Fayoum University 1
Industrial Engineering
Mechanical Engineering Department
Manufacturing Control
Presented To:
Dr. Hamdia Mansour
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Group 3
Presented by
Mohamed Samy
Faisl Eid
Shaaban Hamdy
Abd El Razik
Angelou
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Manufacturing Control
Manufacturing control is a vital aspect of modern production,
encompassing a wide range of strategies and technologies aimed at
optimizing efficiency, quality, and cost-effectiveness.
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Introduction to Manufacturing Control
1 Strategic Framework 2 Key Objectives
Manufacturing control involves a The primary objectives of
comprehensive approach to manufacturing control are to
managing production processes, enhance productivity, reduce
ensuring adherence to waste, improve quality, and
established standards, and minimize costs.
optimizing resource utilization.
3 Integration of Systems
It involves the integration of various systems, including process monitoring,
data collection, analysis, and decision-making tools.
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The Importance of Process Monitoring and Control
1 Real-Time Insights
Process monitoring provides real-time insights into production performance,
enabling prompt identification of deviations and potential issues.
2 Issue Prevention
Early detection allows for timely intervention, minimizing production delays,
rework, and scrap, thereby improving efficiency and reducing costs.
3 Continuous Improvement
Monitoring data helps in identifying areas for improvement, optimizing
processes, and continuously enhancing overall manufacturing efficiency.
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Lean Manufacturing Principles
Value Stream Mapping Just-in-Time (JIT) Kaizen
Identifying and eliminating waste Minimizing inventory by Continuous improvement
in the production process to producing goods only when through a collaborative
create a streamlined flow of needed, reducing storage costs approach, involving all
value-adding activities. and preventing waste due to employees in identifying and
obsolescence. implementing small, incremental
changes.
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Statistical Process Control (SPC)
Data Collection and Analysis Process Capability Preventive Measures
SPC uses statistical methods to SPC helps determine the process's By analyzing data, SPC enables
monitor and control production ability to meet quality proactive measures to prevent
processes, identifying variations specifications, identifying areas for deviations from target values,
and trends in key parameters. improvement and minimizing ensuring consistent product quality
defects. and reducing variability.
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Automated Data Collection and Analysis
Sensors and Instrumentation
Sensors collect data from various production processes, providing real-
time information on parameters like temperature, pressure, and flow rates.
Data Acquisition Systems
Data acquisition systems collect, process, and store sensor data, ensuring
accurate and reliable information for analysis and decision-making.
Real-Time Analytics
Advanced analytics tools provide insights into production performance,
identifying trends, anomalies, and areas for improvement.
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Preventive and Predictive Maintenance
Preventive Maintenance Predictive Maintenance
Scheduled maintenance tasks based Using sensors and analytics to
on predetermined intervals. predict potential failures and
schedule maintenance proactively.
Reduces downtime and unexpected Minimizes production interruptions
repairs. and extends equipment lifespan.
Cost-effective approach to Optimizes maintenance scheduling and
maintaining equipment reliability. reduces overall maintenance costs.
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Inventory Management Strategies
Material Requirements Planning (MRP)
Planning and managing material requirements to ensure timely
availability of necessary components for production.
Just-in-Time (JIT) Inventory
Minimizing inventory levels by receiving materials and components
just as they are needed for production.
Inventory Optimization Tools
Using advanced software to optimize inventory levels, minimize
holding costs, and ensure timely delivery of materials.
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Quality Assurance and Continuous Improvement
1 Quality Control Measures Defect Prevention Customer Satisfaction
2 3
Implementing rigorous Identifying and eliminating Continuous improvement
inspection and testing potential sources of efforts are aimed at
procedures to ensure product defects to prevent quality enhancing product quality
quality throughout the issues and enhance and customer satisfaction,
manufacturing process. product consistency. building brand loyalty and
competitive advantage.
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Challenges and Emerging Trends in Manufacturing Control
1 Integration of Technologies
Integrating emerging technologies such as IoT, AI, and cloud computing
into manufacturing control systems for enhanced efficiency and automation.
2 Cybersecurity Concerns
Protecting manufacturing control systems from cyberattacks and ensuring
data integrity and system reliability in a connected environment.
3 Sustainability and Circular Economy
Implementing sustainable manufacturing practices and promoting circular
economy principles to reduce environmental impact and resource
consumption.
