Manufacturing strategies Flashcards
What are the manufacturing process families?
* Subtractive Manufacturing:
* Process: Removing material from a (material) block until the finished part is made.
* Materials: Mainly metals, polymers, and resins.
* Advantages: Cost-competitiveness of producing parts in medium to high volumes,
and with good control of critical tolerances.
* Disadvantages: Labour cost related to process setup and parts (re-)positioning, and
limited complexity of geometric designs.
* Forming Manufacturing:
* Process: injection moulding and stamping/pressing/forging.
* Materials: mainly polymers and metals.
* Advantages: Cost-competitiveness of producing high volumes of identical parts.
* Disadvantages: Costs of moulds and dies.
* Additive Manufacturing:
* Process: Adding material layer-by-layer to make a product.
* Materials: Polymers, metals, ceramics, and resins.
* Advantages: Speed to start manufacturing, low labour cost, customization ability,
and highly complex geometric designs.
* Disadvantages: Less competitive cost of high-volume production runs and limited
accuracy and tolerances.
Describe the manufacturing systems evolution
Craftmanship/Craft production (General purpose, machine tools)
Mass Production (Dedicated manufacturing lines)
Mass Customization (Flexible manufacturing systems, creating a “solution space”)
Individual Production (Additive manufacturing, digitalization)
DMS
AMS
FMS
RMS
Reconfigurable manufacturing system
Additive manufacturing systems (very simple description)
- Allows very high level/degree of customization.
- High complexity.
- Machine: low to low medium volume.
- Think of geometry, and volume of production.
Manufacturing Competitive strategies
- Product leadership
- Operational Excellence
- Customer Intimacy
Product leadership
(Best product)
Product differentiation
Product innovation
Ex. Companies in electronics (Apple, Samsung) Not looking for something affordable, you are looking for the best of the market, and the newest on the market.
Reconfigurable Manufacturing systems
Operational excellence
(Best performance)
Operational competence
Low cost, high quality
Additive Manufacturing systems
Costumer Intimacy
(Best service)
Customer Responsiveness
Customization
Manufacturing Operational models
Make to order
Make to stock
Assembly to order
Engineer to order
Configure to order
Make to stock (MTS)
Production and operations are scheduled according to the. Forecast od customer demand, and customer demand is from finished product stock.
Characteristics:
High standard parts ratio
Demand can be forecast with necessary accuracy, demand quantity is large
Production planning is based on forecast, planned well ahead and adjusted if necessary
Make to order (MTO)
Assumes that engineering and design process are completed, and manufacturing process is proven.
Manufacturers use this operational model when demand is unpredictable
and when customer lead-time permits the production process to start upon receiving an order.
Characteristics:
* Low standard parts ratio.
* Demand quantity is small and difficult to forecast.
* Production planning is based on order and cannot be planned.
* Delivery time is much longer, leading to greater risks.
* Customization extent is high, a key source of competition power.
* Manufacturing and other operations are triggered by customer orders
Assembly to order (ATO)
hybrid between MTO,MTS
Standard parts and subassemblies are acquired or manufactured according to forecast, while schedules for remaining components, subassemblies, and the final assembly is not executed until detailed products specifications have been derived from booked customer orders.
Characteristics:
* Medium standard parts ratio.
* Demand quantity is medium and can be forecast.
* Production planning is based on forecast and order, planned well in advance
and adjusted to order.
* Stock cost and delivery time are the reasons of causing risk.
* Customization extend is medium.
* The sources of competition power are cheap prices, relatively fast delivery and
better customization.
* Production is triggered by stock and order.
Engineering to order (ETO)
Build a house, ship, bridge, infrastructure, factory
Products are manufactured to meet specific customers’ needs requiring unique engineering design or specific customization.
Each order results in a unique set of part numbers, bill of
materials and routing.
A product is developed from scratch for each customer.
Characteristics:
* High customization.
* Long delivery time.
* No inventory level.
* High product complexity.
* The source of competition is based on differentiation and technology.
* High quantity restrictive (one of kind products are common in these systems)
Configure to order (CTO)
It was introduced by Dell Computers.
* It provides standard customization, where the customer is obtaining certain variations that can result in a differentiate product.
* The manufacturing process is completed when an order is placed.
* Components are bought and assembled into the final product after the reception of an order, in such a way that the inventory is held by the supply chain.
* The key issue is to define the right number of alternatives that will satisfy the customer demand and avoid complexity by ensuring that the product is designed with common parts and modular subassemblies.
Advantages, disadvantages: ETO
- Level of customization: High
- Cutsomer-driven design: High
- Quality restiction: High (low volume)
- Cycle time: Large
- Inventory: None
- Total cost: high
- Supply chain integration: None
Advantages, disadvantaged: MTO
- Level of customization: Tailored
- Cutsomer-driven design: None
- Quality restiction: Medium
- Cycle time: Large
- Inventory: Low
- Total cost: high
- Supply chain integration: None
Advantages, disadv. : ATO
- Level of customization: Standard
- Cutsomer-driven design: None
- Quality restiction: High (low volume)
- Cycle time: short
- Inventory: medium
- Total cost: low
- Supply chain integration: medium
Adv., disadv. : MTS
- Level of customization: None
- Cutsomer-driven design: None
- Quality restiction: High (low volume)
- Cycle time: Immediatly availability
- Inventory: High
- Total cost: low
- Supply chain integration: None
Adv., disadv. : CTO
- Level of customization: Standard
- Cutsomer-driven design: Medium
- Quality restiction: Medium
- Cycle time: Short
- Inventory: Medium
- Total cost: Medium
- Supply chain integration: High
Typical business growth model – For a manufacturing enterprise
A generic manufacturing capability maturity model:
Quality
Trust (Time/volume Measures)
Profitability (Cost Measures)
Flexibility
Sustainability
Industry 4.0
Industry 4.0 is revolutionizing the way companies manufacture, improve and distribute their products. Manufacturers are integrating new technologies, including Internet of Things (IoT), cloud computing and analytics, and AI and machine learning into their production facilities and throughout their operations.
Digitalizing the industry basically
