manufacturing processs 8

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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