Manufacturing Systems Engineering: A Unified Approach to Manufacturing Technology, Production Management and Industrial Economics

557 Pages·1996·17.56 MB·English

by  Katsundo Hitomi

Manufacturing Systems Engineering
A unified approach to manufacturing technology, production
management, and industrial economics

Manufacturing Systems
Engineering
A unified approach to manufacturing technology,
production management, and industrial economics
SECOND EDITION
KATSUNDO HITOMI
Ryukoku University and
Nanjing University
Taylor &Francis
J Publishers since 1798
UK Taylor & Francis Ltd, 1 Gunpowder Square, London EC4A 3DE
USA Taylor & Francis Inc., 1900 Frost Road, Suite 101, Bristol, PA 19007
First published 1975 in Japanese by Kyoritsu Shuppan Co Ltd
Translated into English by Taylor & Francis Ltd, 1979
Copyright © Katsundo Hitomi 1996
All rights reserved. No part of this publication may be reproduced, stored in a retrieval
system, or transmitted, in any form or by any means, electronic, electrostatic, magnetic
tape, mechanical, photocopying, recording or otherwise, without the prior permission of
the copyright owner.
British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library
ISBN 0-/484-0323-X (cased)
ISBN 0-7484-0324-8 (paperback)
Library of Congress Cataloguing in Publication Data are available
Cover design by Grand Union Design
Contents
Foreword page xii
Preface xiii
About the author xix
par t o n e Essentials of Manufacturing Systems 1
1 Fundamentals of Manufacturing 3
1.1 Definitions of production and manufacturing 3
1.2 Principles of manufacturing 5
1.3 Resources of production—inputs for production 8
1.4 Goods produced—outputs of production 11
1.5 Production processes—transformation of inputs into outputs 14
1.6 Production organisation 22
Notes 22
References 23
Supplementary reading 23
2 Fundamentals of Systems 24
2.1 Basic concepts of systems and chaos 24
2.2 Definition of systems 25
2.3 Basic problems concerning systems 29
2.4 Systems design 30
2.5 Decision-making procedures 38
Notes 45
References 45
Supplementary reading 46
3 Fundamentals of Manufacturing Systems 47
3.1 Meaning of the term‘manufacturing systems’ 47
3.2 Structural aspect of manufacturing systems 48
3.3 Transformational aspect of manufacturing systems 48
v
VI CONTENTS
3.4 Procedural aspect of manufacturing systems 50
3.5 Integrated manufacturing systems (IMS) 55
3.6 Manufacturing systems engineering—an academic discipline 56
Notes 58
References 58
Supplementary reading 59
4 Modes of Production 61
4.1 Types of production 61
4.2 Mass production 62
4.3 Multi-product, small-batch production 65
4.4 Product diversification 72
Notes 73
References 73
Supplementary reading 73
5 Integrated Manufacturing and Management Systems 74
5.1 Basic functions and structures of management systems 74
5.2 Basic framework of integrated manufacturing management systems 76
5.3 Framework of an integrated manufacturing system 79
References 82
Supplementary reading 82
par t tw o Process Systems for Manufacturing 83
6 Material and Technological Information Flows in Manufacturing
Systems 85
6.1 Logistic systems 85
6.2 Material flow 85
6.3 Technological information flow 88
References 88
Supplementary reading 89
7 Product Planning and Design 90
7.1 Product planning 90
7.2 Product design 93
7.3 Product structure and explosion 103
Notes 106
References 106
Supplementary reading 106
8 Process Planning and Design 107
8.1 Scope and problems of process planning 107
8.2 Process design 107
8.3 Operation design 114
8.4 Optimum routing analysis 125
8.5 Line balancing 130
References 134
Supplementary reading 134
CONTENTS vii
9 Layout Planning and Design 135
9.1 Scope and problems of layout planning 135
9.2 Systematic layout planning (SLP) 138
9.3 Mathematical layout design 143
9.4 Production flow analysis 145
References 146
Supplementary reading 146
10 Logistic Planning and Design 147
10.1 Transportation problems 147
10.2 Distribution problems 152
Notes 153
References 153
Supplementary reading 153
11 Manufacturing Optimisation 154
