Contents:
1.1 Manufacturing industries.
Part 1 – Fundamental Concepts
1.2 Types of production.
1.3 Function in manufacturing.
Chapter 1
1.4 Organization and information processing
INTRODUCTION TO MANUFACTURING SYSTEM
1.5 Automation strategies
1.6 Advanced manufacturing charactreistics
1.7 Production concepts and mathematical models
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1.1 Manufacturing industries
1.1 Manufacturing industries
Basis industries in general: Manufacturing or Service?
Advertising
Aerospace
Auto-motive (cars, trucks, buses)
Beverages
Building materials
Cement
Chemicals
Clothing
Drugs, soaps, cosmetics
Basis industries in general: Manufacturing or Service?
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Equipment/machinery
Financial (Banks, investment companies, loans)
Foods
Health care service
Hotels / restaurants
Insurance
Transportation (railroad, Airline, trucking,...)
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1.1 Manufacturing industries
1.1 Manufacturing industries
Manufacturing industry vs Process industry
Classification: Manufacturing industries:
Industries
Aerospace
Car
Beverage
Building materials
Cement
Chemicals
Clothing
Soaps, cosmetic,...
Produce discrete items: cars, mobile, TV, clothes,...
Representative companies
Boeing,…
General Motors, Toyota, Mitsubishi…
Coca-Cola, Pepsi-cola, Tribeco,…
US. Gypsum, Southern steel,…
Sao mai, Hà tiên,..
EI. Du pont, Nippon,
Hanes-Corp., V. Thắng, Thắng lợi,…
Proctor&Gambles, Unilever, Kao,…
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1.1 Manufacturing industries
1.1 Manufacturing industries
Classification: Manufacturing industries:
Classification: Process industries:
Produce discrete items: cars, mobile, TV, clothes,...
Produce continuous items: liquid, pure water,
beverage, beer, milk
Petro processing
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Paint processing
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1.1 Manufacturing industries
1.1 Manufacturing industries
Classification: Process industries:
Three classifications in manufacturing industries:
Produce continuous items: liquid, pure water,
beverages, beer, milk
a. Basic producer: transforms natural resources into raw
materials (for others industrial firms)
b. Converter: intermediate link in the chain (semiproducts or components).
c. Fabricator: final products assembly to market.
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1.1 Manufacturing industries
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1.1 Manufacturing industries
Yarn Co.: basis producer
Input: silk-worm,...
Output: thread,...
Textile Co.: converter
Input: thread,...
Output: clothing,
Garment Co.: fabricator
Input: clothing, button,
thread,...
Output: shirts, clothes
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Tires M. Co.: converter
Input: rubber,...
Output: inner tubes & tires,...
Plastic Co.: converter
Input: raw materials,...
Output: plastic components,
Honda Co.: fabricator
Input: moto-bike
components,...
Output: Airblade, Wave,
Vision, Future,...
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1.2 Types of production
1.2 Types of production
1. Jobbing / Project Production: very small volume
1. Jobbing / Project Production: very small volume
2. Batch Production: small volume
3. Mass Production: large volume
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1.2 Types of production
1.2 Types of production
1. Jobbing / Project Production: very small volume
1. Jobbing / Project Production: very small volume
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1.2 Types of production
1.2 Types of production
1. Jobbing / Project Production: very small volume
2. Batch Production: small volume
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1.2 Types of production
1.2 Types of production
2. Batch Production: small volume
3. Mass Production: large volume
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1.2 Types of production
1.2 Types of production
3. Mass Production: large volume
Mass production
Batch production
Jobbing
Volume/quantity
Production rate
Worker skills level
Multi-functional
Equipment
single-functional
Special tools
Process focus
Plant Layout
Product focus
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1.3 Functions in manufacturing
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1.3 Functions in manufacturing
1. Processing
Raw
materials
1. Processing
2. Assembly
3. Materials handling
4. Inspection and test
Items
a. basic processes: raw material to initial form  make
initial sharp of product
b. secondary processes: initial form to final desired
geometry  final sharp
c. Operations to enhance physical properties:
improved all product functions  value added.
5. Process control
d. finishing operations: final process performed 
smooth, attractive to customers
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1.3 Functions in manufacturing
1.3 Functions in manufacturing
2. Assembly operations: assembly/joining process 
make/combine all components to final products.
4. Inspection and test: generally considered part of
quality control  to test/confirm for items’
qualification to customers
3. Material handling: moving & storing materials,
components for next processing and assembly
operations  materials/components available to
production planning.
5. Control process: both regulations for individual jobs
& assembly operations, and the management of
plant-level activities
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1.4 Organization & Information processing
1.4 Organization & Information processing
1. Business functions:
2. Product/item design:
Customer negotiation:
Including some documents as follows:
a/. Make to order contracts (specific orders);
- Specific product design drawings,
b/. Meet customers’ demand from stock (make to
stock contracts);
- Product characteristics and materials requirement
c/. Forecasting demand contracts (based on forecast
information/data).
