Part I

OVERVIEW OF MANUFACTURING
Chapters:
2. Manufacturing Operations
3. Manufacturing Models and Metrics
2008 Pearson Education, Inc., Upper Saddle River, NJ. All
rights reserved. This material is protected under all copyright laws
as they currently exist.
No portion of this material may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
1

Ch 2 Manufacturing Operations
Sections:
1. Manufacturing Industries and Products
2. Manufacturing Operations
3. Production Facilities
2008
Pearson Education, Relationships
Inc., Upper Saddle River, NJ. All
4. Product/Production
rights
reserved.
This material is protected under all copyright laws
5. Lean
Production
as they currently exist.
No portion of this material may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
2

Manufacturing Defined Technological Definition

Application of physical and chemical processes to
alter the geometry, properties, and/or appearance of
a given starting material to make parts or products
Manufacturing also includes the joining of multiple
parts
to make
assembled
products
2008
Pearson
Education,
Inc., Upper
Saddle River, NJ. All
rights
reserved. This by
material
is protectedofunder
all copyright
Accomplished
a combination
machinery,
tools,laws
as they
currently
power,
andexist.
manual labor.
Noportion
ofalways
this material
mayout
beas
reproduced,
in any
Almost
carried
a sequence
of form or by
any means,
without permission in writing from the publisher. For
operations
the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
3

Manufacturing Defined Technological Definition

Fig. 2.1.a

2008 Pearson Education, Inc., Upper Saddle River, NJ. All

rights reserved. This material is protected under all copyright laws
as they currently exist.
No portion of this material may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
4

Manufacturing Defined Economic Definition

Transformation of materials into items of greater value
by means of one or more processing and/or assembly
operations
Manufacturing adds value to the material
2008
Pearson Education, Inc., Upper Saddle River, NJ. All
Examples:
rights reserved. This material is protected under all copyright laws
Converting iron ore to steel adds value
as they currently exist.
Transforming
sand
into
adds value
No portion
of this material
may
be glass
reproduced,
in any form or by
Refining
any means,
withoutpetroleum
permissioninto
in writing
plastic from
addsthe
value
publisher. For
the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
5

Manufacturing Defined Economic Definition

Fig. 2.1.b

2008 Pearson Education, Inc., Upper Saddle River, NJ. All

rights reserved. This material is protected under all copyright laws
as they currently exist.
No portion of this material may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
6

Classification of Industries
1. Primary industries cultivate and exploit natural
resources
Examples: agriculture, mining
2. Secondary industries convert output of primary
industries
into products
2008
Pearson Education,
Inc., Upper Saddle River, NJ. All
rights reserved.
This material
is protected
under
all copyright laws
Examples:
manufacturing,
power
generation,
as they currently
exist.
construction
No3.portion
of this
materialmay
be reproduced,
Tertiary
industries
service
sector in any form or by
any means, without permission in writing from the publisher. For
Examples: banking, education, government, legal
the exclusive
use of adopters of the book
services,
retailSystems,
trade, transportation
Automation,
Production
and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
7

Manufacturing Industries
ISIC Code
Food, beverages, tobacco
31
Textiles, apparel, leather and fur products
32
Wood and wood products, cork
33
2008
Pearson
Education,
Inc., Upper
Saddle River, NJ. All
Paper,
printing,
publishing,
bookbinding
34
rights
reserved. This
material
is protected
under
all copyright
Chemicals,
coal,
petroleum
and their
products
35 laws
as they currently exist.
Ceramics, glass, mineral products
36
No portion of this material may be reproduced, in any form or by
Basic without
metals,permission
e.g., steel,inaluminum
37 For
any means,
writing from the publisher.
theexclusive
use of
adopterse.g.,
of thecars,
bookmachines, etc. 38
Fabricated
products,
Automation,
Productione.g.,
Systems,
andtoys
Computer-Integrated39
Other products,
jewelry,
Manufacturing, Third Edition, by Mikell P. Groover.
8

More Industry Classifications

Process industries, e.g., chemicals, petroleum, basic
metals, foods and beverages, power generation
Continuous production
Batch production
2008
Discrete
product
(and part)
industries,
e.g.,
cars,
Pearson
Education,
Inc., Upper
Saddle
River,
NJ.aircraft,
All
appliances,
their component
parts
rights
reserved. machinery,
This materialand
is protected
under all copyright
laws
as they
currently exist.
Continuous
production
No portion
this material may be reproduced, in any form or by
Batchofproduction
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
9

