Manufacturing systems engineering
Definition
Manufacturing systems engineering is the design and operation of factories.
Product realisation process is an integrated, iterative process that starts with the design of the product. The next step is the design of the process by which the product is made.
The design of the manufacturing system consists of three steps: the choice of the structure of the factory (the system architecture), the selection of the machines, and the design of the spaces to hold work-in-process inventory.
The operating policy – the process by which decisions are made in the course of production – is chosen next.
The factory design is evaluated. It can be done by simulation, by computation based on analytical methods, or by the experience of the designers.
If the performance is predicted to be satisfactory, the design is accepted and the factory is built (or an existing factory is rebuilt). If not, the process is iterated starting at the required stage until the predicted performance is satisfactory.
The future of manufacturing systems engineering
Stanley B. Gershwin
International Journal of Production Research, 2018
Vol. 56, Nos. 1–2, 224–237,
Design and Analysis of Integrated Manufacturing Systems
https://www.nap.edu/download/1100
Analysis and Modeling of Manufacturing Systems
Stanley B. Gershwin, Yves Dallery, Chrissoleon T. Papadopoulos, J. MacGregor Smith
Springer Science & Business Media, 06-Dec-2012 - Business & Economics - 429 pages
Analysis and Modeling of Manufacturing Systems is a set of papers on some of the newest research and applications of mathematical and computational techniques to manufacturing systems and supply chains. These papers deal with fundamental questions (how to predict factory performance: how to operate production systems) and explicitly treat the stochastic nature of failures, operation times, demand, and other important events.
Analysis and Modeling of Manufacturing Systems will be of interest to readers with a strong background in operations research, including researchers and mathematically sophisticated practitioners.
https://books.google.co.in/books?id=kZ7aBwAAQBAJ
Production Systems Engineering
Main Areas of Manufacturing
The informal definitions and classifications given below are subjective and based solely on the authors' experience and understanding.
Manufacturing – the process of transforming raw materials into a useful product. Everything, which is done at or for the factory floor operations, we view as manufacturing.
Manufacturing matters. The wealth of a nation can be either taken from the ground (natural resources and agriculture) or manufactured (value added by processing materials). Thus, being one of just two ways of generating national wealth, manufacturing is of fundamental importance.
Manufacturing can be classified into two groups: continuous and discrete.
Quite informally, manufacturing can be classified into the following five areas:
Machine tools and material handling devices. The main problem here is: Given a desired material transformation and/or relocation, design, implement, and maintain a machine or a material handling device, which carries out its function in an efficient manner. This is a mature engineering field with numerous achievements to its credit.
Production systems. Main problem: Given machines and material handling devices, structure a production system so that it operates as efficiently as the machines in isolation. This can be achieved by maintaining smooth flow of parts throughout the system, so that mutual interference of the machines does not cause losses of production. The term "structure" is used here to include both design of new and improvement of existing production systems. To-date, this field lacks in rigorous quantitative methods and fundamental engineering knowledge.
Production planning and scheduling. Main problem: Given a production system and customer demand, calculate a production plan and schedule delivery of materials so that the demand is satisfied in an economically efficient manner. Numerous quantitative methods, often based on optimization, are available in this relatively mature field of manufacturing.
Quality assurance. Main problem: Structure and operate the production system so that parts produced are of the desired quality. To-date, statistical quality control is a major quantitative tool for maintaining product quality.
Work systems. Main problem: Organize personnel training and operation so that the production process is carried out safely and efficiently. This includes, in particular, designing wage and incentive systems so that the maximum of the utility function of an individual worker coincides with that of the manufacturing enterprise as a whole and, thus, self-interest of the worker leads to high efficiency of the manufacturing enterprise. At present, this field is still in its infancy.
In addition to the above classification, discrete part manufacturing can be subdivided into two groups: job-shop and large volume manufacturing. Job-shop is concerned with manufacturing "one-of-a-kind" products: unique instruments, highly specialized equipment, some aerospace systems, etc. Large volume manufacturing is intended to produce parts and products in multiple copies: cars, computers, refrigerators, and other items of wide use.
This textbook is devoted to one area of manufacturing production systems, although some structural issues of quality assurance are also addressed. While some methods included here might be useful for job-shops as well, the emphasis is on production systems in large volume manufacturing.
http://www.productionsystemsengineering.com/Booktoc_pseaa.html
Sample chapters
http://www.productionsystemsengineering.com/Booksamples_pseaa.html
For Industrial Audience
http://www.productionsystemsengineering.com/home_pseia.html
PSE IA Textbook Preface
Managers of production systems are well aware that to ensure high productivity they must:
Identify, protect, and improve bottlenecks;
Ensure leanness of work-in-process, raw materials, and finished goods inventory;
Guarantee desired level of customer demand satisfaction in quantity and quality of products shipped.
This book provides a simple and practical answer to this question and to offers software that facilitates applications. Methods described here use traditional terms, such as “bottleneck”, “leanness”, “continuous improvement”, etc., but infuse them with rigorous engineering knowledge and, thereby, offer a possibility of designing and operating production systems with the highest efficiency and guaranteed performance.
These methods are based on fundamental laws that have been discovered in the emerging field of Production Systems Engineering (PSE) and summarized, along with numerous industrial case studies, in our university-level textbook: J. Li and S.M. Meerkov, Production Systems Engineering, Springer, 2009 (below, we refer to this book as PSE, Springer, 2009). The goal of the current volume is to present these laws and methods in a format suitable for an industrial audience – without lengthy mathematical derivations but with logical justifications and emphasis on applications. That is why we use the title Production Systems Engineering for Factory Floor Management (PSE FFM) and view this volume as an industrial textbook. It can be used for either self-study or as a text for an industrial short course (2-3 days) on production systems management.
