3c.

Process Selection / Process design / Process analysis

Process : set of tasks that transform inputs into useful outputs Process usually consists of set of tasks flow of material & information that connect set of tasks storage of material & information

Task : accomplishes to a certain degree the transformation of input into desired output Flow: i. of material involves the transfer of a product from one task to its next task ii. of information helps in determining how each of transformation has been done in the previous task & what exactly remains to be completed in the present task. Storage : neither a task nor a transfer ( move ) , then stored . Goods in storage , waiting to be processed by the next task , are called WIP ( work-in - process) inventory .

Process selection :deals with kind of production process to have in plant Process Technologies Conversion : changing into different form e.g. iron ore to steel sheets , ingredients to tooth paste, granules to plastic parts Fabrication :changing raw material into specific form e.g. making sheet metal into car fenders Assembly : Assembling car fender , putting electronic components on PCB ( printed circuit board ) Testing : not a fundamental process , but stand alone major activity

Operation time = Set up time + Run Time

Throughput time = average time for a unit to move through the system ( first unit ) Cycle time = average time between completion of units ( repetitive )

Throughput rate

1 = --------------------------Cycle time

Efficiency

Productivity

Utilization

Actual Output = --------------------------Standard Input Output = --------------------------Input Time activated = --------------------------Time Available

Process Design : complete delineation and description of specific steps in the production process and the linkages among steps

Process Plans : workable instructions for manufacture , including information necessary equipment & tooling , component sourcing ,job descriptions & procedures for workers & computer program for automated machine Process Flow : how a factory organizes material flow during the production process

Key decisions in Process Design 1. Organizing the process flows 2. Relating process design to process flow 3. Evaluating the process

Relation of process design to Types of process flow : 1. 5 process flow types forming a continuum 2. Best choice for a process depends on the value & degree of customization required for the process 3. A process choice might apply to an entire process or just one sub-processes within it e.g. one of a service facilitys process may be best described as a job process and another process as a line process

Selection of Types of Production Systems / Production Process for a product : Three main factors determine the place of production planning products and control in an organization:
1. The type pf production, i.e. the quantities of finished products and the regularity of manufacture

2. The size of the plant

3. The type of industry i.e. the field of specialization of the plant.

Depending upon the process flows : there are 5 types of distinctive manufacturing processes , which can be grouped in 2 basic groups A. Intermittent 1.Project 2.Job-shop 3.Batch B. Continuous 4.Assembly Line or line 5.Continuous flow

Low volume , make to order process : Project or job process 1. Less vertical integration 2. More resources flexibility 3. More customer involvement 4. Less capital intensity / automation

High volume , make -to-stock : Line or continuous Process 1. More vertical integration 2. Less resources flexibility 3. Less customer involvement 4. more capital intensity / automation

1.Project Process 2.Job Process

Type of production
Intermittent Production Project Production Job Productio n Batch Productio n Continuous production Mass & flow production Process production

Project

Job

Batch

Mass

Project / one

Process
Continuous / many

Degree of repetitiveness

Intermittent

Project System Job-Shop System Batch System

Project System

Characteristics 1.definite beginning & end 2.non-uniform requirement of resources 3.involvement of different agencies 4.fixed position layout 5.high cost over runs 6.personnel problems 7.scheduling & control

Examples of Project Process 1.Selection of location for new plant in Europe 2.Installing ERP for manufacturing firm business processes 3.Construction of bridge 4.Quadrupling of railway tracks between Borivali & Virar

Job-shop system Characteristics Small production runs 1.discontinuous flow of materials 2.disproportionate manufacturing cycle time 3.general purpose machines & process layout 4.highly skilled labor 5.highly competent knowledgeable supervision 6.large WIP 7.limited functions of PPC

Examples: large turbo-generators, large engines, boiler, processing, equipments, special electronic equipment, Barber shop polyclinic

