3.c.process analysis

7/29/2019 3.c.process analysis

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3c. Process Selection / Process

design / Process analysis


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Process : set of tasks that transform inputs intouseful outputs

Process usually consists of

set of tasks flow of material & information that connect set

of tasks

storage of material & information


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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 taskii. of information helps in determining how each of

transformation has been done in the previous task &

what exactly remains to be completed in the presenttask.

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 .


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Process selection :deals with kind of productionprocess to have in plant

Process Technologies

Conversion : changing into different forme.g.iron ore to steel sheets , ingredients to tooth paste,granules to plastic parts

Fabrication :changing raw material into specific

forme.g. making sheet metal into car fenders Assembly : Assembling car fender , putting

electronic components on PCB ( printed circuitboard )

Testing : not a fundamental process , but standalone major activity


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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 )


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1

Throughput rate = ---------------------------

Cycle time

Actual Output

Efficiency = ---------------------------

Standard InputOutput

Productivity = ---------------------------

InputTime activated

Utilization = ---------------------------

Time Available


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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 necessaryequipment & 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


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Key decisions in Process Design

1. Organizing the process flows

2. Relating process design to process flow3. Evaluating the process


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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

process3. 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 bestdescribed as a job process and another process

as a line process


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Selection of Types of Production Systems /

Production Process for a product :

Three main factors determine the place of productionplanning products and control in an organization:

1. The type pf production, i.e. the quantities offinished 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.


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Depending upon the process flows :

there are 5 types of distinctivemanufacturing processes , which

can be grouped in 2 basic groups

A. Intermittent1.Project

2.Job-shop

3.Batch

B. Continuous

4.Assembly Line or line

5.Continuous flow


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Low volume , make to order

process : Project or jobprocess

1. Less vertical integration

2. More resources flexibility3. More customer involvement

4. Less capital intensity /

automation


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High volume , make -to-stock :

Line or continuous Process

1. More vertical integration

2. Less resources flexibility

3. Less customer involvement4. more capital intensity /

automation


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1.Project Process

2.Job Process


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Type of

production

Intermittent

Production

Project

Production

Job

Productio

n

Batch

Productio

n

Mass &

flow

production

Process

production

Continuous

production


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Job

Batch

Mass

ProcessProject / one

Continuous /

many

Project

Degree of repetitiveness


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Intermittent

Project System

Job-Shop System

Batch System


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Project System

Characteristics1.definite beginning & end

2.non-uniform requirement of resources

3.involvement of different agencies4.fixed position layout

5.high cost over runs

6.personnel problems7.scheduling & control


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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 betweenBorivali & Virar


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Job-shop system

Characteristics

Small production runs

1.discontinuous flow of materials2.disproportionate manufacturing

cycle time

3.general purpose machines &process layout

4.highly skilled labor

5.highly competent knowledgeablesupervision

6.large WIP

7.limited functions of PPC


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Examples:

large turbo-generators,large engines,

boiler,

processing, equipments,special electronic equipment,

Barber shop

polyclinic


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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 toqueues

Large WIP

Flexibility of production schedules


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Examples Batch Process

Forging process to make fittings for

pressure vesselsProducing a batch of text books

Bakery


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Continuous

Mass and Flow

Systems

Assembly-Line System

Flow System :

Process Systems

Process Plants

Ch t i ti Of A bl Li


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Characteristics Of Assembly Lines

1. Continuous flow of material

2. Special purpose machines

3. Product layout4. Mechanized materials handling

5. Low skilled labor

6. Short manufacturing cycle time7. Easy supervision

8. Limited WIP

9. Lesser flexibility in production schedules10.Some of assembly line products are :


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Examples of LineProcess

Auto Assembly

Bread LineParle Biscuit Line

TV ,

Fridge,

Washing Machines


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Continuous Process Flow System

Process production is characterized bymanufacture 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 arepacked as required. sugar , cement ,paper ,

milk ,coke etc


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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


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Selection of manufacturing process

In reality , very few organizations use onlyone 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 & somesubassemblies and flow production for final

assembly


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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


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project

continuous

Mass &

flow

batch

Introduction

( use project

form )Growth ( use

batch form )Maturity( use

mass form )


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Manufacturing process flow design

Specifies & focuses on specific processes thatraw materials , parts& sub-assemblies

follows as they move through plantTools to do are :

1. Assembly drawings

2. Assembly charts3. route sheets

4. Flow process charts


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Assembly Drawings : exploded view of

products showing its components parts

Assembly Chart: order / sequence of assembly

of parts ( Gozinto Chart)


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A

1

A

2

A

3

A

4

A

5

S

A1

S

A2

a

c

d

g

e

h

f

b

i

k

j

o

l

A

6

A

7

A

8

S

A3 I1

I2

Gozinto Chart

Assembly chart for Electrical Heatera: Body

b: Assemble Bracket to body

c: Bracket

d: Insulatore: 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 Platesr: Assemble end plates to body

s: Plastic End Caps

t: Assemble End Caps to body

u: Screen

v: Install Screen

w: Final Inspection

t

v

r

pm

w

s

q

u

n


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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


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Characteristics of a well designed

service system

1 Each element of service system is consistent


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1. Each element of service system is consistentwith the operating focus of the firm

2. It is user friendly :ATM

3. It is robust : computer back up system4. 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 cracks6. It manages the evidence of service quality in

such a way that customers see the value ofservice provided

7. It is cost effective

Service Process Technologies


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Service Process Technologies

Low customer

contact

High customer contact

Capital

intensive

Postal shop services

Cheque processing

Custom-shop services

Charter travel services

Medical treatment

Labor

intensive

Mass services

Teaching

Live entertainment

cafeteria

Professional services

Barber shop

Legal counseling

Medical diagnosistutoring


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Q1. depending upon the flow of

material in manufacturing ,

describe various types of

manufacturing processesQ2. prepare process flow chart

from waking up to reaching

college

Q3.Prepare gozinto chart for a

product

3.c.process analysis

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