Various Manufacturing Systems

Classification of Manufacturing Systems

• Manufacturing systems are classified based on different factors
 Various Manufacturing Systems
Classification of Manufacturing Systems (continued)
Type of operations performed
• First of all, manufacturing systems are distinguished by the types of operations they perform.
• At the highest level, the distinction is between
(1) processing operations on individual workunits, and

(2) assembly operations to combine individual parts into assembled entities.

 Various Manufacturing Systems
Classification of Manufacturing Systems (continued)
Type of operations performed (continued)
• Additional parameters of the product that play a role in determining the design of the
manufacturing system include: type of material processed, size and weight of the part or
product, and part geometry
 Various Manufacturing Systems
Classification of Manufacturing Systems (continued)
Type of operations performed (continued)
• For example, machined parts can be classified according to part geometry as rotational and
nonrotational.
• Rotational parts are cylindrical or disk shaped and require turning and related rotational
operations.

• Nonrotational (also called prismatic) parts are rectangular or cube like and require
milling and related machining operations to shape them.
 Various Manufacturing Systems
Classification of Manufacturing Systems (continued)
Type of operations performed (continued)
• Manufacturing systems that perform machining operations must be distinguished according to
whether they make rotational or nonrotational parts.
• The distinction is important not only because of differences in the machining processes and
machine tools required, but also because the material handling system must be engineered
differently for the two cases.
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Classification of Manufacturing Systems (continued)
Number of workstations and system layout
• The number of workstations is a key factor in our classification scheme.
• It exerts a strong influence on the performance of the manufacturing system in terms of
production capacity, productivity, cost per unit, etc.
• Let us denote the number of workstations in the system by the symbol n.
• As the number of stations is increased, the amount of work that can be accomplished by the
system increases.
• This translates into a higher production rate, certainly as compared with a single workstation’s
output, but also compared with the same number of single stations working independently.
• The synergistic benefit might be derived from the fact that the totality of work performed on the
part or product is too complex to engineer at a single workstation.
• There are too many individual tasks to perform at one workstation.
• By assigning separate tasks to individual stations, the task performed at each station is
simplified.
 Various Manufacturing Systems
Classification of Manufacturing Systems (continued)
Number of workstations and system layout (continued)
• More stations also mean that the system is more complex and therefore more difficult to
manage and maintain.
• The system consists of more workers, more machines, and more parts being handled.
• The logistics and coordination of the system become more involved.
• Maintenance problems occur more frequently.
• Closely related to number of workstations is the arrangement of workstations, that is, the way
the stations are laid out.
• This, of course, applies mainly to the systems with multiple stations.
• Are the stations arranged for variable routing or fixed routing?
• Workstations layouts organized for variable routing can have a variety of possible
configurations.
• Layouts organized for fixed routing are usually arranged linearly, as in production line.
• The layout of stations is an important factor in determining the most appropriate material
handling system.
• Our classification scheme is applicable to manufacturing systems that perform either
processing or assembly operations.
• Although these operations are different, the manufacturing systems to perform them possess
similar configurations.
 Various Manufacturing Systems
Classification of Manufacturing Systems (continued)
Number of workstations and system layout (continued)
• According to the number of stations and the layout of the stations, our classification scheme
has three levels:
Type I
Single station: This is the simplest case,
consisting of one workstation (n =1), usually
including a production machine that can be
manually operated, semi-automated, or fully
automated.
Type II
Multiple stations with variable routing: This
manufacturing system consists of two or more
stations (n > 1) that are designed and
arranged to accommodate the processing or
assembly of different part or product styles.
Type III
Multiple stations with fixed routing: This system
has two or more workstations (n > 1), which
are laid out as a production line.
 Various Manufacturing Systems
Classification of Manufacturing Systems (continued)
Level of automation
• The level of automation is another important factor that characterizes the manufacturing
system.
• As we have seen, the workstations (machines) in a manufacturing system can be manually
operated, semi-automated, or automated.
Manning level
• Closely related to the level of automation is the proportion of time that direct labour must be in
attendance at each station.
• The manning level of a workstation, symbolized Mi is the proportion of time that a worker is in
attendance at the station.
• If Mi = 1 for station i, it means that one worker must be at the station continuously.
• If one worker tends four automatic machines, then Mi = 0.25 for each of the four machines,
assuming each machine requires the same amount of attention.
• On portions of an automobile final assembly line, there are stations where multiple workers
perform assembly tasks on the car, in which case Mi = 2 or 3 or more.
• In general, high values of Mi (Mi >= 1) indicate manual operations at the workstation, while low
values of (Mi <1) denote some form of automation.
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Classification of Manufacturing Systems (continued)
Level of automation (continued)
• The average manning level of a multi-station manufacturing system is a useful indicator of the
direct labour content of the system.
• Let us define it as follows.

