Importance of Manufacturing Culture
Primary values – Cost - Quality - Cycle time – Safety
Steps in the manufacturing process & material used
Repetitive manufacture – Variation & other problems
Scope of errors
Technical change
Manufacturing – Social technology System
Significance of quality in manufacturing
Design
Conformance
Performance
1) Taguchi’s Views on Quality
Genichi Tagushi – Total cost of pour quality
2) Quality loss function
Total cost (C) or a function of the deviation of product quality (y)
from targeted quality (T)
C = f (T-y)
3) Design for manufacture & Product Life Cycle
Cost & Quality of a product are determined by the design of the
product’s systems, components & packaging.
DFM – Design For Manufacturing
The goals of DFM include…
Improvement of product quality
An increase in productivity & capital utilization
Reduction of lead time
Product flexibility to adapt to market changes
The rules of thumb that DFM practitioners have advocated are…
1 Reduce the numbers of parts 6 Design robustness
2 Foolproof to assemble designs 7 Parts must be designed to consistently
oriented
3 Design variability 8 Design for ease of assembly
4 Avoid tight tolerance 9 Utilize common parts & materials
5 Easy access 10 Design for ease of servicing the product
Loci of introduction of new technologies in Manufacturing
systems
Technological change can occur in any aspect of a production
system…
Technical innovation may occur in any part of a production
system…
Innovation in Unit Process
Technological innovation implemented in the unit processes of a
manufacturing system as…
The invention of a new nit process may be required by…
Innovation in Unit Process Control
Research & Technological innovation can improve unit process
control in two ways…
Real time control through intelligent sensing & control
Experimental design for processes one can not presently
model
Real time control requires
Sensors that can observe the important physical variables in
the unit manufacturing process
Physical models & decision algorithms that compare sensed
data with desired physical performance & prescribe
corrective action
Physical actuators that alter controllable variables in the
physical processes to control the manufacturing process
Manufacturing & the concept of economies of scale, scope &
integration
The major reasons for exercising this approach have been …
To take advantage of learning curve effects
To minimize changeover times
To maintaining a manufacturing focus
Rapid manufacturing technology implementation in
Japanese are those which increased the importance of
economics of scope in manufacturing strategy which include …
Shorter product life cycles
Greater product diversity
Fragmented markets
Widespread product alternatives
More rigorous product quality standards
Sophisticated customers
Primary values – Cost - Quality - Cycle time – Safety
Steps in the manufacturing process & material used
Repetitive manufacture – Variation & other problems
Scope of errors
Technical change
Manufacturing – Social technology System
Significance of quality in manufacturing
Design
Conformance
Performance
1) Taguchi’s Views on Quality
Genichi Tagushi – Total cost of pour quality
2) Quality loss function
Total cost (C) or a function of the deviation of product quality (y)
from targeted quality (T)
C = f (T-y)
3) Design for manufacture & Product Life Cycle
Cost & Quality of a product are determined by the design of the
product’s systems, components & packaging.
DFM – Design For Manufacturing
The goals of DFM include…
Improvement of product quality
An increase in productivity & capital utilization
Reduction of lead time
Product flexibility to adapt to market changes
The rules of thumb that DFM practitioners have advocated are…
1 Reduce the numbers of parts 6 Design robustness
2 Foolproof to assemble designs 7 Parts must be designed to consistently
oriented
3 Design variability 8 Design for ease of assembly
4 Avoid tight tolerance 9 Utilize common parts & materials
5 Easy access 10 Design for ease of servicing the product
Loci of introduction of new technologies in Manufacturing
systems
Technological change can occur in any aspect of a production
system…
Technical innovation may occur in any part of a production
system…
Innovation in Unit Process
Technological innovation implemented in the unit processes of a
manufacturing system as…
The invention of a new nit process may be required by…
Innovation in Unit Process Control
Research & Technological innovation can improve unit process
control in two ways…
Real time control through intelligent sensing & control
Experimental design for processes one can not presently
model
Real time control requires
Sensors that can observe the important physical variables in
the unit manufacturing process
Physical models & decision algorithms that compare sensed
data with desired physical performance & prescribe
corrective action
Physical actuators that alter controllable variables in the
physical processes to control the manufacturing process
Manufacturing & the concept of economies of scale, scope &
integration
The major reasons for exercising this approach have been …
To take advantage of learning curve effects
To minimize changeover times
To maintaining a manufacturing focus
Rapid manufacturing technology implementation in
Japanese are those which increased the importance of
economics of scope in manufacturing strategy which include …
Shorter product life cycles
Greater product diversity
Fragmented markets
Widespread product alternatives
More rigorous product quality standards
Sophisticated customers
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