All Chapters Final Exam
What is the minimum numbers of workstations for a FMS?
4
*Magnificent Seven* 1. Control Charts 2. Histograms 3. Pareto Charts 4. Check Sheets 5. Defect Concentration Diagrams 6. Scatter Diagrams 7. Cause and Effect Diagrams
7 Tools of Statistical Process Control
What is a Flexible Manufacturing System?
A group of highly automated GT machine cells or workstations, interconnected by an automated material handling and storage system, and controlled by an integrated computer system.
What is Quality Function Deployment (QFD)?
A systematic procedure for defining customer desires and requirements and interpreting them in terms of product features and process characteristics
What is cellular manufacturing?
Application of group technology in which dissimilar machines or processes are aggregated into cells, each of which is dedicated to the production of a part family or limited group of families
What is the Key Machine concept?
Applies in cells when there is one (or more) machine(s). The Key machine is more expensive or performs certain supporting machines -other machines in cell are supporting machines -important to maintain high utilization of key machine, even if this means lower utilization of supporting machines
Can cellular manufacturing be automated?
Automated cell - automated processing and integrated handling -flexible manufacturing systems
What is Autonomation?
Automation with human touch Production machines operate autonomously as long as they are functioning properly. When they do not function properly (e.g., they produce a defect), they are designed to stop.
What types of performance metrics are used in Cell operations?
Cycle time Production rate, Manufacturing lead time Utilization
What are the four elements of Concurrent Engineering?
Design for Manufacturing and Assembly Design for Quality Design for Cost Design for Life Cycle
quality focused program that aims at improving an organization's operational performance Developed and implemented by Motorola Corp around 1980
Six Sigma
*DMAIC* *D*efine customer needs and project goals *M*easure the process to assess its current performance *A*nalyze the process to determine the root causes of variations & defects *I*mprove the process by reducing variations and defects *C*ontrol the future process performance by institutionalizing the improvements
Six Sigma Procedure
*Good Technology* -traditional statistical tools -modern measurement tech modern inspection tech *Good Management* -achieving customer satisfaction -continuous improvement -encouraging involvement of entire workforce
Two main goals of modern quality control
*1. Random Variations* ex) human variations from cycle to cylce, minor variations in starting materials, machine vibrations *2. Assignable Variations* ex) operator errors, defective raw materials, equipment malfunctions (process tends to be out of statistical control)
Two types of variation in manufacturing process
* Customers are external to the organization and sales and marketing department are responsible for customers * Company is organized by functional departments ex)design, quality, sales * Quality control is the responsibility of the inspection department; Inspection done after production * Knowledge of Statistical Quality Control (SQC) techniques resides only in the minds of the SQC experts in the organization
Typical management principles and practices
What is the purpose of production planning and control (PPC) process?
Used to solve logistics problems by managing information
*Unable to achieve customer satisfaction* ex) customer complaint and returns, lost sale, loss of good will for the company *Unable to keep cost down* ex) large inventory of scrapped parts, larger lot sizes for scraps, rework sortation, re-inspection, lost sales, warranty cost
What happens if quality is not maintained
What are the three types of maintenance that are performed under Total Productive Maintenance (TPM)?
*1. Emergency maintenance* repair equipment that breaks down *2. Preventive maintenance* routine repairs to avoid breakdowns *3. Predictive maintenance* anticipating malfunctions before they occur
What are the different ways to identify part families?
*1. Intuitive Grouping* (Visual Inspection) using best judgement to group parts into appropriate families, based on the parts or photos of the parts *2. Parts classification and coding* identifying similarities and differences among parts and relating them by means of a coding scheme *3. Production flow analysis* using information contained on route sheets to classify parts
What are three types of input that are used for Material Requirement Planning (MRP)?
