Lecture #1

Introduction to
Manufacturing Systems
1.1 Meanings of Manufacturing Systems

Definitions of Manufacturing
Production means "to make something new“
Manufacturing is defined as " a series of
interrelated activities and operations involving the
design, materials selection, planning,
manufacturing production, quality assurance,
management and marketing of the products of
the manufacturing industries.“
Or Manufacturing is “the transformation of raw
materials into value-added products that meet
specifications.”
1.1 Meanings of Manufacturing Systems
Definitions of Systems
" a system is a collection of recognizable units
having relationships among the units“

" a system is a collection of recognizable units

having relationships among the units, aiming at
a specified single or multiple objectives subject
to its external environment"
1.1 Meanings of Manufacturing Systems
Definitions of Manufacturing Systems
" The manufacturing system is defined as the conversion process
of the factors of production, particularly the raw materials, into
the finished products, aiming at a maximum productivity.“
Definitions of Manufacturing Systems
A Manufacturing system to be a collection of
integrated equipment and human resources, whose
function is to perform one or more processing and /or
assembly operations on a starting raw material, part,
or set of parts.
Equipment includes:
_ Production machines and tools
_ Material handling and work positioning devices
_ Computer systems
Human resources
_ are required either full-time or periodically to keep the system
running
Examples of manufacturing systems include:
One worker tending one machine, which
operates one semi-automatic cycle.
A cluster of semi-automatic machines, attended
by one worker
A fully automated assembly machine,
periodically attended by a human worker.
A group of automated machines working on
automatic cycles to produce a family of similar
parts.
A team of workers performing assembly
operations on a production line.
Example of manufacturing system include:
1.2 Types of Manufacturing Systems
a) According to Layout Designs:
Manufacturing Systems are classified according to
the arrangement of machines and departments
within manufacturing plants. Based on these,
manufacturing systems can be classified into:
Functional layout (or a Job shop system),
Line Layout (or Flow line system), and
Cell layout (or Cellular Manufacturing system)
1.2 Types of Manufacturing Systems
a) Functional or process layout (Job Shop system)
a) Functional or process layout (Job Shop system)
i) Job Shop system:
 Machines are grouped according to the process
they perform.
 General purpose machine tools
 Large variety of parts
 Small lot size
 Flexible material handling
1.2 Types of Manufacturing Systems
b) Line or Product Layout (Flow line System or Flow Shop)
b) Line or Product Layout (Flow line System or Flow Shop)

ii) Flow line system:

Machines are ordered in lines according to the

operation sequence of one or more part types.
One part types at a time
Long setup times
Automated material handling
1.2 Types of Manufacturing Systems
c) Cell layout (or Cellular Manufacturing system)
:
c) Cell layout (or Cellular Manufacturing system)

iii) Cellular Manufacturing system:

Machines are grouped according to the
processes required for part families
Group technology application, part family
formation
Each cell becomes independent for detailed
scheduling and control
1.2 Types of Manufacturing Systems
b) According to Volume-Variety Relationship:
Based on the production volume and variety of the
products, production techniques can be classified into three
distinct systems:
 high-volume and low-variety (Transfer Line Systems)
 medium-volume and medium variety (Special
Manufacturing System, Flexible Manufacturing System,
and Cellular Manufacturing System) and
 low-volume and high-variety (Stand-Alone CNC)
1.2 Types of Manufacturing Systems
b) According to Volume-Variety Relationship:
1.2 Types of Manufacturing Systems
b) According to Volume-Variety Relationship:
Key characteristics of various Manufacturing systems:
Transfer line:
 Dedicated machines
 Almost no flexibility
 Max. utilization and high throughput
 Minimal labor
 Low unit cost
Special Systems:
 Fixed path material handling system
 Multi-spindle heads
 Low-level controller
 High production rate and low unit production cost
Transfer Line:
1.2 Types of Manufacturing Systems
b) According to Volume-Variety Relationship:
Key characteristics of various Manufacturing systems:
Flexible Manufacturing Systems:
 Mid-volume and mid-variety
 CNC, automated material handling and supervisory computer control
 Sequential and random routing of parts.
Manufacturing cell:
 Low-to-medium volume
 Batch production
 More flexible than an FMS but lower production rate
Stand-Alone CNC:
 High flexibility
 Low utilization and low production volume
 Unit cost higher that transfer line
1.3 Components of a manufacturing system
A manufacturing system consists of several
components. In a given system, these components
usually include:
Production machines plus tools, fixtures,
and other related hardware.
Material handling system
Computer systems to coordinate and/or
control the above components
Human workers
1.3 Components of a manufacturing system
Production machines:
The machines can be classified as:
Manually operated
Semi-automated
Fully automated

Material handling system:

Functions in factory or plant are:
Loading and unloading work units
Positioning the work units at each station
Transporting work units between stations is also required
A temporary storage function
1.3 Components of a manufacturing system
Computer control system:
Typical computer system functions include the following:
Communicate instructions to workers
Download part programs to computer-controlled
machines
Material handling system control
Schedule production
Failure diagnosis
Safety monitoring…….etc.

Human resources:
Direct labor
Indirect labor
Example for MS: