EA ZC412 / MM ZC412 / DM ZC412

FLEXIBLE MANUFACTURING
SYSTEMS
BITS Pilani Girish Kant Garg
Department of Mechanical Engineering
Pilani Campus

1
Contents

 Course Handout
– Importance of Manufacturing (Chapter 1 and 2)

– What is Flexible Manufacturing System

– Course Plan (Theory)

– Evaluation

– Guidelines

2
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-1, 3/8/24 BITS Pilani, Pilani Campus
 What is Manufacturing?
 Manufacturing (Latin word): Manus + Factus : Made by hands
 A value addition process by which raw materials are
converted into finished product.

Definition of manufacturing Definition of manufacturing

as a technological process as an economic process
3
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-1, 3/8/24 BITS Pilani, Pilani Campus
Importance of Manufacturing
 Manufacturing (Latin word): Manu + Factus : Made by hands
 A value addition process by which raw materials are
converted into finished product.
 GDP of a country is a function of manufacturing. Higher the
level of manufacturing higher the standard of living. (In U.S,
manufacturing contributes more than 12% to GDP, employ
18% of workforce and 40% of export).
 Manufacturing accounts for 37% of global energy demand.

4
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-1, 3/8/24 BITS Pilani, Pilani Campus
Importance of Manufacturing

Manufacturing
37% Machine tools
75%

Mining, construction
and others
63%

Casting, forming and others

25%

Global Energy Demand

5
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-1, 3/8/24 BITS Pilani, Pilani Campus
Importance of Manufacturing
 Provides the hand on experience about different processes
required for production of different products.
 A value addition process by which raw materials are converted
into finished product.
 GDP of a country is a function of manufacturing. Higher the level
of manufacturing higher the standard of living. (In U.S,
manufacturing contributes more than 12% to GDP, employ 18% of
workforce and 40% of export).
 Manufacturing accounts for 37% of global energy demand.
 Manufacturing cost represent about 40% of a product’s selling
price. 6
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-1, 3/8/24 BITS Pilani, Pilani Campus
Importance of Manufacturing

7
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-1, 3/8/24 BITS Pilani, Pilani Campus
Importance of Manufacturing

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-1, 3/8/24 BITS Pilani, Pilani Campus
Importance of Manufacturing

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-1, 3/8/24 BITS Pilani, Pilani Campus
Importance of Manufacturing

Casting Forming Metal Cutting Joining

Processes Processes Processes Processes

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-1, 3/8/24 BITS Pilani, Pilani Campus
What is Flexible Manufacturing
System
 Flexible + Manufacturing + System
 Manufacturing System
 It is a collection of people, equipment and procedures
organized to perform the manufacturing operations of a
company.

11
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-1, 3/8/24 BITS Pilani, Pilani Campus
What is Flexible Manufacturing
System

Manual Work
System

12
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-1, 3/8/24 BITS Pilani, Pilani Campus
What is Flexible Manufacturing
System

Worker Machine
System

13
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-1, 3/8/24 BITS Pilani, Pilani Campus
What is Flexible Manufacturing
System

Automated
System

14
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-1, 3/8/24 BITS Pilani, Pilani Campus
What is Flexible Manufacturing
System
 Manufacturing Support System

15
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-1, 3/8/24 BITS Pilani, Pilani Campus
What is Flexible Manufacturing
System
 System capable of processing a variety of different parts
simultaneously and quantity of production can be adjusted in
response to changing demand patterns.
 A flexible manufacturing system (FMS) consists of a group of
processing workstations, interconnected by an automated
material handling and storage system, and controlled by a
distributed computer system.

16
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-1, 3/8/24 BITS Pilani, Pilani Campus
Course Handout

Textbook

T1 Groover, Mikell P., “Automation, Production Systems, and Computer

Integrated Manufacturing”, Prentice-Hall of India, 3rd Ed., 2012.

References Book

R1 Talavage Joseph, “Flexible Manufacturing Systems in Practice”, Marcel

Dekker (CRC Press), 1998.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-1, 3/8/24 BITS Pilani, Pilani Campus
Course Plan - Theory

Lecture Learning Chapter

No. Objectives Topics to be covered
No.
1 Introduction to  Significance of manufacturing
Manufacturing  Manufacturing operations
 Manufacturing systems 1,2
Systems
2 Automation in  Automated Manufacturing Systems
Manufacturing  Manual labour in manufacturing systems
Systems  Automation principle and strategies 1,2
 Production facilities
 Product/Production relationships
3 Group  Design of Process Layout
Technology and  Design of Product Layout
Cellular  Line Balancing Algorithms 18
Manufacturing  Concept of part family and machine groups
 Cellular manufacturing,
 Analysis of Cellular manufacturing

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-1, 3/8/24 BITS Pilani, Pilani Campus
Course Plan - Theory
Lecture Learning Chapter
No. Objectives Topics to be covered
No.
4 Manufacturing  Production Performance Metrics
Metrics and  Manufacturing Costs
3
Economics
5 Automation and  Introduction to automation 4,5
Control Systems  Overview of industrial control systems
6-7 Numerical Control  Applications of NC, Advantages and
Disadvantages of NC
 Engineering analysis of NC Positioning 7
Systems – Open loop & Closed loop
positioning systems.
 NC Part Programming – Manual Part
programming, Words, format of coding
 Computer Assisted Programming –
various commands, formats
 Examples of programming
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-1, 3/8/24 BITS Pilani, Pilani Campus
Course Plan - Theory
Lecture Learning Chapter
No. Objectives Topics to be covered
No.
8 Review Session  Review of 1-7 -
Mid Semester Examination (Closed Book)
9 Material Handling  Introduction to MH systems, design
and Transport considerations.
Systems  Types of Material handling equipment, 10
applications
 Analysis of MH Systems – Vehicle
based & Conveyors
10 Storage Systems  Conventional storage methods and
and Automatic equipment
Identification and  Automated storage systems 11,12
Data Capture  Automatic identification methods

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-1, 3/8/24 BITS Pilani, Pilani Campus
Course Plan - Theory
Lecture Learning Objectives Chapter
No. Topics to be covered
No.
11 Introduction to  Components of a manufacturing
Manufacturing system
Systems & Single-  Types of manufacturing systems 13,14
Station  Single station manned cells
Manufacturing Cells  Single station automated cells.
 Analysis of single station cells
12 Manual Assembly  Fundamentals of Manual Assembly 15
Lines lines
 Analysis of Single Model Assembly
lines

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-1, 3/8/24 BITS Pilani, Pilani Campus
Course Plan - Theory
Lecture Learning Objectives Chapter
No. Topics to be covered
No.
13 Automated  Fundamentals of Automated
Production Lines and Production Lines
Assembly Systems  Applications of Automated Production 16,17
Lines
 Analysis of Transfer Lines
 Fundamentals of Automated
Assembly Systems
 Analysis of Automated Assembly
Systems
14 Flexible  Concept of FMS, Types of FMS 19
Manufacturing  Components of FMS – Workstations,
Systems  Application & benefits of FMS

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-1, 3/8/24 BITS Pilani, Pilani Campus
Course Plan - Theory
Lecture Learning Objectives Chapter
Topics to be covered
No. No.
15 Flexible  FMS planning and implementation
Manufacturing issues – planning and design issues,
Systems operational issues 19
 Quantitative analysis of FMS –
Bottleneck model, Extended
Bottleneck model, Sizing of FMS
16 Review Session  Review of 9-15 -
Comprehensive Examination (Open Book)

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-1, 3/8/24 BITS Pilani, Pilani Campus
Course Handout
Evaluation scheme
Evaluation Name Type Duration Weight Day, Date, Session, Time
Component

EC-1 Quiz Online - 10 % To be announced

Lab 1 – Computer Online - 20% To be announced
aided Design &
Computer Aided
Manufacturing
using Fusion360
EC - 2 Mid-Semester Closed 2 hours 30%
Saturday, 21/09/2024
Test Book
(EN)

EC - 3 Comprehensive Open 2½ 40% Saturday, 30/11/2024

Exam Book hours (EN)

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-1, 3/8/24 BITS Pilani, Pilani Campus
Guidelines
 Syllabus for Mid-Semester Test (Closed Book): Topics in
Contact Hours: 1 to 16
 Syllabus for Comprehensive Exam (Open Book): All topics
 Elearn portal: [Link]
 Refer the Elearn portal for the latest announcements and
deadlines.