*1. Master Production Schedule* (MPS) expressed in terms of time buckets *2. Bill of Materials* (BOM) product structure and list of component parts *3. Inventory record file* includes: ▪ Item master data - part number, order quantities, lead times ▪ Inventory status - time-phased record of inventory status ▪ Subsidiary data - purchase orders, engineering changes
What are the four types of machine cell layout?
*1. U-shape:* manual part handling (most popular) *2. In-line:* mechanized part handling *3. Loop:* mechanized part handling *4. Rectangular:* mechanized part handling
1. What do the letters of "DMAIC" stand for?
*D* define *M* measure *A* analyze *I* improve *C* control
What are the two types of FMS based on the levels of Flexibility?
*Dedicated FMS* • Designed to produce a limited variety of part styles • The complete universe of parts to be made on the system is known in advance • Part family likely based on product commonality rather than geometric similarity *Random-order FMS* • Appropriate for large part families • New part designs will be introduced • Production schedule is subject to daily changes
Which techniques are appropriate for dependent and independent demand for inventory control?
*Dependent Demand* MRP *Independent Demand* Order Point Inventory Systems
What is Group Technology? How does it improve the production in manufacturing?
*Group Technology:* manufacturing philosophy in which similar parts are identified and grouped together to take advantage of their similarities in design and/or manufacturing processes *Improvement* achieved by organizing the production facilities into manufacturing cells that specialize in the production of certain part families
What are the problems in implementing Group Technology?
*Identifying Part Families* reviewing all of the parts made in the plant and grouping them into part families is a substantial task *Rearranging production machines into GT cells* time-consuming and costly to physically rearrange the machines into cells
How can various manufacturing concepts be interpreted differently for a traditional organization and a lean organization?
*Inventory* Traditional: an asset, defined by accounting terms Lean: a waste, tied up capital *Ideal Economic Order Quantity & Batch Size* Traditional: very large Lean: ONE - efforts made to make downtime = zero *People Utilization* Traditional: all people busy at all times Lean: because work is done based on demand, people may not be busy *Process Utilization* Traditional: use high speed processors and run them at all times Lean: processors need to only be designed to keep up with demand *Work Scheduling* Traditional: build products to forecast Lean: build products to demand *Labor Costs* Traditional: variable Lean: fixed *Work Groups* Traditional: traditional departments Lean: cross-function teams *Accounting* Traditional: FASB guildlines Lean: through-put accounting *Quality* Traditional: inspect/sort work at end of process to make sure we find all errors Lean: processes, products, and services are designed to eliminate errors
Is product design a linear, or an iterative process?
*Iterative*
What are the different categories of Manufacturing Planning and Control for computer application?
*Manufacturing Planning* -Computer Aided Process Planning -CAD/CAM assisted NC part programming -Computerized work standards -Computer-aided assembly line balancing -Cost estimating -Production and inventory planning *Manufacturing Control* -Process monitoring and control -Quality Control -Shop Floor Control -Inventory Control -Just-in-Time production systems
What is modular fixtures and parametric programming?
*Modular Fixtures* Easily reconfigurable for different applications. Can also be dismantled when not in use *Parametric Programming* mathematical optimization where problem is solved as a function of one or more parameters
What is the meaning of some of the Japanese words used in lean manufacturing such of "Muda", "Kanban", "Jidoka", "Poka-yoke", "Kaizen", and "Seiketsu"?
*Muda*: wastefulness *Kanban*: scheduling system for lean and JIT manufacturing *Jidoka*: intelligent automation or autonomation *Poka-yoke*: inadvertant error prevention *Kaizen*: change for better (improvement over time) *Seiketsu*: standardized cleanup
What are three phases of Shop Floor control? What are their functions?
*Order Release* - provides documentation to process a production order through the factory *Order Scheduling* - assigns production orders to work centers in the plant by creating the dispatch list - solves two types of problems in production control ▪ Machine loading - allocating orders to work centers ▪ Job sequencing - determining the sequence in which orders will be processed through each work center by using Priority Control. *Order Progress* - monitors the status of the orders in the plant, WIP, and the other parameters that indicate production progress and performance - purpose is to provide information useful to the factory based on data collected from the factory - generates WO status reports, progress reports, exception reports
What is the Part Family concept? Do the parts which belong to a family tree have to be exactly same in design and manufacturing process?
