Assignment

Module: Manufacturing Systems

Module Code: MMD4013-N

School of Science, Engineering & Design

Teesside University

Session: 2019/2020
Part A

i) Provide a review of Manufacturing Systems and the Key Performance

Indicators (KPI’s). Give your views whether the developments in
Manufacturing Systems have addressed the competitiveness issues.

[10 marks]

ii) Describe an approach which can be used to establish performance

measures at the shop floor level (Product/batch) production. Also explain
how these measures can be implemented in manufacturing companies
to achieve the corporate objectives.
[10 marks]

iii) Explain Product Flow Analysis (PFA) and Value Stream Mapping (VSM).
Demonstrate the use of PFA and VSM by giving examples of their
implementation in manufacturing companies.
[10 marks]

iv) Describe the different types of plant layouts and show their benefits by
giving examples relevant to production varieties, production volume and
economies of scale.
[5 marks]
v) Provide a critical review and comparison of the various tools and
techniques available for process improvement within the scope of lean
manufacturing systems.
[10 marks]
vi) Define the following acronyms;
CNC,CAD,BOM,CAM,CAPP,AGV,MPS,MRP,FMS,CIM,ERP

[5 marks]
 Part B
Case Study [30 marks]

Title: Performance Assessment of Manufacturing Plant.

Please refer to the data provided for this case study.

The assessment applies to any manufacturing “Plant”; a “plant” being defined as a

relatively self- contained unit with its own management staff which can be identified
either by separate facilities, by separate products or by a separate management
structure. The quick assessment of the manufacturing performance on the plant will
enable opportunities for beneficial improvements identified. The programme is
intended for employees who may not be manufacturing specialists, but who know their
own plants.
The assessment is divided into 4 sections;
1. Business and site information
2. Opportunities and benefits
3. Performance assessment
4. Performance index
You are required to work through the sections completing all the questions, if possible.
In some cases exact numerical values may not be available to answer the questions.
In these circumstances you should use best judgement to estimate the value. Every
effort should be made to complete all the assessment regarding the manufacturing
plant.
You are required to write a report which will estimate the potential value for
improvements in manufacturing and score your present performances. Also suggest
possible improvement options based on the key performance indicators (KPI’s) and
highlight the areas relevant to the topics covered in the module.
Data for the case study
Please refer to case studies (A, B & C) under learning materials.

Part C [10 marks]

Individual Presentations
Choose one topic and give presentation for 10 minutes

1. World Class Manufacturing

2. Agile Manufacturing
3. Computer Integrated Manufacturing
4. Benchmarking
5. Total Productive Maintenance
6. Total Quality Management
 7. Lean Manufacturing
8. Toyota Production System
9. Statistical Process Control
10. Value Stream Mapping
11. Supply Chain Management
12. Process Variability
13. Simulation

Part D [10 marks]

Review Questions

Answer any two questions, each question is five marks.

Question 1

Explain Little’s Law

Question 2

What are the main advantages of cell design compared to

typical mass production system?

Question 3

List seven tools of quality control used by workers to control

process and achieve zero defects.

Question 4

What are the advantages and disadvantages of levelling of

levelling production?

Question 5

What do you understand by standard work?

Question 6

Briefly explain Kaizen and continuous improvement.

Question 7

Why is flexibility important in a manufacturing system?