ch6 mfg pro.sel. & design
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TRANSCRIPT
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Manufacturing Process Selection and Design
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Overall development of processing plans
Design specifications
Functional design
Production design, setting minimum possible costs
Drawings and specifications of what to make
Product analysis, Assembly charts, Flow charts etc.
Make or Buy decisions
Process decisions, selection from alternative processes
Sales forecasts, Customer orders
Make
Route sheets and Operation sheets
Modifications of process plans due to layout, Quality preferences and machine availability
Workplace design and Tool Design
Buy
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Product-Flow CharacteristicsProduct-Flow Characteristics
Types of Product FlowTypes of Product Flow– Line FlowLine Flow– Batch FlowBatch Flow– Project FlowProject Flow
Characteristics of Flows Characteristics of Flows
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Line FlowLine Flow
paintdrill bend
Task or work station
Product flow
cut
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Batch FlowBatch Flow
Cut Paint
Task or work station Product flows
Bend
Drill
BatchA
BatchB
BatchC
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Classification by Type of Classification by Type of Customer OrderCustomer Order
Make to Stock (MTS)Make to Stock (MTS)
Make to Order (MTO)Make to Order (MTO)
Assemble to Order (ATO)Assemble to Order (ATO)
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Process Selection DecisionsProcess Selection Decisions
Process characteristics matrixProcess characteristics matrix
Factors affecting process choiceFactors affecting process choice
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Factors Affecting Process ChoiceFactors Affecting Process Choice
Market conditions and competitionMarket conditions and competition
Capital requirementsCapital requirements
Labor supply and costLabor supply and cost
State of technologyState of technology
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Schematic Layout of a Product focused Production System
1
2
3
2
3
3 4
Raw Material
Components (procured)
Procured Sub Assemblies
Components (made)
Sub Assemblies
Sub Assemblies Assemblies
Assemblies
Finished Product
1 - Component manufacturing Section
2 – Sub Assembling Section
3 – Assembling Section
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How to make a car : The production process in a
Modern Car Plant includes lots of checks on quality and Extensive Treatment to Prevent Corrosion
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Process Manufacturing System- A Layout in a Cement
Plant
CrusherLimestone
Hopper 1 Feeder 1
Hopper 2 Feeder 2
Hopper 3 Feeder 3
Hopper 4
Feeder
Dispatch Silo Cement Mill
Iron One
Clay
Gympsum
Raw Mill
Blending Silo
Firing Kiln
Hopper 5
Feeder
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Process Focused Production – A Schematic Layout
Receiving raw materials
storage
Foundry Welding and
soldering
Lathe section
Quality control
Painting and
packaging
Job A
Job B
: : :
::
: : :
:
: : :
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Types of Processes
Conversion (ex. Iron to steel)
Fabrication (ex. Cloth to clothes)
Assembly (ex. Parts to components)
Testing (ex. For quality of products)
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Process Flow Structures
Job shop (Ex. Tailoring Shop )
Batch shop (Ex. Garment Manufacturer / Pharmaceutical Products)
Assembly Line (ex. Automobile manufacturer)
Continuous Flow (ex. Petroleum Products manufacturer)
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Product-Process StrategyProduct-Process Strategy
Strategy must consider not only the Strategy must consider not only the product or service, but also how to product or service, but also how to produce it.produce it.
As many industries move through their As many industries move through their product life cycles, they also move through product life cycles, they also move through a process life cycle. e.g. the traditional a process life cycle. e.g. the traditional bread bakery vs. the modern automated bread bakery vs. the modern automated bakery.bakery.
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Product Life Cycle StagesProduct Life Cycle Stages
Low volume-low standardization, one of a Low volume-low standardization, one of a kindkind
Multiple products, low volumeMultiple products, low volumeFew major products, higher volumeFew major products, higher volumeHigh volume-high standardization, High volume-high standardization,
commodity productcommodity product
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Process Life Cycle StagesProcess Life Cycle Stages
Jumbled flow (job shop)Jumbled flow (job shop)Disconnected line flow (batch)Disconnected line flow (batch)Connected line flow (assembly line)Connected line flow (assembly line)Continuous flowContinuous flow
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IV.Continuous
Flow
III.Assembly
Line
II.Batch
I.Job
Shop
LowVolume,One of a
Kind
MultipleProducts,
LowVolume
FewMajor
Products,HigherVolume
HighVolume,
HighStandard-
izationCommercial
PrinterFrench
Restaurant
HeavyEquipment
AutomobileAssembly
Burger King
SugarRefinery
Flexibility (High)Unit Cost (High)
Flexibility (Low)Unit Cost (Low)
These are the major stages of product and process life cycles
These are the major stages of product and process life cycles
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Relationship between Product Design and Batch Size
Process focused job shopC
Product focused batch system
Cellular manufacturing
ProductFocused,Dedicated
System
D
B
Bat
ch s
ize
Number of product designs
A
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Manufacturing Process Flow Design
A process flow design can be defined as a mapping of the specific processes that raw materials, parts, and subassemblies follow as they move through a plant
The most common tools to conduct a process flow design include assembly drawings, assembly charts, and operation and route sheets
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21Example: Assembly Chart (Gozinto)
A-2SA-2
4
5
6
7
Lockring
Spacer, detent spring
Rivets (2)
Spring-detent
A-5Component/Assy Operation
Inspection
From Exhibit 5.14From Exhibit 5.14
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Example: Process Flow Chart
Material Received from Supplier
Inspect Material for Defects Defects
found?
Return to Supplier for Credit
Yes
No, Continue…
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Question Bowl
What is the break-even in demand for a new
process that costs Rs25,000 to install, will
generate a service product that customers
are willing to pay Rs500 per unit for, and
whose labor and material costs for each unit
is Rs100?
a. 400 units
b. 250 units
c. 100 units
d. 62.5 units
e. None of the above
Answer: d. 62.5 units (25,000/(500-100)=62.5)
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Question Bowl
Which of the following is an example of a
Continuous Flow type of process flow
structure?
a. Fast food
b. Grocery
c. Hospitals
d. Chemical company
e. None of the above
Answer: d. Chemical company
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Question Bowl
Which type of process is by changing of raw
materials into some specific form (such as
sheet metal into a car fender)?
a. Conversion
b. Fabrication
c. Assembly
d. Testing
e. None of the above
Answer: b. Fabrication