*Part Family:* a collection of parts that possess similarities in geometric shape and size, or in the processing steps used in their manufacture Do not have to have exact same design/manufacturing process, just similar
What are the typical planning and design issues of FMS?
*Planning* 1. Part family considerations 2. Processing requirements 3. Physical characteristics of work parts 4. Production volume *Design* 1. Types of workstations (including load/unload stations) 2. Material handling system (primary and secondary) 3. Work-in-progress and storage capacity 4. Tooling 5. Pallet fixtures
What are the two aspects of Quality in Design and Manufacturing?
*Product Features* How well the product meet customer need - Design department is responsible for product features *Freedom from Deficiencies* How well the product has been made - Manufacturing department is responsible.
What are Resource requirements planning (RRP), Rough-cut capacity planning (RCCP), and Capacity requirements planning (CRP)?
*RRP* Evaluate whether the Aggregate Production Plan is feasible *RCCP* Asses feasibility of Master Production Schedule *CRP* Detailed capacity calculation for individual departments and work cells. Done with Material Requirement Planning (MRP)
What are the two types of process variabilities?
*Random Variations* human variations from cycle to cycle, minor variations in starting materials, machine vibration *Assignable Variations* operator errors, defective raw materials, equipment malfunctions
What are some of the examples of user driven products and technology driven products?
*Tech Driven* computer hard disk drive *User Driven* office chair coffee maker
What is the difference between Traditional and Six Sigma distribution?
*Traditional* defect rate=2700 defects per million (3sigma) *Six Sigma* defect rate=0.002 defects per million (actually 3.4 defects per million)
What are the different factors used to classify various FMS?
*Types of Operations* processing or assembly *Number of Machines* single machine cell (n=1) flexible manufacturing cell (FMC: n=2 or 3) flexible manufacturing system (FMS: n=4 or more)
What are the different types of noise factors that affect Robust design of a product or a process?
*Unit-to-Unit* due to variability in materials, machinery, or human participation *Internal Noise* time-dependent factors such as wear, spoilage operational errors such as improper machine settings *External Noise* outside temp, humidity, input voltage
What are the unsustainable industry practice? How can it be changed to a sustainable practice?
*Unsustainable* Take, Make, Waste *Sustainable* materials, production, distribution, use, disposal
What are the basic rules to follow while designing for automated assembly?
*Use modularity in product design* -Each subassembly should have a maximum of 12 or so parts -Design the subassembly around a base part to which other components are added *Reduce the need for multiple components to be handled at once* *Limit the required directions of access* Adding all components vertically from above is the ideal *Use high quality components* -Poor quality parts jams feeding and assembly mechanisms *Minimize threaded fasteners* *Use snap fit assembly*
What is visual management and 5S?
*Visual Management* the status of the work situation should be evident just by looking at it -Objects that obstruct the view are not allowed -Build-up of WIP is limited to a specific height -Andon boards located above the assembly line indicate the status of the workstations -Worker training includes use of photos and diagrams to document work instructions *5S* Seiri - Sort Seiton - Set in order, simplify access Seiso - shine, sweep, scrub Seiketsu - standardize Shitsuke - self-discipline, sustain
What are the four components of production planning?
1. Aggregate Production Planning 2. Master Production Planning 3. Material Requirement Planning 4. Capacity Planning
What are the seven tools of Statistical Process Control (SPC), which are called "magnificent seven"?
1. Control charts 2. Histograms 3. Pareto charts 4. Check sheets 5. Defect concentration diagrams 6. Scatter diagrams 7. Cause and effect diagrams
What are different FMS analysis techniques?
