Design of a Manufacturing System
Manufacturing systems encompass the production activities that convert raw materials, components, and subassemblies into finished products. Design of a manufacturing system consists of a set of interdependent, related activities that must be completed in order to produce a product. These activities include, among others, product design, process selection and facility layout, equipment selection, workforce selection, facility location and operation management. The goal of a manufacturing system design is to create a system that not only produces the highest quality products in the shortest time, but is also cost-efficient and safe.
Product design is often the starting point when designing a manufacturing system, as it will determine the materials, processes, and equipment used, as well as the layout of the facility. It is important to consider the product’s design requirements, such as the size and shape of the part or assembly, product life cycle, and cost targets. Once the design has been established, the next step is to select the process and then decide on the facilities and equipment needed in order to manufacture the product.
The layout of the facility will depend on the process selected. The size, shape, and location of the facility should be chosen to maximize efficiency and safety. For example, a production process requiring close proximity between workers and machines should be located in a smaller facility, while large batch production processes are better suited to larger facilities.
Equipment selection is also a crucial step in manufacturing system design. Careful consideration should be given to the types of machines, tools, and automation needed to execute the process efficiently and safely. Questions to consider include the size and number of production machines needed, the number of workstations, and the types of safety measures needed. Automated processing can help reduce labor costs, but the cost of the equipment and maintenance should also be taken into consideration.
The selection of workers to operate the machines and other steps in the manufacturing process is another important factor to consider. It is important to choose workers with the necessary skill set and experience needed to run the machines and execute the processes safely. This can require training or the use of experienced personnel. In some cases, the use of contract workers or third-party labor may be necessary.
The location of the facility is another important factor in the design of a manufacturing system. In addition to taking into account factors such as raw materials availability, labor availability and cost, transportation costs, and access to suppliers and customers, the plant location should also be chosen based on its proximity to existing infrastructure to reduce cost and time to implement the system.
Finally, operation management is essential for ensuring efficient and safe production. This requires the establishment of procedures to control quality, manage inventory and labor, set goals and objectives, and monitor performance. These procedures should be documented and implemented to ensure product quality and customer satisfaction, as well as to increase efficiency and reduce costs.
In summary, designing a manufacturing system requires a thorough understanding of the process, the material, equipment, and personnel involved, as well as the location of the facility. Careful consideration should be given to each of these factors, as well as to operation management to ensure the highest quality products in the shortest time, while minimizing cost and risk of accidents. By following these steps, manufacturers can design an efficient and safe manufacturing system that meets their objectives.