where M = average manning level for the system; wu = number of utility workers assigned to the
system; wi = number of workers assigned specifically to station i, for i = 1, 2, …, n; and w =
total number of workers assigned to the system.
• Utility workers are workers who are not specifically assigned to individual processing or
assembly stations; instead they perform functions such as (1) relieving workers at stations for
personal breaks (2) maintenance and repair of the system (3) tool changing, and (4) loading
and/or unloading work units to and from the system.
• Even a fully automated multi-station manufacturing system is likely to have one or more
workers who are responsible for keeping it running.
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Classification of Manufacturing Systems (continued)
Automation in the classification scheme
• Including automation in our classification scheme, we have two possible automation levels for
single stations and three possible levels for multi station systems.
• The two levels for single stations (type I) are M = manned station and A = fully automated.
• The manned station is identified by the fact that one or more workers must be at the station
every cycle.
• This means that any machine at the station is manually operated or semi-automatic and that
manning is equal to or greater than one (M >= 1).
• However, in some cases, one worker may be able to attend more than one machine, if the
semi-automatic cycle is long relative to the service required each cycle of the worker (thus, M
<1).
• A fully automated system requires less than full-time attention of a worker (M < 1).
• For multiple station systems (type II and III), the levels M and A are applicable, and a third level
is possible: H = hybrid, in which some stations are manned and others are fully automated.
• Listing the alternatives, we have the following:
Type I M Single station manned cell.
• The basic case is one machine and one worker (n = 1, w = 1). The machine is manually operated or
semi-automatic, and the worker must be in continuous attendance at the machine.
 Various Manufacturing Systems
Classification of Manufacturing Systems (continued)
Automation in the classification scheme (continued)
Type I A Single station automated cell
• This is a fully automated machine capable of unattended
operation (M < 1) for extended periods of time (longer than one
machine cycle).
• A worker must periodically load and unload the machine or
otherwise service it.
Type II M Multi-station manual system with variable
routing
• This has multiple stations that are manually
operated or semi-automated.
• The layout and work transport system allow for
various routes to be followed by the parts or
products made by the system.
• Work transport between stations is either manual or
mechanized.
Type II A Multi-station automated system with
variable routing
• This is the same as the previous system, except the
stations are fully automated ( n>1, wi = 0, M <1).
• Work transport is also fully automated.
 Various Manufacturing Systems
Classification of Manufacturing Systems (continued)
Automation in the classification scheme (continued)
Type II H Multi-station hybrid system with variable routing
• This manufacturing system contains both manned and
automated stations.
• Work transport is manual, automated or a mixture (hybrid).