1. Deterministic models (bottleneck model, extended bottleneck) 2. Queueing models 3. Discrete event simulation 4. Other approaches, including heuristics
What are the different steps of building House of Quality (HoQ)? What is the input and output of the HoQ?
1. Identify Customer Requirements 2. Identify product features needed to meet customer requirements 3. Determine technical correlations among product features 4. Develop matrix between customer needs and product features 5. Develop customer ratings -customer importance ratings 6. Comparative evaluation of output technical requirements -technical eval of competing products -establishing target values for proposed products
What are the two major challenges in manufacturing various parts?
1. Identifying the part families 2. Rearranging production machines into machine cells
What are the two ways to apply ISO 9000?
1. Implement the standards simply for the sake of improving a firm's quality systems 2. ISO 9000 Registration formal certification that the facility satisfies the standard
What methods can be used to eliminate wastes in manufacturing?
1. Just in Time Production 2. Autonomation 3. Worker Involvement
What are a few output of MRP?
1. Planned order releases - Purchase orders - to buy raw materials and parts - Work orders - to make parts and products 2. Report of planned order releases in future periods 3. Rescheduling notices 4. Cancellation notices 5. Inventory status reports 6. Performance reports 7. Exception reports 8. Inventory forecasts
What are two types of analysis that are used to form cells for group technology?
1. Rank Order Clustering for grouping the machines in a cell: -helps to determine how the machines should be grouped into machine cells 2. Arranging machines in a GT Cell: Once part-machine grouping is identified, Hollier method is used to organize the machines into most logical sequence using from-to chart, and network chart
What are the different parts of the deign process where CAD can be used?
1. Recognition of need 2. Problem definition 3. Synthesis 4. Analysis & Optimization 5. Evaluation 6. Presentation
What are the different steps of the Design Process?
1. Recognition of need 2. Problem definition 3. Synthesis 4. Analysis & Optimization 5. Evaluation 6. Presentation
What are the four types of part movement possible in machine cell layout design?
1. Repeat Operation (part does not move) 2. In-sequence move 3. Bypassing move 4. Backtracking move
What are the four components of Production Control?
1. Shop Floor Control 2. Inventory Control 3. Manufacturing Resource Planning 4. Enterprise Resource Planning
What are the three aspects of Autonomation?
1. Stop the process ("Jidoka" ) 2. Error prevention ("Poka-yoke") 3. Total Productive Maintenance (TPM)
What are the functions of Factory data collection system?
1. To supply status and performance data to the Shop Floor Control (SFC) system 2. To provide current information to production foremen, plant management, and production control personnel
What are the two measures of Utilizations?
1. Utilization of Key Machine 2. Utilization of the overall cell (arithmetic average of all the machines in the cell)
What are the objectives of cellular manufacturing?
1. shorten manufacturing lead times 2. reduce WIP 3. improve quality 4. simplify production scheduling 5. reduce setup times
What are the four simple rules of Design of Environment (DOE)?
1. with industrial materials that can be recycled continually with no loss in performance, thereby creating new industrial materials. 2. with natural materials that can be fully returned to the earth's natural cycles, thereby creating new natural materials. 3. that do not produce unnatural, toxic materials that cannot be safely processed by either natural or industrial cycles. 4. with clean, renewable sources of energy, rather than fossil fuels.
What are the management principles and practices of Total Quality Management (TQM)?
1.Focused on customer (Internal and external) satisfaction 2.Goals are driven by top management 3.Quality control is pervasive in the organization 4.Quality must be built into the product, not inspected in afterward 5.Continuous improvement
1. Robust Design 2. Taguchi Loss Function
2 Concepts for Taguchi Method in Quality Engr
*1. For Variables* ex) time, money, length, width, depth, weight, etc. Two principle types: -Mean chart -Range chart *2. For Attributes* ex) number of defects, mistakes, errors, etc. Two principle types: -probability chart -count chart
2 Types of Control Charts
*1.Product Features:* how well the product meets customer needs -design department is responsible for product features *2.Freedom from Deficiencies:* how well the product has been made -manufacturing department is responsible
2 aspects of quality
1. Implement standards simply for the sake of improving a firm's quality systems 2. ISO 9000 Registration - formal certification that the facility satisfies the standard
2 ways to apply ISO 9000
What is the concept of a composite part? Is it a real or hypothetical part?
