Production Engineering

Production Engineering
Production Engineering
Production engineering (PE) has the responsibility for developing a
plan to manufacture new or modified product that was generated
through the concurrent engineering (CE) process.
The PE has seven elements:
1. Process planning
2. Production machine programming
3. Tool and fixture engineering
4. Work and production standards
5. Plant engineering
6. Analysis for manufacturability and assembly
7. Manufacturing cost estimating
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Manufacturing Enterprise Model
Figure Z
Production Engineering area is different from Plant / Shop floor area.

3
1 – Process Planning
Process planning is often called
manufacturing planning, material
processing and machine routing by
different industry groups.
Process planning is the procedure

used to develop a detailed list of
manufacturing operations required
for the production of a part or
product.
Top left box gives typical product

documentation generated to support
a design.
Figure G
4
The first activity performed on each
part of an assembly is a make-
versus-buy decision made by PE.
Secondly, a routing sheet is

prepared for every part to be made
and assembled in-house.
Routing sheets describe the

sequence of operations or
manufacturing processes required to
produce the finished product.
The resources used to complete the

routing and operations sheets are
listed in the box adjacent to the
routing sheet box shown in Figure G.
Figure G
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An example routing sheet for lot size of 100 stainless steel spindles is
illustrated in Figure F.
Figure F: Routing sheet for spindle.
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Third stage in process planning is
generating operations sheet which
includes detail of each of the
operations on the routing sheet.
These operation include:
1.tooling
2.jigs and fixtures needed to hold the
part
3.sketches of setups
4.semi finish dimensions
5.machine settings
6.assembly instructions
7.handling requirements
8.inspection and testing
requirements
9.operator skill level Figure G
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Shop packet is a package of
documents used to plan and control
the movement of an order on the
shop floor
Normally includes a manufacturing

order, operation and routing sheets,
engineering documentation, move
tickets, inspection tickets, and time
tickets etc.
Figure G
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In CIM enterprises, computer
software can be used to generate
most of data in the packet.
In addition, the packet need not to

move physically from work center to
work center in paper form.
Operators can view the data files

containing packet of information on
computer terminals in the work
center.
Figure G
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2 – Production Machine
Programming
The need for machine programming developed as
automation on the plant floor evolved to computer-driven
machines and processes.
In many organization, the responsibility for the

programming of the production machines falls in the PE
area in the enterprise, commonly known as computer aided
manufacturing (CAM).
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3 – Tools and Fixture Engineering
The third responsibility of PE is the specification and design of the
tooling required in the production of the part.
In metal and nonmetal processing, the tooling (jigs and fixtures) holds
and position the raw material and parts in machines while tools shape
and finish the parts.
In CE the tooling is specified as a

part of the product design process;
as a result, the parts and production
tooling are developed in parallel.
The result is tooling and parts that fit

like "a hand in a glove."
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4 – Work and Production
Standards
Motion and time study is a business efficiency technique to increase
productivity and reduce unit cost.
Time study is developed to establish standard times while motion study

evolved into a technique for improving work methods. These two
techniques are applied to industrial as well as service organizations to
improve and upgrade the work systems.
Workflow measurement:
Operator
Equipment/Tools
Material
Information
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Standards
The objective of applying motion and time study is to obtain the optimum
use of the human and material resources to increase the productivity.
Benefits of applying work study technique includes.
1.Increases production by optimizing the processing time

2.Reduces the cost of labour, material and overheads
3.Improves quality
4.Improves the conditions which involve excessive human resource,
fatigue or danger
5.Better control of expenditures
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Standards
Both motion and time study can be carried out by different techniques
Flow Diagram Multi-activity Chart

Operations Chart Gantt Chart
Process Chart Multi-machine Chart
Flow Process Charts Left Hand / Right Hand Chart
Work Cell Load Chart Stop Watch Time Study
Work Balancing (Work Cell / Plant /

Routing Sheet
Assembly Line)
Operation Analysis Chart Activity / Work Sampling
Operator/Machine Chart Predetermined Time Standards Systems

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5 – Plant Engineering
The fifth element in the PE plan is plant engineering. In
some cases, the production requirements for a new
product require a new or modification of the manufacturing
facility.
Plant engineering addresses the design of a production

facility.
Some manufacturers that have frequent model changes,

such as those in the automotive industry, have large plant
engineering group as part of PE to make major facility
changes annually.
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6 – Analysis for Manufacturability
and Assembly
The concept of design for manufacturing and assembly
(DFMA) is also embedded in PE domain.
DFMA ensures that the finished design is optimal for both

the manufacturing processes required and the assembly
techniques needed.
DFMA is effective only if it is performed by PE as part of

the design process via CE concept.
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Component Elimination
Example: Rollbar Redesign
‘..If more than 1/3 (33%) of the components in a product are
fasteners, the assembly logic should be questioned.’
 24 Parts
 8 different parts (not similar)  2 Parts
 2 Manufacturing processes
 multiple mfg. & assembly
 one assembly step
processes necessary
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7 – Manufacturing Cost
Estimating
A crucial role for PE is the estimation of the product cost based
on design-drawing data and work and production standards
information.
Before the manufacturing cost could be determined, the

production process had to be established (routing and
operations sheet for every part to be established, the labor and
overhead for each planned operation).
Integrating manufacturing cost estimating process into the

design activity through CE concept is essential to obtain an
order winning or qualifying criterion.
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Production Engineering

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Production Engineering

The PE has seven elements:

Production Engineering area is different from Plant / Shop floor area.

Process planning is the procedure

Top left box gives typical product

Secondly, a routing sheet is

Routing sheets describe the

The resources used to complete the

Figure F: Routing sheet for spindle.

These operation include:

Normally includes a manufacturing

In addition, the packet need not to

Operators can view the data files

In many organization, the responsibility for the

In CE the tooling is specified as a

The result is tooling and parts that fit

Time study is developed to establish standard times while motion study

Benefits of applying work study technique includes.

1.Increases production by optimizing the processing time

Flow Diagram Multi-activity Chart

Work Cell Load Chart Stop Watch Time Study

Work Balancing (Work Cell / Plant /

Operation Analysis Chart Activity / Work Sampling

Operator/Machine Chart Predetermined Time Standards Systems

Plant engineering addresses the design of a production

Some manufacturers that have frequent model changes,

DFMA ensures that the finished design is optimal for both

DFMA is effective only if it is performed by PE as part of

Before the manufacturing cost could be determined, the

Integrating manufacturing cost estimating process into the

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