2 810f2.810Manufacturing System ComparisonsT. GutowskiRef; John Miltenberg;gKen McKayRon Tharp’s SpreadsheetRon Tharp s Spreadsheetoutlineoutline1Framework for Mfg Systems (Miltenburg)1.Framework for Mfg Systems (Miltenburg)2. Mfg Era’s (McKay)3Eltli3.Example cost analysisOutline of Miltenburg’s Framework1.What do you want from your mfg.sys?1.What do you want from your mfg.sys?2. How will this help you beat your competition?competition?3. Set specific targets4Match goals with system characteristics4.Match goals with system characteristics-select system5Put in place infrastructure to support5.Put in place infrastructure to support systemMiltenburg’s Manufacturing SWkhStrategy WorksheetSee: Miltenburg, J. (1995), Manufacturing Strategy, Productivity Press, PortlandManufacturing OutputsManufacturing OutputsStep 1Where are you now?Internal Assessment•Mfg System•InfrastructureStep 2Where do you want to be?Benchmark•Market qualifying•Order winningStep 3How do you get there?•Changes in Mfg Sys•Changes in InfrastructureInfrastructure“Mfg Levers”Infrastructure Mfg Levers1Human Resources1.Human Resources2. Organizational Structure and Controls3Pd ti Pl i dC tl3.Production Planning and Control4. Sources5. Processing Technology6Facilities6.FacilitiesSix Eras of Manufacturing Practice, Ken McKay1Pioneering1.Pioneering2. Systemization3Thl dP3.Technology and Process4. Internal Efficiency5. Customer Service6Systems Level Re-engineering6.Systems Level ReengineeringKen McKay–12Ken McKay 1, 21. Pioneering-sellers2. Systemization - firm 1. Pioneeringsellers market, competition is not by manufacturing, ygrows and system gets complex, gross inefficiency becomes large margins emphasize th h t tyapparent, competition begins to make its presence felt. Need for throughput not efficiency pstandard operating procedures, demand still high, inventory used to g, ybuffer against instabilities.Ken McKay–34Ken McKay 3, 4• 3. Technology and 4. Internal Efficiency-gyProcess – competition is increasing, sales are softening, manufacturing ycompetition “cherry pickers” enter the market they don’t offer all of the options and parts ser ice b t foc s onggis still in early maturity and competition is limited to firms in similar and parts service but focus on the 20% which yields 80% of the revenue stream. Internal plant is put into order, situation. Product options grow. Mfg focus shifts to efficiency.pp ,problems are pushed outside to suppliers, best in class, bench marking identifies the silver bullet Still usingysilver bullet. Still using inventory to cushion production support variety, and maintain functional features.Ken McKay-56Ken McKay5, 65. Customer Service-6. System Level Re-5. Customer Servicetalk to the customer, identify yengineering - firms have addressed the internal system andcore competency, outsource, be idinternal system and factory – no more to squeeze out – look to responsive, reduce lead time, eliminate feature creepimproving indirect and overhead, supply chain development. feature creep, focused factory. pDesigning a cell for the “Rod Support”Gl t 25itGoal one part every 2.5 minutes• Material; Aluminum extrusion• Tolerance + 0.005”, except for the two 0.50” radius corners which have +1/64”Process planningProcess planningHow would you machine this part?Assumption:Assumption:1. We begin with a stock size of 2.5” X 2.25” X 12”2. This will be manufactured in a job shop for very low quantityWe will use:- A bandsaw to roughly cut the stock to size- A manual vertical mill to create the planar features and the holesA belt sande to sand the adii ( ass ming the tole ance is not-A belt sander to sand the radii ( assuming the tolerance is not very high)Process planProcess planMachine OperationHorizontal band saw Saw stock to ~4.125”Mill two ends to length 4”Mill width to 2”Manual vertical mill Mill out 2”X1.5”X4”Drill hole 1” diameterBore 1” radiusBelt senderSand 0.5 radiiBelt senderSand 0.5 radiiTime estimation (minutes)MachineOperation (V = Volume, A = Area, P = Perimeter)Fixture Tool ChangeRun (R=Rough, F=Finish)Deburr/Inspect/MeasureHorizontal band sawSaw stock to ~4.125”A = 5.6525 in2, P = 9 in0.23 - 2.02 0.30D, 0.05IMill two ends to length 4”V = 0.703 in3A = 11.25 in2, P = 19in0.200.2020.13R0.75F0.63D, 0.05I,0.13MMill width to 2”MltilMill width to 2V = 2.5 in3A = 10 in2, P = 13in0.20 -0.46R0.67F0.43D, 0.05I,0.13MMill out 2”X1.5”X4”V=12 in3--2.19R 0.50D, 0.05IManual vertical millV 12 inA = 14 in2, P = 15in0.93F 0.13M, 0.13MDrill hole 1” diameter-Center drill-Pilot drill ½”0.202220.030.050040.21D, 0.05I0 17M-Pilot drill 63/64”-Ream220.040.010.17MBore 1” radiusV = 0.79 in30.20 20.96R0 01F0.24D, 0.05I0 06MA = 1.57 in2, P = 7.28in0.01F0.06MBelt senderSand 0.5 radiiV = 0.05 in3A = 0.79 in2, P = 3.14in0.08 -0.20R0.21F0.10D, 0.05I0.06M, 0.06MSummary Times(minutes)Summary Times (minutes)fixture tool change cutting inspectSaw0.23 2.02 .35MillMill-ends 0.4 2.0 0.88 .81-width 0.2 1.13 .61-hog out 3.12 .81-hole 0.2 8.0 0.13 .43b022009735-bore0.22.00.97.35Sand0.8 0.41 .27TOTAL13112 0866363TOTAL1.3112.08.663.63Total = 25.6 minutesSummary Times(minutes)Summary Times (minutes)fixture tool change cutting inspectSaw0.23 2.02 .35MillMill-ends 0.4 2.0 0.88 .81-width 0.2 1.13 .61-hog out 3.12 .81-hole 0.2 8.0 0.13 .43b022009735-bore0.22.00.97.35Sand0.8 0.41 .27TOTAL13112 0866363TOTAL1.3112.08.663.63Total = 25.6 minutesCell FeaturesCell Features1Start with extrusion (eliminate milling)1.Start with extrusion (eliminate milling)2. Use form drill3U h l tt f 1” di3.Use hole cutter for 1” diaCellular Layout (One operator)Cellular Layout (One operator)Radial Arm Drill Press/h lCold Saww/ hole sawDrill PressBelt SanderDrill Press w/ form drillBelt SanderCellular Layout (One operator)Cellular Layout (One operator)#MachineOperation (V = volume, A=Area, P = FixtureTool ChangeRun (R= rough, F =finish)Deburr, Inspect, Measure Manual TimeMachine Timeperimeter) finish)(Time)20Radial Arm 1" Rad half hole use 01200240350470240.720.32 00.72 010 Cold SawSaw extrusion to 4", A=2, P=9 without D+I+M0.32 20Drill Press hole cutter0.1200.240.350.470.2430 Drill Press 1" dia from drill 0.12 0 0.04 0.43 0.55 0.040.2 0 0.1 0.270.2 0 0.10.10.4Sand 2*0.5" radBelt Sander40 0.8Note; Times in minutesCellular Layout (One operator)Cellular Layout (One operator)RA Drill PressRA Drill Press .47+.05/.24Wl ki Ti02Cold Saw .32+.05/.72manualWalking
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