unitary and
continue renewable renewables small series
unique
- list of list of - list of Cutting conditions
phases phases phases Ranges Machining time
card form form simple Preparation time
technique technique technique Workers' utilization
Machine usage

Most means
optimization Simmograms universal
ranges possible
with ongoing Valorisation
Operator
qualified
Manufacturing Ranges
optimization Simmograms
ranges
with ongoing Valorisation

Choice of
means
Gantt chart
Scheduling Analysis of progress
Flow management
and in progress Batch management

Implantation
 Gammes de Fabrication
What is a manufacturing range?
It is a document (or series of documents) including the suite
ordered logic of phases, sub-phases, operations.
The Phase:Understand the sequence of sub-phases and operations
performed at the same workstation.
The Sub-phase: Includes the logical sequence of operations
performed on a part without changing its
positioning.
The Operation: It is the smallest element in the range. It
corresponds to a passage from the tool on the part
producing a modification of it.
Examples: classical machining: pump body
CNC machining:
micro-drill sole
 Manufacturing Ranges
Simplified presentation of a manufacturing range:
RANGE HEADER
Time
Phase Average Operations
Operative Preparation
10 M1 nn Nn xx…………..

20 M2 Nn nn xx…………...

30 M3 Nn Nn xx…………...

40 M4 Nn Nn xx…………..

50 M5 nn nn xx…………..

Types of ranges:
Machining range: Piece obtained by material transformation
Assembly range: Part obtained by assembling components
Control range: Series of certification instructions for a product

Main range: Basic manufacturing process

Replacement (substitution, alternative) range: Slightly process
different from the basic process but just as acceptable
 Manufacturing Ranges
Types of processes:
1 phase involving 1 means
HeaderoftheOF(client,product,quantity,..)
Phase Medium Weather Operationalmode
10 M1 T1 xx………………..

1 to n phases involving 1 means In reality, 1 to n operations of a single phase.

Header of the OF (client, product, quantity,...)
Phase Means Weather Operatingprocedure
10 M1 t1 xx………………..
20 M1 t2 xx………………..
30 M1 t3 xx………………..
40 M1 t4 xx………………..

in phases involving n resources (each phase includes only 1 operation)

Header of the OF (client, product, quantity, ..)
Phase Average Operating Time
10 M1 t1 xx………………..
20 M2 t2 xx………………..
30 M3 t3 xx………………..
40 M4 t4 xx...............
 Manufacturing Ranges
Example of range:
HESTIM

OGP Gamme de fabrication

Finished product
Range No.
Main range of substitution
Product of the Plan No:
range Preparateur:
Weather
Post Phase BSM Designation
Série ( ) Unit ( )
 Manufacturing Ranges
Example of range:

9 7
1

5 8
2
3
6
4
9
5 Bolt 1
9 Plateau 1 4 Wheel 1
8 Sleeve 2 3 Support 2
7 Bolts 4 2 Structure 1
6 Wheel axle 1 1 Benne 1
Rep Designation Qté Rep Désignation Qté

wheelbarrow
 Manufacturing Ranges
Production (assembly) nomenclature:
n (Ml)
Tube rond Structure 1a
m (Ml)
Bar Support Structure 1a
plate +Support
1a Structure
p Kg painted 1a
Painting Together 1a
1a important
Together
Wheel Benne 1 unit
run
Wheelbarrow
Bolt
1a 1a
Axe
t (m²) Benne
Sheet metal
u un
Bolts 2 un

Mittens
 Manufacturing Ranges
Production management nomenclature:
Nomenclature "multi-level" or "tree-like":
Round tube Components can be themselves.
made up of components. If a component
Bar Structure intervient plusieurs fois, il n ’est mentionné
plate +Support only once per subset but can
exist in several subsets.
Painting Characterized by the maximum number of
levels.
Wheel We note on each branch of the tree structure.
the number of components of the same nature
Wheelbarrowentering into the realization of a component of
Bolt
higher level.
Axe Types of components:
Purchased:
Supplied products at the
Bolts external suppliers.
Manufactured:
Subsets created in
the company or with subcontractors at
Sleeves based on the purchased components.
Every 'node' is a GERE article in stock.
Sheet metal Benne Each article corresponds to only one
GPAO manufacturing range.
Level 3 Level 2 Level 1
 Manufacturing Ranges
Transition from "methods" ranges to "GPAO" ranges:
The ranges "methods":
The "method" ranges are reputed to be good.
The "methods" ranges are designed for an efficient execution of
products generally anticipating the simultaneous implementation of non-assemblies
managed in stock (in workshop process) and assembled at the end.
The manufacturing of a product often involves the use of several ranges.
of manufacturing "methods".
The ranges 'GPAO': For each subset managed in stock
corresponds to (and only one) range of
fabrication.
Together Level 1
The ERP software does not generate,
GPAO range generally, just ranges of
sequential fabrication.
Article 1 Subset Level 2
GPAO range

