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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

Watts steam engine


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

Second Industrial revolution


i. Mass production - 1900 US population was 76 millons
ii. Assembly lines 1916 Henry Ford Model T ( < 500 USD)
deber
iii. Scientific management movement deber
iv. electrification factories

1900

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

PROCESS DEFINITION
MANUFACTURING:

Manus = hand
Factus = make

Make by hands. This term appears around 1567

Kinds os process
Services process
Manufacturing process VA -NVA
Management process
Manufacturing process
Manufacturing can be defined as the 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.

MANAGEMENT PROCESS ISO 9001

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 (deber Toyota)

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

Lean

Value-adding activities
Auxiliary activities
Wasteful activities
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)

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