ME 101: High Mix/Low Volume Manufacturing (3 units)
CATALOG DESCRIPTION
Fundamentals of high mix/low volume (HMLV) manufacturing systems including manufacturing fundamentals, unit operations and manufacturing line considerations for work in process (WIP), manufacturing lead time (MLT), economics, quality monitoring; HMLV systems fundamentals including just in time (JIT), kanban, buffers and line balancing; class project/case studies for design of competitive manufacturing systems.
COURSE PREREQUISITES
C124 or consent of instructor.
TEXTBOOK(S) AND/OR OTHER
REQUIRED MATERIAL
Required text: R. G. Askin and J. B. Goldberg, Design and Analysis of Lean Production Systems, 2002.
Reference texts:
M. P. Groover, Automation, Production Systems, and Computer Integrated Manufacturing, 2nd Ed., Prentice-Hall, Englewood Cliffs, NJ, 2001. (or 1st edition, 1987)
R. M. Mahoney, High Mix Low Volume Manufacturing, Prentice Hall, Upper Saddle River, New Jersey, 1997.
J. O. McClain, L. J. Thomas and J. B. Mazzola, Operations Management, Prentice-Hall, Englewood Cliffs, NJ, 1992.
S. Kalpakjian, Manufacturing Engineering and Technology, Addison-Wesley, 1989.
This course is to enable students analyze
manufacturing line in order to understand
production process and improve production efficiency covering
complete manufacturing process from production planning
to quality control. This course will provide practical
knowledge and skills which can be used in real
manufacturing industry. Students are given a chance to practice
and implement what they learn during lectures by
conducting projects with manufacturing companies nearby.
DESIRED COURSE OUTCOMES
Students will understand the whole process of manufacturing from production planning to quality control, which can be helpful to setup manufacturing lines for various products. Students will be capable of identifying sources of manufacturing problems by analyzing the production line and produce multi-level solutions to solve or improve manufacturing efficiency as well.
TOPICS COVERED
Process analysis:
Basic metrics to define cycle time, production rate,
efficiency, utilization, availability, work-in-process,
manufacturing lead time, MTTR, MTBF;
production types and transfer line analysis;
flexible manufacturing systems;
line balancing, buffer analysis, material handling;
economic analysis;
Production planning and supply chain management:
Demand forecast, master production schedule,
manufacturing resource planning, bill of materials, etc.;
time fencing, just-in-time system;
supply chain management, Kanban system;
Quality control:
Quality assurance, six sigma control;
statistical process control;
inspection;
CLASS/LABORATORY SCHEDULE
Three hours of lecture per week.
CONTRIBUTION OF THE COURSE TO MEETING
THE PROFESSIONAL COMPONENT
This course contributes primarily to the
students' knowledge of manufacturing process,
identifying problem sources, problem solving techniques.
This course also encourages students in developing
entrepreneurship skills.
Various practical issues including economic analysis,
global manufacturing environment, concurrent
manufacturing issues, some exposure
to social and cultural issues of labor are
covered to insure students are well
prepared for international manufacturing competition.
RELATIONSHIP OF THE COURSE TO ABET PROGRAM OUTCOMES
An ability to apply knowledge of mathematics, science, and engineering;
an ability to design a system, component, or process to meet desired needs;
an ability to identify, formulate, and solve engineering problems;
a recognition of the need for, and an ability to engage in life-long learning;
a knowledge of contemporary issues;
an ability to use the techniques, skills, and modern engineering tools necessary
for engineering practice.
ASSESSMENT OF STUDENT PROGRESS TOWARD COURSE OBJECTIVES
-
Homework assignments on a weekly basis.
- Term examinations and pop-quizzes.
- Class participation on discussion on various subjects.
- Term project.