The target audience includes plant, shop, and department managers; production supervisors; industrial, manufacturing, production, and quality engineers; production system designers; and supply chain specialists. As far as prerequisites are concerned, we believe that high school algebra and elementary statistics are sufficient to learn the techniques described here; an engineering degree would be helpful but not mandatory.
You will learn from this volume answers to the questions listed below.
Question 1: In a serial production line with identical machines and identical buffers, which machine is the bottleneck? If the machines are not identical, is the worst machine necessarily the bottleneck?
Question 2: To maximize production system’s throughput, would you prefer machines with long or short up- and downtime, provided that their stand-alone throughput remains the same?
Question 3: To maximize the throughput, would you allocate work so that buffers are full, or empty, or neither? In the latter case, which buffer occupancy indicates that work is allocated optimally? Similarly, which buffer occupancy indicates the best buffer capacity allocation?
Question 4: How would you select lean buffering for a production system? For example, are buffers of capacity 1000 parts lean? How about a buffer of capacity 10?
Question 5: In a production system with parts transported on carriers, how would you select the number of carriers so that throughput is maximized?
Some of these questions can be answered without any measurements or calculations – just based on fundamental laws that govern production systems, such as laws of reversibility, monotonicity, and improvability. Others require measurements, typically, machines’ up- and downtime, or blockages and starvations, or buffers’ occupancy. Still others are based on both measurements and calculations.
http://www.productionsystemsengineering.com/Booksamples_pseia.html
Manufacturing Systems Engineering: A Unified Approach to Manufacturing Technology, Production Management and Industrial Economics
Katsundo Hitomi
Routledge, 19-Oct-2017 - Technology & Engineering - 560 pages
This second edition of the classic textbook has been written to provide a completely up-to-date text for students of mechanical, industrial, manufacturing and production engineering, and is an indispensable reference for professional industrial engineers and managers.
In his outstanding book, Professor Katsundo Hitomi integrates three key themes into the text:
* manufacturing technology
* production management
* industrial economics
Manufacturing technology is concerned with the flow of materials from the acquisition of raw materials, through conversion in the workshop to the shipping of finished goods to the customer. Production management deals with the flow of information, by which the flow of materials is managed efficiently, through planning and control techniques. Industrial economics focuses on the flow of production costs, aiming to minimise these to facilitate competitive pricing.
Professor Hitomi argues that the fundamental purpose of manufacturing is to create tangible goods, and it has a tradition dating back to the prehistoric toolmakers. The fundamental importance of manufacturing is that it facilitates basic existence, it creates wealth, and it contributes to human happiness - manufacturing matters. Nowadays we regard manufacturing as operating in these other contexts, beyond the technological. It is in this unique synthesis that Professor Hitomi's study constitutes a new discipline: manufacturing systems engineering - a system that will promote manufacturing excellence.
Key Features:
* The classic textbook in manufacturing engineering
* Fully revised edition providing a modern introduction to manufacturing technology, production management and industrial economics
* Includes review questions and problems for the student reader
Course Materials for Manufacturing System Design
Peter L. Jackson, John A. Muckstadt, John M. Jenner
School of Operations Research and Industrial Engineering
Cornell University
https://people.orie.cornell.edu/jackson/aseehtml.html
The Manufacturing System Development Game
PERMANENT LINK(S) https://hdl.handle.net/1813/8749
AUTHOR Muckstadt, J. A.; Jackson, P. L.; Jenner, J. M.
ABSTRACT
This paper published in the "Journal of Algorithms" 13 (SODA '90 special issue) 79-98
https://ecommons.cornell.edu/handle/1813/8749
Topic 4: Manufacturing Systems Design
Topic 5: Robotics
Teachers
Dr. G. Bengu, IE Dept.
Objective
To introduce large scale manufacturing systems design and concepts. Students will learn and experiment with different designs of manufacturing systems. The manufacturing systems concepts such as Flow Line Systems, Flexible Manufacturing Systems, Automated Storage and Retrieval Systems, Just In Time Production Systems will be introduced. Interactive Simulation/Animation tools are used for this purpose as well as for the economical analysis of manufacturing systems design. Students will access the simulation/animation tools through a hypertext/multimedia environment, for example view a simulated factory floor, change relevant key parameters and observe the effects on the system performance. Students will analyze the trade offs with different design alternatives using economical analysis functions as well as direct performance measures. Students will also be introduced to the use of spreadsheet tools for such analysis. The spin off benefit of this lecture will be the use of other tools and techniques from topics such as in Quality Control and Concurrent Engineering and the resulting synergy accross manufacturing curriculum. The chosen application areas will focus on personal computer production.
Lecture Material
The layout of production facilities, in a factory floor as well as the choice of the characteristics of individual production facilities such as type of machine are largely based on the nature of the product and can be categorized in terms of type of production.
Flow Line Assembly: System design for large volume standard productions such as cars, televisions, radios, etc. The product is a standard one which can be mass produced.
Just in time and flexible manufacturing systems(JIT & FMS): Design for moderate volume but high variety products such as consumer electronics. There are similar products produced but they are in moderate numbers but not in large quantities and there are many batches like these.
Job Shop: Every product is unique and hence each has to be produced in different ways. The storage of raw material, work-in-process inventory as well as finished product requires a storage area and a retrieval process. Next subject will touch these issues with the following example.
Automated Storage and Retrieval Systems(AS/RS): Design of a automated warehouse system facilitated by conveyor, elevators and barcode readers. The delivery of materials between work centers usually occurs thorough a material handling system. The last example will touch issues in this area.
Material Handling systems: Design of automated quickest vehicle track.
https://www.ewh.ieee.org/soc/es/Aug1996/030/cd/en495w16/begin.htm
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