28-02-2013, 02:30 PM
A CASE STUDY ON AKAKI SPARE PARTS AND HAND TOOLS SHARE COMPANY
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INTRODUCTION
Background
Manufacturing activity has become far more competitive than ever almost in all
markets. Due to the fastidiousness of customers and technological advancement,
manufacturers are forced to rapidly change and develop their manufacturing
capabilities so as to take a major share in the markets competition, This had been
made possible through transforming production system from mass production to
the production of a large product mix. Moreover this rapid advancement in
technology tends to render products obsolete far more quickly than before. As a
result of this, companies came to realize that developing advanced methodologies
for modeling, design, analysis, and performance evaluation, scheduling and
control of these systems is vital for increasing the capacity of producing many
small volume batches consisting of complex parts in a short production period.
Resort to this new approach is not as simple as it appears at the first blush, for it
brings a host of challenges which not only renders the management's task more
cumbersome, but also invites unwanted consequences such as an increase in
production cost, and a decrease in efficiency of the mass production systems.
One approach which has been proved and to be most effective in solving these
problems is the adoption of manufacturing philosophy which is known as Group
Technology (GT).
Applications of the results
Since the developed CCS will improve efficiency, ASPHT S.Co. will be
benefited from the study. Following are the advantages, which the CCS could
bring to the plant.
• Permitting effective design and drawing data retrieval: if a designer
faced with the task of developing a new part, it is possible to use this
design retrieval system to determine weather a similar part is already
available or not. Since a simple change in an existing part would be
much less time-consuming than starting from scratch, it would save
the designer’s precious time which might otherwise be unnecessary
waste.
• Providing reliable work piece statistics.
• Providing better machine tool utilization and better use of tools,
fixture and manpower, etc.
Scopes and Limitation
Due to the time constraint while conducting the study, the classification and coding
system will be made in such a way that to classify and retrieve drawings only for
rotational parts made in the machine shop. Although, more than four hundred
sample drawings are taken and analyzed, only small numbers are entered into the
data base for the demonstration purpose. Therefore, with similar procedures, it is
possible to continue for the non-rotational parts and different cast to make the
CCS system complete.
Organization of the thesis
The report is organized as follows: chapter one is an introduction part and chapter
two offers the basic of manufacturing systems. The impact of globalization in the
current manufacturing trend is also discuss in chapter three. The present
manufacturing trends of Ethiopian industries is presented in chapter four. A
literature review with special emphasis and detailed introduction of Group
Technology manufacturing system is also presented in chapter five. In chapter six,
principles, methods, procedures of classification and coding and the different
approaches on this respect are presented.
BASICS OF MANUFACTURING
INTRODUCTION
The word manufacturing, which is derived from two Latin words manu and factum,
means to make something by hand [16]. With the changing times and the
changing style of manufacturing, the term may be a misnomer as fewer and fewer
processes are labor-intensive. In the course of protracted technological
development the concept has evolved from designating the mere art of manual
operation in to representing complex science of mechanized process. In its
present meaning the word applied to a complex set of ideas. Therefore
manufacturing is a transformation process in which the inputs (raw materials,
equipment, tooling, fixture, electrical energy, and labors) are converted into
completed work-piece which carries some definite value in the marketplace. This
transformation process usually involves a number of steps, in which the materials
are brought closer to the desired final state in each step. These individual steps
are generally called production operations, and includes such processes as
planning, design, procurement, production, inventory, marketing, distribution, sales
and management [17,28].
Classification According to Volume of Production
Another way of classifying manufacturing process can be made according to the
volume and rate of production. These includes, project, jobbing, batch, line, and
continuous process production [17,22]
1. Project Production this deals with the provision of a unique product requiring
large-scale inputs to be coordinated, so as to achieve a consumer’s requirement.
The resource inputs will normally be taken to the point where the product is to be
built, since it is not feasible to move it once completed. Typical example of this
kind may include civil engineering projects, the construction of large-scale
manufacturing or military facilities and aerospace programs. The most important
tools supporting these activities are various network planning techniques including
critical path analysis and PERT.