25
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-1, 3/8/24 BITS Pilani, Pilani Campus
Thanks

26
BITS Pilani, Pilani Campus
 EA ZC412 / MM ZC412 / DM ZC412
FLEXIBLE MANUFACTURING
SYSTEMS
BITS Pilani Girish Kant Garg
Department of Mechanical Engineering
Pilani Campus

1
Review Lecture-1

 Course Handout
– Importance of Manufacturing

– What is Flexible Manufacturing System

– Course Plan (Theory)

– Evaluation

– Guidelines

2
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-2, 10/8/24 BITS Pilani, Pilani Campus
 Learning Objectives
 Introduction to Production or Manufacturing Systems (Ch-1)
– Manufacturing Systems

– Automation in Manufacturing Systems

– Manual Labor in Manufacturing Systems

– Automation Principle and Strategies

3
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-2, 10/8/24 BITS Pilani, Pilani Campus
Manufacturing Systems
 Manufacturing System

 It is a collection of people, equipment and procedures

organized to perform the manufacturing operations of a
company.

4
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-2, 10/8/24 BITS Pilani, Pilani Campus
Manufacturing System Facility
 The facilities include the factory, production machines and toolings,
material handling equipments, inspection equipments, and computer
systems that control the manufacturing operations.
 It also includes plant layout.
Plant layout : The way the equipment is physically arranged in the
factory.
Manufacturing systems: Logical groupings of equipment and workers
in the factory.
 Production line
 Stand-alone workstation and worker

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-2, 10/8/24 BITS Pilani, Pilani Campus
Manufacturing Systems
Three categories in terms of the human participation in
the processes performed by the manufacturing system:
1. Manual work systems - a worker performing one or more
tasks without the aid of powered tools.
2. Worker-machine systems - a worker operating powered
equipment.
3. Automated systems - a process performed by a machine
without direct participation of a human.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-2, 10/8/24 BITS Pilani, Pilani Campus
Manufacturing Systems
 Manual Work System

Manual Work
System

7
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-2, 10/8/24 BITS Pilani, Pilani Campus
Manufacturing Systems
 Worker Machine System

8
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-2, 10/8/24 BITS Pilani, Pilani Campus
Manufacturing Systems
 Automated System

9
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-2, 10/8/24 BITS Pilani, Pilani Campus
Manufacturing Support
Systems
It involves a cycle of information-processing activities that
consists of four functions:
1. Business functions - sales and marketing, order entry, cost
accounting, customer billing.
2. Product design - research and development, design
engineering, prototype.
3. Manufacturing planning - process planning, master
scheduling, MRP, capacity planning.
4. Manufacturing control - shop floor control, inventory control,
quality control.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-2, 10/8/24 BITS Pilani, Pilani Campus
Manufacturing Support
Systems

11
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-2, 10/8/24 BITS Pilani, Pilani Campus
Automation in Production
Systems
 Two categories of automation in the production system:
 Automation of manufacturing systems in the factory

 Computerization of the manufacturing support systems

 The two categories overlap because manufacturing

support systems are connected to the factory
manufacturing systems.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-2, 10/8/24 BITS Pilani, Pilani Campus
Automated Manufacturing
Systems
Automated Manufacturing Systems operate in the factory on the
physical product.
Examples:
 Automated machine tools that process parts.
 Transfer lines that performs a series of machining
operations.
 Automated assembly systems.
 Industrial robots that perform processing or assembly
operations.
 Automated material handling and storage systems to
integrate manufacturing operations.
 Automatic inspection systems for quality control.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-2, 10/8/24 BITS Pilani, Pilani Campus
Automated Manufacturing
Systems
Three basic types:
1. Fixed automation
2. Programmable automation
3. Flexible automation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-2, 10/8/24 BITS Pilani, Pilani Campus
Fixed Automation

A system in which the sequence of processing (or

assembly) operations is fixed by the equipment
configuration.
Typical features:
 Suited to high production quantities.
 High initial investment for custom-engineered equipment.
 High production rates.
 Relatively inflexible in accommodating product variety.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-2, 10/8/24 BITS Pilani, Pilani Campus
Programmable Automation

A system designed with the capability to change the

sequence of operations to accommodate different
product configurations.
Typical features:
 High investment in general purpose equipment.
 Lower production rates than fixed automation.
 Flexibility to deal with variations and changes in product
configuration.
 Most suitable for batch production.
 Physical setup and part program must be changed
between jobs (batches).

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-2, 10/8/24 BITS Pilani, Pilani Campus
Flexible Automation

 An extension of programmable automation in which the

system is capable of changing over from one job to
the next with no time lost between jobs.
Typical features:
 Flexibility to deal with soft product variety.
 High investment for custom-engineered system.
 Continuous production of variable mixtures of products.
 Medium production rates.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-2, 10/8/24 BITS Pilani, Pilani Campus
Computerized Manufacturing
Support Systems
 To reduce the amount of manual and clerical effort in
product design, manufacturing planning and control, and
the business functions.
 Integrates computer-aided design (CAD) and computer-
aided manufacturing (CAM) in CAD/CAM.
 CIM includes CAD/CAM and the business functions of
the firm.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-2, 10/8/24 BITS Pilani, Pilani Campus
Reasons for Automating

 To increase labor productivity.

 To reduce labor cost.
 To mitigate the effects of labor shortages.
 To reduce or remove routine manual and clerical tasks.
 To improve worker safety.
 To improve product quality.
 To reduce manufacturing lead time.
 To accomplish processes what cannot be done
manually.
 To avoid the high cost of not automating.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-2, 10/8/24 BITS Pilani, Pilani Campus
Manual Labor in Production
Systems
Is there a place for manual labor in the modern
production system?
– Answer: YES
Two aspects:
1. Manual labor in factory operations
2. Labor in manufacturing support systems

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-2, 10/8/24 BITS Pilani, Pilani Campus
Manual Labor in Factory
Operations
 The long term trend is toward greater use of automated
systems to substitute for manual labor.
When is manual labor justified?
– Some countries have very low labor rates and automation
cannot be justified.
– Task is too technologically difficult to automate.
– Short product life cycle.
– Customized product requires human flexibility.
– To cope with ups and downs in demand.
– To reduce risk of product failure.
– Lack of capital

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-2, 10/8/24 BITS Pilani, Pilani Campus
Labor in Manufacturing
Support Systems
Product designers who bring creativity to the
design task.
Manufacturing engineers who
– Design the production equipment and tooling
– And plan the production methods and routings
 Equipment maintenance.
 Programming and computer operation.
 Engineering project work.
 Plant management.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-2, 10/8/24 BITS Pilani, Pilani Campus
Automation Principles and
Strategies
1. The USA Principle
2. Ten Strategies for Automation and Process
Improvement
3. Automation Migration Strategy

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-2, 10/8/24 BITS Pilani, Pilani Campus
U.S.A Principle

1. Understand the existing process

– Input/output analysis
– Value chain analysis
– Charting techniques and mathematical modeling
2. Simplify the process
– Reduce unnecessary steps and moves
3. Automate the process
– Ten strategies for automation and production systems
– Automation migration strategy

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-2, 10/8/24 BITS Pilani, Pilani Campus
Ten Strategies for Automation
and Process Improvement
1. Specialization of operations
2. Combined operations
3. Simultaneous operations
4. Integration of operations
5. Increased flexibility
6. Improved material handling and storage
7. On-line inspection
8. Process control and optimization
9. Plant operations control
10. Computer-integrated manufacturing

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-2, 10/8/24 BITS Pilani, Pilani Campus
Automation Migration Strategy
for Introduction of New Products
Phase 1 – Manual production
– Single-station manned cells working independently
– Advantages: quick to set up, low-cost tooling
Phase 2 – Automated production
– Single-station automated cells operating independently
– As demand grows and automation can be justified
Phase 3 – Automated integrated production
– Multi-station system with serial operations and automated
transfer of work units between stations

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-2, 10/8/24 BITS Pilani, Pilani Campus
Automation Migration Strategy

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-2, 10/8/24 BITS Pilani, Pilani Campus
Thanks

28
BITS Pilani, Pilani Campus
 EA ZC412 / MM ZC412 / DM ZC412
FLEXIBLE MANUFACTURING
SYSTEMS
BITS Pilani Girish Kant Garg
Department of Mechanical Engineering
Pilani Campus

1
 Review Lecture-2
 Introduction to Production or Manufacturing Systems (Ch-1)
– Manufacturing Systems

– Automation in Manufacturing Systems

– Manual Labor in Manufacturing Systems

– Automation Principle and Strategies

2
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
 Learning Objectives

 Case Study
– Optimization of tool geometry parameters for turning operations based
on the response surface methodology

