1 Chapter 1 - Introduction
1.1 Background of the study
The automotive manufacturing field today is undergoing many challenges, development and innovation. Manufacturing companies cannot ignore these changes because they are constantly happening and at rapid pace. Globalisation has created a competitive market for the manufacturing sector by the varying demands in product mix and volume. Many companies fail to keep up with the market because they are still operating using traditional manufacturing systems and they understand that a paradigm shift is required. This general problem of not being able to stay competitive with the changing environment has spurred much research efforts to look for, study and design a new manufacturing system. Studies and research efforts help improve the approach of companies towards manufacturing. In the 21st century, manufacturing has become very product-focused because consumers demand their products to suit their specifications, with constantly changing needs. Reconfigurable Manufacturing Systems (RMS) is the result of extensive research to come up with a new manufacturing system.
Reconfigurable manufacturing system is a new approach which tackles the problems mentioned above. RMS is designed so that it can quickly respond to changes in the market whether they may be production of new models of products or fluctuations in the product volume. An approach such as this fully utilises the high yield of dedicated manufacturing lines (DML) and the flexibility of flexible manufacturing systems (FMS). Responsiveness is also an advantage of RMS and it refers to the speed at which a company can change goals, produce new and different products. In short, the function of reconfigurable manufacturing system (RMS...
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...me frame of manufacturing automotive parts
2. To provide detailed and accurate lead times for overall operation of each component manufactured
3. To compare the performance between dynamic scheduling systems using various priority rules and the standard optimal schedule in practise
1.4 Scope of the study
1. The system is designed for the production scheduling of automotive parts
2. The operation duration of operations involving very small number of part are ignored
3. Automotive parts considered must be part of a family of products which are essentially the same parts, but involves different operations and sequence of jobs
4. Setup time, manufacturing, loading and unloading are specified as the scope of the operation during
5. Only the fabrication processes of the automotive parts are being studied while the design and assembly lead times are not taken into account
The United States recession (which lead to a world recession), began in 1997 and significantly impacted the United States automobile industry during the recession period. The United States automobile industry is still reeling from the effects of the recession throughout the period of economic recovery that continues today. According to Chu and Su, “In this credit-driven recession, one of the hardest hit sectors was the automotive industry, along with the housing and financial markets. Chrysler and General Motors were pushed into bankruptcy; and 276,000 jobs in the automobile and parts industry were destroyed, a whopping 36 percent of the total employment in the sector”.
Purchasing a car is one of the biggest and most important decisions that someone will make during their lifetime. Over the past several years, the prices of a vehicle have increased significantly due to the rise of inflation. Economists compare averages of vehicles to calculate and determine the cost of every vehicle that ends up on the car lot. To determine the cost they interpret all the above information and include everything from the cost of making the vehicle to the time of selling it. In the long run, the demand for vehicles is inelastic because they become a necessity for many people. However, in the short run, the demand is elastic because the purchase of a new vehicle can be put off for a while.
The world of technology is ever changing and advancing. With the automotive industry in play technology is constantly surpassing what is available today with what can be done for tomorrow. Technology and the automotive industry go hand in hand with constant improvement to components of cars. Due to technology advancement there is competition within the car industry, especially between American car companies and European car companies. European car companies provide their buyers with innovative variety and revolutionary luxuries. European car technology is superior to American car technology due to their safety, entertainment, and luxury features.
The Global Manufacturing Revolution: Product-Process-Business Integration and Reconfigurable Systems, Yoram Koren, John Wiley & Sons, Inc. c 11/04/2010, ISBN: 0470583770, ISBN-13: 978047058377
The automotive industry is one of the most important sectors of the economy for every country in the world. It involves a large number of corporations and institutions engaged in the manufacturing process of motor vehicles including designing, developing, manufacturing, marketing, and selling. It contributes to the global economic growth by generating a significant return and creating a ripple effect on supporting the supply chain as well as providing job opportunities for the skilled workers (ACEA, 2016).
Throughout the history of modern civilization, there have been a number of inventions, contraptions, and processes to have made profound impacts on everyday life, and redefine the world, as we know it. With effective quality management, measures American industrialist and innovator Henry Ford used the assembly line to streamline the automotive manufacturing process and transform the American Industry. With the implementation of the assembly line in his manufacturing process Ford was able to offer the American consumer an affordable automobile, while at the same time cutting costs to his company, therefore maximizing his overall productiveness and profit while ensuring his customers’ needs were met.
So it’s important to research the product and the vendor to make certain that you select the right system for your business. You’ve got to have a system that fully integrates all aspects of running your manufacturing business, offers advanced features and options but is intuitive and easy to use so employees can grasp hold quickly, and adapts to the way you do business rather than forcing you to adapt to the software.
The development of the manufacturing industry, quality and control, manufacturing capacity increase or the duration and the need to reduce cost has arisen is inevitable. Thus automation and programming concepts were started years ago. Automation is a machine's operative procedures and their sequence start form beginnig to end without human intervention, and its done automatically. Programming of the sequence of operations is prerared and tranfered to the counter. A bench during the operation of the program, and in the process, this will provide for amendments to the alignment and speed, then the counter is called flexibility.
A vehicle is one of the biggest purchases a person will ever make. Over the years, the prices of an automobile have increased due to the rise of inflation. Due to a price index, the price of an automobile changes over a certain period of time. Economists compare averages of automobiles to calculate the cost of each vehicle that presents itself on a car lot. When all of the above is calculated within the purchase of an automobile, it affects every area of making the automobile to selling the automobile. All of these factors are impacted together for the automobile industry as a whole.
The business environment is increasingly becoming competitive and challenging. In the recent past, manufacturers have found themselves facing the threat of dwindling profit margins due to unfortunate global events such as the 2007 global financial crisis and the on going Europe economic crisis. The need to improve operation efficiency so as to ensure current and future investment yield the highest rate of return has therefore become extremely important. Manufacturers are now actively engaged in, managing their costs, Research and Development, adopting best procurement strategies, among other Actions. While such actions might eventually lead to positive results, additional business value can be achieved through proper management of the supply chain (Waymer, Ivanaj & Mussa 2009; Krivda 2004).
Operations – To work out the right layout and work flow process in the company. The manpower resource allocation is also critical in the situation on the right balance of resource to handle the production. If possible, adopt a hybrid model to handle the flexibility in the product nature, make both the production line being able to configure standard and customized so to reduce setup and changeover time and cope with the demands.
(6) Pandremenos, J., J. Paralikas, K. Salonitis, and G. Chryssolouris. "Modularity Concepts for the Automotive Industry: A Critical Review." CIRP Journal of Manufacturing Science and Technology 1.3 (2009): 148-52. Print.
Toyota has implemented many different systems such as performance monitoring software, the Just in time (JIT) inventory system, electronic quality control system, communication system and information system thought out their value chain which enable to make correct decision during the manufacturing process. They have identified that having large inventories of spares cost them extensive capital and they have implemented the Just in time (JIT) inventory system which advices the suppliers the exact spares that the product line required and provides a time frame. Toyota adopted continuous learning and embraces change allowing their staff to research and innovation (Toyota
Computer integrated manufacturing is a relatively new technology arising from the application of many computer science sub disciplines to support the manufacturing enterprise. The technology of CIM emphasizes that all aspects of manufacturing should be not only computerized as much as possible but also linked together via a computer communication network into an integrated whole. In short, CIM has the potential to enable manufacturers to build cheaper, higher-quality products and thus improve their competitiveness.
In manufacturing process there are different steps and jobs needs to be done in specific ways and time such as sourcing the parts we need in the production, make the items, and shipping it for the customers.