prodman c7 manufacturing process

8/18/2019 Prodman c7 Manufacturing Process

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MANUFACTURING

PROCESSALDREX G. LAXAMANA

PRODUCTION AND OPERATIONS MANAGEMENT MODULE


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Classifcation o Industi!s

". Pi#a$ industi!s % culti&at! and!'(loit natual !souc!s• E'a#(l!s) a*icultu!+ #inin*

,. S!conda$ industi!s % con&!t out(uto (i#a$ industi!s into (oducts• E'a#(l!s) #anuactuin*+ (o-!

*!n!ation+ constuction

. T!tia$ industi!s % s!&ic! s!cto• E'a#(l!s) /an0in*+ !ducation+

*o&!n#!nt+ l!*al s!&ic!s+ !tail tad!+tans(otation



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Manuactuin* Industi!s

ISIC Cod!

• Food+ /!&!a*!s+ to/acco "

• T!'til!s+ a((a!l+ l!at1! and u (oducts ,

• 2ood and -ood (oducts+ co0

•

Pa(!+ (intin*+ (u/lis1in*+ /oo0/indin* 3• C1!#icals+ coal+ (!tol!u#+ 4 t1!i (oducts 5

• C!a#ics+ *lass+ #in!al (oducts 6

• 7asic #!tals+ !.*.+ st!!l+ alu#inu# 8

• Fa/icat!d (oducts+ !.*.+ cas+ #ac1in!s+ !tc. 9

• Ot1! (oducts+ !.*.+ :!-!l$+ to$s ;



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Mo! Indust$ Classifcations

•Poc!ss industi!s+ !.*.+ c1!#icals+ (!tol!u#+/asic #!tals+ oods and /!&!a*!s+ (o-!*!n!ation

•Disc!t! (oduct


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Poc!ss Industi!s andDisc!t! Manuactuin*

Industi!s



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Manuactuin* Indust$

• Tanso#ation O(!ations• Mac1in! Poc!ssin*• Ass!#/l$

•Addin* &alu!

•Ot1! O(!ationsMat!ial 1andlin*

Ins(!ction and t!stin*Coodination and contol

Transformation Process

Raw

Material

Part or

Product

Power

Tools

Macines

La!our

Scra" or

#aste



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Classifcation

o#anuactuin* (oc!ss!s



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Poc!ssin* O(!ations

• S1a(in* o(!ations• Solidifcation (oc!ss!s• Paticulat! (oc!ssin*•

D!o#ation (oc!ss!s• Mat!ial !#o&al (oc!ss!s

• Po(!t$>!n1ancin* o(!ations fl# d!(osition


http://images.google.ie/imgres?imgurl=http://powerpressindia.com/images/250k1.jpg&imgrefurl=http://powerpressindia.com/&h=381&w=335&sz=44&hl=en&start=21&usg=__ZT0dLkOASKOu6WlC3fV9G4Zc1zs=&tbnid=UcF25LD6t9YhCM:&tbnh=123&tbnw=108&prev=/images%3Fq%3Dpower%2Bpress%26start%3D18%26gbv%3D2%26ndsp%3D18%26hl%3Den%26sa%3DNhttp://images.google.ie/imgres?imgurl=http://powerpressindia.com/images/250k1.jpg&imgrefurl=http://powerpressindia.com/&h=381&w=335&sz=44&hl=en&start=21&usg=__ZT0dLkOASKOu6WlC3fV9G4Zc1zs=&tbnid=UcF25LD6t9YhCM:&tbnh=123&tbnw=108&prev=/images%3Fq%3Dpower%2Bpress%26start%3D18%26gbv%3D2%26ndsp%3D18%26hl%3Den%26sa%3DNhttp://product-image.tradeindia.com/00174221/b/Nickle-Plating-Plant.jpghttp://product-image.tradeindia.com/00174221/b/Nickle-Plating-Plant.jpghttp://product-image.tradeindia.com/00174221/b/Nickle-Plating-Plant.jpghttp://product-image.tradeindia.com/00174221/b/Nickle-Plating-Plant.jpghttp://images.google.ie/imgres?imgurl=http://www.tantel.ca/Images/Lathe/Lathe%2520trial_3.jpg&imgrefurl=http://www.tantel.ca/Lathe..html&h=600&w=800&sz=152&hl=en&start=7&usg=__pyDvMQe0ACg4h7GOKBKndRZkgLg=&tbnid=X0Cv663g0m2OJM:&tbnh=107&tbnw=143&prev=/images%3Fq%3Dlathe%26gbv%3D2%26hl%3Denhttp://images.google.ie/imgres?imgurl=http://powerpressindia.com/images/250k1.jpg&imgrefurl=http://powerpressindia.com/&h=381&w=335&sz=44&hl=en&start=21&usg=__ZT0dLkOASKOu6WlC3fV9G4Zc1zs=&tbnid=UcF25LD6t9YhCM:&tbnh=123&tbnw=108&prev=/images%3Fq%3Dpower%2Bpress%26start%3D18%26gbv%3D2%26ndsp%3D18%26hl%3Den%26sa%3DN


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Ass!#/l$ O(!ations

• ?oinin* (oc!ss!s•2!ldin*•7a@in* and sold!in*•Ad1!si&! /ondin*

•M!c1anical ass!#/l$• T1!ad!d ast!n!s

•

Ri&!ts• Int!!!nc! fts

•Ot1!