Process Industries and

Discrete Manufacturing Industries

2008 Pearson Education, Inc., Upper Saddle River, NJ. All

rights reserved. This material is protected under all copyright laws
as they currently exist.
No portion of this material may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
10

Manufacturing Operations
There are certain basic activities that must be carried out
in a factory to convert raw materials into finished products
For discrete products:
1. Processing and assembly operations
2. Material
handling Inc., Upper Saddle River, NJ. All
2008
Pearson Education,
rights
This
material
is protected under all copyright laws
3. reserved.
Inspection
and
testing
as they
currently exist.and control
4. Coordination
No portion
of this material may be reproduced, in any form or by
A processing operation transforms a work material from one state of
any means, without permission in writing from the publisher. For
completion to a more advanced state using energy to alter its shape,
the exclusive use of adopters of the book
properties or appearance to add value to the material.
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
11

Fig. 2.3

Classification of
manufacturing
processes

2008 Pearson Education, Inc., Upper Saddle River, NJ. All

rights reserved. This material is protected under all copyright laws
as they currently exist.
No portion of this material may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
12

Processing Operations
Shaping operations
1. Solidification processes
2. Particulate processing
3. Deformation processes
2008
Education,
Upper Saddle River, NJ. All
4.Pearson
Material
removalInc.,
processes
rights reserved. This material is protected under all copyright laws
Property-enhancing operations (heat treatments)
as they currently exist.
Surface
processing
operations
Noportion
of this
material may
be reproduced, in any form or by
Cleaning
any means,
without permission
and surface
in treatments
writing from the publisher. For
the exclusive
use ofand
adopters
of the
book
Coating
thin-film
deposition
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
13

Assembly Operations
Joining processes
Welding
Brazing and soldering
Adhesive bonding
Mechanical assembly
2008
Inc.,bolts
Upper
River, NJ. All
Pearson
ThreadedEducation,
fasteners (e.g.,
andSaddle
nuts, screws)
rights reserved.
Rivets This material is protected under all copyright laws
as they currently
exist.
Interference
fits (e.g., press fitting, shrink fits)
No portion
of this material may be reproduced, in any form or by
Other

any means, without permission in writing from the publisher. For

the exclusive
use ofoperation
adopters joins
of thetwo
book
An assembly
or more components to create
Automation,
Production
Systems,
Computer-Integrated
a new entity
which is
called anand
assembly,
subassembly, etc.
Manufacturing, Third Edition, by Mikell P. Groover.
14

Other Factory Operations

Material handling and storage
Inspection and testing
Coordination and control
2008 Pearson Education, Inc., Upper Saddle River, NJ. All
rights reserved. This material is protected under all copyright laws
as they currently exist.
No portion of this material may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
15

Material Handling
A means of moving and storing materials between processing and/or
assembly operations
Material transport
Vehicles, e.g., forklift trucks, AGVs, monorails
Conveyors
2008
Education,
Pearson
Hoists and
cranes Inc., Upper Saddle River, NJ. All
rights
reserved.
This material is protected under all copyright laws
Storage
systems
Unitizing
equipment
as they
currently
exist.
Automatic
identification
and data
capture (AIDC)
No portion
of this
material may
be reproduced,
in any form or by
Bar codes
any means,
without permission in writing from the publisher. For
RFID
the exclusive
ofequipment
adopters of the book
Otheruse
AIDC

Automation, Production Systems, and Computer-Integrated

Manufacturing, Third Edition, by Mikell P. Groover.
16

Time Spent in Material Handling

Fig. 2.4

2008 Pearson Education, Inc., Upper Saddle River, NJ. All

rights reserved. This material is protected under all copyright laws
as they currently exist.
No portion of this material may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
17

Inspection and Testing

Inspection examination of the product and its
components to determine whether they conform to
design specifications
Inspection for variables - measuring
Pearson
Inspection
of attributes
gaging
2008
Education,
Inc., Upper
Saddle River, NJ. All
rightsTesting
reserved. This
material
protected(or
under
copyright laws
observing
theis product
part,allmaterial,
as they
currently exist.
subassembly)
during actual operation or under
No portion
of thisthat
material
be reproduced,
in any form or by
conditions
mightmay
occur
during operation
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
18