3
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Automation Principles and
Strategies
1. The USA Principle
2. Ten Strategies for Automation and Process
Improvement
3. Automation Migration Strategy

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
U.S.A Principle

1. Understand the existing process

– Input/output analysis
– Value chain analysis
– Charting techniques and mathematical modeling
2. Simplify the process
– Reduce unnecessary steps and moves
3. Automate the process
– Ten strategies for automation and production systems
– Automation migration strategy

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Ten Strategies for Automation
and Process Improvement
1. Specialization of operations
2. Combined operations
3. Simultaneous operations
4. Integration of operations
5. Increased flexibility
6. Improved material handling and storage
7. On-line inspection
8. Process control and optimization
9. Plant operations control
10. Computer-integrated manufacturing

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Automation Migration Strategy
for Introduction of New Products
Phase 1 – Manual production
– Single-station manned cells working independently
– Advantages: quick to set up, low-cost tooling
Phase 2 – Automated production
– Single-station automated cells operating independently
– As demand grows and automation can be justified
Phase 3 – Automated integrated production
– Multi-station system with serial operations and automated
transfer of work units between stations

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Automation Migration Strategy

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Manufacturing Process
(Modelling and Optimization)

9
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
 Manufacturing Process
(Modelling and Optimization)
• Predictive Modelling
– Analytical

– Numerical

– Empirical

• Optimization
– Conventional (Taguchi, RSM)

– Non-conventional (GA, SA, PSO, ACO, GRA etc.)

10
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Mechanism of chip formation

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Numerical Modelling
(Machining) - Results

43
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Numerical Modelling (Machining)
 2d-fem simulation of the orthogonal high speed cutting process

 Computer simulation of orthogonal cutting using a tool with multiple coatings

 Dependence of machining simulation effectiveness on material and friction

modelling

 Estimation of tool wear of carbide tool in orthogonal cutting using fem

simulation

 Wear modelling in mild steel orthogonal cutting when using uncoated carbide
tools

 Estimation of tool wear in orthogonal cutting using the finite element analysis

 A comparison of orthogonal cutting data from experiments with three different

finite element models

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Empirical Modelling

Response
Artificial
Surface
Neural
Methodology
Network

Empirical
Models

Support Fuzzy
Vector Set
Machines Theory

45
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Empirical Modelling (Machining)
 Integrated ANN-GA for estimating the minimum value for machining
performance
 Surface roughness (Ra) prediction model for turning of AISI 1019 steel using
response surface methodology and Box-Cox transformation
 Power consumption and tool life models for the production process
 Surface roughness predictive modeling neural networks versus regression
 Support vector machines models for surface roughness prediction in CNC
turning of AISI 304 austenitic stainless steel
 Application of fuzzy logic and regression analysis for modeling surface
roughness in face milling
 A rule-based system for trade-off among energy consumption, tool life, and
productivity in machining process

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
Optimization (Machining)
 A method integrating Taguchi, RSM and MOPSO to CNC machining parameters
optimization for energy saving
 Optimization of machining parameters and cutting fluids during nano-fluid based
minimum quantity lubrication turning of titanium alloy by using evolutionary
techniques
 Optimization of machining parameters considering minimum cutting fluid
consumption
 Selection of optimum parameters in multi-pass face milling for maximum energy
efficiency and minimum production cost
 Empirical models for specific energy consumption and optimization of cutting
parameters for minimizing energy consumption during turning
 An energy consumption optimization strategy for CNC milling
 Multi-objective optimization of milling parameters: the trade offs between energy,
production rate and cutting quality.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-3, 17/8/24 BITS Pilani, Pilani Campus
 BITS Pilani
Pilani Campus

Case Study (Optimization of tool geometry parameters

for turning operations based on the response surface
methodology)
Thanks

49
BITS Pilani, Pilani Campus
 EA ZC412 / MM ZC412 / DM ZC412
FLEXIBLE MANUFACTURING
SYSTEMS
BITS Pilani Girish Kant Garg
Department of Mechanical Engineering
Pilani Campus

1
Review Lecture - 3

 Case Study
Optimization of tool geometry parameters for turning operations
based on the response surface methodology

2
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
 BITS Pilani
Pilani Campus

Group Technology and Cellular Manufacturing (Ch-18)

Learning Objectives

 Facility Layout
 Process Layout
 Part Families and Machine Groups
 Cellular Manufacturing
 Analysis of Cellular Manufacturing

4
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Production Facilities

 A manufacturing company attempts to organize its

facilities in the most efficient way to serve the particular
mission of the plant.
The most appropriate type depends on:
 Production quantity
 Product variety

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Basic Layouts

 Process layout
 group similar activities together according to process or
function they perform

 Product layout
 arrange activities in line according to sequence of operations
for a particular product or service

 Fixed-position layout
 are used for projects in which product cannot be moved

6
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Production Quantity

Number of units of a given part or product

produced annually by the plant.
Three quantity ranges:
1. Low production – 1 to 100 units
2. Medium production – 100 to 10,000 units
3. High production – 10,000 to millions of
units

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Product Variety

Refers to the number of different product or part designs or

types produced in the plant.
Inverse relationship between production quantity and
product variety in factory operations.
Product variety is more complicated than a number.
 Hard product variety – products differ greatly.
Few common components in an assembly
Ex: Difference between car and truck.
 Soft product variety – small differences between products.
Many common components in an assembly
Difference between car models in same production
line.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Low Production Quantity

Job shop – makes low quantities of specialized and

customized products
Also includes production of components for these products
Products are typically complex (e.g., specialized
machinery, prototypes, space capsules)
Equipment is general purpose

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Fixed-Position Layout

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Fixed-Position Layout
• Typical of projects
• Bulky, heavy items
• Equipment, workers & materials brought to site
• Highly skilled labor
• Typically low fixed cost
• Often high variable costs

11
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Medium Production Quantities

1. Batch production – A batch of a given product is

produced, and then the facility is changed over to
produce another product.
– Changeover takes time – setup time
– Typical layout – process layout
– Hard product variety

2. Cellular manufacturing – A mixture of products is

made without significant changeover time between
products.
– Typical layout – cellular layout
– Soft product variety

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Process Layout

13
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
High Production

1. Quantity production – Equipment is dedicated to the

manufacture of one product.
– Standard machines tools for high production (e.g., stamping presses, molding
machines)

2. Flow line production – Multiple workstations arranged

in sequence.
– Product requires multiple processing or assembly steps
– Product layout is most common

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Product Layout

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Comparison of Product and
Process Layout
Product Process
Description  Sequential  Functional
arrangement of grouping of
activities activities
 Continuous, mass  Intermittent, job
Type of process
production, mainly shop, batch
assembly production, mainly
fabrication
Product  Standardized,  Varied, made to
made to stock order
Demand  Stable  Fluctuating
Volume  High  Low
Equipment  Special purpose  General purpose

16
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Comparison of Product and
Process Layout
Product Process
Workers  Limited skills  Varied skills
Inventory  Low in-process, high  High in-process, low
finished goods finished goods
Storage space  Small  Large
Material handling  Fixed path (conveyor)  Variable path (forklift)
Aisles  Narrow  Wide
Scheduling  Part of balancing  Dynamic
Layout decision  Line balancing  Machine location
Goal  Equalize work at each  Minimize material
station handling cost
Advantage  Efficiency  Flexibility

17
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Designing Process Layout

 Goal: minimize material handling costs

 Block Diagramming
 use when quantitative data is available
 minimize nonadjacent loads
 Relationship Diagramming
 use when quantitative data is not available
 based on location preference between areas

18
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Block Diagramming
 Unit load  Steps
• quantity in which • Create From/To chart or load
material is normally summary chart
moved • Calculate composite (two way)
movements
 Nonadjacent load • Develop trial layouts minimizing
• distance farther number of nonadjacent loads
than the next block

19
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Example
Barko, Inc. makes bark scalpers, processing equipment that strips the bark off trees and turns
it into nuggets or mulch for gardens. The facility that makes bark scalpers is a small-job shop
that employs 50 workers and is arranged into five departments:
1) bar stock cutting 2)Sheet metal 3)Machining 4) Painting 5) Assembly
The average number of loads transported between the five departments per month is
given in the accompanying load summary chart. The current layout of the facility is
shown schematically on the 2 × 3 grid. There is quite a bit of flexibility in the facility,
as indicated by six possible locations available for five departments.

20
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
 Example
Forklift used in the facility is flexible allowing horizontal, vertical and diagonal
movement of material.
Management anticipates that a new plant will soon be necessary and would
like to know if a similar layout is to be used or if a better layout can be designed.
Propose a new layout on a 2 X 3 grid that will minimize the number of nonadjacent
loads.

