86503 - Automotive Manufacturing and Assembly Systems

Learning outcomes

Students know general criteria and quantitative methods for planning, design and management of manufacturing and assembly systems of modern flexible factory and supply chain.

Course contents

FLEXIBLE MANUFACTURING SYSTEMS (FMS)

Group Technology (GT) principles for the determination of part families. Algorithms: Rank Order Clustering (ROC). The flexible manufacturing systems (FMS) and the main constituent elements: operating machines, workpiece handling systems (pallets, equipment and feeding methods), tool management. Guidelines for designing an FMS: utilization rate of a resource, determination of the number of machines, determination of the number of operators.

FLEXIBLE ASSEMBLY SYSTEMS (FAS)

Design for assembly (DFA). Layout of an assembly line. Balancing of an assembly line with optimal methods (ALBP1 and ALBP2) and with heuristic methods (Largest-candidate rule, Kilbridge and Wester’s method, Ranked Positional Wights, Kottas-Lau). Assembly line feeding systems.

THE MANAGEMENT OF MATERIALS REQUIREMENTS

Materials requirements management: demand systems and stock systems. Material Requirement Planning (MRP): advantages, application limits, necessary inputs, software supports and closed loop systems. Just in Time (JiT): advantages, application limits. Kanban as JiT operative tools: information content and models for optimal number design. Stock systems: fixed order quantity models (Economic Order Quantity - EOQ-ROP). The definition of the reorganization level (ROP). Sizing the Safety Stock (SS).

Readings/Bibliography

Recommended book (in Italian):

A. PARESCHI, Impianti Industriali, Collana Progetto Leonardo, Ed. Esculapio, Bologna, 2 Edizione, Edizione n. 2 Nuova (2007-10), ristampa 2012/2013

A. Pareschi, E. Ferrari, A. Persona, A. Regattieri. (2011). Logistica Integrata e Flessibile per i sistemi produttivi dell’industria e del terziario con applicazioni numeriche e progettuali (2° edizione). Società Editrice Esculapio, Bologna. ISBN: 978-88-7488-464-3.

Other papers for individual additional study (in English):

Kaighobadi, M., & Venkatesh, K. (1994). Flexible manufacturing systems: an overview. International Journal of Operations & Production Management, 14(4), 26-49.

Yadav, A., & Jayswal, S. C. (2018). Modelling of flexible manufacturing system: a review. International journal of production research, 56(7), 2464-2487.

Sivasankaran, P., & Shahabudeen, P. (2014). Literature review of assembly line balancing problems. The International Journal of Advanced Manufacturing Technology, 73, 1665-1694.

Hackman, S. T., Magazine, M. J., & Wee, T. S. (1989). Fast, effective algorithms for simple assembly line balancing problems. Operations research, 37(6), 916-924.

Faccio, M., Gamberi, M., Persona, A., Regattieri, A., & Sgarbossa, F. (2013). Design and simulation of assembly line feeding systems in the automotive sector using supermarket, kanbans and tow trains: a general framework. Journal of Management Control, 24, 187-208.

Lecturer's notes and exercises on AMS CAMPUS

Teaching methods

The course is organized in frontal lectures in which the basic elements of the various parts of the program are presented. Many lessons devoted to the resolution of numerical applications and specific problems follow theoretical presentations of each topic. This aspect underlines the applied nature of the class aiming at allowing students to develop the ability to translate in mathematical language a concrete problem to determine a possible successful solution ready to apply in real industrial contexts.

Assessment methods

Achievements will be assessed by the means of a final exam. This is based on an analytical assessment of the "expected learning outcomes" described above.

In order to properly assess such achievement the examination is composed of a written exam divided in 2 different sections: one based on numerical applications and the other based on theoretical questions.

To obtain a passing grade, students are required to at least demonstrate a knowledge of the key concepts of the subject, ability for critical application, and a comprehensible use of technical language on industrial system design.

Teaching tools

Practical exercises with PC if necessary.

Office hours

See the website of Francesco Gabriele Galizia