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Manufacturing Process Selection and Design
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Overall development of processing
plansDesign 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
M a n u f a c t
u r i n g
P r
o c e s s p l a n n i n g
P r o d u c t d e s i g n
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4-3
Product-Flow Characteristics
Types of Product Flow
– Line Flow
– Batch Flow
– Project Flow
Characteristics of Flows
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Line Flow
paintdrill bend
Task or work station
Product flow
cut
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Batch Flow
Cut Paint
Task or work station Product flows
Bend
Drill
BatchA
BatchB
BatchC
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Classification by Type of
Customer Order
Make to Stock (MTS)
Make to Order (MTO) Assemble to Order (ATO)
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Process Selection Decisions
Process characteristics matrix
Factors affecting process choice
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Factors Affecting Process Choice
Market conditions and competition
Capital requirements
Labor supply and cost
State 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
AssembliesAssemblies
Assemblies
Finished
Product
1 - Component manufacturingSection
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
Crusher Limestone
Hopper 1 Feeder 1
Hopper 2 Feeder 2
Hopper 3 Feeder 3
Hopper 4
Feeder
Dispatch Silo Cement Mill
Iron One
Clay
Gympsum
RawMill
Blending Silo
Firing Kiln
Hopper 5
Feeder
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Process Focused Production – ASchematic 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 Productsmanufacturer)
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Product-Process Strategy
Strategy must consider not only the
product or service, but also how to
produce it.
As many industries move through their
product life cycles, they also move through
a process life cycle. e.g. the traditional
bread bakery vs. the modern automatedbakery.
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Product Life Cycle Stages
Low volume-low standardization, one of a
kind
Multiple products, low volume
Few major products, higher volume
High volume-high standardization,
commodity product
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Process Life Cycle Stages
Jumbled flow (job shop)
Disconnected line flow (batch)
Connected line flow (assembly line)Continuous flow
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IV.
Continuous
Flow
III.
AssemblyLine
II.
Batch
I.
Job
Shop
Low
Volume,One of a
Kind
Multiple
Products,Low
Volume
Few
Major
Products,Higher
Volume
High
Volume,
HighStandard-
izationCommercial
Printer
French
Restaurant
Heavy
Equipment
Automobile
Assembly
Burger King
Sugar
Refinery
Flexibility (High)
Unit Cost (High)
Flexibility (Low)
Unit Cost (Low)
These arethe 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
Product
Focused,
Dedicated
System
D
B
B a t c h s i z e
Number of product designs
A
20
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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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Example: 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 5.14
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Example: Process Flow Chart MaterialReceived
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 unitsc. 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 aContinuous 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