21
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Example
Nonadjacent Loads
110+40=150
110

100 200
1 2 3
150 50 50

60
4 5
40
Grid 1

22
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Example

Nonadjacent Loads: 0
2 3 200 loads
2 4 150 loads
1 3 110 loads
1 2 100 loads
4 5 60 loads
3 5 50 loads
2 5 50 loads
3 4 40 loads
1 4 0 loads
1 5 0 loads

23
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Example
• Block Diagram
• type of schematic layout diagram; includes space requirements
(a) Initial block diagram (b) Final block diagram

1 4
1 2 4 2

3 5 3 5

24
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Problem - 1
Avalanche, Inc. is a manufacturer of premium snow skis. The work is a combination
of precision machining and skilled craftsmanship. Before completion, skis are
processed back and forth between six different departments: (1) molding, (2) cutting,
(3) fiberglass weaving, (4) gluing, (5) finishing, and (6) waxing. Avalanche is opening
a new production facility and wants to lay it out as efficiently as possible. The number
of loads of material moved from department to department at existing operations in
other plants is shown below. Arrange the department for Avalanche’s new plant in a 2
3 grid so that nonadjacent loads are minimized.

25
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Problem - 2
ABC company has recently changed management, and the new owners want to revise
the current layout. The store performs six main services: (1), (2), (3), (4), (5), and (6).
Each is located in a separate department, as shown here. The load summary chart
gives the current level of interaction between the departments. Calculate the number of
nonadjacent loads for the current layout. Design an alternative layout to minimize the
number of nonadjacent loads.

26
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Relationship Diagramming
• Muther’s grid
format for displaying manager
preferences for department
locations
• Schematic diagram that uses
weighted lines to denote
location preference

27
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Relationship Diagramming
(a) Relationship diagram of original layout

Offices Locker Shipping

room and
receiving

Key: A
E
I
Stockroom Toolroom Production
O
U
X

28
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Relationship Diagramming
(b) Relationship diagram of revised layout

Stockroom

Offices Shipping
and
receiving

Toolroom Production Locker Key: A

room E
I
O
U
X

29
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Thanks

30
BITS Pilani, Pilani Campus
 EA ZC412 / MM ZC412 / DM ZC412
FLEXIBLE MANUFACTURING
SYSTEMS
BITS Pilani Girish Kant Garg
Department of Mechanical Engineering
Pilani Campus

1
Learning Objectives

 Facility Layout
 Process Layout
 Part Families and Machine Groups
 Cellular Manufacturing
 Analysis of Cellular Manufacturing

2
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Production Facilities

 A manufacturing company attempts to organize its

facilities in the most efficient way to serve the particular
mission of the plant.
The most appropriate type depends on:
 Production quantity
 Product variety

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Basic Layouts

 Process layout
 group similar activities together according to process or
function they perform

 Product layout
 arrange activities in line according to sequence of operations
for a particular product or service

 Fixed-position layout
 are used for projects in which product cannot be moved

4
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Production Quantity

Number of units of a given part or product

produced annually by the plant.
Three quantity ranges:
1. Low production – 1 to 100 units
2. Medium production – 100 to 10,000 units
3. High production – 10,000 to millions of
units

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Product Variety

Refers to the number of different product or part designs or

types produced in the plant.
Inverse relationship between production quantity and
product variety in factory operations.
Product variety is more complicated than a number.
 Hard product variety – products differ greatly.
Few common components in an assembly
Ex: Difference between car and truck.
 Soft product variety – small differences between products.
Many common components in an assembly
Difference between car models in same production
line.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Low Production Quantity

Job shop – makes low quantities of specialized and

customized products
Also includes production of components for these products
Products are typically complex (e.g., specialized
machinery, prototypes, space capsules)
Equipment is general purpose

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Fixed-Position Layout

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Fixed-Position Layout
• Typical of projects
• Bulky, heavy items
• Equipment, workers & materials brought to site
• Highly skilled labor
• Typically low fixed cost
• Often high variable costs

9
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Medium Production Quantities

1. Batch production – A batch of a given product is

produced, and then the facility is changed over to
produce another product.
– Changeover takes time – setup time
– Typical layout – process layout
– Hard product variety

2. Cellular manufacturing – A mixture of products is

made without significant changeover time between
products.
– Typical layout – cellular layout
– Soft product variety

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Process Layout

11
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
High Production

1. Quantity production – Equipment is dedicated to the

manufacture of one product.
– Standard machines tools for high production (e.g., stamping presses, molding
machines)

2. Flow line production – Multiple workstations arranged

in sequence.
– Product requires multiple processing or assembly steps
– Product layout is most common

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Product Layout

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Comparison of Product and
Process Layout
Product Process
Description  Sequential  Functional
arrangement of grouping of
activities activities
 Continuous, mass  Intermittent, job
Type of process
production, mainly shop, batch
assembly production, mainly
fabrication
Product  Standardized,  Varied, made to
made to stock order
Demand  Stable  Fluctuating
Volume  High  Low
Equipment  Special purpose  General purpose

14
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Comparison of Product and
Process Layout
Product Process
Workers  Limited skills  Varied skills
Inventory  Low in-process, high  High in-process, low
finished goods finished goods
Storage space  Small  Large
Material handling  Fixed path (conveyor)  Variable path (forklift)
Aisles  Narrow  Wide
Scheduling  Part of balancing  Dynamic
Layout decision  Line balancing  Machine location
Goal  Equalize work at each  Minimize material
station handling cost
Advantage  Efficiency  Flexibility

15
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Designing Process Layout

 Goal: minimize material handling costs

 Block Diagramming
 use when quantitative data is available
 minimize nonadjacent loads
 Relationship Diagramming
 use when quantitative data is not available
 based on location preference between areas

16
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Block Diagramming
 Unit load  Steps
• quantity in which • Create From/To chart or load
material is normally summary chart
moved • Calculate composite (two way)
movements
 Nonadjacent load • Develop trial layouts minimizing
• distance farther number of nonadjacent loads
than the next block

17
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Example
Barko, Inc. makes bark scalpers, processing equipment that strips the bark off trees and turns
it into nuggets or mulch for gardens. The facility that makes bark scalpers is a small-job shop
that employs 50 workers and is arranged into five departments:
1) bar stock cutting 2)Sheet metal 3)Machining 4) Painting 5) Assembly
The average number of loads transported between the five departments per month is
given in the accompanying load summary chart. The current layout of the facility is
shown schematically on the 2 × 3 grid. There is quite a bit of flexibility in the facility,
as indicated by six possible locations available for five departments.

18
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
 Example
Forklift used in the facility is flexible allowing horizontal, vertical and diagonal
movement of material.
Management anticipates that a new plant will soon be necessary and would
like to know if a similar layout is to be used or if a better layout can be designed.
Propose a new layout on a 2 X 3 grid that will minimize the number of nonadjacent
loads.

19
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Example
Nonadjacent Loads
110+40=150
110

100 200
1 2 3
150 50 50

60
4 5
40
Grid 1

20
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Example

Nonadjacent Loads: 0
2 3 200 loads
2 4 150 loads
1 3 110 loads
1 2 100 loads
4 5 60 loads
3 5 50 loads
2 5 50 loads
3 4 40 loads
1 4 0 loads
1 5 0 loads

21
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Example
• Block Diagram
• type of schematic layout diagram; includes space requirements
(a) Initial block diagram (b) Final block diagram

1 4
1 2 4 2

3 5 3 5

22
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Problem - 1
Avalanche, Inc. is a manufacturer of premium snow skis. The work is a combination
of precision machining and skilled craftsmanship. Before completion, skis are
processed back and forth between six different departments: (1) molding, (2) cutting,
(3) fiberglass weaving, (4) gluing, (5) finishing, and (6) waxing. Avalanche is opening
a new production facility and wants to lay it out as efficiently as possible. The number
of loads of material moved from department to department at existing operations in
other plants is shown below. Arrange the department for Avalanche’s new plant in a 2
3 grid so that nonadjacent loads are minimized.

23
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Problem - 2
ABC company has recently changed management, and the new owners want to revise
the current layout. The store performs six main services: (1), (2), (3), (4), (5), and (6).
Each is located in a separate department, as shown here. The load summary chart
gives the current level of interaction between the departments. Calculate the number of
nonadjacent loads for the current layout. Design an alternative layout to minimize the
number of nonadjacent loads.

