Ops Mgt and Technology
Compared to 50's & 60's technology, computer technology allows production of technologically different components & assemblies more flexibly and with greater added value. Technologically unsuccessful companies and nations stand to lose heavily (consider retailing as a service industry example). A general view holds that Britain's manufacturing recovery in world terms depends on advanced engineering. Consider the following innovations:Computerised Numerical Control (CNC). Machinery, tools & equipment are computer controlled e.g. for automatic positioning & direction drills on an engine block. Contour controlled cutting operations supersede repeated manual resetting of cutting machines.
CAD - computer-aided design speeds up product design and bringing new products to market faster. CAD costs are enormous but once established, each component can be defined and its place in the whole product fully specified. Specifications can be immediately passed on to engineers as CNC instructions to set up the manufacturing tools to perform the job. Component lists and specifications for sub-contracting to suppliers are easily produced. Components modifications involve amending documentation (re-drawing of blueprints).
Robotics. Most industrial robots work from a fixed position with restricted computer controlled movements. A typical robot may be a dexterous computer-controlled arm on which many tool-attachments perform a variety of jobs from painting to welding. it may also be a complex welding frame which can adjust itself to the shape of panels being welded. The computer-controlled automated systems extend to high-speed bottling lines and continuous flow process systems.
Media Image and Reality
The industrial use & capabilities of robots has increased as tactile or visual ability and flexibility have improved. Fewer 'drity' jobs may be required but more skilled programmer-engineers (information workers) are needed.Industrial robots feature heavily in e.g. the car industry for welding, spraying. Japan has driven robotic applications into electronics - precision assembly of electronic circuit boards.
Robots aid continuous operation, improve quality & free people from repetitive, unsatisfying jobs. Cost limits wider use cost of the robot itself, software development, more highly trained staff & machine tools. Recession or cheap labour block such expense. Viewing the world market, companies like Rover and Electrolux faced the fact that survival depended on greater commitment than ever before to staff training in the new technologies. Engineers today need skills in CNC, technical analysis and database interrogation more than muscle-bound panel-beating.
Flexible Manufacturing Systems
FMS involves advanced manufacturing engineering directed towards better consumer choice & a quicker response to customer demand using less working capital. It embraces
- CNC based equipment
- automated transport systems for moving tools & workpieces and bringing the right parts & raw materials to the assembly points for a specific order at exactly the moment needed
- the whole system is computer-controlled with software for scheduling, tool/part selection, fault finding, machine breakdown detection etc.
In a car plant FMS enables many versions (of a Ford Mondeo to be built on the same line with automatic resetting of tools & specific parts arriving on time to assembly points. Instead of all the cars on the line today being Red 1.3L's (with identical parts), down the line comes a pink 1.7GLS with Pioneer CD player and go-faster stripes, a green 2.3 Ghia with a stereo radio-cassette and jacuzzi, a 1.3 Popular with an "I Luv Ford" sticker, a 1.5 Laser eFi with a built in Filofax and ejector seat.
A typical FMS will incorporate a multiple machine tool system and CNC machines that can do different machine-tool operations eg drilling several different sized holes in sequence in one item and a computerised coordination/information system linking customer orders and specifications to stores and engineering bays, supplier deliveries and staff work assignments etc. The advantages are:
- higher productivity with better utilisation of plant, stores & staff
- more product variants in smaller batches giving better customer response
- reduced set-up times, manufacturing lead times & flexibility
- less inventory at all stages of production, fewer parts, less work-in-progress & less finished stock
- improved production & quality control
Robotics involves initial setup costs i.e. investment funding. Investment payback depends on long runs unless there is a deliberate policy decision not to stress utilisation but to stress flexibility. Automation pays off well for profitable, a high volume producers. Low volumes do mean higher unit automation costs.
As competence to program robots and flexible manufacturing systems itself becomes more widespread and flexible, differentiation within the product range is possible because frequent tooling changes are possible. The ability to produce with reduced costs and more flexibility can be balanced with marketing objectives (giving consumers more and higher quality choice)
Innovation in technology offers more efficient/effective production systems but at a high cost . The investment of itself is no guarantee of success. There are affects on the workforce -
- FMS can reduce dirty, noisy, onerous jobs.
- A more highly educated a trained workforce is needed - but the national educational system and attitudes to employment in manufacturing need to be supportive.
- More interesting opportunities for organisational restructuring are offered if managements can and wish to take advantage of these.
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