Production Engineering

An Introduction to
the Production
What is Production?
n Production is the
act of
manufacturing a
product
n Different Types
n Mass Production
n Intermittent
Production
n Custom
Manufacturing
http://www.ridgerunner.biz/production/production-line.jpg
What is Mass Production?
n Mass Production is
a way to make
many products
faster and cheaper
http://www.generalatomic.com/jetmakers/assemblyline.jpg
A Revolutionary Idea
n Mass Production
fueled the Industrial
Revolution
n Made many products
available cheaply
n Provided jobs for
unskilled laborers
n Change from Agrarian
to Industrial Society
http://www.umbc.edu/history/CHE/techerpages/KDavies/MILLGIRL.GIF
How Does Mass Production
Work?
n Mass Production uses
many things to create
products, following a
System Model
n Standardized Parts
n Interchangeable Parts
n Assembly Line
n Unskilled Labor
n Transportation
n Energy
http://www.nps.gov/edis/edisonia/graphics/29410116.jpg
Systems Model
INPUT PROCESS OUTPUT
FEEDBACK & IMPACTS
People
Materials
Tools & Machines
Energy
Information
Finances
Time
Design Engineering
Production Engineering
Organization & Management
Marketing
Financial Processes
Manufactured Goods
Scrap
Waste
Pollution
Environmental Impacts
Future
Standardized Parts
n The same part is
used in all of the
products being
manufactured
n Prior to Mass
Production, all
parts were custom
made by different
manufacturers
http://www.owariseiki.co.jp/jp/products/reikan/img/c_pd-rei-mini.jpg
Interchangeable Parts
n When a part wears
out or is defective,
it can be replaced
by another part
n Parts are readily
available
n Replacement parts
used to have to be
custom
manufactured
http://www.made-in-
china.com/showimages/111/186309/0/Motor_Vehicle_Installation_Assembly_Line.jpg
Assembly Line
n Allows parts to be
made in sub-
assemblies, and the
sub assemblies are
assembled to create
the final part
n Allows people to do
one thing and one
thing only
n Workers know their job
well
n Workers get bored and
sloppy
http://pnwcheese.typepad.com/photos/uncategorized/che
ese_assembly_line_2.JPG
Unskilled Labor
n Mass Production
requires very little
skill for assembly
n Reduced cost of labor
n Created jobs for those
moving into cities from
the country
n People who didnt
know how to do
things could still work
on the line and create
parts
http://www.workerseducation.org/crutch/graphics/dosch/dosch03.jpg
Transportation
n As parts could be
manufactured
more rapidly,
Transportation
became a huge
factor
n Bringing in raw
materials
n Getting workers to
work
n Shipping & Distributing
finished product
http://dotlibrary.dot.gov/Historian/images/INTERM.jpg
Energy
n Massive amounts of
energy were needed
to fuel the Mass
Production machinery
n Human power
n Steam Power
n Internal Combustion
n Electricity
! Solar/Wind/
Geothermal
http://news.nationalgeographic.com/kids/2004/07/images/pollutionbigpic.jpg
Assembly Line Management
n Assembly lines
must be organized
so that operations
are carried out
correctly
n Safety and Product
Quality must be
checked to make
sure products are
satisfactory
http://www.christophers.net/Ford_Assembly_Line.jpg
Flow Charts
n Flow Charts are
used to "map out#
how a product will
be made on the
assembly line
http://www.free-software-download.com/flowchart-software/images/process-flowchart-big.gif
Flow Chart Components-
Leaders
n Leader lines indicate
movement of process
between an Action
Box, Check Box and
Queues
n Arrow shows direction
of movement
n Leaders should not
cross
Flow Chart Components-
Start/End
n Clearly OVAL in
shape
n Indicate where a
process starts and
ends
n Start oval can also
name the process
being performed
START
END
Flow Chart Components-
Action Box
n Indicates an action
will take place
n Brief description of
action is written
inside ACTION
Flow Chart Components-
Check Box
n Indicate an action
where a decision must
be made
n At least two leaders
must leave the box,
to indicate what
happens based on the
decision made
n Often used as safety
or quality checks
CHECK
BOX
Flow Chart Components-
Queue
n Used to indicate
where a input is
taken from, or
where an output is
stockpiled
n Should clearly be
drawn as a circle
QUEUE
Sample Flow Chart
START
Brush Teeth
Get
Toothbrush
Toothbr
ushes
Rinse
Toothbrush
Is toothbrush
clean?
Add toothpaste
Toothpa
ste
Close
toothpaste
Are Teeth
Clean?
Brush Teeth
Rinse off
Toothbrush
Is Toothbrush
clean?
Put toothbrush
away
END
Brush Teeth
Yes
Yes
Yes
No
No
No