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Chap-2 Process Analysis

The document discusses various manufacturing processes and systems. It provides details on: 1. Process design which determines the sequence of operations to achieve product specifications. 2. Different manufacturing processes like conversion, forming, machining and assembly processes. 3. Classification of manufacturing systems including project processes, job shops, batch, repetitive and continuous processes. 4. Flexible manufacturing systems (FMS) which use computer control, automation and reprogrammable controllers to produce different products flexibly. 5. Computer-integrated manufacturing (CIM) which integrates information from different organizational areas like design, purchasing and production planning through a host computer.

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75 views35 pages

Chap-2 Process Analysis

The document discusses various manufacturing processes and systems. It provides details on: 1. Process design which determines the sequence of operations to achieve product specifications. 2. Different manufacturing processes like conversion, forming, machining and assembly processes. 3. Classification of manufacturing systems including project processes, job shops, batch, repetitive and continuous processes. 4. Flexible manufacturing systems (FMS) which use computer control, automation and reprogrammable controllers to produce different products flexibly. 5. Computer-integrated manufacturing (CIM) which integrates information from different organizational areas like design, purchasing and production planning through a host computer.

Uploaded by

sushant chaudhary
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Process Selection/ Process Design/

Process Analysis
Process Design
Production Process
1. Inputs
2. Transformation Process:
 Planning & control factors of Production
 Procurement of Raw materials
 Receipt , Storage & Issue of Raw Materials
 Material Handling (Movement)
 Inspection of In process and Parts
 Storage of Finished goods
 Instructions, Authorizations, Inspections, Information
Storage/ Retrieval etc.
3. Output : Goods & Services
Process Design
 Process design is concerned with overall sequence of
operations required to achieve the product specifications
 It specifies the type of work stations, the machines and
equipments necessary ad the quantities in which each is
required
 Sequence of operations determined by
 Nature of the product
 Materials used
 Quantities being produced, and
 Existing physical layout of the plant
Different manufacturing operations
1. Conversion Process :
2. Manufacturing Process:
 Forming Process: forging , stamping, embossing
and spinning etc.
 Machining Process: Turning, milling, drilling,
grinding, shaping, planning, boring etc.
 Assembly Process: Welding, brazing, soldering,
riveting, fastening using nuts & bolts.
3. Testing Process :
When Process Decisions must be
made
 A new or modified product or service is being offered
 Quality must be improved
 Competitive priorities have changed
 Demand for a product is changing
 Cost or availability of materials has changed
 Competitors are doing better by using a new technology or a
new process.
A Simplified Process Flow Chart for
Shirt Manufacturing
Inventory of Cloth
& Other materials WIP
Inventory
Stitching 1

Spreading Cutting
Stitching 2

Pressing &
Inspection Assembly

Inventory of
Shirts
Planning Premises in Process Design

 Three generic planning premises are in use in


operations management
 Make-to-Stock (MTS): more amenable for systems with
fewer product varieties and high production volume as in
the case of continuous and streamlined flow systems
 Assemble-to-order (ATO): useful for intermittent flow
systems catering to the mid-volume mid-variety situations
 Make-to-order (MTO): organizations typically belong to
manufacturer of high product variety (jumbled flow
process systems) use this planning methodology
1. Classification Of Manufacturing
Systems (Process Choices)
1. Project Process
2. Job shop Process
3. Batch Process
4. Repetitive Process
5. Continuous Process
1. Project Production
Characteristics:
 Definite Beginning
 Non uniform requirement of resources
 Involvement of different Agencies
 Fixed Position Layout
 High Cost Overrun
 Personnel Problems
 Scheduling Control Techniques
2. Job shop Process
Characteristics:
 Small Production runs
 Discontinuous flow of Materials
 Disproportionate manufacturing cycle time
 General purpose machined & process layout
 Highly skilled labour
 Highly competetent knowledgeable supervision
 Large work in progress
 Limited functions of production planning mid control
Jumbled Flow
3. Batch Process
 Short runs
 Skilled labours in specific trades
 Supervision to Process knowledge of a specific process
 Limited span of control
 General purpose machined & process layout
 Manual material handling
 Manufacturing cycle time affected due to queues
 Large work in progress
 Flexibility of production schedules
 Need to have PPC
4. Repetitive Process
 Continuous flow of materials
 Special purpose machines & Product type layout
 Mechanized materials handling
 Low skilled labours
 Short manufacturing cycle time
 Easy supervision
 Limited work-in-progress
 Lesser flexibility in production schedules
5. Continuous Process Production
 Special purpose machines with built in control
 Highly mechanized materials handling
 Very low manufacturing cycle time
 Low skilled labour
 Negligible work-in -progress
CNC Machine
Flexible manufacturing system (FMS)
 A flexible manufacturing system (FMS) is a group of machines
that include supervisory computer control, automatic material
handling, and robots or other automated processing equipment.
Reprogrammable controllers enable these systems to produce a variety
of similar products. Systems may range from three or four machines to
more than a dozen. They are designed to handle intermittent
processing requirements with some of the benefits of automation and
some of the flexibility of individual, or stand-alone, machines (e.g.,
N/C machines).
 Flexible manufacturing systems offer reduced labor costs and more
consistent quality when compared with more traditional
manufacturing methods, lower capital investment and higher flexibility
than “hard” automation, and relatively quick changeover time. Flexible
manufacturing systems often appeal to managers who hope to achieve
both the flexibility of job shop processing and the productivity of
repetitive processing systems
Computer-integrated
manufacturing (CIM)
 Computer-integrated manufacturing (CIM) is a system
that uses an integrating computer system to link a broad range of
manufacturing activities, including engineering design, flexible
manufacturing systems, purchasing, order processing, and
production planning and control. Not all elements are absolutely
necessary. For instance, CIM might be as simple as linking two or
more FMSs by a host computer. More encompassing systems can
link scheduling, purchasing, inventory control, shop control, and
distribution. In effect, a CIM system integrates information from
other areas of an organization with manufacturing. The overall
goal of using CIM is to link various parts of an organization to
achieve rapid response to customer orders and/or product
changes, to allow rapid production, and to reduce indirect labor
costs.
Comparison of Operations on the Basis
of Some Operational Measures
Continued
Service Process Design
 Three basic components:
 Physical facilities, processes and procedures
 Employee behavior
 Employee professional judgment
Key Service Dimensions

Customer contact and interaction

Labor intensity

32
Customization
An illustration of degrees of complexity
Service Positioning
Degree of Divergence: An Illustration

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