Article 2 Article 3 Level 3

 Manufacturing Ranges
Flow graph (wheelbarrow):

debit to debit debtor

to bend plier to prune

Pierce the pliers

souder
SUPPORT

Pierce it solder
STRUCTURE

SouderE1 Pierce the

STRUCTURE BIN
+SUPPORT

To paint

assembler
the whole
IMPORTANT

assemble it
wheelbarrow
 Manufacturing Ranges
GPAO range of the wheelbarrow:
Elements to be manufactured that are the subject of basic ranges:
Structure + Support
HESTIM
Benne
Wheelbarrow OGP Gamme de fabrication

Range No.
Finished product Wheelbarrow
Main range of substitution
Product of the Plan No: x
range Structure + Support Preparateur: DK
Weather
Post Phase Designation
Series ( ) Unit ( )
10 min
20 SC1 0.5 Flow of the tubes
30 CIN1 1.5 Bending
40 SO1 1.3 Welding
50 PE1 1 Drilling STRUCTURE
60 SC2 0.5 X Bar current
70 PL1 1.5 Folding
80 PE2 1 Drilling SUPPORT
90 SO2 1.5 Welding STRUCTURE + SUPPORT
100
 Manufacturing Ranges
Execution constraints of a manufacturing process?

Constraints Solutions
Respect for the rating Method of potentials for scheduling the
manufacturing constraints.
Positioning in space Principles of isostasy.
Choice of (or the) tool Depending on the type of machine (power capacity)
engine, in stiffness...) ;
Depending on the number of rooms;
Suivant le type d’opération à effectuer.

Choice of conditions of Machine settings

Fabrication and optimization
 Manufacturing Ranges
Execution constraints of a production process?

Constraints Solutions
Manufacturing time calculations Determination of the different execution times of
Or cycle times. the phase (drawing of the simmogram).
Determination of worker activity or use UTm
Determination of the activity or machine use UTt
Determination of passage time (work of a
operator on multiple machines).
Determination of outstanding amounts.

Study of optimization of the Determination of launch economic series

production (ranges) Overlap or fragmentation study of
phases, for series production.
Determination of the cost price by phase.
Determination of the cost price for the series.
 Manufacturing Ranges
Execution times:
The knowledge of execution times is the result of measurements:
To establish the time allocated => worker's salary
manufacturing deadlines
To study, compare several operating methods and determine the
best method at a given time, in given conditions.
Main types of weather:
During a phase carried out at a workstation, we distinguish
According to their nature:
several categories of time:
Manual (human) time Corresponds to a human work (physical or mental).
In the case of physical work, it is the time during which the work
results solely from the action of the operator aided or not by a means
inert (to write, to take a part...).
Technological time Its duration depends solely on the technical conditions.
execution and is not subject to any influence from the operator, (treatments
thermal, cutting time with automatic feed.
Techno-manual time Time during which the operator's activity depends
technical conditions for physical and chemical transformation of the
material or the behavior of machines, tools and devices (drilling
without automatic advance).
 Manufacturing Ranges
Main types of weather:
According to their arrangement in the phase:
Masked time Time of a job accomplished during the execution of a
other work (deburring or inspection of a part
during the machining with automatic feed of another
piece).
Residual time Downtime corresponding to the difference between the
technological time and masked time.
Balancing time: Time added to a cycle to achieve synchronization
of several cycles.
According to their frequency:
Temps de préparation (tps série)TsTemps mis à régler la machine ou le poste
work.
Frequency time Corresponds to the duration of a work carried out only once
for n units produced (samples). Ex.: control a
one piece out of ten.