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Mat!ial andlin*

•Mat!ial tans(ot• B!1icl!s+ !.*.+ o0lit tuc0s+ AGBs+ #onoails• Con&!$os•

oists and can!s•Stoa*! s$st!#s

•Uniti@in* !ui(#!nt

•Auto#atic id!ntifcation and data ca(tu!• 7a cod!s• RFID• Ot1! AIDC



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Ins(!ction and T!stin*

Ins(!ction % cono#anc! to d!si*ns(!cifcations• Ins(!ction o &aia/l!s > #!asuin*

• Ins(!ction o atti/ut!s % *au*in*

T!stin* % o/s!&in* t1! (oduct


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Coodination and Contol

•R!*ulation o t1! indi&idual(oc!ssin* and ass!#/l$ o(!ations•Poc!ss contol

•ualit$ contol•Mana*!#!nt o (lant l!&!l acti&iti!s

•Poduction (lannin* and contol•

ualit$ contol



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Poduction Faciliti!s and La$out

•Faciliti!s o*ani@!d in t1! #ost!ci!nt -a$ to s!&! t1! (aticula#ission o t1! (lant and d!(!nds on)•

T$(!s o (oducts #anuactu!d•Poduction quantity•Poduct variety



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Poduction uantit$


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Poduct Bai!t$


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Poduct Bai!t$


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Lo- Poduction uantit$



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Fi'!d>Position La$out



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M!diu# Poduction uantiti!s


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C!llula La$out



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i*1 Poduction


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P R!lations1i(s

Q

P



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Poduct and Pat Co#(l!'it$

• Poduct co#(l!'it$ n p J nu#/! oco#(on!nts in (oduct

•Pat co#(l!'it$ no

J nu#/! o(oc!ssin* o(!ations (! (at



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Facto$ O(!ations Mod!l

Si#(lif!d )

• Total nu#/! o (oduct units Qf J PQ

• Total nu#/! o (ats (oduc!d n pf J PQn p

• Total nu#/! o o(!ations nof J PQn pno

where

P = Product variety Q = Product quantity

n p = Number of parts in product

no = Number of operations in product



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Sa#(l! Po/l!#

,.,) T1! A7C Co#(an$ is (lannin* a n!- (oduct lin! and -ill/uild a n!- (lant to #anuactu! t1! (ats o a n!-(oduct lin!. T1! (oduct lin! -ill includ! 5 di!!nt#od!ls. Annual (oduction o !ac1 #od!l is !'(!ct!d to /!" units. Eac1 (oduct -ill /! ass!#/l!d o 3

co#(on!nts. All (oc!ssin* o (ats -ill /! acco#(lis1!d inon! acto$. T1!! a! an a&!a*! o 6 (oc!ssin* st!(s!ui!d to (oduc! !ac1 co#(on!nt+ and !ac1 (oc!ssin*st!( ta0!s ". #inut!


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Solution

This problem neglects the eect of assembly time:

(a nof = PQn pno = !"(#"""($""(% = 120,000,000operations in the factory per year&

(c Total operation time = (#'" #"%

ops(#min&)(%"min&)hr = '*"""*""" hr)yr&

+t '""" hours)yr per wor,er* w = = 1000 workers&

(b Number of wor,stations n = w = #"""&

Total -oorspace = (#""" stations('!" m' )station =250,000 m2



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Manuactuin* Ca(a/ilit$

• T!c1nolo*ical (oc!ssin*ca(a/ilit$ > t1! a&aila/l! s!t o

#anuactuin* (oc!ss!s• P1$sical si@! and -!i*1t o(oduct

• Poduction ca(acit$ (oduction uantit$t1at can /! #ad! in a *i&!nti#!



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L!an Poduction

O(!atin* t1! acto$ -it1 t1! #ini#u# (ossi/l!!souc!s and $!t #a'i#i@in* t1! a#ount o -o0acco#(lis1!d

• Utili@ation o R!souc!s > -o0!s+ !ui(#!nt+ ti#!+s(ac!+ #at!ials

• Mini#i@in* ti#!

• Ma'i#i@in* ualit$


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Po*a#s Associat!d -it1L!an Poduction

• ?ust>in>ti#! d!li&!$ o (ats

•2o0! in&ol&!#!nt

•

Continuous i#(o&!#!nt•R!duc!d s!tu( ti#!s

•Sto( t1! (oc!ss -1!n so#!t1in* is-on*

•Eo (!&!ntion

• Total (oducti&! #aint!nanc!



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Po/l!#

• T1! X Co#(an$ is (lannin* to intoduc! a n!- (oduct lin! and -ill/uild a n!- acto$ to (oduc! t1! (ats and ass!#/l$ t1! fnal(oducts o t1! (oduct lin!. T1! n!- (oduct lin! -ill includ! "di!!nt #od!ls. Annual (oduction o !ac1 #od!l is !'(!ct!d to /!" units. Eac1 (oduct -ill /! ass!#/l!d o 6 co#(on!nts. All(oc!ssin* o (ats and ass!#/l$ o (oducts -ill /! acco#(lis1!d in

on! acto$. T1!! a! an a&!a*! o " (oc!ssin* st!(s !ui!d to(oduc! !ac1 co#(on!nt+ and !ac1 (oc!ssin* st!( ta0!s s!c.


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Solution

•

prodman c7 manufacturing process

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