A composite part for a given family is a *hypothetical* part that includes all of the design and manufacturing attributes of the family. Composite part concept: (a) the composite part for a family of machined rotational parts, and (b) the individual features of the composite part
What is Six Sigma? What are the general goals of Six Sigma?
A quality-focused program that aims at improving an organization's operational performance. Goals: • Better customer satisfaction • High quality products and services • Reduced defects • Improved process capability • Continuous improvement • Cost reduction by more effective & efficient processes
What is the goal of Inventory control?
Achieve an appropriate compromise between minimizing the cost of holding inventory and maximizing customer service
What are key aspects of the variant type and the generative type of CAPP?
Based on group technology, parts classification, and coding For each new part, the standard plan is edited if modifications are needed
Reduce frequency of quality audits by customer firms Qualify for establishing business partnerships with companies that require ISO certification
Benefits of ISO Certification
What are the challenges faced by product designers while designing a new product?
Business *viable* Technical *feasible* People *desirable*
Used in prelim stages of a study of a quality problem 2 Types: 1. Defective item check sheet -types and frequencies of defects on the product 2. Defect location check sheet -were defects occur on the product
Check Sheet
What is Enterprise Resource Planning (ERP)? What are the benefits of ERP?
Computer software system that organizes and integrates all of the data and business functions of an organization through a single, central database. Benefits: -Elimination of the duplication, discontinuity and redundancy in data -Provides information across departments in real time -Increased productivity, better inventory management - promotes better quality, reduced material cost, and many more.
What is Manufacturing Execution System (MES)?
Computer software that supports the Shop Floor Control (SFC) - It responds to on-line inquiries about the status of orders in the shop - Other MES functions may include generation of process instructions, real-time inventory control, and labor tracking
What is CAPP? What are the different types of computer-aided process planning (CAPP) methods that are available in the industry?
Computer-Aided Process Planning 2 Types: 1. Retrieval Systems 2. Generative Systems
What is Manufacturing Resource Planning (MRP II)? What are the three major modules or MRP II?
Computer-based system for planning, scheduling, and controlling the materials, resources, and supporting activities needed to meet the master production schedule
How is concurrent engineering different from traditional method of design and manufacturing?
Concurrent engineering is a method of designing and developing products, in which the different stages run simultaneously, rather than consecutively
"Process Characteristic" vs "Time" Used to determine if the process remains in statistical control
Control Charts
A drawing of the product (all relevant views), onto which the locations and frequencies of various defect types are added • Useful for analyzing the causes of product or part defects • By analyzing the defect types and corresponding locations, the underlying causes of the defects can possibly be identified
Defect Concentration Diagram
What is process planning and who does it?
Determining the most appropriate manufacturing process and the sequence in which they should be performed Process planning done by manufacturing engineers
What does Lean Production mean? Which company this philosophy is based on?
Doing more work with fewer resources Based on Toyota Production System
How does a manufacturing system qualify for FMS?
Each answer should be yes *1. Part Variety Test:* Can it process different part styles in a non-batch mode? *2. Schedule change test:* Can it accept changes in production schedule? *3.Error recovery test:* Can it respond to equipment malfunctions and breakdowns? *4. New part test:* Can it accommodate introduction of new part designs?
What are the seven types of waste (MUDA)? What is DOWNTIME?