Coordination and Control

Regulation of the individual processing and assembly
operations
Process control
Quality control
2008
Pearson Education,
Saddle River, NJ. All
Management
of plantInc.,
levelUpper
activities
rightsreserved.
Thisplanning
material is
protected
Production
and
controlunder all copyright laws
as they currently exist.
Quality control
No portion of this material may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
19

Production Facilities
A manufacturing company attempts to organize its
facilities in the most efficient way to serve the particular
mission of the plant
Certain types of plants are recognized as the most
appropriate way to organize for a given type of
2008 Pearson Education, Inc., Upper Saddle River, NJ. All
manufacturing
rights reserved. This material is protected under all copyright laws
Thecurrently
most appropriate
type depends on:
as they
exist.
Types
of products
made
No portion
of this
material may
be reproduced, in any form or by
any means,
without quantity
permission in writing from the publisher. For
Production
the exclusive
usevariety
of adopters of the book
Product
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
20

Production Quantity
Number of units of a given part or product produced
annually by the plant
Three quantity ranges:
1. Low production 1 to 100 units
2. Medium
productionInc.,
100
to 10,000
units NJ. All
2008
Pearson Education,
Upper
Saddle River,
rights
This material
is protected
underofallunits
copyright laws
3. reserved.
High production
10,000
to millions
as they currently exist.
No portion of this material may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
21

Product Variety
Refers to the number of different product or part
designs or types produced in the plant
Inverse relationship between production quantity and
product variety in factory operations
2008
Pearson
Education,
Inc.,complicated
Upper Saddlethan
River,
NJ. All
Product
variety
is more
a number
rights reserved.
This material
copyright laws
Hard product
varietyisprotected
productsunder
differall
greatly
as they currently exist.
Few common components in an assembly
No portion of this material may be reproduced, in any form or by
Softwithout
product
variety insmall
differences
between For
any means,
permission
writing
from the publisher.
products
the exclusive
use of adopters of the book
Many
Automation,
Production
Systems,
and Computer-Integrated
common
components
in an assembly
Manufacturing, Third Edition, by Mikell P. Groover.
22

Product Variety vs.

Production Quantity
Fig. 2.5

2008 Pearson Education, Inc., Upper Saddle River, NJ. All

rights reserved. This material is protected under all copyright laws
as they currently exist.
No portion of this material may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
23

Low Production Quantity

Job shop makes low quantities of specialized and
customized products
Also includes production of components for these
products
2008
Pearsonare
Education,
Upper(e.g.,
Saddle
River, NJ. All
Products
typicallyInc.,
complex
specialized
rightsmachinery,
reserved. This
material space
is protected
under all copyright laws
prototypes,
capsules)
asthey
currently is
exist.
Equipment
general purpose
No portion of this material may be reproduced, in any form or by
Plant layouts:
any means, without permission in writing from the publisher. For
Fixeduse
position
the exclusive
of adopters of the book
Process
Automation,
Production
layout Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
24

Fixed-Position Layout
Fig. 2.6 (a)

2008 Pearson Education, Inc., Upper Saddle River, NJ. All

rights reserved. This material is protected under all copyright laws
as they currently exist.
No portion of this material may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
25

Process Layout
Fig. 2.6 (b)

2008 Pearson Education, Inc., Upper Saddle River, NJ. All

rights reserved. This material is protected under all copyright laws
as they currently exist.
No portion of this material may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
26

Medium Production Quantities

1. Batch production A batch of a given product is
produced, and then the facility is changed over to
produce another product
Changeover takes time setup time
Typical
process
layout
2008
Pearsonlayout
Education,
Inc., Upper
Saddle River, NJ. All
reserved.
Hard product
variety is protected under all copyright laws
rights
This material
as
currently
exist.
2. they
Cellular
manufacturing
A mixture of products is made
No portion
this material
may be reproduced,
in anyproducts
form or by
withoutof
significant
changeover
time between
any means,
without
permission
in layout
writing from the publisher. For
Typical
layout
cellular
the exclusive use of adopters of the book
Soft product variety
Automation,
Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
27

Cellular Layout
Fig. 2.6 (c)

2008 Pearson Education, Inc., Upper Saddle River, NJ. All

rights reserved. This material is protected under all copyright laws
as they currently exist.
No portion of this material may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
28

High Production (mass production)

