Topic: Manufacturing Systems
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29th November 2020
Part A
Manufacturing system is a collection of integrated equipment’s and human resources which process raw materials into desired output. The system undergoes one or more assembly or processing operations which brings the product closer to the desired output. Basically, operations can be classified under input, transformation and output. Input operation entails human labor, raw materials and machines. On the other hand, transformation entails procurement and material operation. Output is the final product.
Organizations should choose an appropriate manufacturing system to maximize their production. There are various factors affecting selection of manufacturing systems. These factors include volume, flexibility, lead time, and efficiency. Examples of manufacturing systems include lean, single station cells, machine lines and manual assembly lines.
Key Performance Indicator (KPI) is a measurable value that defines how a company is achieving its key objectives of business. High level KPI focuses in overall performance of the business while low level KPI focuses on departmental activities like sales, marketing and the rest. KPI as a form of communication is always overlooked by many organizations. Modern systems are associated with technological developments. Organizations are characterized with stiff competition. Based on my opinion, the development in Manufacturing Systems have addressed the competitiveness issues.
Modern manufacturing systems are characterized with fierce competition. There is dire need to construct an efficient and effective shop floor. However, changes in the shop floor is one of the major challenges facing this industry. These changes include unstable customer demand, changes in part floor routing, and different operators. A company must assess the shop floor changes through a number of techniques.
There are very many approaches used in shop floor analysis such as thorough mathematical modeling and simulation. However, simulation is the most popular technique. Discrete event simulation is achieved by simulation programs such as WITNESS, Simul8, and Automod. Changes in shop floor are literally unavoidable. A company should work on finding solution to these changes. To achieve cooperate objectives of the system, the approach should be implemented alongside a number of strategies.
Assumptions must be made during the simulation of the model. Some of the assumptions include continuous flow of process and equal volume for all parts. Verification is done after the assumptions are made. Throughput rate, machine Utilization and Operator utilization are the three basic measurement criteria for performance.
Product Flow Analysis (PFA) is essential for understanding the current condition of manufacturing process facility. All elements of production like raw materials and other equipments can be identified through PFA. Efficient production is associated with efficient flow. A robust insight of how your facility can evolve efficiently can be achieved through enhanced material flow and layout improvements. This technique can be used to simultaneously identify product requirement and process grouping.
Value Stream Mapping (VSM) is a lean management tool. It is also known as material and information-flow mapping. This tool is used for the analysis of the current state and the possible future state of a series of events from product design until it reaches the customer. Just from the name, the tool visualizes all the processes. Flowcharts are basically used to visualize the processes. This tool plays a vital role in introspection and process improvement.
Value Stream Mapping should include all the resources that will form part of the final product. Value adding steps and non-value adding steps must be followed when implementing this strategy. VSM takes a picture of the whole process. It is therefore the most preferred tool for analysis. PFA can be used to identify the possibilities for improvement by grouping similar processes under one category. All relevant information about a product or a service are gathered and analyzed through these techniques.
Plant layout can be grouped under various categories. An organization which choose a specific type of layout depending on its objectives. Basically, fixed position and group layout techniques are widely used in modern manufacturing systems.
Fixed position layout is also known as project type layout. Just from the name, all tools and materials remain in a fixed location. It is mostly used when one or more pieces of similar heavy products are to be manufactured. In the same vein, the layout is widely used in assembling heavy parts. The technique is associated with a number of benefits. It helps in upgrading the skills of operators. In addition to that, the layout is associated with low layout capital investment. This type of layout is also very flexible.
Group layout is also known as cellular layout. It is one of the most complex plant layouts. Modern manufacturing systems are associated with the highest levels of flexibility. This layout entails grouping elements into one family. Components are compared, analyzed and then grouped into families based on similarities. There are two basic steps in group layout technology.
The first step entails determining the families of various components. After that, the plants are grouped into various categories using GT. The main aim of this technique is to reduce the cost of transportation and purchasing various equipments. The technique is associated with component standardization and rationalization, reliable estimates, and customer service. Based on these benefits, the technology is widely used in modern manufacturing systems.
The origin of lean manufacturing can be traced back to Japan. This type of manufacturing is associated with a number of tools and techniques. These tools include TPM, total quality management, and Failure Mode and Effect Analysis (FMEA). In lean manufacturing systems, the basic building block is Total Productive Maintenance (TPM). To facilitate sustainable improvements, various principles of TPM are applied. On the other hand, total quality management is based on long-term success. However, various techniques such as customer satisfaction must be put into consideration. All members of an organization must share the same objective.
Just from the name, Failure Mode and Effect Analysis (FMEA) focuses on identification of various failure modes and subsequent effects of the failures. It is a step by step process. Failure modes should be easily identified to facilitate the search for solution. Documentation of current knowledge and steps leading to the solution must be done.
