m2-process engineering 1

8/9/2019 m2-Process Engineering 1

1/53

INDUSTRIAL

ENGINEERINGBJTM 3023


2/53

PROCESS ENGINEERING


3/53

LECTURE SCOPE

What is Process Engineering?

Process Engineering 6 step

sequence.


4/53

What is Process Engineering? Process engineering is also called:

anu!acturing planning" production

engineering" process planning" aterialprocessing and achine routing.

Responsi#le o! de$eloping a plan !or theanu!acture o! the ne% or odi!ied product.


5/53

What is Process Engineering?

Concern %ith the design o!

the actual process to #eused in the anu!acture o!

the product


6/53

Process Engineering 6 step

sequence

&e!ining the product structure andspeci!ication

'ssessing each coponent(sanu!actura#ilit) Process selection Cost e$aluation

&eterining the sequence in %hich theoperation are to #e per!ored

&ocuenting the process


7/53

&e!ining the product structure

and speci!ication


8/53

*. &e!ining the product

structure and speci!ication

Product structure are o!ten sho%n in a

hierarchical chart that sho%s all o! the

su#asse#lies" su#+su#asse#lies"coponents and ra% aterials that

coprise the product.


9/53

*. &e!ining the product

structure and speci!ication

Product structure Sho%s sequence in

%hich coponentsare asse#led

,o% and %hen the

su#asse#lies are

put together to

a-e the !inal

product.

Product


10/53

EERC/SE *

0i$en the !ollo%ing

diagra !or a

product" deterinethe quantit) o! each

coponent

required to

asse#le one unito! the !inished

product.


11/53


12/53

&e!ining the product structure

and speci!ication

2ills o! 5aterials 32O54 List o! all coponents needed to produce

the product Contains:

u#er and nae o! all the parts

The source o! each part 3purchase or

anu!acture4

u#er and nae o! the copleted product


13/53

E7aple o! #ill o! aterials


14/53

'ssessing each coponent(s

anu!actura#ilit)


15/53

1. 'ssessing each

coponent(s anu!actura#ilit)

5anu!actura#ilit):

' easure o! the relati$e ease or

di!!icult) o! producing the ite %ithin

tolerance

The tighter the tolerances" in general" the ore

e7pensi$e the ite %ill #e to produce.


16/53

Process Selection


17/53

' processis a ethod o! doing

soething" generall) in$ol$ing a

nu#er o! steps or operations.

Process designis the de$elopingand designing o! the steps.


18/53

8actors in!luencing process

design

Product design and qualit) le$el.

&eand patterns and !le7i#ilit)

needed. 9uantit)capacit) considerations.

Custoer in$ol$eent.

5a-e or #u) decision


19/53

PRODUCTDESIGN

%hat to

produce?

PROCESS

DESIGN

ho% to

produce?

CAPACITY

,o% uch to

produce?

CUSTOMER


20/53


Reasons to a-e in+house Can produce !or less cost than a supplier

To utilise e7isting equipent to the !ulleste7tend

To -eep con!idential processes %ithin

control o! the !ir. To aintain qualit).

To aintain %or-!orce.


21/53


Reasons to #u) out Requires less capital in$estent.

Uses specialised e7pertise o! suppliers. 'llo%s the !ir to concentrate on its o%n

area o! specialisation.

Pro$ides -no%n and copetiti$e prices.


22/53

5a-e or #u) decision Cost

Capacit) 9ualit)

Speed

E7pertise


23/53


24/53


25/53


26/53


27/53

Process Selection

Process t)pes:

;o# shop

2atch

5ass production

Continuous production

Pro


28/53

Lo%

Lo%

,igh

,igh

Project

3custoer


29/53

BATCH MASS CONTINUOUS PROJECT

Types ofproduct

Made-to-order(cuto!"ed#

Made-to-toc$(ta%dard"ed#

Co!!od"t& U%"'ue

Type ofcustomer

e) "%d"*"dua+cuto!er

Ma !ar$et Ma !ar$et O%e-at-a-t"!e

Productdemand

+uctuate Sta,+e er& ta,+e I%.re'ue%t

Demand o!ume Lo) to !ed"u! /"1 er& 1"1 er& +o)

No" of d#$erentproducts

Ma%& *ar"ed e) er& .e) I%%"te *ar"et&

Product#onsystem

D"crete 4o,1o5

Re5et"t"*eae!,+& +"%e

Co%t"%uou5roce"%dutr"e

Lo%-ter! 5ro4ect

E%u#pment Ge%era+-5ur5oe S5ec"a+ 5ur5oe /"1+&auto!ated

ar"ed

&or'er s'#!!s 6"de ra%e o.$"++

L"!"ted ra%e o.$"++

E'u"5!e%t!o%"tor

E75ertcra.t5ero%

Adanta(es +e7","+"t& 'ua+"t& E8c"e%c& 5eed+o) cot

/"1+& e8c"e%t+are ca5ac"t&

eae o. co%tro+

Cuto! )or$+atet tec1%o+o&

D#sadanta(es Cot+& +o)d"8cu+t to!a%ae

Ca5"ta+"%*et!e%t +ac$o.re5o%"*e%e

D"8cu+t toc1a%e .ar-reac1error +"!"ted*ar"et&

No%-re5et"t"*e!a++ cuto!er,ae

E)amp!es Mac1"%e 1o5,a$er"eeducat"o%

Auto!o,"+ete+e*""o% .at.ood

Stee+ 5a5eruar u55+&"%e+ectr"c"t& to1o!e a%d

,u"%ee

Co%truct"o%1"5,u"+d"%


30/53

&/SCUSS/O *

What -ind o! process is used !or a-ing

each o! the !ollo%ing products?

