Engineering

ECM2106 - Manufacturing Systems (2010)

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MODULE TITLEManufacturing Systems CREDIT VALUE15
MODULE CODEECM2106 MODULE CONVENERProf David Zhang (Coordinator), Dr Mark Errington
DURATION: TERM 1 2 3
DURATION: WEEKS
Number of Students Taking Module (anticipated)
DESCRIPTION - summary of the module content
AIMS - intentions of the module
To provide an understanding of modern manufacturing systems and their design and management.
INTENDED LEARNING OUTCOMES (ILOs) (see assessment section below for how ILOs will be assessed)
Note: List A comprises core outcomes that will be covered fully in lectures and must be achieved by all students to meet the minimum university requirement for progression. List B comprises outcomes that are EITHER more difficult to achieve OR are to be achieved by private study (or both). All outcomes will be assessed, and coverage of List B outcomes is essential for both BEng and MEng students. A: THRESHOLD LEVEL Understanding of manufacturing; systems concepts; materials, information and cost flows in manufacturing systems; types of systems, job, batch, mass and flow production, dominance of batch manufacture. Understanding material flows in manufacturing systems - conversion processes, handling, and storage; the roles of inventory; typical mechanical form conversion techniques. Understanding and knowledge of process planning - process routes, the role of process planning, flow patterns, criterions for best workflow, optimum routing analysis. Understanding of line balancing - the cycle time, delays, optimum number of workstations, minimum cycle time problem. Understanding of layout planning and design - problems and purpose of layout planning, layout patterns, systematic layout planning. Knowledge of production planning - linear programming for short term planning, product mix analysis, product structure and BOM, MRP 1 and 2, MPS, capacity planning. Understanding of production scheduling and control, knowledge of OPT, JIT, Kanban. Understanding the economics of batch production; the cost of WIP; set up procedures and costs; a simple Economic Batch Formula (EBQ); break situations. EBQs in single product manufacture. Batch re-ordering methods, lead times, uncertainty of demand in lead time and/or length of lead time; costs of ordering too soon or too late. Understanding of automation, flexibility in manufacturing, flexible automation, the role of computer, and CIM. Analysis of manufacturing systems: measures of performance; systems design, analysis, modelling techniques, simulation, IDEF0, SADT, SSADM. B: GOOD TO EXCELLENT Understand the evolution of manufacturing systems and driving forces behind. Knowledge of typical conversion techniques – electronics perspective. Knowledge of using dynamic programming approaches for routing analysis. Some understanding of multi-product problems. Some knowledge of mathematical layout design, cellular layout, production flow analysis. Understanding of stochastic and multi-objective planning. MRP II, integrated MRP and capacity planning. Some knowledge of operations scheduling, job shop scheduling, dispatching rules, process, inventory and quality control. Use and limitations of EBQs in manufacturing; use in Purchasing with price. Multi-product EBQ (EMBQs); optimization criteria, batch balancing, production cycle, batch size formulae; EMBQs in multiple batches and ‘part’ batches per cycle and resulting scheduling problems. Minimising annual operating costs, use of Poisson and Normal Distributions to model demand in lead time. Cost formulae for late delivery including quantity dependent and time dependent costs or combination of both. Knowledge of flexible manufacturing systems; CNCs, Robots, materials handling and AGVs, etc. Understanding different simulation principles; advanced systems concepts, agile manufacturing, supply chain, and virtual enterprises.
SYLLABUS PLAN - summary of the structure and academic content of the module
Introduction to manufacturing, systems concepts, manufacturing systems and their classifications; Process planning, line balancing and plant layout; Production planning, scheduling and control, product quantities/mix analysis, MRP 1 and 2, capacity planning, JIT, Kanban, and OPT. Batch production, the unit of production, economic batch quantities in purchasing: including price break points and manufacture, economic batch quantities in single product and multi-product manufacture. Optimisation criterion, batch balancing, batch size formulae. Batch reordering methods, lead times and stock-out penalties. Determination of optimum re-order levels. Balancing of production lines, determination of transfer and buffering requirements. Dealing with uncertainty in demand. Systems modelling, simulation and analysis techniques. Specification of logistic systems modelling. Quality management. Advanced systems concepts, automation and flexible manufacturing systems, agile manufacturing, mass customisation, supply chain management and virtual enterprises.
LEARNING AND TEACHING
LEARNING ACTIVITIES AND TEACHING METHODS (given in hours of study time)
Scheduled Learning & Teaching Activities Guided Independent Study Placement / Study Abroad
DETAILS OF LEARNING ACTIVITIES AND TEACHING METHODS
ASSESSMENT
FORMATIVE ASSESSMENT - for feedback and development purposes; does not count towards module grade
SUMMATIVE ASSESSMENT (% of credit)
Coursework 30 Written Exams 70 Practical Exams
DETAILS OF SUMMATIVE ASSESSMENT
DETAILS OF RE-ASSESSMENT (where required by referral or deferral)
RE-ASSESSMENT NOTES
RESOURCES
INDICATIVE LEARNING RESOURCES - The following list is offered as an indication of the type & level of
information that you are expected to consult. Further guidance will be provided by the Module Convener

Reading list for this module:

Type Author Title Edition Publisher Year ISBN Search
Set Silver, E.A., Pyke, D.F. and Petersen, R. Inventory Management and Production Planning and Scheduling 3rd Wiley 1998 0-471-11947-4 [Library]
Set Hitomi, K Manufacturing Systems Engineering 2nd Taylor and Francis 1996 0748403248 [Library]
Set Adam, E.E. and Ebert, R.J. Production and operations management : concepts, models and behaviour 3rd Prentice Hall 1992 0-137-24832-6 [Library]
Extended Grover, M.P. Automation Production Systems and Computer-integrated manufacturing Prentice Hall 2001 [Library]
Extended Wu Manufacturing Systems Design and Analysis Chapman and Hall 1992 0-412-40840-6 [Library]
Extended Hill, T. Production Operations Management 3rd (out of print) Prentice Hall 1983 0-137-24997-7 [Library]
Extended Bedsworth, D.D. and Bailey, J.E. Integrated Production Control Systems 2nd (out of print) Wiley 1987 0-471-82179-9 [Library]
Extended Waters, D. Operations Management Kogan Page, London 1999 0-749-42776-0 [Library]
CREDIT VALUE 15 ECTS VALUE 7.5
PRE-REQUISITE MODULES None
CO-REQUISITE MODULES None
NQF LEVEL (FHEQ) 2 AVAILABLE AS DISTANCE LEARNING No
ORIGIN DATE Thursday 15 December 2011 LAST REVISION DATE Thursday 15 December 2011
KEY WORDS SEARCH None Defined