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1.4 Organization & Information processing
1.5 Automation strategies (10)
1. Specialization of operations.
3. Production planning:
Production planning and implementation based on:
+ final design of item,
+ technology process/facilities requirements,
+ and production/implementation,…
2. Combined operations.
3. Simultaneous operations.
4. Integration operations.
4. Production control:
5. Increased flexibility.
Inspection and test/monitoring (product, job,
process, machines,…).
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1.5 Automation strategies (10)
6.
Improved material handling and storage.
7.
Online inspection.
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1.6 Advanced manufactuirng characteristics (9)
1. Top managers pay more attention to their
production.
2. Quality problems consideration.
8.
Process control and optimization.
9.
Plant operations control.
3. Human resources consideration.
10. Computer integrated manufacturing - CIM.
4. Cost factors consideration.
5. Specialization consideration.
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1.6 Advanced manufactuirng characteristics (9)
6. Old/disadvantage mass production tools are
troublesome to develop.
1.7 Production concepts & mathematical model
1.
Manufacturing Lead Time - MLT
MLT includes all processing time at each machine/work station
m
7. Mechanization consideration.
TMLT =  (Ts + QTp + Tn )i
(1)
i =1
8. Application of Computer and software in
production and operations management.
where: i: machine order in process
m: number of machines that products will be processed
9. Application of useful theories.
Q: product volume/batch;
Ts: set up time/machine
Tn: none-operating time;
Tp: unit processing/service time
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1.7 Production concepts & mathematical model
If total times spending at each Work station (WS) are equivalent, then
TMLT = n (Ts + QTp + Tn)
(2)
+ For jobbing case (Q=1)
TMLT = n (Ts + Tp + Tn)
(3)
+ For mass production (with one machine case)  Q is very high.
TMLT = QTp
or
TMLT = Tp
(1 item) (4)
Or
TMLT = (Tt + max[Tp])i
(5)
(1 item)
Example: one order includes 50 items to produce over
8 work stations in a factory. The set-up time (everage)
for each WS is 3 hours, the processing time (everage)
is 6 munites / 1 item / 1 WS. The none-productive
time (everage) is 7 hours / 1 WS.
Determine the completion time of this order (days),
given that working time is one shift (7 hours) per day.
Hint: manufacturing
formula (2)
+ For flow line (including n machines)
TMLT = Q(Tt + max[Tp])i
1.7 Production concepts & mathematical model
(5’)
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lead
time
is
calculated
as
TMLT = 8x(3 + 50x0.1 + 7) = 120 (hours)
Required days:
120 / 7 = 17.14 (days)
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1.7 Production concepts & mathematical model
1.7 Production concepts & mathematical model
2. Production rate – Rp
2. Production rate – Rp
Production rate of a production line/machine is
product quantity produced per hour (hourly rate)
If defective rate is q then required volume is Q/(1–q)
(Tp) = (Tb)m /Q
(6)
If the processing time at each WS is equivalent, then
processing time is calculated as follow:
(Tb)m = (Ts + QTp)m
(7’)
The average processing time per unit as follow:
+ For batch production, processing time at kth WS:
(Tb)k = (Ts + QTp)k
(Tb)m = (Ts + QTp /[1-q])m
So production rate of certain WS as follow:
Rp = 1/(Tp) = Q/(Tb)m
(7)
(8)
(9)
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1.7 Production concepts & mathematical model
2. Production rate – Rp
(9’)
Capacity – Ca is total quantity of items
produced in a consideration time 
week/month !
For mass production, processing time: (TMLT = Tp )
Rp = 1/(Tp)
1.7 Production concepts & mathematical model
3. Capacity – Ca
For jobbing, Q = 1, manufacturing lead time: (Ts+Tp )
Rp = 1/(Ts + Tp)m
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(9’’)
 Capacity and productivity are the same
dimensions (unit of product/certain period).
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1.7 Production concepts & mathematical model
3. Capacity – Ca
Capacity
1.7 Production concepts & mathematical model
3. Capacity – Ca
vs
Weekly/monthly
Units
Total items in factory
Productivity
Denoted that:
Hourly
+ W: number of WS (No. of machines) in factory;
Units
+ Rp: productivity (in consideration time – hour)
Total items in machine
+ H: time per shift (in hours)
+ S: No. of shifts (in consideration time – week/month)
Ca = W x SxH x Rp
(10)
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1.7 Production concepts & mathematical model
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1.7 Production concepts & mathematical model
3. Capacity – Ca
3. Capacity – Ca
Example: a factory has 6 machines (lathe) that can
If products required N machines ( production line
includes N machines) to finish N jobs (work
elements), then Ca can be calculated as follows:
produce a certain item, production manager said that
this factory runs 10 shifts each week, with realistics
operating time is 6,4 hours per shift, and equipment
productivity is 17 items per hour. Determine the
weekly capacity of this factory?
