INTRODUCTION TO PRODUCTION SYSTEMS

HYSTORY OF MANUFACTURING
8000 3000 BC Wood working forming firing
3500 1500 BC Bronze age metallurgy and metalworking
Iron Gold copper silver tin
Gold sheet - jewelry
Wiring
2000- 1000 BC Iron forging process

1000 1 BC Iron age

Iron melting heat treatment as quenching
stamping - coining
1- 1000 AC - Zinc - steel
Armors
Coining spades
1000 1700 blast furnace
cannonry
Wiring
1760- 1830

Industrial revolution
Changes form economy based on agriculture and handicraft
To economy based on industry and manufacturing

i.
ii.
iii.
iv.
1850

Second Industrial revolution

i.
ii.
iii.
iv.

1900

Watts steam engine

Machine tools Wilkinson 1775 cutting lathe
spinning jenny and power loom
factory system

Mass production - 1900 US population was 76 millons

Assembly lines 1916 Henry Ford Model T ( < 500 USD)
Scientific management movement
electrification factories

fusion welding process

Scientific management movement

F. Taylor Gilbreath
i. Motion study
ii. Time study
iii. Stardards
iv. Piece rate system
v. Data collection, record keeping, cost accounting

DEFINITION
MANUFACTURING:

Manus = hand
Factus = make
Make by hands. This term appears around 1567
Since handicraft to specialized task

PROCESS
Input process oulet

Services process
Manufacturing process VA -NVA
Management process

ECONOMIC REALITIES

Globalization
International outsourcing
Local outsourcing
Contract manufacturing
Trend toward the service sector
Quality spectations
The need for operational efficiency

APROACH TECHNOLOGIES
Modern manufacturers employ technologies, such as:

Automation
Material handling strategies
Manufacturing systems
Flexible manufacturing
Quality programs
Computer integrated manufacturing
Lean production JIT

LEAN MANUFACTURING (cap 26)

Lean production mean operates de factory with the minimum possible resources and yet maximizing
the amount of work that is accomplished with the resources.
Resources:
1.
2.
3.
4.
5.

Worker
Equipment
Time
Space
Materials

Manufacturing activities

Value-adding activities
Auxiliary activities
Wasteful activities

Lean production programs

Just in time (Kanban)
Work involvement (empowerment)
Continuous improvement (quality circle, 5S)
1. Seiri Classify
2. Seiton Order
3. Seiso cleaning
4. Seiketsu Standardizer
5. Shitsuke Discipline
Reduce setup time (smed)
Stopping the process when something is wrong (andon)
Error prevention (poka yoke)
Total productive maintenance (TPM)