Manufacturing Systems: An Overview of Unit I - Introduction to World-Class Manufacturing, Diapositivas de Ingeniería Industrial

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Manufacturing

topics

Unit I: Introduction to

world-class manufacturing.

What is a system?

A system is a set of entities that work

together in order to accomplish a certain

goal.

What is a product?

A tangible good produced after mixing raw

materials on several processes.

Important concepts

Quality

The degree of

excellence on

something.

Lead time

The time that occurs

between the start and

the completion of a

certain product.

Defect

An error, imperfection

or lack of a certain

attribute.

Scrap

An object that has been

rejected due to a lack of

attributes.

Philosophy

A set of principles

oriented to study

certain topics.

Also known as Custom

manufacturing system,

it’s used for very

specific product lines or

small companies that

have the ability to work

cosely with their

customers. That means,

the finish goods are

always tailored precisely

to customer

requirements.

Artisanal manufacturing system

Examples

*Furniture built in a local

carpentry.

*Food made in a family-

owned restaurant.

*** A cake with a certain**

design or decoration.

An intensive system,

also known as

continuous production

system. Requires a lot

of resources and a high-

level of automatization.

The cost per unit is

cheaper compared to

other systems.

Massive manufacturing system

Examples

*Almost every product

assembled/manufactured

on a factory (maquila).

*Continuous production on

a medium enterprise (if

reaches conditions related

with continuous flow,

installations,

automatization and

inventories).

Advantages and disadvantages of mass

manufacturing

There’s a high level of

quality on the products.

Advantages

Disadvantage

s

Less production time

due to automatization

systems.

Reduction of personnel

cost and high volume of

production.

Inflexible system due to

incapacity to re-design

a current manufactured

product.

There’s a minimum

level of diversity of

products.

Initial costs for the

system will be risky to

recover.

Production management on agile system

The customer will want

an innovative yet

minimalist product,

¿how can we produce it

fast and easy?

Product

design:

Divide the whole

productive process

onto easy and small

operations, able to

mix and substitute

them (modular

stations).

Example: Production

cells.

Production management on agile system

IT/IOT:

The Informatic/Information

technology will be a

perfect ally to manage the

production sequence (data

management diffusion)

Allowing to have a

fast diffusion and

accessible

information for the

corp staff will

increase the answer

velocity for work

orders.

Example: SAP/ERP

systems.

Production management on agile system

The corporation must

be in disposition to

change and adapt to

market/customer

requirements.

Invest on training:

Employees are the

face of the company,

the corp will be open

to train them with

their own systems or

invest in wisdom for

these employees.

Example:

Certifications.

Advantages and disadvantages of agile

manufacturing

Maximizes the usage of

automatization

systems.

Advantages

Disadvantage

s

Improves the production

management.

Personnel will be

“updated” and open to

globalization/changes.

The system is very

expensive to fund.

Certain systems require

special programmation

language,

Personnel rotation will

be common due to

updated employees

looking for better

incomes.

The classical vision of manufacturing

was focused only on efficiency and

cost reductions.

World-class manufacturing has a

strong focus on the full satisfaction

of customer.

World-class manufacturing wants to create a

synergy with all the departments on a coporation,

mainly focused on the customer.

Capacities and skills of the workforce

• (^) Internal training for employees: Given as an

intensive course or re-training, focused on skills,

work habits and motivating the personnel.

Compete through quality

• (^) Align processes and finished goods, oriented to

customer requirements.

• (^) Give a special emphasis to product design.
• (^) Involve every activity/department onto the final

quality for the product.

Workforce integration

• (^) Develop a trust relationship between every

operator and every department.

• (^) Promote daily face to face interactions on almost

every department.

• (^) Develop activities/policies that promote

integration of every employee.