Excessive (Over) Processing Motion (excessive) Inventories (excessive) Transportation Waiting Overproduction Defective Production *D*efective Production *O*verproduction *W*aiting *N*on-used Employee Talent *T*ransportation *I*nventory *M*otion *E*xcessive (over) Processing
1. Management commitment and leadership 2. Team approach to problem solving 3. Emphasis on continuous improvement 4. SPC training for all employees 5. A recognition and communication system to recognize successful SPC efforts
Five Elements of Implementing Successful Statistical Process Control
What is scope of CAD, CAM and CIM?
From order receipt, through design and production, to product shipment
• Better customer satisfaction • High quality products and services • Reduced defects • Improved process capability • Continuous improvement • Cost reduction by more effective & efficient processes
General goals of 6 Sigma
What are some of the environmental impacts of the industry?
Global Warming Resource Depletion Solid Waste Water Pollution Air Pollution Land Degradation
At which level are Aggregate planning decisions made?
High level corporate Coordinated with product design, production, marketing and sales
* Bar graph * Useful for visualizing data such as: -shape of distribution -central tendencies -approx mean and mode -amount of scatter in data
Histograms
What is ISO 9000? Is it industry specific?
ISO = International Organization for Standardization ISO 9000 is set of international standards for quality *Generic* NOT industry specific
How can you reduce batch size and cost?
Ideal situation is to have lot sizes of one pulled from one process to the next...often not feasible! Use Economic Order Quantity (EOQ) to reduce batch size.
What are the benefits of FMS?
Increased machine utilization Reduced direct labor requirements Opportunity for unattended production
What is "Kanban" mechanism that is used effectively in JIT production system?
It provides a control mechanism at each workstation to produce only the minimum quantity of parts needed to feed the next process in sequence.
Which Material handling system in FMS would you choose for mid-volume, and mid-variety production.
Linear transfer system with secondary parts handling system at each workstation
What are the two broad applications of CAM?
Manufacturing Planning Manufacturing Control
What are the two life cycles?
Natural Biological Life Cycle Product Industrial Life Cycle
Is it easy to innovate?
No Dupont estimates that it takes 250 ideas to yield one marketable product
Different types of noise factors: 1. Unit-to-unit noise factors - due to variability in materials, machinery, or human participation 2. Internal noise factors - time-dependent factors such as wear, spoilage - operational errors such as improper machine settings 3. External noise factors - outside temperature, humidity, input voltage
Noise factors that affect robust design
1. Improve quality of process output 2. Reduce process variability & achieve process stability 3. Solve processing problems
Objectives of Statistical Process Control (SPC)?
Special form of histogram in which attribute data is arranged according to some criterion such as cost or value
Pareto Charts
The vital few and the trivial many 80%-20% rule 80% of the nations wealth is divided among 20% of the nation's population
Pareto's Law
What is Just-in-time (JIT) Production? How can JIT be achieved?
Production and delivery of exactly the required number of each component to the downstream operation in the manufacturing sequence just at the moment when the component is needed (at right amount, at right time, at right place). JIT can be achieved by : (a) A Pull system of production control such as the Kanban system. (b) Batch size and Set up time reduction (c) Stable and reliable production operations
Which one among Dedicated and Random-order is capable of accepting new part design?
Random order (system is designed for new part designs)
Which one among FMC and FMS performs better in error recovery test?
Random order since machine redundancy minimizes effect of machine breakdowns Dedicated FMS is limited by sequential processes
The process continues to produce good product despite disturbances and variations in operating environment (noise factors).
Robust Process Design
What are the different types of documentation that are included in a shop packet?
Route Sheet Material Requisitions Job Cards Move Tickets Parts List (if assembly)
What is a route sheet? How does it compare to engineering drawings?
Route sheet specifies the details of the process plan. includes all manufacturing operations to be performed on the work part listed in order route sheet to process planner = engineering drawing to product designer
What are the three types of FMS based on number of workstations?
Single Cell (n=1) Flexible Manufacturing Cell (n=2 or 3) Flexible Manufacturing System (n=4 or more)
What is SMED? What is the goal of SMED?