11.1 Evaluation criteria for manufacturing optimisation 154
11.2 Optimisation of single-stage manufacturing 156
11.3 Optimisation of multistage manufacturing systems 174
Notes 183
References 183
Supplementary reading 184
par t three Management Systems for Manufacturing 185
12 Managerial Information Flow in Manufacturing Systems 187
12.1 Managerial information flow 187
12.2 Decision problems in managerial information flow 188
References 189
13 Aggregate Production Planning 190
13.1 Production planning defined 190
13.2 Short-term production planning 190
13.3 Multiple-objective production planning 205
13.4 Product mix analysis 209
13.5 Lot-size analysis 213
13.6 Material requirements planning (MRP) and machine loading 217
13.7 Long-term production planning 225
13.8 Production forecasting 228
Notes 233
References 233
Supplementary reading 234
14 Production Scheduling 235
14.1 Scope of production scheduling 235
14.2 Operations scheduling 237
14.3 Project scheduling—PERT and CPM 258
Notes 268
References 268
Supplementary reading 269
viii CONTENTS
15 Inventory Management 270
15.1 Inventory function in manufacturing 270
15.2 Fundamentals of inventory analysis 271
15.3 Inventory systems 271
15.4 Multiple-product inventory management 277
15.5 Probabilistic inventory models 279
References 281
Supplementary reading 281
16 Production Control 282
16.1 Scope and problems of production control 282
16.2 Process control 283
16.3 Just-in-time (JIT) production 285
16.4 Productive maintenance 288
16.5 Replacement 294
References 301
Supplementary reading 301
17 Quality Engineering 302
17.1 Quality control (QC) 302
17.2 Quality function deployment (QFD) 307
17.3 Quality engineering 309
Notes 311
References 311
Supplementary reading 311
PART four Value Systems for Manufacturing 313
18 Value and Cost Flows in Manufacturing Systems 315
18.1 Value/cost flow in manufacturing systems 315
18.2 Concepts of cost and time-series value of money 317
References 318
19 Manufacturing Cost and Product Cost Structure 319
19.1 Classification of costs 319
19.2 Product cost structure 319
19.3 Selling price 320
19.4 Computing the manufacturing cost 322
References 324
Supplementary reading 324
20 Profit Planning and Break-even Analysis 325
20.1 Profit planning 325
20.2 Break-even analysis 328
Notes 333
References 333
Supplementary reading 333
21 Capital Investment for Manufacturing 334
21.1 Investment for manufacturing automation 334
CONTENTS ix
21.2 Evaluation methods of capital investment 334
Notes 338
References 338
Supplementary reading 338
part five Automation Systems for Manufacturing 339
22 Industrial Automation 341
22.1 Towards automation 341
22.2 Meanings of automation 342
22.3 Kinds of automation 343
22.4 Development of automatic manufacturing 344
Notes 352
References 352
Supplementary reading 352
23 Principles of Computer-integrated Manufacturing (CIM) 353
23.1 Essentials of computer-integrated manufacturing systems 353
23.2 Definition of CIM 354
23.3 Effectiveness of CIM 355
Notes 357
References 357
Supplementary reading 357
24 Computer-aided Design (CAD) 358
24.1 Brief history of computer-aided design (CAD) 358
24.2 Computer-aided design/drawing (CADD) 359
24.3 Computer-automated process planning (CAPP) , 364
24.4 Automatic operation planning—autoprogramming system 370
24.5 Computerised layout planning 373
References 379
Supplementary reading 379
25 Factory Automation (FA), Computer-aided Manufacturing (CAM) and
Computer-integrated Manufacturing (CIM) Systems 381
25.1 Automatic machine tools for mass production 381
25.2 Numerically controlled (NC) machine tools 384
25.3 Computer-controlled manufacturing systems 389
25.4 Flexible manufacturing system (FMS) 390
25.5 Automated assembly 395
25.6 Automatic materials handling 399
25.7 Automatic inspection and testing 404
25.8 Computer-integrated automation system—unmanned factory 406
References 408
Supplementary reading 408
par t six Information Systems for Manufacturing 409
26 Fundamentals of Information Technology 411
26.1 Concept of information 411