24
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-4, 24/8/24 BITS Pilani, Pilani Campus
Relationship Diagramming
• Muther’s grid
format for displaying manager
preferences for department
locations
• Schematic diagram that uses
weighted lines to denote
location preference

25
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Relationship Diagramming
(a) Relationship diagram of original layout

Offices Locker Shipping

room and
receiving

Key: A
E
I
Stockroom Toolroom Production
O
U
X

26
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Relationship Diagramming
(b) Relationship diagram of revised layout

Stockroom

Offices Shipping
and
receiving

Toolroom Production Locker Key: A

room E
I
O
U
X

27
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Process Layout

Assembly

4 6 7 9

5 8

2 10 12

1 3 11

A B C Raw materials

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Route Matrix

Machines
Parts 1 2 3 4 5 6 7 8 9 10 11 12
A x x x x x
B x x x x
C x x x
D x x x x x
E x x x
F x x x
G x x x x
H x x x

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Reordered route Matrix

Machines
Parts 1 2 4 8 10 3 6 9 5 7 11 12
A x x x x x
D x x x x x
F x x x
C x x x
G x x x x
B x x x x
H x x x
E x x x

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Revised Cellular Layout

Assembly

8 10 9 12

11
4 Cell 1 Cell 2 6 Cell 3
7

2 1 3 5

A C B
Raw materials

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Overview of Group Technology

• Parts in the medium production quantity range are usually

made in batches
• Disadvantages of batch production:
 Downtime for changeovers
 High inventory carrying costs
• GT minimizes these disadvantages by recognizing that
although the parts are different, there are groups of parts
that possess similarities

32
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Group Technology (GT) Defined

 A manufacturing philosophy in which similar parts are

identified and grouped together to take advantage of their
similarities in design and production
 Similarities among parts permit them to be classified into
part families
 In each part family, processing steps are similar
 The improvement is typically achieved by organizing the
production facilities into manufacturing cells that specialize
in production of certain part families

33
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
When to Use GT and
Cellular Manufacturing

1. The plant currently uses traditional batch production and a

process type layout
 This results in much material handling effort, high in-process
inventory, and long manufacturing lead times
2. The parts can be grouped into part families
 A necessary condition to apply group technology
 Each machine cell is designed to produce a given part family, or a
limited collection of part families, so it must be possible to group
parts made in the plant into families

34
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Problems in Implementing GT

1. Identifying the part families

 Reviewing all of the parts made in the plant and grouping them into
part families is a substantial task
2. Rearranging production machines into GT cells
 It is time-consuming and costly to physically rearrange the
machines into cells, and the machines are not producing during the
changeover

35
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Part Families and
Cellular Manufacturing

 GT exploits the part similarities by utilizing similar

processes and tooling to produce them
 Machines are grouped into cells, each cell specializing in
the production of a part family
 Called cellular manufacturing
 Cellular manufacturing can be implemented by manual or
automated methods
 When automated, the term flexible manufacturing system
is often applied

36
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Part Family

• A collection of parts that possess similarities in geometric

shape and size, or in the processing steps used in their
manufacture
• Part families are a central feature of group technology
 There are always differences among parts in a family
 But the similarities are close enough that the parts can be grouped
into the same family

37
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Part Families

Two parts that are identical in shape and size but quite
different in manufacturing: (a) 1,000,000 units/yr, tolerance
= 0.010 inch, 1015 CR steel, nickel plate; (b) 100/yr,
tolerance = 0.001 inch, 18-8 stainless steel

38
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Part Families

• Ten parts are different

in size, shape, and
material, but quite
similar in terms of
manufacturing
• All parts are
machined from
cylindrical stock by
turning; some parts
require drilling and/or
milling

39
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Ways to Identify Part Families

1. Intuitive grouping (aka visual inspection)

 Using best judgment to group parts into appropriate families, based
on the parts or photos of the parts
2. Parts classification and coding
 Identifying similarities and differences among parts and relating
them by means of a coding scheme
3. Production flow analysis
 Using information contained on route sheets to classify parts

40
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Intuitive Grouping

• Least sophisticated and least expensive method

• Involves the classification of parts into families by
experienced technical staff in the plant who examine either
the physical parts or their photographs and arrange them
into groups having similar features.
• Least accurate out of three methods.

41
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Parts Classification and Coding

42
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Parts Classification and Coding

43
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Parts Classification and Coding

44
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Production Flow Analysis (PFA)

• Method for identifying part families and associated machine

groupings based on production route sheets rather than
part design data
• Workparts with identical or similar route sheets are
classified into part families
• Advantages of using route sheet data
 Parts with different geometries may nevertheless require the same
or similar processing
 Parts with nearly the same geometries may nevertheless require
different processing

45
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Steps in Production Flow
Analysis

1. Data collection – operation sequence and machine routing

for each part
2. Sortation of process routings – parts with same sequences
and routings are arranged into “packs”
3. Cluster analysis – purpose is to collect packs with similar
routings into groups
 Each machine group = a machine cell

46
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Process Layout

Assembly

4 6 7 9

5 8

2 10 12

1 3 11

A B C Raw materials

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Route Matrix

Machines
Parts 1 2 3 4 5 6 7 8 9 10 11 12
A x x x x x
B x x x x
C x x x
D x x x x x
E x x x
F x x x
G x x x x
H x x x

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Reordered route Matrix

Machines
Parts 1 2 4 8 10 3 6 9 5 7 11 12
A x x x x x
D x x x x x
F x x x
C x x x
G x x x x
B x x x x
H x x x
E x x x

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Revised Cellular Layout

Assembly

8 10 9 12

11
4 Cell 1 Cell 2 6 Cell 3
7

2 1 3 5

A C B
Raw materials

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Rank Order Clustering

• How machines in an plant should be grouped into machine

cells.
• It starts with the intial part machine incidence matrix.
• Algorithm has the following steps

51
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Rank Order Clustering

• In each row of the matrix, read the series of 1s and 0s

(blank) from left to right as a binary number. Rank the rows
in order of decreasing value.
• Number from top to bottom
• Reorder the rows in part machine incidence matrix by
listing them in the decreasing rank order.
• In each column of the matix, read the series of 1s and 0s
from top to bottom as a binary number. Rank the columns
in order of decreasing value.
• Number from left to right
• Reorder the columns in part machine incidence matrix by
listing them in the decreasing rank order, starting with left
column 52
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Problem-1

Apply the rank order clustering technique to the part machine incidence matrix in
the following table to identify logical part families and machine groups. Parts are
identified by letters and machines are identified numerically.

53
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Problem-2

Apply the rank order clustering technique to the part machine incidence matrix in
the following table to identify logical part families and machine groups. Parts are
identified by letters and machines are identified numerically.

54
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Problem-3
Jetaway, a small manufacturer of replacement parts for the aircraft industry, had always
maintained a simple layout—all like machines were located together. That way the firm could
be as flexible as possible in producing small amounts of the variety of parts its customers
required. No one questioned the production arrangement until Chris Munnelly started to work
for the company. Chris was actually hired to upgrade Jetaway’s computer system. In the process
of creating a database of part routings, Chris began to see similarities in the parts produced. A
part routing matrix for nine of the most popular parts is shown below, along with a schematic of
the factory layout.
Chris, who was already tired of being a programmer, decided to reorder the matrix
and see what he could find. If he could identify distinct part families, he could reorganize the
placement of machines into the cells he had been reading about in his business magazines.
Maybe then someone would notice his management potential. Help Chris gain status in
Jetaway by creating a cellular layout for the company. Show your results in a schematic
diagram. Be sure to include the reordered routing matrix.

