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Manufacturing System Design
Unit-I
Introduction to Manufacturing Systems
Sripriyankaruthapandi
PSG College of Technology
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08M702 MANUFACTURING SYSTEMS DESIGN
INTRODUCTION TO MANUFACTURING SYSTEMS AND MODELS: Evolution of industrial engineering,
fields and functions of industrial engineering. Types and principles of manufacturing systems, types and
uses of manufacturing models, physical models, mathematical models, model uses, model building
DESIGN OF AUTOMATED LINES: Assembly lines-Reliable serial systems, approaches to line balancing
COMSOAL and RPW, Transfer lines and general serial systems paced lines without buffers. Flexible
manufacturing systems- system components, Introduction to planning and control.
LAYOUT DESIGN : Group technology- introduction ,part classification and coding, assigning machines to
groups-Rank order clustering algorithm, Facility layout
Sequential layout planning.
SUPPORTING COMPONENTS: Machine setup and operation sequencing, Material handling systems-conveyor
analysis, AGV systems. Warehousing-storage and retrieval systems, order picking.
SIMULATION IN SYSTEM DESIGN: Empirical simulation models-Event models, process models, simulation
system, example manufacturing system
SYNCHRONIZATION MANUFACTURING: Synchronization Vs Optimization, defining the structure,
identifying the constraint, Exploitation, Buffer Management.
PRODUCTION PLANNING AND CONTROL: Introduction, objectives, components of PPC, forecasting,
product planning, loading and scheduling, dispatching, production control, material handling principles,
case studies.
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Evolution of Industrial Engineering
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Frederick Winslow Taylor
18561915
Father of Scientific Management and Efficiency Movement
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Taylor investigated the "science" of shoveling.
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Major Contribution
Scientific Management
Standards
Process design
Time study
Incentive plans
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Scientific Management
Scientific management is a theory of management that analyses and
synthesizesworkflow. Its main objective is to improve economic
efficiency, especially in labour productivity.
It was actually one of the earliest attempts of applying science to theengineering of process and management.
It was developed by Frederick Winslow Taylor between 1880s and
1890s within the manufacturing industries.
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According to Fredrick Winslow Taylor, "Scientific management means
knowing exactly what you want men to do and seeing that they do it in the
best and the cheapest way."
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Time Study
time and motion study: an analysis of a specific job in an effort to find the
most efficient method in terms of time and effort
Time study is a direct and continuous observation of a task, using a
timekeeping device (e.g., decimal minute stopwatch, computer-assistedelectronic stopwatch, and videotape camera) to record the time taken to
accomplish a taskand it is often used when
there are repetitive work cycles of short to long duration,
wide variety of dissimilar work is performed,
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Incentive plans
Incentive plans are part of an employee's compensation or pay.
The incentive plan gives an employee the opportunity to
increase his annual pay based upon either company
performance or individual performance. Incentive plans are a
way for companies to keep employees motivated to perform tothe best of their abilities, thus increasing company profit.
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Lillian Moller Gilbreth
1868
1926 Occasional lecturer at Purdue University
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Gilbreth investigated the bricklayer
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Major Contribution
Motion economy
Worker fatigue
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Henry Gantt
18611919
Contribution is scheduling Chart.
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Scheduling Chart
Frequently used in project management, a Gantt chart provides a graphical
illustration of a schedule that helps to plan, coordinate, and track specific
tasks in a project.
Such as MS Projects and Excel
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Blackett
1897 1974
Contribution is Operation Research (OR)
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George Dantzig
1914
2005 American Mathematical scientist who made important contributions
to Linear programming .
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It is a mathematical technique to find the best outcome with limited
resources i.e. to achieve maximum profit with minimum cost. This method
is possible only with the linear relationships. This technique is also called
as linear optimization.
Linear programming is often used in business to find maximum profit or
minimum cost
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Industrial Engineering Functions
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