1

Manufacturing Process Selection and Design

2

Overall development of processing plans

Design 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

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Product-Flow CharacteristicsProduct-Flow Characteristics

Types of Product FlowTypes of Product Flow– Line FlowLine Flow– Batch FlowBatch Flow– Project FlowProject Flow

Characteristics of Flows Characteristics of Flows

Line FlowLine Flow

paintdrill bend

Task or work station

Product flow

cut

Batch FlowBatch Flow

Cut Paint

Task or work station Product flows

Bend

Drill

BatchA

BatchB

BatchC

Classification by Type of Classification by Type of Customer OrderCustomer Order

Make to Stock (MTS)Make to Stock (MTS)

Make to Order (MTO)Make to Order (MTO)

Assemble to Order (ATO)Assemble to Order (ATO)

Process Selection DecisionsProcess Selection Decisions

Process characteristics matrixProcess characteristics matrix

Factors affecting process choiceFactors affecting process choice

Factors Affecting Process ChoiceFactors Affecting Process Choice

Market conditions and competitionMarket conditions and competition

Capital requirementsCapital requirements

Labor supply and costLabor supply and cost

State of technologyState of technology

9

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 Assemblies Assemblies

Assemblies

Finished Product

1 - Component manufacturing Section

2 – Sub Assembling Section

3 – Assembling Section

10

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

11

Process Manufacturing System- A Layout in a Cement

Plant

CrusherLimestone

Hopper 1 Feeder 1

Hopper 2 Feeder 2

Hopper 3 Feeder 3

Hopper 4

Feeder

Dispatch Silo Cement Mill

Iron One

Clay

Gympsum

Raw Mill

Blending Silo

Firing Kiln

Hopper 5

Feeder

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Process Focused Production – A Schematic Layout

Receiving raw materials

storage

Foundry Welding and

soldering

Lathe section

Quality control

Painting and

packaging

Job A

Job B

: : :

::

: : :

:

: : :

13

Types of Processes

Conversion (ex. Iron to steel)

Fabrication (ex. Cloth to clothes)

Assembly (ex. Parts to components)

Testing (ex. For quality of products)

14

Process Flow Structures

Job shop (Ex. Tailoring Shop )

Batch shop (Ex. Garment Manufacturer / Pharmaceutical Products)

Assembly Line (ex. Automobile manufacturer)

Continuous Flow (ex. Petroleum Products manufacturer)

Product-Process StrategyProduct-Process Strategy

Strategy must consider not only the Strategy must consider not only the product or service, but also how to product or service, but also how to produce it.produce it.

As many industries move through their As many industries move through their product life cycles, they also move through product life cycles, they also move through a process life cycle. e.g. the traditional a process life cycle. e.g. the traditional bread bakery vs. the modern automated bread bakery vs. the modern automated bakery.bakery.

Product Life Cycle StagesProduct Life Cycle Stages

Low volume-low standardization, one of a Low volume-low standardization, one of a kindkind

Multiple products, low volumeMultiple products, low volumeFew major products, higher volumeFew major products, higher volumeHigh volume-high standardization, High volume-high standardization,

commodity productcommodity product

Process Life Cycle StagesProcess Life Cycle Stages

Jumbled flow (job shop)Jumbled flow (job shop)Disconnected line flow (batch)Disconnected line flow (batch)Connected line flow (assembly line)Connected line flow (assembly line)Continuous flowContinuous flow

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IV.Continuous

Flow

III.Assembly

Line

II.Batch

I.Job

Shop

LowVolume,One of a

Kind

MultipleProducts,

LowVolume

FewMajor

Products,HigherVolume

HighVolume,

HighStandard-

izationCommercial

PrinterFrench

Restaurant

HeavyEquipment

AutomobileAssembly

Burger King

SugarRefinery

Flexibility (High)Unit Cost (High)

Flexibility (Low)Unit Cost (Low)

These are the major stages of product and process life cycles

These are the 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

ProductFocused,Dedicated

System

D

B

Bat

ch s

ize

Number of product designs

A

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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

21Example: 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 5.14From Exhibit 5.14

22

Example: Process Flow Chart

Material Received from Supplier

Inspect Material for Defects Defects

found?

Return to Supplier for Credit

Yes

No, Continue…

23

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 units

c. 100 units

d. 62.5 units

e. None of the above

Answer: d. 62.5 units (25,000/(500-100)=62.5)

24

Question Bowl

Which of the following is an example of a

Continuous 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

25

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