55
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Problem-3

56
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Thanks

57
BITS Pilani, Pilani Campus
 EA ZC412 / MM ZC412 / DM ZC412
FLEXIBLE MANUFACTURING
SYSTEMS
BITS Pilani Girish Kant Garg
Department of Mechanical Engineering
Pilani Campus

1
Learning Objectives

 Facility Layout
 Process Layout
 Part Families and Machine Groups
 Cellular Manufacturing
 Analysis of Cellular Manufacturing

2
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Overview of Group Technology

• Parts in the medium production quantity range are usually

made in batches
• Disadvantages of batch production:
 Downtime for changeovers
 High inventory carrying costs
• GT minimizes these disadvantages by recognizing that
although the parts are different, there are groups of parts
that possess similarities

3
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Group Technology (GT) Defined

 A manufacturing philosophy in which similar parts are

identified and grouped together to take advantage of their
similarities in design and production
 Similarities among parts permit them to be classified into
part families
 In each part family, processing steps are similar
 The improvement is typically achieved by organizing the
production facilities into manufacturing cells that specialize
in production of certain part families

4
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
When to Use GT and
Cellular Manufacturing

1. The plant currently uses traditional batch production and a

process type layout
 This results in much material handling effort, high in-process
inventory, and long manufacturing lead times
2. The parts can be grouped into part families
 A necessary condition to apply group technology
 Each machine cell is designed to produce a given part family, or a
limited collection of part families, so it must be possible to group
parts made in the plant into families

5
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Problems in Implementing GT

1. Identifying the part families

 Reviewing all of the parts made in the plant and grouping them into
part families is a substantial task
2. Rearranging production machines into GT cells
 It is time-consuming and costly to physically rearrange the
machines into cells, and the machines are not producing during the
changeover

6
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Part Families and
Cellular Manufacturing

 GT exploits the part similarities by utilizing similar

processes and tooling to produce them
 Machines are grouped into cells, each cell specializing in
the production of a part family
 Called cellular manufacturing
 Cellular manufacturing can be implemented by manual or
automated methods
 When automated, the term flexible manufacturing system
is often applied

7
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Part Family

• A collection of parts that possess similarities in geometric

shape and size, or in the processing steps used in their
manufacture
• Part families are a central feature of group technology
 There are always differences among parts in a family
 But the similarities are close enough that the parts can be grouped
into the same family

8
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Part Families

Two parts that are identical in shape and size but quite
different in manufacturing: (a) 1,000,000 units/yr, tolerance
= 0.010 inch, 1015 CR steel, nickel plate; (b) 100/yr,
tolerance = 0.001 inch, 18-8 stainless steel

9
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Part Families

• Ten parts are different

in size, shape, and
material, but quite
similar in terms of
manufacturing
• All parts are
machined from
cylindrical stock by
turning; some parts
require drilling and/or
milling

10
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Ways to Identify Part Families

1. Intuitive grouping (aka visual inspection)

 Using best judgment to group parts into appropriate families, based
on the parts or photos of the parts
2. Parts classification and coding
 Identifying similarities and differences among parts and relating
them by means of a coding scheme
3. Production flow analysis
 Using information contained on route sheets to classify parts

11
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Intuitive Grouping

• Least sophisticated and least expensive method

• Involves the classification of parts into families by
experienced technical staff in the plant who examine either
the physical parts or their photographs and arrange them
into groups having similar features.
• Least accurate out of three methods.

12
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Parts Classification and Coding

13
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Parts Classification and Coding

14
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Parts Classification and Coding

15
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Production Flow Analysis (PFA)

• Method for identifying part families and associated machine

groupings based on production route sheets rather than
part design data
• Workparts with identical or similar route sheets are
classified into part families
• Advantages of using route sheet data
 Parts with different geometries may nevertheless require the same
or similar processing
 Parts with nearly the same geometries may nevertheless require
different processing

16
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Steps in Production Flow
Analysis

1. Data collection – operation sequence and machine routing

for each part
2. Sortation of process routings – parts with same sequences
and routings are arranged into “packs”
3. Cluster analysis – purpose is to collect packs with similar
routings into groups
 Each machine group = a machine cell

17
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Process Layout

Assembly

4 6 7 9

5 8

2 10 12

1 3 11

A B C Raw materials

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Route Matrix

Machines
Parts 1 2 3 4 5 6 7 8 9 10 11 12
A x x x x x
B x x x x
C x x x
D x x x x x
E x x x
F x x x
G x x x x
H x x x

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Reordered route Matrix

Machines
Parts 1 2 4 8 10 3 6 9 5 7 11 12
A x x x x x
D x x x x x
F x x x
C x x x
G x x x x
B x x x x
H x x x
E x x x

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Revised Cellular Layout

Assembly

8 10 9 12

11
4 Cell 1 Cell 2 6 Cell 3
7

2 1 3 5

A C B
Raw materials

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Rank Order Clustering

• How machines in an plant should be grouped into machine

cells.
• It starts with the intial part machine incidence matrix.
• Algorithm has the following steps

22
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Rank Order Clustering

• In each row of the matrix, read the series of 1s and 0s

(blank) from left to right as a binary number. Rank the rows
in order of decreasing value.
• Number from top to bottom
• Reorder the rows in part machine incidence matrix by
listing them in the decreasing rank order.
• In each column of the matix, read the series of 1s and 0s
from top to bottom as a binary number. Rank the columns
in order of decreasing value.
• Number from left to right
• Reorder the columns in part machine incidence matrix by
listing them in the decreasing rank order, starting with left
column 23
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Problem-1

Apply the rank order clustering technique to the part machine incidence matrix in
the following table to identify logical part families and machine groups. Parts are
identified by letters and machines are identified numerically.

24
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Problem-2

Apply the rank order clustering technique to the part machine incidence matrix in
the following table to identify logical part families and machine groups. Parts are
identified by letters and machines are identified numerically.

25
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Problem-3
Jetaway, a small manufacturer of replacement parts for the aircraft industry, had always
maintained a simple layout—all like machines were located together. That way the firm could
be as flexible as possible in producing small amounts of the variety of parts its customers
required. No one questioned the production arrangement until Chris Munnelly started to work
for the company. Chris was actually hired to upgrade Jetaway’s computer system. In the process
of creating a database of part routings, Chris began to see similarities in the parts produced. A
part routing matrix for nine of the most popular parts is shown below, along with a schematic of
the factory layout.
Chris, who was already tired of being a programmer, decided to reorder the matrix
and see what he could find. If he could identify distinct part families, he could reorganize the
placement of machines into the cells he had been reading about in his business magazines.
Maybe then someone would notice his management potential. Help Chris gain status in
Jetaway by creating a cellular layout for the company. Show your results in a schematic
diagram. Be sure to include the reordered routing matrix.

26
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Problem-3

27
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-5, 31/8/24 BITS Pilani, Pilani Campus
Cellular Manufacturing

• Application of group technology in which dissimilar

machines or processes are aggregated into cells, each of
which is dedicated to the production of a part family or
limited group of families
• Typical objectives of cellular manufacturing:
 To shorten manufacturing lead times
 To reduce WIP
 To improve quality
 To simplify production scheduling
 To reduce setup times

28
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-6, 7/9/24 BITS Pilani, Pilani Campus
Composite Part Concept

• A composite part for a given family is a hypothetical part

that includes all of the design and manufacturing attributes
of the family
• In general, an individual part in the family will have some of
the features of the family, but not all of them
• A production cell for the part family would consist of those
machines required to make the composite part
• Such a cell would be able to produce any family member,
by omitting operations corresponding to features not
possessed by that part

29
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-6, 7/9/24 BITS Pilani, Pilani Campus
Composite Part Concept

Composite part concept: (a) the composite part for a family of

machined rotational parts, and (b) the individual features of
the composite part

30
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-6, 7/9/24 BITS Pilani, Pilani Campus
Part Features and Corresponding
Manufacturing Operations

Design feature Corresponding operation

1. External cylinder Turning
2. Face of cylinder Facing
3. Cylindrical step Turning
4. Smooth surface External cylindrical grinding
5. Axial hole Drilling
6. Counter bore Counterboring
7. Internal threads Tapping

31
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-6, 7/9/24 BITS Pilani, Pilani Campus
Machine Cell Designs

1. Single machine
2. Multiple machines with manual handling
 Often organized into U-shaped layout
3. Automated cell – automated processing and integrated
handling
 Flexible manufacturing cell
 Flexible manufacturing system

32
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-6, 7/9/24 BITS Pilani, Pilani Campus
Machine Cell with Manual
Handling

33
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-6, 7/9/24 BITS Pilani, Pilani Campus
Machine Cell Layouts

In-line layout using mechanized work handling between

machines

34
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-6, 7/9/24 BITS Pilani, Pilani Campus
Cell with Semi-Integrated
Handling

Loop layout allows variations in part routing between machines

35
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-6, 7/9/24 BITS Pilani, Pilani Campus
Four Types of Part Moves in
Cellular Manufacturing

36
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-6, 7/9/24 BITS Pilani, Pilani Campus
Arranging Machines in a GT cell

• After part machine groupings have been identified, the next

work is to organize the machines into logical sequence.
• Hollier method is used, which uses the data contained in
from-to charts to place the machines in an order that
maximizes the proportion of in-sequence moves within the
cell.

37
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-6, 7/9/24 BITS Pilani, Pilani Campus
Hollier Method

 Develop the from-to chart.

Data contained in the chart indicates the number of parts moves between the
machines in the cell. Moves into and out of the cell are not included in the chart.
 Determine the from-to ratio for each machine
This is done by summing all the From trips and To trips for each machine. The
From sum for a machine is determined by adding the entries in the
corresponding row and the To sum is determined by adding the entries in the
corresponding column. For each machine, the From-to ratio is calculated by
taking the From sum for each machine and dividing by the respective To sum.
 Arrange machines in order of decreasing from-to ratio.

