MANAGEMENT OF MACHINES AND MATERIALS (MS-5) UNIT 3 PROCESS SELECTION

Roshan Gnyawali

Contents
Introduction Strategy Process Types
Project Intermittent Flow Continuous Flow Processing
Technology in Process Selection CAD/CAM Flexible Manufacturing System Robot and Robotics Group Technology Computer Integrated Manufacturing (CIM)

Process Selection
Break-even Analysis
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Introduction
Process selection
Deciding on the way production of goods or services will be organized Strategic Decision

Major implications
Capacity planning Process Selection has major and Impact on Cost, Productivity Layout of facilities Competitiveness Equipment Design of work systems Human Resources
3-3

Links to Process Selection

Forecasting Capacity Planning Facilities and Equipment

Product and Service Design Process Selection

Layout

Technological Change

Work Design

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Process Selection Strategy

Key aspects of process strategy

Capital intensive equipment/labor Process flexibility Volume and Variety Produce-to-stock / Produce-to-order Environment and Technological Change

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Process Selection Strategy

Design
Purchasing

Production

Assembly

Delivery

CFL Lamp Fast Food, Computer Restaurant, Clothing, Molding Plane Building, Furniture

Make To Stock

Assemble To Order

Make To Order

Purchase To Order

Engineering To Order

Process Types
Project Form Intermittent Flow Continuous Flow Processing

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Project Form

Example: Building of Ship, Aircraft; Construction of Roads, Buildings; Annual Conference; Training

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Project Form
Short Life Cycle Matrix Organization Different Functional Specialization Scheduling and Control is important
CPM/ PERT techniques

Time-bound, Different functional specialization, Immobile Product, Temporary team

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Intermittent Flow

Example: Fork Lift Trucks, Home Appliances

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Intermittent Flow
Various Standard Operations Material Handling and In-Process Inventory High Difficulty in Management of Resources Variety at Low Cost High Capacity Utilization Highly skilled workers Complex operation planning and control

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Techniques for Intermittent Flow

Computerized Production and Inventory Control Systems Integrated CAM Manufacturing Resource Planning (MRP II) Group Technology

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Computer-Aided Manufacturing
Manufacturing Systems utilizing computer software programs that control the actual machine on the shop floor. Benefits
Reliable Instructions to machines Product quality consistent Close tolerances can be obtained Lower labor costs
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Group Technology
A way of organizing and using data for components that have similar properties and manufacturing requirements. Families of Component Parts, Machines, Equipments or People Grouped in cells so that volumes are higher and variety smaller Taking advantages of continuous flow
Time and cost reduced Material handling reduced Shorter throughput time In-process inventory reduced

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Continuous Flow

Example: Refrigerator assembly, Car Assembly, Fast Food Restaurants, Bank Counter

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Continuous Flow

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Continuous Flow
Difficult to adapt Problem of balancing the line Possibility of stoppage of line Low worker morale Capital Intensive

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Techniques for Continuous Flow

Computer Numerical Control (CNC) / Direct Numerical Control (DNC) Robotics CAD / CAM / CAE (Computer Aided Engineering) Flexible Manufacturing (FMS)

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Flexible Manufacturing System (FMS)

It is a computer-controlled process technology suitable for producing a moderate variety of products in moderate volumes. It contains several automated programmable work stations. Automated Material-handling equipment are used.

Flexible Manufacturing System (FMS)

Introduce flexibility to continuous process in terms of component design, operation sequence, batch sizes, production capacity Combine advantages of continuous flow process and intermittent flow process Increased variety, improved response to customer order, updated product design
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Flexible Manufacturing System (FMS)

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Robotics
Robot: A programmable machine capable of moving materials and performing routine, repetitive tasks.
Replace humans for heavy, dirty, dangerous, unpleasant, monotonous tasks.

Robotics: The science of selecting robots for various applications.

Processing Industry

Example: Fertilizer, petrochemicals, milk, drugs

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Processing Industry
Single Input Analytic and Synthetic Process Continuous Processing Low Labor Required Capital Intensive

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Process Selection
Combination to take advantage of more forms Stage in Life-cycle of product Suited to the Market Competitor approach Technological Changes Environmental Changes Break-even analysis of processes

Break Even Analysis

Intermittent Project Continuous

Cost

Volume

Computer Integrated Manufacturing

CIM is a concept of a fully automated factory, where all manufacturing processes are integrated and controlled by computers. CIM integrates information flows in marketing, design, manufacturing, engineering, resource requirements planning, purchasing, production process, quality assurance, administration etc.
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Discussion Questions
Define FMS. What is the general field of FMS application significant in terms of potential market size for its capability? State with reference to any production unit. Why is mass production preferred over in some types of products with large volume? Explain the key elements of mass production with some examples. Differentiate continuous flow processes from intermittent flow processes. Give examples. On the basis of material flow, classify production systems and give examples for each type.

End of Unit 3

UNIT 4: Facilities Location UNIT 4: Facilities Location