1. Quantity production Equipment is dedicated to the
manufacture of one product
Standard machines tooled for high production (e.g.,
stamping presses, molding machines)
Typical
process
layout
2008
Pearsonlayout
Education,
Inc., Upper
Saddle River, NJ. All
2. Flow
line production
workstations
arranged
in
rights
reserved.
This material isMultiple
protected
under all copyright
laws
sequence
as they
currently exist.
No portion
of thisrequires
materialmultiple
may be reproduced,
form or by
Product
processinginorany
assembly
any means,
without permission in writing from the publisher. For
steps
the exclusive
uselayout
of adopters
of the
book
Product
is most
common
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
29

Product Layout
Fig. 2.6 (d)

2008 Pearson Education, Inc., Upper Saddle River, NJ. All

rights reserved. This material is protected under all copyright laws
as they currently exist.
No portion of this material may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
30

Relationships between Plant Layout

and Type of Production Facility
Fig. 2.7

2008 Pearson Education, Inc., Upper Saddle River, NJ. All

rights reserved. This material is protected under all copyright laws
as they currently exist.
No portion of this material may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
31

Product/Production Relationships
P

Total number of product units = Qf = Q j

j 1
Product variety
Hard product variety = differences between
products
2008 Pearson Education, Inc., Upper Saddle River, NJ. All
Soft product variety = differences between models
rights reserved.
This material is protected under all copyright laws
of products
as they currently
exist.
Product
andmaterial
part complexity
Noportion
of this
may be reproduced, in any form or by
Product
any means,
without
permissionnin
from
the publisher.
For
complexity
number
of parts
in product
p =writing
the exclusive
of adopters
the bookof operations per part
Part use
complexity
no =ofnumber
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
32

Factory Operations Model

Simplified for purposes of conceptualization:
Total number of product units Qf = PQ
Total number of parts produced npf = PQnp
2008
Pearson
Education,
Inc., Upper
NJ. All
Total
number
of operations
nof = Saddle
PQnpnRiver,
o
rights reserved. This material is protected under all copyright laws
as they currently exist.
No portion of this material may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
33

Limitations and Capabilities of a

Manufacturing Plant
Manufacturing capability - the technical and physical
limitations of a manufacturing firm and each of its plants
Three dimensions of manufacturing capability:
1. Technological processing capability - the available set
2008of
Pearson
Education,processes
Inc., Upper Saddle River, NJ. All
manufacturing
rights
is protected
under all copyright laws
2. reserved.
PhysicalThis
sizematerial
and weight
of product
as they currently exist.
3. Production capacity (plant capacity) max production
No portion of this material may be reproduced, in any form or by
quantity
thatpermission
can be made
in a given
time
under For
any means,
without
in writing
from the
publisher.
assumed
operating
the exclusive
use of
adopters conditions
of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
34

Lean Production
Operating the factory with the minimum possible
resources and yet maximizing the amount of work
accomplished
Resources include workers, equipment, time, space,
materials
2008
Pearson Education, Inc., Upper Saddle River, NJ. All
rights
reserved.
materialproducts
is protected
under
all copyright
laws
Also
implies This
completing
in the
minimum
possible
as they
exist. a very high quality level to completely
time currently
and achieving
Nosatisfy
portionthe
of this
material may be reproduced, in any form or by
customer
any
permissionmeans
in writing
from
the publisher.
Inmeans,
short,without
lean production
doing
more
with less, For
and
thedoing
exclusive
use of adopters of the book
it better
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
35

Lean Production and

Manufacturing Activities
Manufacturing activities can be divided into three categories:
1. Value-adding activities - contribute real value to the work
unit
2. Auxiliary activities - support the value-adding activities but
2008
Pearson
Education,
Upper
Saddle River, NJ. All
do not
contribute
valueInc.,
to the
product
rights
reserved.
This material
is protected
under
laws
3. Wasteful
activities
- do not
add value
nor all
do copyright
they support
as they
exist.activities
the currently
value adding
No portion of this material may be reproduced, in any form or by
If not performed, there would be no adverse effect on
any means, without permission in writing from the publisher. For
the product
ELIMINATE
!
the exclusive
use of adopters
of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
36

Programs Associated with

Lean Production
Just-in-time delivery of parts
Worker involvement
Continuous improvement
Reduced setup times
Education,
Upper Saddle
River, NJ. All
2008
Stop Pearson
the process
whenInc.,
something
is wrong
rights reserved. This material is protected under all copyright laws
Error prevention
as they currently exist.
NoTotal
productive
maintenance
portion
of this material
may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
37