*. So!t drin-s

1. Wedding in$itations

>. 'utoo#iles

. Paper

@. Custo hoes

6. 5otorc)cles


31/53

Cost e$aluation


32/53

. E$aluating the cost o! each

process


33/53

Cost e$aluation

8i7ed costs ot $ar) %ith the $olue produced

Eg: purchase costs o! achiner) andtools" setup costs.


34/53

Cost e$aluation

Aaria#le costs Costs that $ar) %ith the quantit)

produced. Eg: direct la#our" direct aterial.


35/53

Total cost B 8i7ed cost 3Aaria#le cost per

unit43nu#er o! units produced4

Then"

TC B 8C ACx

unit cost B Total cost B TC

nu#er o! units produced x


36/53

E7aple

' process designer has a choice o!

t%o ethods !or a-ing an ite.

5ethod ' has a !i7ed cost o! R51DDD!or tooling and per unit. 5ethod 2

requires a special achine costingR51D DDD and the $aria#le costs are

R5* per unit.


37/53


38/53

Aolue3units4

Total cost 3R5 Unit cost 3R54

5ethod ' 5ethod 2 5ethod ' 5ethod 2

1DDD DDD 11 DDD .DD **.DD

DDD * DDD 1 DDD >.@D 6.DD

6DDD 1D DDD 16 DDD >.>> .>>

DDD 16 DDD 1 DDD >.1@ >.@D

*D DDD >1 DDD >D DDD >.1D >.DD

*1 DDD > DDD >1 DDD >.*F 1.GF

* DDD DDD > DDD >.* 1.>

*6 DDD @D DDD >6 DDD >.*> 1.1@


39/53

Cost equalisation

point

5ethod '

5ethod 2

Aolue 3*DDD units4

Cost

3R5*DDD4

G


40/53

E$aluating the cost o! each

process

Act##ty*+unct#on

Batc, Mass Cont#nuous Pro-ect

Costest#mat#on

D"8cu+t torout"%e

Rout"%e Rout"%e Co!5+e7

Cost per

un#t

/"1 to

!oderate

Lo) Lo) er& 1"1

+#)ed costs Lo) to!oderate

/"1 er& 1"1 ar"ed

.ar#a/!ecosts

/"1 to!oderate

Lo) er& +o) /"1

Mar'et#n( Pro!oteca5a,"+"t"ee!"-ta%dardood a%der*"ce

Pro!oteta%dard"edood a%der*"ce

Pro!oteta%dard"edood a%der*"ce

Pro!oteca5a,"+"t"e


41/53

&eterining the sequence o!

operations


42/53

@. &eterining the sequence

o! operations

Operations that %ill #e used to

trans!or the aterial into its

desired !inal shape.


43/53

The sequence usuall) de$eloped

#ased on: 5iniiHation o! part handling 3shortest

path !ro achine to achine4

'ssuring that no succeeding operation

ad$ersel) a!!ects pre$ious operations


44/53

Process docuentation


45/53

Scheatic o! a process

PROCESS

3%or- steps4

EN#IRONMENT

/nternal

E7ternal

OUTPUT

3Custoers4

INPUT

3Suppliers4

COMPONENTS

People

5ethods

Equipent


46/53

&ocuenting the process

8lo% chart ' diagra that traces the !lo% o! in!oration"

custoers" equipent" or aterials through the

$arious steps o! a process.

Process chart 'n organiHed %a) o! docuenting all o! the

acti$ities per!ored #) a person" #) a achine"at a %or-station" %ith a custoer or on

aterials.
http://var/www/apps/conversion/tmp/scratch_4/%23action%3Fjump=nextslidehttp://var/www/apps/conversion/tmp/scratch_4/%23action%3Fjump=nextslide


47/53

8lo% charts

Tas-s or operations

Storage areas or queues

&ecision points

8lo% o! aterial custoers


48/53

8lo%chart o! the Sales Process !ora Consulting Copan)

Figure 4.3


49/53

Figure 4.16

8lo%chart o!

TelephoneOrderingProcess


50/53

Process Charts

Figure 4.8

Process$ Emergency room

admissionSu%ject$ Ankle injury patient

Be&ii&$ Enter emergency room

Edi&$ Leave hospital

Step

o'

Ti!e

(!i)

Distace

(*t)

Su!!ar+

Nu!%ero* stepsActi"it+

Ti!e(!i)

Distace(*t)

Step descriptio

Isert Step

Apped Step

Re!o"e Step

, Eter e!er&ec+ roo!- approach patiet .ido.

/ Sit do. ad *i00 out patiet histor+

1 Nurse escorts patiet to ER tria&e roo!

2 Nurse ispects ijur+

3 Retur to .aiti& roo!

4 5ait *or a"ai0a%0e %ed

6 Go to ER %ed

7 5ait *or doctor

8 Doctor ispects ijur+ ad 9uestios patiet

,: Nurse ta;es patiet to radio0o&+

,, Techicia


51/53


52/53

Process chart

/nspection Chec-s or $eri!ies soething #ut does

not change it.

&ela) Occurs %hen the su#


53/53

Thank you

m2-process engineering 1

Documents