There are very many acronyms used in manufacturing systems. CNC means Computer Numerical Control, CAD stands for Computer Aided Design, BOM is an acronym for Bill of Materials, CAM stands for Common Area Maintenance charges while CAPP stands for Computer Aided Process Planning. In the same vein, AGV stands for Automated Guided Vehicle, MPS (Master Production Schedule), MRP (Master Resource Planning), FMS (Flexible Manufacturing System), CIM represents Computer Integrated Manufacturing, and ERP stands for Enterprise Resource Planning software.
Part B (Case Study)
Introduction
Manufacturing system is a critical part of a production unit. The report is based on assessment of manufacturing plants in terms of performance. Competition has taken over the world of business. Due to innovation and creativity, technological developments has given birth to many people ideas. Individuals or organization should be prepared to face stiff competition from already established business. Success relies on the level of creativity and innovation alongside customer satisfaction. Management should ensure that cases related to manufacturing systems are properly handled. Key Performance Indicators (KPI) is a metric used to gauge the possibility of success of a plant. Modern organizations are associated with goals and objectives. Lean-based KPI consists of a number of tools and principles that are implemented at different stages of business. The report justifies the use of lean-based KPI in performance assessment.
Research Methodology
To identify the current state of the research, a tool known as SLR was used. The first and most basic step of the research is to describe the research. In this case, the research question was based on assessing the performance of a manufacturing plan through lean-based KPI. There was need to identify the key words by using appropriate database. Boolean “AND” operator was used to combine the key words and also examine the results of the research. To limit the number of publications used during the research, the number of years were not mentioned. A total of 10 articles were used during the research. Information for the study was retrieved from these sources. Inclusive and exclusive techniques were used to select the appropriate documents for the research. The main subject of the research was using lean-based KPI to identify possibility of success. There was need to establish the context of the case study.
Literature Review Discussion
The word lean can be defined from different perspectives. Some people define it in terms of philosophy while others define it as a process. However, the right definition of lean is a process. The research describes lean from two major perspectives; structural and operational approach. Lean can be coined from five main principles: Defining value from the customer perspective, identifying the value stream, making value flow, implementation of pull based production and continuous strive for perfection.
In this approach, the importance of waste elimination is given a lot of emphasis. There are different types of wastes including transport, inventory, motion, waiting, over-processing, over-production and defects. Lean approach can be used to identify Key Performance Indicators of a manufacturing plant. Identification of better methods for eliminating waste products is promoted by lean approach. This also improves the value of customers. To facilitate high rate of production and accomplishment of other activities, an organization must invest on waste elimination. Various steps for implementation of assessment tools can be identified through the Lean Six Stigma approach.
The approach is basically known as DMAIC (Define, Measure, Analyze, Improve and Control). From the definition, it is clear that the approach is made up of five main stages. Activities are aligned with the policies and procedures of the organization during the define stage. In the same vein, the demands of the customers must be aligned with the performance of the organization. Two main principles are applied at this stage: Voice of Customer (VOC) and Voice of Business (VOB).
The specifications of VOB and VOC are translated into measurable and controllable factors during the measure and analyze phase. The main tool used in this stage is Critical Quantity Tool (CQT). Improve and control phase is the last stage. Proposed strategies for improvements are implemented at this stage. At this stage, web applications should be used appropriately.
The performance of an organization can be measured by Key Performance Indictors (KPIs). In modern manufacturing plants, lean-based KPIs is used to identify the performance. KPI is associated with failures and successes of an organization. Example of KPIs include financial statements, communication, mission, objectives, and goals of an organization.
Case Study- Signal-Based Condition Monitoring System
Modern engineering are complex. System health monitoring plays a critical role in modern engineering systems. The efficiency of a management system has a direct impact on cost-effectiveness. Classical methods are used to monitor the product through a condition monitoring system. Prediction of the system maintenance helps in making proper decisions.
Normal machine sensing use time-based signals. A remote control monitoring system was developed by a CNC manufacturer based in Australia. The main aim of the project was to reach all customers in the world. To develop integrated systems, new products were required. Improved sources of information were incorporated during the research.
Conclusions
We can understand an organization deeper through lean thinking. Based on the research, it lol as if asking questions was overlooked. The first step was to exam in the current state of the manufacturing plant. After that, necessary actions could be taken to ensure that resources are channeled in the right direction. Lean-based KPIs played a critical role in assessing performance.
Part D
Question 4
Advantages
- Better customer service
- Quality improvement
- Improved cash flow
- Reduced cost of labor
Disadvantage
- Accumulation of large stock inventory
Question 6
Kaizen is a Japanese word meaning ‘change for better’ or ‘continuous improvement.’ It is a Japanese business philosophy. It involves all employees and methods for improving production. This concept is associated with a wide range of ideas. Kaizen and continuous improvement seek to make the working environment more efficient and effective. In the same vein, it also promotes teamwork.