Unit time corresponds to the duration of work performed for each unit.
produced.
 Manufacturing Ranges
Units used:
These different times are expressed in dmh (ten thousandths of an hour)
Or in ch (hundredth of an hour)
Or in cmin (hundredth of a minute)

x 100 x 100
1 100 10000
hour ch dmh

x 60 x 100
1 60 6000
hour min cmin

Estimation time methods:

For the Tt => by calculation with the knowledge of the cutting conditions.
For the others => by timing (direct measurement)
- by pre-established time cards, BTE method (elementary time office)
- by analyzing movements and pre-established times MTM (method time measurement).
 Manufacturing Ranges
Representation of the cycle (simmogram):
The simmogram of a phase simplifies writing and facilitates analysis.
of proportion.
Example:
Phase 10: Performing two operations A and B on a 2-head inline drill.

Work fraction Nature Value in dmh

take and place the part under the first head Tm1 20
tighten the part and engage the feed and cutting speed. Tm2 30
Execution of operation A automatically Tt3 100
loosen part and stop machine Tm4 30
take and place the part under the 2nd head Tm5 20
Operation B execution (manual advance) Ttm6 40
evacuate room to control post Tm7 20
control piece No 30
 Manufacturing Ranges
Representation of the cycle (simmogram):

Nature
desTPs
Tt3
Tt

Ttm6
Ttm
Tz
Tm1 Tm2 No Tm4 Tm5 Tm7 Tm8
Tm
Period or Unit Time (Tu) TPs

Period = You = ΣTm +ΣTtm +ΣTt -ΣTz= 20+30+100+30+20+40+20+30-30 =260 dmh

Worker utilization rate ΣTm +ΣTtm = 20+30+30+20+40+20 = 0.6153 => 61.53%

=
Period(You) 260
ΣTt + ΣTtm 100+40
Machine utilization rate = = = 0.5384 => 53.84%
Period (You) 260
 Manufacturing Ranges
Representation of the cycle (simmogram):
Nature Machine A
desTPs TtA3
Tt The simultaneous operation of 2 machines is often
applied because it aims at a workers' use
Ttm close to 100% provided that it understands
TAz TAr (residual) compensatory breaks: effort correctors D,
TmA1 TmA2 TmA5 TmA4 of the position P, the monotony M, and the atmosphere A
Tm
TPs
Unit Period or Time (TuA) Possible that under certain conditions:

Nature Machine B The periods of each cycle must be equal

desTPs TtB3
Tt The worker's use on each machine must
was clearly below 50%.
Each cycle must include a residual time.
Ttm
greater than the sum of the Tm and Ttm of
TBz Residual TBr the other machine.
TmB1 TmB2 TmB5 TmB4
Tm The machines must be installed close
TPs one another so that the operator can pass
Period or Unit Time (TuB)
easily from one to another.
 Manufacturing Ranges
Representation of the cycle (simmogram) :
Nature
desTPs TtA3 TtB3 TtA3 TtB3
Tt

Ttm
Residual Tar
TAz TBz TBr (residual)
TmA1 TmA2 TmA5 TmB4 TmB1 TmB2 TmB5 TmA4 TmA1 TmA2 TmA5 TmB4 TmB1 TmB2 TmB5 TmA4
Tm
Time of Time of Time of Time of TPs
passage passage passage passage

Period or Unit Time (TuA)

Period or Unit Time (TuB)

During the residual time Tr, the worker must:

going from one machine to another
perform, on the second machine, the Tm and Ttm at the end of the cycle and then the Tm and Ttm at the beginning of the next cycle.
return to the first machine, where the Tr ends, carry out the end-of-cycle work and then the start-of-
next cycle.
restart
Note: Moving from one machine to another takes a time called: Temps de passage = Tr - (ΣTm +ΣTtm)
2
For an organization with n machines, it is necessary to place (n-1) times. Passing time = Tr - (n-1)(ΣTm +ΣTtm
the Tm and the Ttm: n-1
 Manufacturing Ranges
Execution times: (determination of Tm)

By Mental decomposition of work

Arbitrary, inaccurate times for certain quotes
estimation

By Comparison with equivalent known time work

comparison A degree of arbitrariness for quote

By
measurement
By timing
By timing
of observations
global of the past time snapshots
unstable conditions
stabilized conditions
for testing and pre-production after analysis of the position.
for series work
 Manufacturing Ranges
By timing By "camera or
for 'tuning' videotape recorder
systematic
-for unit work or
stabilized conditions somewhat repetitive (interview...)
after analyzing the position. as much as for work of
for series work series