Type III M Multi-station manual system with fixed routing

• This manufacturing system consists of two or more
stations (n > 1), with one or more workers at each
station (wi >=1).
• The operations are sequential, thus necessitating a
fixed routing, usually laid out as a production line.
• Work transport between stations is either manual or
mechanized.
Type III M Multi-station automated system with fixed routing
• This system consists of two or more automated systems
( n > 1, wi = 0, M <1) arranged as a production line or
similar configuration.
• Work transport is fully automated.
 Various Manufacturing Systems
Classification of Manufacturing Systems (continued)
Automation in the classification scheme (continued)
Type III H Multi-station hybrid system with fixed routing
• This system includes both manual and automated stations ( n > 1, wi >=1 for some
stations, wi = 0 for other stations, M >0).
• Work transport is manual, automated, or a mixture (hybrid).
 Various Manufacturing Systems
Classification of Manufacturing Systems (continued)
Part or product variety
• A fourth factor that characterizes a manufacturing system is the degree to which it is capable of
dealing with variations in the parts or products it produces.
• Example of possible variations that a manufacturing system may have to cope with include:
•Variations in type and / or colour of plastic of moulded parts in injection moulding
•Variations in electronic components placed on a standard size printed circuit board
•Variations in the size of printed circuit boards handled by a component placement machine
•Variations in geometry of machined parts
•Variations in parts and options in an assembled product on a final assembly line.
Model variations: Three cases
• Manufacturing systems can be distinguished according to their capability to deal with variety in
the work units produced.
• Three cases of part or product variation in manufacturing systems are distinguished:
(1) single model
(2) batch model, and
(3) mixed model.
• The three cases are identified by letters S, B and X, respectively.
 Various Manufacturing Systems
Classification of Manufacturing Systems (continued)
Part or product variety (continued)
Model variations: Three cases (continued)
• The typical level of product variety can also be correlated with the three categories. These
features are summarized in the table below.

• Hard product variety is when the products differ substantially.

• In an assembled product, hard variety is characterized by a low proportion of the common parts
among the products; in many cases, there are no common parts.
• For example, the difference between a car and a truck manufactured by an automotive
company is hard.
• Soft product variety is when there are only small differences between products, such as the
differences between car models made on the same production line.
• There is a high proportion of common parts among assembled products whose variety is soft.
• The variety between different product categories tends to be hard; the variety between different
models within the same product category tends to be soft.
 Various Manufacturing Systems
Classification of Manufacturing Systems (continued)
Part or product variety (continued)
Model variations: Three cases (continued)
• In the single model case, all parts or products made by the manufacturing system are
identical.
• There are no variations.
• In this case, demand for the item must be sufficient to justify dedication of the system to
production of that item for an extended period of time, perhaps several years.
• Equipment associated with the system is specialized and designed for the highest possible
efficiency.
• Fixed automation in single model systems are common.
• In the batch model case, different parts or products are made by the system but they are
made in batches because a change over in physical set-up and / or equipment programming
is required between models.
• Changeover of the manufacturing system is required because the differences in part or
product style are significant enough that the system cannot cope, unless changes in tooling
and programming are made.
• It is a case of hard product variety.
• The time needed to accomplish the changeover requires the system to be operated in a batch
mode, in which a batch of one product style is followed by a batch of another, and so on.
 Various Manufacturing Systems
Classification of Manufacturing Systems (continued)
Part or product variety (continued)
Model variations: Three cases (continued)
• Batch production is illustrated in Figure below.

