Download - Process planning (lesson 1)
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PROCESS PLANNING
Presented by:
Prof.Dr.P.T. SRINIVASAN
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Process planning
Begins with
Product Selection
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Product Selection
• is a strategic decision i.e. long term decisions• decisions like technology to be used, capacity
of the production system, location of the facility, organization of the production function, planning, and control systems depend on this
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involves other functional areas like marketing, research and development, and the top management
Product Selection
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• The process of selecting a product is highly integrative
• Product function, cost, quality and reliability are other inputs to product selection
Product Selection
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Organizations try to get synergistic results by exploiting the following factors:
1. Familiarity with similar products / services
2. Familiarity with the same or similar production process
3. Familiarity with the same or similar market segments
4. Familiarity with the same or similar distribution channels 6
Product Selection
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Development effort improves the performance of the product, adds options and additional features
Also adds variants to the basic productDevelopment starts after research has established
an idea that has been examined, evaluated and refined
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Product Development
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PM / L 1 / S 8
includes dimensional specifications, specifications regarding capacity, horse power, speed, colour etc.
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Product Design
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There are two distinctly different priorities that can affect the design of a product or service
1. Standardization
2. Modularization
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Product Variety
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Higher the standardization, the greater will be the ease in producing
It reduces variety in the product Ensures better use of productive facilities It reduces unit costs
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Standardization
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Simplifies operational proceduresRaw materials can be purchased in bulk at
reduced priceEnables steady flow of materials through
work centresReduces the number of production set-ups
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Advantages of Standardization
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Reduces the total inventory of raw materials, work-in-process, and finished goods
Provides economies of scales due to high volume of production
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Advantages of Standardization
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Used to obtain variety and yet hold down the cost
Modules are interchangeable and each different combination gives a new variety of the product
Design simplification without compromise on quality can reduce production costs
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Modularization
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FunctionCostQualityReliabilityAppearanceEnvironmental impact
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Key Elements in Product Design
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From Product Design Stage let us now move on to Process Planning
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Processes are the essence of operations management.
They transform inputs into outputs.
More than products or technologies, the ability to do things well- processes – constitutes a firm’s competitive advantage.
Process – Meaning
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Planning in which the conditions necessary for transforming material from one state to another are determined.
It determines how a work is to be done.
It converts designs into workable instructions for manufacture, along with associated decisions on component purchase or fabrication and process and equipment selection.
Process Planning - Definition
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Projects: It is one-of-a kind production of a product to customer order.
Batch Production: Batch production systems process many different jobs through the system in groups (or batches).
Mass production(Line processes) : It produces large volumes of a standard product for a mass market.
Continuous production: They are used for very high volume commodity products.
Types of Processes
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Project Batch Mass ContinuousProduct Unique Made to order Made to stock Commodity
Customer Singly Few individuals Mass market Mass market
Demand Infrequent Fluctuates Stable Very stable
Volume Very low Low to med High Very high
Variety Infinite Many, high Low Very low
System Long-term Intermittent Flow lines Process industry
Equipment Varied General Special Highly automated
Type of work Contracts Fabrication Assembly Mix, treat, refine
Skills Experts, Wide range Limited range Equipment
craftspeople monitors
AdvantagesCustom work, Flexibility, Efficiency, Highly efficient
quality speed, low cost large capacity
Disadv. Nonrepeating Costly, slow Capital invest. Difficult to change
Example Construction Printing, bakery Autos, TV’s Paint, oil, food
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Underlying Process Relationship Between Volume and Standardization Continuum
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• Process planning is a key element in project management that focuses on selecting resources for use in the execution and completion of a project
• In a manufacturing setting, this aspect of planning also includes establishing the general sequence of steps that begin with the acquisition of materials and end with the creation of a finished product.
Process Planning
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FUNCTIONAL DESIGN
PRODUCTION DESIGN
DRAWING & SPECIFICATIONOF WHAT TO MAKE
PRODUCT ANALYSIS & ASSEMBLY CHARTS
MAKE (OR) BUY DECISION
PROCESS DECISION, SELECTION FROMALTERNATIVE PROCESSES
ROUTE / SPECIFICATION SHEET
WORK PLACE &TOOL DESIGN
MODIFICATION OF PROCESS PLANSDUE TO LAYOUT,QUALITY PERFORMANCE AND M/C AVAILABILITY
PRODUCT DESIGN
PROCESS DESIGN
MANUFACTURE PLANING
DECISION ON WHAT TO MAKE DEMAND FORECAST
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Make-or-buy decisions
Process selection
Capacity Planning
Assembly Chart
Process Planning
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A firm’s Make-or-Buy choices should be based on the following considerations:
1. Cost (fixed cost + variable cost) make = Cost (fixed cost + Variable cost) buy
2. Available capacity
3. Quality considerations
4. Speed
5. Reliability
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Make-Or-Buy Decisions
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• Determination whether to produce a component part internally or to buy it from an outside supplier. This decision involves both qualitative and quantitative factors. Qualitative considerations include product quality and the necessity for long-run business relationships with subcontractors. Quantitative factors deal with cost. The quantitative effects of the make-or-buy decision are best seen through the Relevant Cost Approach
• For example, assume a firm has prepared the following cost estimates for the manufacture of a subassembly component based on an annual production of 8000 units:
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Make-Or-Buy Decisions
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• The supplier has offered the subassembly at a price of $16 each. Two-thirds of fixed factory overhead, which represents executive salaries, rent, depreciation, and taxes, continue regardless of the decision. Should the company buy or make the product? The key to the decision lies in the investigation of those relevant costs that change between the make or buy alternatives. Assuming that the productive capacity will be idle if not used to produce the subassembly, we can make the following analysis
• he make-or-buy decision must be investigated in the broader perspective of available facilities. The alternatives are: (1) leaving facilities idle; (2) buying the parts and renting out idle facilities; or (3) buying the parts and using unused facilities for other products.
