Module
Code
4.0
Credits
GPA/NGPA GPA
Module Title
Manufacturing Systems
Total Hours
Lectures
Assignment
55hrs
10hrs
Thorough knowledge in
PreRequisites Manufacturing
Technology
Aims:
A manufacturing system can be defined as the arrangement and operation of machines, tools,
material, people and information to produce a value-added physical, informational or service product
whose success and cost is characterized by measurable parameters. Therefore, course aims to discuss
on how much of the product is needed, how quickly the product must be produced and how unique the
product must be to ensure sufficient sales. The discussion of application of computers,
microprocessors and information technology, where appropriate, is encouraged.
Learning Outcomes:
After studying this course the student should be able to understand the following in a modern manufacturing
environment:
A. Single-station manufacturing cells
B. Manual Assembly lines
C. Automation Productions lines
D. Automated Assembly System
E. Cellular manufacturing
F. Flexible manufacturing systems
G. Control of Manufacture
Syllabus:
1. Introduction and overview of manufacturing systems –04 hours
Manufacturing Systems in the Production System; Definition of manufacturing system;
Components of a Manufacturing System; A Classification Scheme for Manufacturing Systems;
Components of a Manufacturing System; A classification of production machines; Work
Transport Between Stations; Typical computer functions in a manufacturing system;
Classification of manufacturing systems: Factors that define and distinguish manufacturing
systems; Types of Operations Performed; Number of Workstations; System Layout (applying
to multi-station systems; Automation and machine levels; Part and Product variety and
flexibility
Manufacturing Systems for Medium or High Product Complexity; Manufacturing Systems for
Low Product Complexity; single station and multi-station with fixed and variable routing
1. Single Station Manufacturing Cells –06 hours
Single-Station Manned Workstations; Single-Station Automated Cells; Applications of SingleStation Cells; Analysis of Single-Station Cells; Classification of Single-Station Manufacturing
Cells; Single-Station Manned Cell and variations to it; Enablers for Unattended Cell Operation;
Parts Storage Subsystem and Automatic Parts Transfer; Parts Storage Capacity; Applications
of single station manned cells; Application of single station automated cells.
2. Manual Assembly lines –06 hours
Fundamentals of Manual Assembly Lines; Manual Assembly Line Defined; Factors favoring the
use of assembly lines; Why Assembly Lines are so Productive; Typical products made on
assembly lines; Typical operations performed on assembly lines; Work transport system
(manual and mechanized); Asynchronous Transport; Material Handling Equipment for
Mechanized Work Transport; pacing, line with pacing and no pacing
Analysis of Single Model Assembly Lines: Single model assembly line (SMAL); Batch model
assembly line (BMAL); Mixed model assembly line (MMAL); Line balancing problems; cycle
time, precedence constraints
Line Balancing Algorithms: Mixed Model Assembly Lines; Workstation Considerations; Other
Considerations in Assembly Line Design; Alternative Assembly Systems
Single worker manual cells and team worker manual cells; benefits from single worker and team
cells.
3. Automated Production Lines –08 hours
Fundamentals of Automated Production Lines; System configurations for automated
production lines; Applications of Automated Production Lines; Transfer lines and systems and
analysis of Transfer Lines (linear, synchronous and rotary, belt driven, walking beam transfer
systen, Geneva mechanism with six slots, Cam Mechanism to Drive Dial Indexing Table, etc.);
Storage buffers of production lines and analysis of storage buffers; Control Functions in an
Automated Production Line;
4. Automated Assembly Systems – 08 hours
Fundamentals of Automated Assembly Systems
Fixed automation systems; typical products assembled and assembly process using
automation systems; Fundamentals of Automated Assembly Systems; control functions;
system configurations; different types of assembly machines (ex. In line assmbly and dial
indexing machines, Carousel Assembly System, etc); parts delivery at wotkstations (bowl
feeders, selector, orientors, etc.)
Quantitative Analysis of Assembly Systems
Parts delivery system at workstations; Multi-station assembly machines; Single-station
assembly cell;
Measures of performances; line efficiency
Single station assembly machines
Partial automation
5. Cellular Manufacturing – 08 hours
Group Technology (GT) and overview of GT; problems and benefits of introducing GT.
Cellular Manufacturing
Comparison of between cellular manufacturing and the plant currently uses traditional batch
production and a process type layout; comparison between traditional plant layout and cellular
layout based on GT
Part Families and cellular manufacturing, when to use GT and Cellular manufacturing; Parts
Classification and Coding; features of parts classification and coding; parts design attributes,
parts manufacturing attributes;
Production flow analysis; steps in production flow analysis
Cellular manufacturing: objectives of cellular manufacturing; composite part concept in cell
manufacturing; Part Features and Corresponding Manufacturing Operations; machine cell
design; Machine Cell with Manual Handling; cell with semi-integrated machining;
determination the most appropriate cell layout; key machine concept
Applications in Group Technology; different ways of forming machine cells; automated process
planning; Modular fixtures; Parametric programming in NC
Product design applications of GT;
Quantitative Analysis in Cellular Manufacturing: Grouping parts and machines by Rank Order
Clustering; Arranging machines in a GT Cell using Hollier’s method;
6. Flexible Manufacturing – 08 hours
Definition of FMS; evolution of FMS; FMS equipment (including AGVs); Types of FMS;
CAD/CAM integrated systems; applications of FMS; FMS different approaches; advantages
and disadvantage; development of FMS; FMS layout; how FMS works; ROBOTS and their
programming; a real world example; software used in FMS; FMS quantitative models;
7. Assess production and inventory control systems, system capacity and maintenance strategies
and techniques: - 06 hours
8.
Assess



production and inventory control systems
KANBAN
OPT (Optimised Production Technology)
MRPII
Assess




Assess
system capacity and reliability
run-time
delivery performance
work in progress (WIP)
throughout time
maintenance strategies and techniques
Control of Manufacture - 04 hours
Quantity Control: Ordering systems; inventory optimization; line-of balance charts; job
sequencing, work loading; MRPII
Quality Control: Planning product quality; sampling; Total Quality Control; Plant maintenance
and Reliability
Assessment:
Continuous Assessment: (40%)
Assignments, Case studies, field visits etc.
Final examination: (60%)
References:
Manufacturing Systems: Theory and Practice by George Chryssolouris
Handbook of Cellular Manufacturing by Shahrukh A. Irani (Editor)
Flexible Manufacturing System H. K. Shivanand
IESL College of Engineering
Syllabus Format for IESLCE Engineering Course