• The plot shows production quantity as a function of time, with interruptions between batches for
changeover (setup).
• In the mixed model case, different parts or products are made by the manufacturing system, but
the system is able to handle these differences without the need of a changeover in setup and / or
program.
• This means that the mixture of different styles can be produced continuously rather than in batches.
• The requirement for continuous production of different work unit styles is that the manufacturing
system be designed so that whatever adjustments need to be made from one part or product style
to the next, these adjustments can be made quickly enough that it is economical to produce the
units in batch sizes of one.
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Classification of Manufacturing Systems (continued)
Part or product variety (continued)
Flexibility in manufacturing systems
• Flexibility is the term used for the attribute that allows a mixed model manufacturing system to cope
with a certain level of variation in part or product style without interruptions in production for
changeovers between models.
• Flexibility is generally a desirable feature of a manufacturing system.
• Systems that possess it are called flexible manufacturing systems, or flexible assembly systems, or
similar names.
• They can produce different part styles or can readily adapt to new part styles when the previous
ones become obsolete.
• To be flexible, a manufacturing system must possess the following capabilities:
1) Identification of the different work units:
•Different operations are required on different part or product styles.
•The manufacturing system must identify the work unit to perform the correct operation.
•In a manually operated or semi-automatic system, this task is usually an easy one for the
worker(s).
•In an automated system, some means of automatic work unit identification must be engineered.
 Various Manufacturing Systems
Classification of Manufacturing Systems (continued)
Part or product variety (continued)
Flexibility in manufacturing systems (continued)
2) Quick changeover of operating instructions:
•The instructions, or part program in the case of computer controlled production machines, must
correspond to the correct operation for the given part.
•In the case of a manually operated system, this generally means workers who (1) are skilled in
the variety of operations needed to process or assemble the different work unit styles, and (2)
know which operations to perform on each work unit style.
•In semi-automatic and fully automated systems, it means that the required part programs are
readily available to the control unit.
3) Quick changeover of physical setup:
•Flexibility in manufacturing system means that the different work units are not produced in
batches.
•For different work unit styles to be produced with no time lost between one unit and the next, the
flexible manufacturing system must be capable of making any necessary changes in fixturing and
tooling in a very short time. (The changeover should correspond approximately to the time
required to exchange the completed work unit for the next unit to be processed.)
 Various Manufacturing Systems
Classification of Manufacturing Systems (continued)
Part or product variety (continued)
Flexibility in manufacturing systems (continued)
• These capabilities are often difficult to engineer.
• In manually operated manufacturing systems, human errors can cause problems: operators not
performing the correct operations on the different work unit styles.
• In automated systems, sensor systems must be designed to enable work unit identification.
• Part program changeover is accomplished with relative ease using today’s computer technology.
• Changing the physical set-up is often the most challenging problem, and its solution becomes more
difficult as part product variety increases.
• Endowing a manufacturing system with flexibility increases its complexity.
• The material handling system and / or pallet fixtures must be designed to hold a variety of part
shapes.
• The required number of different tools increases.
• Inspection becomes more complicated because of part variety.
• The logistics of supplying the system with the correct quantities of starting workparts is more
involved.
• Scheduling and coordination of the systems become more difficult.
• Flexibility itself is a complex issue. It is recognized as a significantly important attribute for a system
to possess.
 Various Manufacturing Systems
Classification of Manufacturing Systems (continued)
Part or product variety (continued)
Reconfigurable manufacturing systems
• In an era where new product styles are being introduced with ever changing life cycles, the cost of
designing, building, and installing a new manufacturing system every time a new part or product
must be produced is becoming prohibitive, both in terms of time and money.
• One alternative is to reuse and reconfigure components of the original system in a new
manufacturing system.
• In modern manufacturing engineering practice, even single model manufacturing systems are being
built with features that enable them to be changed over to new product styles when this becomes
necessary.
• These kinds of features include:
•Ease of mobility: Machine tools and other production machines designed with a three point base
that allows them to be readily lifted and moved by a crane or forklift truck. The three point base
facilitates leveling of the machine after moving.
•Modular design of system components: This permits hardware components from different
machine builders to be connected together.
•Open architecture in computer controls: This permits data interchange between software
packages from different vendors.
•CNC workstations: Even though the production machines in the system are dedicated to one
product, they are nevertheless computer numerical controlled to allow for upgrades in software,
engineering changes in the part currently produced, and changeover of the equipment when the
production run finally ends.
 Various Manufacturing Systems
Overview of the classification scheme (continued)
• A sense of the flexibility and productivity of the various types of manufacturing systems is provided
in the P-Q chart of figure below.

• Type I systems, in particular manual systems, inherently possess the greatest flexibility in terms of
part or product variety.
• However, single stations are limited in terms of the part or product complexity they can cope with, as
indicated in Figure below.
 Various Manufacturing Systems
Overview of the classification scheme (continued)
• However, single stations are limited in terms of the part or product complexity they can cope with, as
indicated in Figure below.

• The number of components in an assembly and the number of processing steps for a part are
reasonable quantitative measures of part or product complexity.

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