Production Systems Engineering: Cost and Performance Optimization

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Production Systems Engineering: Cost and Performance Optimization

Production Systems Engineering: Cost and Performance Optimization

Authors: Richard Gustavson

Published: February 2010

eISBN: 9780071701891 0071701893 | ISBN: 9780071701884

Contents

List of Tables

List of Illustrations

Preface

1 Finding a Better Method for Manufacturing System Design

1.1 The Situation

1.2 Internal Organization of Companies

1.3 Economic Justification

1.4 Manufacturing Methodologies

1.5 Solving the System Design Problem

1.6 Summary

2 Results from Initial Studies

2.1 Background

2.2 Basics of System Design

2.3 Available Time for a Resource

2.4 Allocation of Time Used

2.5 Flexibility of a Resource

2.6 Fixed Cost of a Station

2.7 Variable Cost for a Task

2.8 Quality Rating

2.9 Solution Procedure

2.10 Input Data

2.11 Results

2.12 Summary

3 Real-World Applications Lead to Enhanced Understanding

3.1 Introduction

3.2 Fundamental Principles

3.3 Using a Component/Mate Schematic

3.4 Establishing the Process Plan for an Assembly System

3.5 Specifying the Economic Constraints and Production Requirements

3.6 Determining a Group of Usable Systems

3.7 Details of the Best System

3.8 Management Overview of a System

3.9 Spectrum of Systems for a Range of Production Volumes

3.10 Summary

4 Stochastic Analyses Added to Deterministic Results

4.1 Introduction

4.2 Applicable Discrete Event Distributions

4.3 Using the Triangular Distribution

4.4 Application to a Manufacturing System

4.5 Using the Exponential Distribution

4.6 Application to Synthesis of Systems

4.7 Summary

5 Initial Look at System Configurations

5.1 Introduction

5.2 Geometric Layouts

5.3 Schematic Layout Basis

5.4 Linear System Layout

5.5 Closed Loop System—Without Spacing

5.6 Closed Loop System—With Spacing

5.7 “U” Cell System

5.8 3-D View of a System

5.9 Summary

6 Multiple Disparate Products Produced by One System

6.1 Introduction

6.2 Fundamental Principles

6.3 Establishing the Multiple-Product Task/Resource Matrix

6.4 Specifying the Production Requirements

6.5 Determining a Group of Usable Systems

6.6 Details of the Best Multiple-Product System

6.7 Management Overview of a System

6.8 Summary

7 World-Class Versus Mostly Manual Systems

7.1 Introduction

7.2 The Constant Value Situation

7.3 Nonconstant Yearly Costs

7.4 Changes in Yearly Production Volume

7.5 Changes in Yearly Costs and Production Volume

7.6 Summary

Appendices

A: Determining Allowable Investment

A.1 Introduction

A.2 Description of a New Technique

A.3 Allowable World-Class Investment

B: Economic–Technological Synthesis of Systems

B.1 Introduction

B.2 Basic Ideas

B.3 Annualized Cost (or Capital Recovery) Factor

B.4 Cost Comparison Equation

B.5 Utilization

B.6 Applicable Technology Chart

B.7 Finding the Least-Cost System

C: Establishing Task Data for Assembly Systems

C.1 Introduction

C.2 Fundamental Principles

C.3 Input Data Requirements

C.4 Exploded View of the Assembly

C.5 The Base Component

C.6 The Exploded View

C.7 An Assembly Sequence

C.8 In-Process Testing

C.9 The Best Assembly Process Plan

C.10 Summary

D: Simultaneous Improvement in Yield and Cycle-Time

D.1 Introduction

D.2 A Different Approach

D.3 Evaluating Production Improvement

D.4 Expected Production Output

D.5 Expected Costs

D.6 Summary

E: Two Case Study Summaries

E.1 Case Study Number 21—Automatic Transmission Final Assembly

E.2 Case Study Number 24—Automatic Transmission and Differential Final Assembly

E.3 Summary

F: Advanced System Design Procedure

F.1 Introduction

F.2 Basic Information

F.3 Optimizing Assembly

F.4 Design of Assembly Systems

F.5 Limitations on Program

References

Index