By
measurement

Elementary times Time motion standards

pre-established BTE decomposition into elementary movements
- by work fraction on stabilized, renewable positions.
stabilized
reconductible.
use machine folders,
post and files 'Bases
practices
 Manufacturing Ranges
Correction factors:
The reference times thus determined are used to
define the theoretical times: Th, by assigning some
rest coefficients that take into account:
• dynamometric efforts without or with participation
mental (combined effort). Coefficient D
• from the position of the worker: standing, lying down on the
two,...Coefficient P
• of muscular or mental monotony: Coefficient M
• of the atmosphere: temperature, humidity: Coefficient A.
This correction factor only affects the time of
compensatory repos
All these coefficients are greater than 1, which gives
the expression of theoretical time:
Th= T0xDxPxM
 Manufacturing Ranges
The fatigue coefficient K is given from the product of the effort coefficient D.
and the coefficient P of the working position.
Corrective coefficients K = DxP
Position

The numbers in Effort

italics Combined
0 to 1 1,08 1,11 1,13 1,15 1,17 1,19 1,24 1,26 1,28 1,32 1,39
corresponding to
0 to 1 1.07 1.10 1.12 1.13 1.15 1.17 1.21
female coefficients.
1 to 3 1,09 1,12 1,14 1,16 1,18 1,20 1,25 1,27 1,29 1,33 1,40
1 à 3 1,08 1,11 1,13 1,15 1,17 1,19 1,23
3 to 6 1,10 1,13 1,15 1,17 1,19 1,21 1,26 1,28 1,30 1,35 1,41
3 to 6 1.10 1.13 1.15 1.17 1.19 1.21 1.26
6 à 10 1,12 1,15 1,17 1,19 1,21 1,24 1,28 1,30 1,33 1,37 1,44
6 to 10 1.13 1.17 1.19 1.21 1.23
10 à 15 1,14 1,17 1,19 1,21 1,24 1,26 1,30 1,33 1,35 1,40 1,46
10 to 15 1.18 1.21 1.24 1.26 1.30
15 à 20 1,16 1,19 1,21 1,23 1,26 1,28 1,32 1,35 1,37 1,42 1,49
20 to 25 1.18 1.21 1.23 1.26 1.28 1.30 1.35 1.37 1.40 1.44 1.51
25 à 30 1,20 1,23 1,25 1,28 1,30 1,32 1,37 1,40 1,42 1,47 1,54
30 à 35 1,22 1,25 1,27 1,30 1,32 1,35 1,39 1,42 1,44 1,49 1,56
35 à 40 1,24 1,27 1,29 1,32 1,34 1,37 1,42 1,44 1,47 1,52 1,59
40 à 45 1,26 1,29 1,31 1,34 1,36 1,39 1,44 1,46 1,49 1,54 1,61
Manufacturing Ranges
The temperature coefficient is given in relation to the hygrometric degree of
the atmosphere considered and the temperature indicated by the dry thermometer.

Deghygro 0%10%20%30%40%50%60%70%80%90%100%
Temperatures
22° 1 1 1 1 1.04 1.07 1.10
24° 1 1 1,04 1,07 1,10 1,17 1,23 1,30
26° 1,04 1,07 1,10 1,17 1,25 1,37 1,45 1,60
28° 1,04 1,07 1,10 1,19 1,25 1,37 1,50 1,65 1,75 1,90
30° 1,04 1,07 1,15 1,25 1,37 1,5 1,65 1,75 1,90 2,06 2,30
32° ["11.0",11.9",13.0",14.1",15.5",17.0",18.3"] 2 2,20 2,47 2,80
34° 1,22 1,30 1,45 1,60 1,75 1,90 2,10 2,36 2,62 3 3.35
36° 1,33 1,45 1,60 1,75 1,98 2,20 2,47 2,80 3,12 3,50 3,90
38° 1,45 1,60 1,75 1,90 2,20 2,55 2,90 3,35 3,66 4 4.5
40° 1,55 1,70 1,90 2,15 2,55 2,94 3,35 3,90 4,20 4,60 5,30
42° 1,65 1,83 2,10 2,39 2,90 3,40 3,80 4,30 4,70 5,10
44° 1,75 1,98 2,30 2,75 3,35 3,90 4,20 4,90 5,40
46° 1,83 2,15 2,62 3,12 3,73 4,20 4,70 5,60
48° 1,95 2,30 2,94 3,50 4,12 4,60 5,40
50° 2,05 2,62 3,28 3,90 4,50 5,30
Manufacturing Ranges
Muscle monotonicity coefficient:
coefficient

1.5

1.4

1.3

1,2

Percentage
1,150 55 60 65 70 75 80 85 90 95 100 the monotony