Ca = (W x SxH x Rp)/N
(11)
So the (W/N) is number of lines in factory
Ca = 6 x 10x6,4 x 17 = 6528 (items/week)
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1.7 Production concepts & mathematical model
1.7 Production concepts & mathematical model
3. Capacity – Ca
3. Capacity – Ca
If factory can produce some types of product, then
we denoted i as product’s kinds.
Ca can be calculated each type of product separately
as follows :
If we replace (weekly) capacity by (weekly) demand
Cai = (W/N)i x SxH x Rpi
(11’)
then we have an other formula to control demand
satisfation as follow:
WxSxH = DxN/Rp
(12)
 Three factors affect the factory capacity that
satisfies weekly demand.
So the (W/N)i is number of lines produce item i.
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1.7 Production concepts & mathematical model
3. Capacity – Ca
WxSxH = DxN/Rp
3. Capacity – Ca
(12)
With multi-product cases, right hand size (RHS) is
total demand.
With a certain product i, RHS is demand of i product
and formula can be rewritten as follow:
WixSxH = DixNi/Rpi
1.7 Production concepts & mathematical model
(12’)
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Example: 3 types of items are produced at some
similar WS, the information (past data) is given in the
below table:
Item
Weekly demand
Productivity (item/hour)
1
2
3
600
1000
2200
10
20
40
Determine number of similar WS to meet all the
above demand, given that this factory runs 10 shifts
per week, and the operating time is 6,5 hours / shift,
No. of machine in each WS is N = 1.
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1.7 Production concepts & mathematical model
3. Capacity – Ca
1.7 Production concepts & mathematical model
4. Utilization – U
Hint:
item 1:
D1/RP1 =
600/10
=
60 hours,
item 2:
D2/RP2 = 1000/20
=
50 hours,
item 3:
D3/RP3 = 2200/40
=
55 hours,
U
is
resource
using
ratio
(equipment,
lines,
machines,...
+ relative to using planning/production planning;
Total required time: (60+50+55) = 165 hours,
+ [operating time] / [available time]
Total required time for each WS: 10x6.5 = 65 hours,
+ [realistic volume] / [capacity]
Min. No. of WS: 165/65 = 2.54 Work stations,
 The minimum No. of WS is 3 to meet all product demand.
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1.7 Production concepts & mathematical model
1.7 Production concepts & mathematical model
4. Utilization – U
4. Utilization – U
Example: a production line can run 65 hours/week,
Hint:
and this line can make 20 units/hour.
Capacity of this line: Ca = 65x20 = 1300 units/week,
This week this production line only produces 1000
Utilization of this line: U = 1000/1300 = 76.92%
units, and the rest time is idle time.
Real operating time of last week:
1. Determine the capacity of this line,
TR = 1000/20 = 50 hours
2. Determine the last week utilization (U) of this line.
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1.7 Production concepts & mathematical model
4. Utilization – U
1.7 Production concepts & mathematical model
4. Utilization – U
+ related to machine operating time (running time of
Denoted:
MTBF the average time between 2
machine), it is considered as a very useful factor to
consecutive failure (Mean Time Between Failures)
control
MTTR the average repair time (Mean Time To
and
measure
the
equipment
(such
as
reliability of equipment), this parameter indicates
the availability of machines/equipment.
Repair)
So, the availability parameter is calculated by formula:
A = (MTBF – MTTR) / MTBF (%)
(13)
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1.7 Production concepts & mathematical model
5. Work-in-process – WIP
WIP = (Ca x U) x (TMLT) / (S x H)
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1.7 Production concepts & mathematical model
5. Work-in-process – WIP
(11)
WIP: number of work in process items/un-finished
where:
items in production line (factory),
Ca: factory capacity in consideration time,
WIP = (Ca x U) x (TMLT) / (S x H)
U: utilization of factory equipment,
(11)
TMLT: processing time/manufacturing lead time,
WIP is the ratio of processing time on available time
S: number of shifts in consideration time,
in factory.
H: number of hours for real operating in shift,
The total none-operating time (95%)
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O. time (5%)
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1.7 Production concepts & mathematical model
5. Work-in-process – WIP
5. Work-in-process – WIP
 Number of machine in real operating in factory:
Nm = WxU x QTp /[Ts + QTp]
1.7 Production concepts & mathematical model
WIP ratio in processing is the ratio of WIP and real
operating machines in factory, can be calcultaed as
follow:
(12)
where:
W: number of machines in factory,
WIPR = WIP / Nm
U: utilization
Q: averagre lot size
(13)
Ideal WIPR is 1:1  each machine makes one WIP at
a period.
Ts : the set up time of machine,
Tp: the processing time of machine,
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1.7 Production concepts & mathematical model
5. Work-in-process – WIP
WIP in time ratio is called TIP ratio, can be calculated
as follow:
TIPR =
TMLT / (N x Tp)
(14)
Ideal ratio is 1:1  difficult.
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