Contd….
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•Stage 1 refers to the preparations phase, which entails creating a multi-disciplinary team, selecting the part, assembly or family of parts for analysis and briefing the team.
•Stage 2 is concerned with data collection.
Make-Or-Buy Process
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Stage 3
• consists of data analysis using a spreadsheet which provides the following:
• Final scores for in-house and for the supplier. The highest score indicates the best option.
• Weighted gaps for each factor area, highlighting the strengths and weaknesses of this option.
• A sensitivity analysis which tests the robustness of the final outcome.
Stage 4
• consists of feeding back the results to the team.
Contd….
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CROSSOVER CHARTS It is a chart of costs at the possible volumes for more than one
process.
Rs
Rs.
Fixed cost Variable cost
Fixed cost – Process A
Fixed cost – Process B
Fixed cost – Process C75,000
80,000
110000
R Total process C costs
Total
proc
ess A
costsProcess A Process B Process C
V1(5000) V2 (15,000) Volume
Total process B costs
Rs
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For a company to produce a new product, the initial investment in plant & equipment is estd. to be Rs.2000. Labour & material cost is approx. Rs.5 per unit. If the rafts can be sold at Rs.10 per unit, what volume of demand would be necessary to break-even?
Fixed cost: Rs. 2000; variable cost: Rs.5 per unit; selling price: Rs.10 per unit.
Then BEP is 2000/ 10-5 = 400 rafts.
Break Even Analysis
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Now the company believes that the demand for their product will far exceed the break-even point. They are now contemplating a larger investment of Rs. 10,000 for more automated equipment that would reduce the variable cost of manufacture to Rs.2 per unit.
what is the BEP for this new process? Compare the earlier process with the process proposed
here. For what volume of demand should each process be chosen?
Soln:
a. The BEP for the new process is: 10000/ 10-2 = 1250 rafts.
b. Lets consider the earlier process as process A and this desired process as process B;
2000 + 5V = 10000 + 2V, V=2667 units
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The solution procedure for process selection consists of 4 steps:
Formulate a total cost equation for each process considered.
Calculate the point of indifference bet 2 alternatives by equating the total cost of each alternative and solve for V, which is the demand volume.
Above the point of indifference, choose the alternative with the lowest variable cost.
Below the point of indifference, choose the alternative with the lowest fixed cost.
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• Capacity planning is the process of determining the production capacity needed by an organization to meet the demands for its products.
• A discrepancy between the capacity of an organization and the demands of its customers results in unfulfilled customers.
Capacity Planning
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It is the systematic examination of all aspects of a process to improve its operation.
A basic tool for process analysis is the flowchart.
Process Analysis
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• Flow charts are easy-to-understand diagrams showing how steps in a process fit together. This makes them useful tools for communicating how processes work, and for clearly documenting how a particular job is done. Furthermore, the act of mapping a process out in flow chart format helps you clarify your understanding of the process, and helps you think about where the process can be improved.
• A flow chart can therefore be used to:
• (i)Define and analyze processes • (ii)Build a step-by-step picture of the process for analysis, • discussion, or communication and
• (iii)Define, standardize or find areas for improvement in a process
Flow Chart
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Assembly charts :gives pictorially step by step assembly sequence and what items to be assembled till finished product is produced.
Assembly Chart
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• Assembly chart gives a macro view of how materials and sub assembly are united to form a finished product. It is a starting point to understand the factory layout needs, equipments needs, training needs for any company to deliver a finished product / service
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Assembly Chart
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Parts of a Wind Mill Turbine
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A-2SA-1
1
2
3
4
Blade
Hub
Generator
Rotor
A-5Component/Assembly Operation
Inspection
Tower
A Windmill Turbine
Example of an Assembly chart
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Shows exploded view of product
Head Neck
Handle
End Cap
Assembly Drawing-Blueprint
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Assembly Chart
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• Operation Process chart represents the sequence of steps or tasks needed to complete a product and details how to build a product at each process. It includes what materials are needed, type of processes, product flow, time taken to process product through each step of flow and thus serves as a basis for examining and possibly improving the way the operation is carried out.
Operation process chart
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Process Re-engineering is a structured approach to process flow analysis used when major business changes are required as a result of:Major new productsQuality improvement neededBetter competitorsInadequate performance
In short, it is the total redesign of a process.
Process Re-engineering
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Thank You