MANUFACTURING PROCESS
Kartika Nur Alfina
Manufacture?
Manufacture?
Tire manufacturing – Building Process
Manufacture
• Manus : hand
• Factus : made
• Manufacturing in 1683
• Manufacturing is the production of products for use
or sale using labor and machines, tools, chemical and
biological processing, or formulation. The term may
refer to a range of human activity, from handicraft to
high tech.
Manufacturing view point in Technology
Manufacturing process are the steps through which raw
materials are transformed into a final product
Manufacturing view point in Economy
Manufacturing process are the steps through which raw
materials are transformed into a added value
Tire Manufacturing Process
History of Manufacturing Management
Push and Pull System
• Push System
Is a manufacturing system in which production is based on
production plan and where information flows from management
to the market, the same direction in which the material flow.
Push and Pull System
• Pull System
Is a manufacturing system in which production is based on actual
demand, and where information flows from market to
management in a direction opposite to that in traditional (push)
system.
Just In Time (JIT)
• Just-In-Time is a Japanese manufacturing management
method developed in 1970s
• Adopted by Toyota manufacturing plants by Taiichi Ohno. The
main concern at that time was to meet consumer demands.
• The ultimate goal of JIT is a balanced, smooth and rapid flow
of materials through the system.
Just In Time (JIT) and Kanban
Just In Time (JIT)
• Benefits of JIT • Disadvantages of JIT
– Continuous improvement – JIT system may not be able
in quality. to manage sudden
– Cost is reduced variations in demand
– Elimination of waste – Production is very reliant
– Manufacturing time is on suppliers and if stock is
down not delivered on time, the
whole production schedule
– Better productivity can be delayed
– Lower Work in progress – There is no spare finished
– Better supplier product available to meet
relationships unexpected orders,
– Cost efficient production because all products are
– Defect free output made to meet actual
orders
Lean Manufacturing
• Provide customers of products or services they like when they
want it and in the most effective and least loss in or missing
• Lean eliminate waste
Types of wastes
Seven types of losses in
the traditional
manufacturing system
and the Lean
manufacturing system:
1. Transportation
2. Inventory
3. Motion
4. Waiting time
5. Over production
6. Over processing
7. Defect
Value Stream Mapping
SIPOC Chart
Value Stream Mapping
Example of Value Stream Mapping
Total Productive Maintenance (TPM)
• Total productive maintenance (TPM) is maintenance
management which recognizes the importance of reliability,
maintenance and economic efficiency in plant design.
Goals of TPM
• Improve equipment effectiveness
• Achieve autonomous maintenance
• Plan maintenance
• Train all staff in relevant maintenance skills
• Achieve early equipment management by
‘maintenance prevention’ (MP)
Organization of the workplace (5S)
• Sort (Seiri). Eliminate what is not needed and keepwhat is
needed.
• Straighten (Seiton). Position things in such a way that they can
be easily reached whenever they are needed.
• Shine (Seiso). Keep things clean and tidy; no refuse or dirt in
the work area.
• Standardize (Seiketsu).Maintain cleanliness and order –
perpetual neatness.
• Sustain (Shitsuke). Develop a commitment and pride in
keeping to standards.
Organization of the workplace (5S)
Continuous Improvement
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