38
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-6, 7/9/24 BITS Pilani, Pilani Campus
Example

• Suppose that four machines, 1, 2, 3, and 4 have been identified as belonging in

a GT machine cell. An analysis of 50 parts processed on these machines has
been summarized in the From-To chart presented below. Additional information
is that 50 parts enter the machine grouping at machine 3, 20 parts leave after
processing at machine 1, and 30 parts leave after machine 4. Determine a
logical machine arrangement using Hollier method.
• Compute the (a) the percentage of in-sequence moves (b) the percentage of by-
passing moves (c) the percentage of backtracking moves

39
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-6, 7/9/24 BITS Pilani, Pilani Campus
Problem-3

40
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-6, 7/9/24 BITS Pilani, Pilani Campus
Problem-4

• In problem-2, two logical machine groups are identified. For each group
determine the (a) the most logical sequence of machines for this data (b)
Construct the network diagram for the data (c) Compute the percentage of in-
sequence moves, by-passing moves and backtracking moves.

41
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-6, 7/9/24 BITS Pilani, Pilani Campus
Thanks

42
BITS Pilani, Pilani Campus
 EA ZC412 / MM ZC412 / DM ZC412
FLEXIBLE MANUFACTURING
SYSTEMS
BITS Pilani Girish Kant Garg
Department of Mechanical Engineering
Pilani Campus

1
 BITS Pilani
Pilani Campus

Manufacturing Models and Metrics (Ch-3)

Learning Objectives

 Manufacturing Models and Metrics (Ch-3)

 Mathematical Models for Production Performance
– Production Rate
– Production Capacity
– Utilization and Availability
 Manufacturing Costs
– Fixed and Variable Costs
– Direct Labor, Material and Overhead

3
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Operation Cycle Time
Cycle time:

 Time that one work unit spends being processed or assembled.

 It is the time between when one work unit begins processing

(assembly) and when the next unit begins.

Typical cycle time for a production operation:

Tc = To + Th + Tt
where
Tc = cycle time,
To = processing time for the operation,
Th = work part handling time (e.g., loading and unloading the production
machine), and
Tt = average tool handling time (e.g., time to change tools)

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Production rate (Rp)

Work units completed per hour (pc/hr)

• Batch production
• Job shop production
• Mass production

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Types of discrete production

(a) Job shop, Q = 1, (b) batch production, sequential, (c) batch production,
simultaneous, (d) quantity mass production, (e) flow line mass production

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Production Rate

Batch production:
Batch time in min,
Tb = Tsu + QTc
Tb = Batch processing time (min/batch)
Tsu = Setup time to prepare for the batch (min/batch).
Q = Batch quantity (pc/batch).
Tc = Cycle time per work unit (min/cycle).
Average production time per work unit
Tp = Tb/Q
Production rate
Rp = 1/Tp
Rp = 60/Tp
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Production Rate

Job shop production:

For job shop production, when Q = 1,
Production time per work unit
Tp = Tsu + Tc
For job shop production, when Q > 1,
Tb = Tsu + QTc
Mass production
As quantity is very high, setup time becomes insignificant.
For quantity high production:
Rp = Rc = 60/Tp since Tsu/Q  0
For flow line production
Tc = Tr + Max To and
Rc = 60/Tc

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
 Ex:1

 A batch of parts is produced on a semi-automated production

machine. Batch size is 200 units. Setup requires 55 min. A
worker loads and unloads the machine each cycle, which
takes 0.44 min. Machine processing time is 2.86 min/cycle,
and tool handling time is negligible. One part is produced
each cycle. Determine (a) average cycle time, (b) time to
complete the batch, and (c) average production rate.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Ex:2

In a batch machining operation, setup time is 1.5 hours and

batch size is 80 units. The cycle time consists of part handling
time of 30 sec and processing time of 1.37 min. One part is
produced each cycle. Tool changes must be performed every
10 parts and this takes 2.0 min. Determine (a) cycle time, (b)
time to complete the batch, and (c) average production rate.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Ex:3
A batch production operation has a machine setup time of 3.0
hours and a processing time of 1.60 min per cycle. Two parts are
produced each cycle. No tool handling time is included in the
cycle. Part handling time each cycle is 45 sec. It consists of the
worker obtaining two starting work units from a parts tray,
loading them into the machine, and then after processing,
unloading the completed units and placing them into the same
tray. Each tray holds 24 work units. When all of the starting work
units have been replaced with completed units, the tray of
completed parts is moved aside and a new tray of starting parts
is moved into position at the machine. This irregular work
element takes 3.0 min. Batch quantity is 2400 units. Determine
(a) average cycle time, (b) time to complete the batch, and (c)
average production rate.
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Ex:4
A flow line mass production operation consists of eight manual
workstations. Work units are moved synchronously and
automatically between stations, with a transfer time of 15 sec.
The manual processing operations performed at the eight
stations take 40 sec, 52 sec, 43 sec, 48 sec, 30 sec, 57 sec,
53 sec, and 49 sec, respectively. Determine (a) cycle time for
the line, (b) time to process one work unit through the eight
workstations, (c) average production rate, and (d) time to
produce 10,000 units.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Production Capacity
 Production capacity is the maximum rate of output that a production
facility is able to produce under a given set of operating conditions.

Plant capacity for facility in which parts are made in one operation
PC = n Hpc Rp
where

PC = Production capacity, pc/period.

n = Number of machines or work centers in the facility.

Hpc = number of hours in the period

Rp = Hourly production rate of each work center.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Ex:1

The automatic lathe department has five machines, all

devoted to the production of the same part. The machines
operate two 8-hr shifts, 5 days/week, 50 weeks/year. Average
production rate of each machine is 15 unit/hour. Determine
the weekly production capacity of the automatic lathe
department.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Utilization

Utilization:
It refers to the amount of output of a production facility
relative to its capacity.

where
Q = quantity actually produced,
PC = production capacity
Utilization can be defined as the proportionate of time that
the facility is operating relative to the time available under
the definition of capacity.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Ex:2

A production machine operates 80 hours/week (2 shifts, 5

days) at full capacity. Its production rate is 20 unit/hour.
During a certain week, the machine produced 1000 parts and
was idle the remaining time. (a) Determine the production
capacity of the machine (b) What was the utilization of the
machine during the week under consideration?

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Availability

Availability:
It is a common measure of reliability for equipment.
It can be defined using two reliability terms mean time
between failures (MTBF) and mean time to repair (MTTR).
MTBF: Average length of time the piece of equipment
runs between breakdowns.
MTTR: Average time required to service the equipment
and put it back into operation when a breakdown occurs.
Calculation of availability:

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Availability-MTBF and MTTR
Defined

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Ex:3

The turret lathe section has six machines, all devoted to the
production of the same part. The section operates 10
shifts/week. The number of hours per shift averages 8.0.
Average production rate of each machine is 17 unit/hour.
Determine the weekly production capacity of the turret lathe
section. If the availability of the machines (A) = 90% and the
utilization of machines U=80%. Determine the expected plant
output.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Manufacturing Costs

Two major categories of manufacturing costs:

1. Fixed costs - remain constant for any output level
2. Variable costs - vary in proportion to production output level
Adding fixed and variable costs
TC = FC + VC(Q)
where TC = total costs, FC = fixed costs (e.g.,
building, equipment, taxes), VC = variable costs
(e.g., labor, materials, utilities), Q = output level.

20
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Fixed and Variable Costs

21
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Manufacturing Costs

Alternative classification of manufacturing costs:

1. Direct labor - wages and benefits paid to workers
2. Materials - costs of raw materials
3. Overhead - all of the other expenses associated with
running the manufacturing firm
• Factory overhead
• Corporate overhead

22
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Manufacturing Costs

23
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Typical Manufacturing Costs
(J Black)

24
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Overhead Rates

Factory overhead rate:

FOHR = FOHC
DLC
Corporate overhead rate:

COHR = COHC
DLC
where DLC = direct labor costs

25
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Example1

 Suppose that all costs have been compiled for a certain

manufacturing firm for last year. The summary is shown in
table below. The company operates two different
manufacturing plants plus a corporate headquarter.
Determine (a) the factory overhead rate for each plant, and
(b) the corporate overhead rate.