Batch system Characteristics Short runs Skilled labor in specific trades Supervisor to possess knowledge of specific process Limited span of control General purpose machines & process type layout Manufacturing cycle time affected due to queues Large WIP Flexibility of production schedules

Examples Batch Process Forging process to make fittings for pressure vessels Producing a batch of text books Bakery

Continuous Mass and Flow Systems Assembly-Line System Flow System : Process Systems Process Plants

Characteristics Of Assembly Lines 1. Continuous flow of material 2. Special purpose machines 3. Product layout 4. Mechanized materials handling 5. Low skilled labor 6. Short manufacturing cycle time 7. Easy supervision 8. Limited WIP 9. Lesser flexibility in production schedules 10.Some of assembly line products are :

Examples of Line Process Auto Assembly Bread Line Parle Biscuit Line TV , Fridge, Washing Machines

Continuous Process Flow System

Process production is characterized by manufacture of a single product and stocked in warehouse awaiting sales. Chemical plants, fertilizer manufacturing units and oil refineries use continuous-flow technologies. Raw materials are processed through different stages in a continuous flow in obtaining finished products, which are packed as required. sugar , cement ,paper , milk ,coke etc

Characteristics Of Process Plants

Special purpose machines with built in controls highly mechanized material handling virtually zero manufacturing cycle time low skilled labor supervisor to be process specialist negligible WIP limited production planning & control functions

Selection of manufacturing process

In reality , very few organizations use only one process type in true sense. Generally , at least 2 or 3 process

Manufacturers of automobile , electric appliances , copiers etc use batch production to manufacture components & some subassemblies and flow production for final assembly

Manufacturing process like a product has a life cycle . 1. Product starts with project form 2. Then small batches in growing stage 3. Then in maturity phase mass & flow

project

batch Mass & flow

continuous

Introduction ( use project form )

Growth ( use batch form )

Maturity( use mass form )

Manufacturing process flow design

Specifies & focuses on specific processes that raw materials , parts& sub-assemblies follows as they move through plant Tools to do are : 1. Assembly drawings 2. Assembly charts 3. route sheets 4. Flow process charts

Assembly Drawings : exploded view of products showing its components parts

Assembly Chart: order / sequence of assembly of parts ( Gozinto Chart)

a c d e
A 2 A 3
S A1

A 1

Gozinto Chart Assembly chart for Electrical Heater

a: Body b: Assemble Bracket to body c: Bracket d: Insulator e: Switch f: Assemble Switch to body g: Internal Wiring h: Electrical Connection i: Cord j: Install Cord k: Resistor wire l: Porcelain rod m: Copper end caps n: Heating Element Assembly o: Install Heater Assembly p: Test q: End Plates r: Assemble end plates to body s: Plastic End Caps t: Assemble End Caps to body u: Screen v: Install Screen w: Final Inspection

i k l
S A3 S A2

A 4 A 5

m n

I1 p
A 6

q
A 7 A 8

t
v

u I2 w

Service process designs

3 contrasting service designs 1. Production line approach : Mc Donalds 2. Self service approach : ATM , Buffet Lunch 3. Personal attention approach : shoe store

Characteristics of a well designed service system

1. Each element of service system is consistent with the operating focus of the firm 2. It is user friendly :ATM 3. It is robust : computer back up system 4. Consistent performance by its people and systems is easily maintained 5. Effective links between the back office & front office so that nothing falls between the cracks 6. It manages the evidence of service quality in such a way that customers see the value of service provided 7. It is cost effective

Service Process Technologies Low customer High customer contact contact Capital Postal shop services Custom-shop services intensive Cheque processing Charter travel services Medical treatment Labor Mass services Professional services intensive Teaching Barber shop Live entertainment Legal counseling cafeteria Medical diagnosis tutoring

Q1. depending upon the flow of material in manufacturing , describe various types of manufacturing processes Q2. prepare process flow chart from waking up to reaching college Q3.Prepare gozinto chart for a product