Process Planning Ppt
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Transcript of Process Planning Ppt
Operations Operations ManagementManagement
Process Strategy andProcess Strategy and Capacity Planning Capacity Planning
Tintu ThomasFm-501
PROCESS PLANNINGPROCESS PLANNING
A production process is a series of manufacturing operations performed at work stations to achieve the design specifications of planned output
Process planning is concerned with planning the transformation processes needed to convert the raw-materials into finished products.
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Process planning consists of two parts namely:
OPERATION DESIGN PROCESS DESIGN
Both stages provide information on process which will be required to effectively utilize existing equipment and machinery and to determine what new equipment and machinery would be required.
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PROCESS DESIGN•It is concerned with the overall sequences of operationsrequired to achieve the product specifications. •It specifies the type of work stations that are to be used,the machines and equipments necessary, to determine what new equipment should be used etc.
The sequences of operations in the manufacturing process are determined by
1. Nature of the product2. Materials used3. Quantities being produced4. Existing layout of the plant 3
STEPS IN PROCESS PLANNING1.Analyze the print to get an overall picture of what is wanted.
2.Make recommendations to or consult with product engineers on product design changes.
3.List the basic operations required to produce the part to the drawing or specification
4.Determine the best way to combine the operations and put them in sequence
5.Specify the gauging required for the process4
Production Process Flow DiagramProduction Process Flow Diagram
Shipping
Customer
Customer sales representative
take order
Prepress Department(Prepare printing plates
and negatives)
Printing Department
Collating Department
Gluing, binding, stapling, labeling
Polywrap Department
Purchasing(order inks, paper,
other supplies)
Vendors
Receiving
Warehousing(ink, paper, etc.)
Accounting
Information flowMaterial flow
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Types of Process StrategiesTypes of Process Strategies
ContinuumContinuum
Process strategies follow a continuum Within a given facility, several strategies may be
used These strategies are often classified as:
Repetitive-Focused
Product-FocusedProcess-Focused
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Process-Focused StrategyProcess-Focused Strategy
Facilities are organized by process. Similar processes are together. Low volume, high variety products. ‘Jumbled’ flow.
OperationProduct A
Product B
1111 2222 3333Other names Intermittent process Job shop
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Process-Focused Strategy ExamplesProcess-Focused Strategy Examples
Bank
© 1995 Corel Corp.
Machine Shop© 1995 Corel Corp.
Hospital© 1995 Corel Corp.
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Process Focused Strategy -Process Focused Strategy - Pros & Cons Pros & Cons
Advantages Greater product flexibility More general purpose equipment Lower initial capital investment
Disadvantages More highly trained personnel More difficult production planning & control Low equipment utilization (5% to 25%)
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Repetitive Focused StrategyRepetitive Focused Strategy
Facilities often organized by assembly lines Characterized by modules
Parts & assemblies made previously
Modules combined for many output options Other names
Assembly line Production line
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Repetitive Focused Strategy -Repetitive Focused Strategy -ConsiderationsConsiderations
More structured than process-focused, but less structured than product focused
Using modules, it enjoys economic advantage of continuous process, and custom advantage of low-volume, high-variety model.
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Repetitive-Focused Strategy - Repetitive-Focused Strategy - ExamplesExamples
Truck
© 1995 Corel Corp.
Clothes Dryer
© 1995 Corel Corp.
Fast Food
McDonald’sover 95 billion served
McDonald’sover 95 billion served
© 1984-1994 T/Maker Co.
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Product-Focused StrategyProduct-Focused Strategy
Facilities are organized by product High volume, low variety products Part of:
Discrete unit manufacturing Continuous process manufacturing
Operation
Products A & B
11 22 33
Also known as Line flow production Continuous production
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Product-Focused StrategyProduct-Focused Strategy Pros & Cons Pros & Cons
Advantages Lower variable cost per unit Lower but more specialized labor skills Easier production planning and control Higher equipment utilization (70% to 90%)
Disadvantages Lower product flexibility More specialized equipment Usually higher capital investment
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Product-Focused ExamplesProduct-Focused Examples
© 1995 Corel Corp.
Light Bulbs (Discrete)
Paper (Continuous)© 1984-1994 T/Maker Co.
© 1995 Corel Corp.
Soft Drinks (Continuous, then Discrete)
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PROCESS FOCUS REPETITIVE FOCUS PRODUCT FOCUS
Small quantity
And large variety
Long runs,
usually standardized Product: Largequantities, small
variety
General purpose Special assembly line; Special-purpose
Operators broadly
skilled
Employees modestly
trained
Operators less
broadly skilled
Many job instruction Repetitive operations Few work orders and job instruction and standardization
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BASIS
Product
Equipment
Skills
Work flow
Tools for Process DesignTools for Process Design
Flow Diagrams Process Charts Time-Function/Process Mapping Service Blueprinting
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Time Function MapTime Function Map
Customer
Sales
Production control
Plant A
Warehouse
Plant B
Transport
Order Product
Process Order
Extrude
Receive product
Wait
Move
Wait Wait Wait
Move
Ord
er
Ord
er
WIP
WIP
WIP W
IP
Prod
uct
Prod
uct
Prod
uct
12 days 1 day 1 day 1 day 1 day13 days 4 days 10 days 9 days
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Process ReengineeringProcess Reengineering The fundamental rethinking and radical redesign of
business processes to bring about dramatic improvements in performance and requires reexamination of the basic process and its objectives.
Focuses on activities that cross boundaries.
The process engineer should therefore: Determine the method of manufacturing a product Establish the sequence and the type of operations involved Select the tools and equipments required and Analyze how the manufacturing of the product will fit into
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Operations Design
It is concerned with the design of the individual manufacturing operation. It consists of examining the man mixing relationship in the manufacturing process for converting the raw materials into the finished products or semi finished products.Operation design must specify how much of man and machine time is required for each unit production.
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Thank You!!