26
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Example2

 A customer order of 50 parts is to be processed thorough

plant 1 the previous example. Raw materials and tooling are
supplied by the customer. The total time for processing the
parts (including setup and other direct labor) is 100hr. Direct
labor cost is $10.00/hr. The factory overhead rate is 250%
and the corporate overhead rate is 600%. (a) Compute the
cost of the job. (b) What price should be quoted to a
potential customer if the company uses a 10% markup?

27
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Thanks

28
BITS Pilani, Pilani Campus
 EA ZC412 / MM ZC412 / DM ZC412
FLEXIBLE MANUFACTURING
SYSTEMS
BITS Pilani Girish Kant Garg
Department of Mechanical Engineering
Pilani Campus

1
 BITS Pilani
Pilani Campus

Manufacturing Models and Metrics (Ch-3)

 Learning Objectives

 Manufacturing Models and Metrics (Ch-3)

 Mathematical Models for Production Performance
 Production Rate
 Production Capacity
 Utilization and Availability
 Manufacturing Costs
– Fixed and Variable Costs
– Direct Labor, Material and Overhead

3
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Operation Cycle Time
Cycle time:

 Time that one work unit spends being processed or assembled.

 It is the time between when one work unit begins processing

(assembly) and when the next unit begins.

Typical cycle time for a production operation:

Tc = To + Th + Tt
where
Tc = cycle time,
To = processing time for the operation,
Th = work part handling time (e.g., loading and unloading the production
machine), and
Tt = average tool handling time (e.g., time to change tools)

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Production rate (Rp)

Work units completed per hour (pc/hr)

• Batch production
• Job shop production
• Mass production

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Types of discrete production

(a) Job shop, Q = 1, (b) batch production, sequential, (c) batch production,
simultaneous, (d) quantity mass production, (e) flow line mass production

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Production Rate

Batch production:
Batch time in min,
Tb = Tsu + QTc
Tb = Batch processing time (min/batch)
Tsu = Setup time to prepare for the batch (min/batch).
Q = Batch quantity (pc/batch).
Tc = Cycle time per work unit (min/cycle).
Average production time per work unit
Tp = Tb/Q
Production rate
Rp = 1/Tp
Rp = 60/Tp
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Production Rate

Job shop production:

For job shop production, when Q = 1,
Production time per work unit
Tp = Tsu + Tc
For job shop production, when Q > 1,
Tb = Tsu + QTc
Mass production
As quantity is very high, setup time becomes insignificant.
For quantity high production:
Rp = Rc = 60/Tp since Tsu/Q  0
For flow line production
Tc = Tr + Max To and
Rc = 60/Tc

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
 Ex:1

 A batch of parts is produced on a semi-automated production

machine. Batch size is 200 units. Setup requires 55 min. A
worker loads and unloads the machine each cycle, which
takes 0.44 min. Machine processing time is 2.86 min/cycle,
and tool handling time is negligible. One part is produced
each cycle. Determine (a) average cycle time, (b) time to
complete the batch, and (c) average production rate.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Ex:2

In a batch machining operation, setup time is 1.5 hours and

batch size is 80 units. The cycle time consists of part handling
time of 30 sec and processing time of 1.37 min. One part is
produced each cycle. Tool changes must be performed every
10 parts and this takes 2.0 min. Determine (a) cycle time, (b)
time to complete the batch, and (c) average production rate.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Ex:3
A batch production operation has a machine setup time of 3.0
hours and a processing time of 1.60 min per cycle. Two parts are
produced each cycle. No tool handling time is included in the
cycle. Part handling time each cycle is 45 sec. It consists of the
worker obtaining two starting work units from a parts tray,
loading them into the machine, and then after processing,
unloading the completed units and placing them into the same
tray. Each tray holds 24 work units. When all of the starting work
units have been replaced with completed units, the tray of
completed parts is moved aside and a new tray of starting parts
is moved into position at the machine. This irregular work
element takes 3.0 min. Batch quantity is 2400 units. Determine
(a) average cycle time, (b) time to complete the batch, and (c)
average production rate.
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Ex:4
A flow line mass production operation consists of eight manual
workstations. Work units are moved synchronously and
automatically between stations, with a transfer time of 15 sec.
The manual processing operations performed at the eight
stations take 40 sec, 52 sec, 43 sec, 48 sec, 30 sec, 57 sec,
53 sec, and 49 sec, respectively. Determine (a) cycle time for
the line, (b) time to process one work unit through the eight
workstations, (c) average production rate, and (d) time to
produce 10,000 units.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Production Capacity
 Production capacity is the maximum rate of output that a production
facility is able to produce under a given set of operating conditions.

Plant capacity for facility in which parts are made in one operation
PC = n Hpc Rp
where

PC = Production capacity, pc/period.

n = Number of machines or work centers in the facility.

Hpc = number of hours in the period

Rp = Hourly production rate of each work center.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Ex:1

The automatic lathe department has five machines, all

devoted to the production of the same part. The machines
operate two 8-hr shifts, 5 days/week, 50 weeks/year. Average
production rate of each machine is 15 unit/hour. Determine
the weekly production capacity of the automatic lathe
department.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Utilization

Utilization:
It refers to the amount of output of a production facility
relative to its capacity.

where
Q = quantity actually produced,
PC = production capacity
Utilization can be defined as the proportionate of time that
the facility is operating relative to the time available under
the definition of capacity.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Ex:2

A production machine operates 80 hours/week (2 shifts, 5

days) at full capacity. Its production rate is 20 unit/hour.
During a certain week, the machine produced 1000 parts and
was idle the remaining time. (a) Determine the production
capacity of the machine (b) What was the utilization of the
machine during the week under consideration?

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Availability

Availability:
It is a common measure of reliability for equipment.
It can be defined using two reliability terms mean time
between failures (MTBF) and mean time to repair (MTTR).
MTBF: Average length of time the piece of equipment
runs between breakdowns.
MTTR: Average time required to service the equipment
and put it back into operation when a breakdown occurs.
Calculation of availability:

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Availability-MTBF and MTTR
Defined

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Ex:3

The turret lathe section has six machines, all devoted to the
production of the same part. The section operates 10
shifts/week. The number of hours per shift averages 8.0.
Average production rate of each machine is 17 unit/hour.
Determine the weekly production capacity of the turret lathe
section. If the availability of the machines (A) = 90% and the
utilization of machines U=80%. Determine the expected plant
output.

EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-7, 14/9/24 BITS Pilani, Pilani Campus
Manufacturing Costs

Two major categories of manufacturing costs:

1. Fixed costs - remain constant for any output level
2. Variable costs - vary in proportion to production output level
Adding fixed and variable costs
TC = FC + VC(Q)
where TC = total costs, FC = fixed costs (e.g.,
building, equipment, taxes), VC = variable costs
(e.g., labor, materials, utilities), Q = output level.

20
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-8, 15/9/24 BITS Pilani, Pilani Campus
Fixed and Variable Costs

21
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-8, 15/9/24 BITS Pilani, Pilani Campus
Manufacturing Costs

Alternative classification of manufacturing costs:

1. Direct labor - wages and benefits paid to workers
2. Materials - costs of raw materials
3. Overhead - all of the other expenses associated with
running the manufacturing firm
• Factory overhead
• Corporate overhead

22
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-8, 15/9/24 BITS Pilani, Pilani Campus
Manufacturing Costs

23
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-8, 15/9/24 BITS Pilani, Pilani Campus
Typical Manufacturing Costs
(J Black)

24
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-8, 15/9/24 BITS Pilani, Pilani Campus
Overhead Rates

Factory overhead rate:

FOHR = FOHC
DLC
Corporate overhead rate:

COHR = COHC
DLC
where DLC = direct labor costs

25
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-8, 15/9/24 BITS Pilani, Pilani Campus
Example1

 Suppose that all costs have been compiled for a certain

manufacturing firm for last year. The summary is shown in
table below. The company operates two different
manufacturing plants plus a corporate headquarter.
Determine (a) the factory overhead rate for each plant, and
(b) the corporate overhead rate.

26
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-8, 15/9/24 BITS Pilani, Pilani Campus
Example2

 A customer order of 50 parts is to be processed thorough

plant 1 the previous example. Raw materials and tooling are
supplied by the customer. The total time for processing the
parts (including setup and other direct labor) is 100hr. Direct
labor cost is $10.00/hr. The factory overhead rate is 250%
and the corporate overhead rate is 600%. (a) Compute the
cost of the job. (b) What price should be quoted to a
potential customer if the company uses a 10% markup?

27
EA ZC412 / MM ZC412/DM ZC412, FMS, Lecture-8, 15/9/24 BITS Pilani, Pilani Campus
Thanks

28
BITS Pilani, Pilani Campus