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ICT in Product
Manufacture
ICT based Production
Scheduling and Logistics
ICT based Production
Scheduling and Logistics
• Because manufacturing systems, such
as Flexible Manufacturing Systems
(FMS) require major capital investment,
it is important to get the most from the
equipment.
• Traditional production scheduling is
quite rigid and will stop in case of
breakdown or changes in production.
• Computer-based scheduling and
logistics systems ensure that
production is 'smoothed' so that small
variations in supply and demand are
managed without causing problems.
This is achieved by careful planning
which spreads the product mix and
quantities evenly over each day in a
month.
The advantages of computer-based
production scheduling
The advantages of computer-based
production scheduling are:
• Flexible fast responses to changing
conditions.
• Optimisation of work in progress.
• Reduced inventory.
• Production is balanced between different
work stations on the production line.
• Increased productivity levels.
A computer based graphical display
in production scheduling software.
Automated stock control using
‘just in time’
Manufacturing systems such as Just
in Time (JIT) rely on
sophisticated, automated ICTbased stock control systems.
• Bar codes or other methods of
identification allow materials and
components to be monitored in
real time throughout production.
• Automatic storage and retrieval
systems (ASRS) and automated
guided vehicles (AGVs) can be
used for material and component
handling.
Advantages of ASC using JIT
• Waste is minimised.
• Inventory is optimised but available on
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demand.
Automated stock control systems
enable the move from batch to
continuous flow production.
Waiting times caused by unbalanced
production times are reduced through
the use of scheduling techniques, such
as line balancing.
People have to work night shifts with
continous production, which has
negative impacts on health: robots
need looking after, and there are still
many jobs only humans can do.
Flexible Manufacturing
Systems (FMS)
Agile manufacturing
• An agile manufacturer
is first to the market
with high quality,
value for money,
consumer focussed
products. Agile
manufacturers work in
partnerships with
customers and
suppliers, and use
FMS to achieve their
agility.
A machining cell
Flexible Manufacturing
Systems
• A flexible manufacturing system
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(FMS) is a manufacturing system that
allows the system to react to changes.
This flexibility is generally considered to
fall into two categories, which both
contain many subcategories:
1.Machine flexibility, covers the system's
ability to be changed to produce new
product types, and ability to change the
order of operations on a part.
2. Routing flexibility, which consists of
the ability to use multiple machines to
perform the same operation on a part,
as well as the system's ability to absorb
large-scale changes, such as in volume,
capacity, or capability.
Components of a FMS
• Most FMS systems are
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comprised of three main
systems:
1. The work machines which
are often automated CNC
machines are connected by
2. a material handling
system to optimize parts
flow and
3. the central control
computer which controls
material movements and
machine flow.
Increased productivity increases profits, yet
workers’ wages have not increased over the
last 25 years. Most of the increased wealth
has gone to the capitalists. There has been a
flow of wealth from poor to rich over the last
25 years. Now the hamans have been
replaced by robots. The humans as a whole
do not seem to be living much better as a
result.
Advantages of FMS:
• High flexibility in managing resources like time and effort.
• Productivity increment due to automation
• Preparation (lead time) time for new products is shorter
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due to flexibility
Saved labor cost, due to automation
Improved production quality, due to automation
It is not always necessary that increasing flexibility also
increases productivity.
A flexible manufacturing cell
• A flexible manufacturing
cell (FMC) consists of
two or more CNC
machines, a cell
computer and a robot.
The cell computer
(typically a
programmable logic
controller) is interfaced
with the
microprocessors of the
robot and the CNCs.
Quick Response Manufacturing
(QRM)
• Quick Response Manufacturing (QRM) is a
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companywide strategy to cut lead times in all
phases of manufacturing and office operations.
QRM focuses on the production of small batches
such as advertising or promotional gifts.
Real-time reprogramming of manufacturing is a
production management tool that offers highvolume, rapid turnover manufacturers savings in
time to market and increased business efficiency.
QRM advantages and a
disadvantage
• QRM aims to provide a better 'time to market'.
• Stock levels are constantly re-evaluated as
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demand patterns change.
The impact of changes to the business or a
manufacturing process will be immediately
reviewable from anywhere in the world.
QRM also presents the possibility for disastrous
levels of confusion unless the information flow is
carefully managed by an effective PDM system
using highly integrated knowledge base.
SUMMARY
• ICT based Production Scheduling and Logistics
• The advantages of computer-based production
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scheduling.
Automated stock control using ‘just in time’ –
advantages.
Flexible Manufacturing Systems (FMS).
Components of a FMS - Advantages of FMS.
Flexible manufacturing cells – advantages.
Quick Response Manufacturing (QRM) advantages and a disadvantage.