Single Minute Exchange of Dies - method for reducing the set up time. Goal is to reduce and convert the *internal* set-up time to *external* set-up time
What are Triple Bottom Line for Product Design?
Social Environmental Financial
What are the benefits of using Group Technology in manufacturing?
Standardization of tooling, fixtures, and setups is encouraged Material handling is reduced Process planning and production scheduling are simplified Work-in-process and manufacturing lead time are reduced Improved worker satisfaction in a GT cell Higher quality work
Use of various methods to measure and analyze a process, either in manufacturing or non-manufacturing situations
Statistical Process Control (SPC)
What is Takt time? How are Cycle time and Takt time related to WIP?
Takt time is the available production time divided by the units a customer demands WIP will build up if cycle time and Takt time are not budgeted correctly
What are the drawbacks of Manual Process Planning?
Tied to personal experience (knowledge of process planner) Time consuming and slow process Slow in responding to changes in product design and production
1. Focused on customer (internal and external) satisfaction 2. Goals are driven by top management 3. Quality control is pervasive in the organization 4. Quality must be built into the product, not inspected in afterward 5. Continuous improvement
Total Quality Management (TQM) principles and practices
*Traditional* includes 9.73% of population defect rate = 2700 defects per million *5 Sigma* includes 99.999% of population defect rate = 0.002 defects per million In reality it is 3.4 defects per million for 6-Sigma
Traditional (3-Sigma) vs Six Sigma
What are the additional ways for designing of machine cell layout?
informal scheduling and routing of similar parts through selected machines to minimize setups virtual machine cells - dedication of certain machines in the factory to produce part families, but no physical relocation of machines
What is "lights out operation"?
machines that run overnight
Why is it important to minimize loss in tolerance design?
to minimize: customer dissatisfaction injuries caused by poor design costs to operate failure to function, maintenance and repair costs
What are a few benefits of CAPP?
• Leads to more logical and consistent process plans than traditional process planning • Process rationalization and standardization • Increased productivity of process planners • Reduced lead time to prepare process plans • Improved legibility over manually written route sheets • Incorporation of other application programs
What are the type of work human workers perform in Flexible Manufacturing Systems?
• Loading and unloading parts from the system • Changing and setting cutting tools • Maintenance and repair of equipment • NC part programming • Programming and operating the computer system • Overall management of the system
Name a few applications for Flexible Manufacturing Systems.
• Machining, Assembly, Sheet metal processing, Forging, etc. • It is more appropriate for soft product variety.
What are the FMS operation management issues?
• Scheduling and dispatching: • Machine loading: deciding on what operations and associated tooling at each workstation • Part routing: selecting routes to be followed by each part • Part grouping: which parts should be on the system at one time • Tool management: when to change tools • Pallet and fixture allocation: limits on fixture types may limit part types that can be processed
What are the functions of FMS computer control system?
• Workstation control • Distribution of control instructions to workstations • Production control • Traffic control • Shuttle control • Tool control • Performance monitoring and reporting • Diagnostics
What are the three aspects of the Worker Involvement?
■ Continuous improvement ("Kaizen") ■ Visual workplace ■ Standard work procedures
What are the three main objectives of Standardized Work Procedures?
■ Increase productivity ■ Balance the workload among all processes ■ Minimize work-in-progress
How to achieve stable and reliable production operations?
■ Production leveling - distribute changes in product mix and quantity as evenly as possible over time ■ On-time delivery of components ■ Defect-free components and materials ■ Reliable production equipment ■ Workforce that is cooperative, committed, and cross-trained ■ Dependable supplier base
What are some of the error prevention strategies?
▪ Detection of work part deviations ▪ Detection of processing and methods deviations ▪ Counting and timing functions ▪ Verification of steps during work cycle
What is the goal of a CAD/CAM system?
➢Automate different phases of design and manufacturing ➢Automate the transition from design to manufacturing
