SESSION-9,10,11,12

Process analysis, Product Analysis and Development

ECE AND EEE

Process Analysis

PROCESS ANALYSIS

PROCESS PROCESS PLANNING

PROCESS DESIGN

PROCESS SELECTION

PROCESS STRATEGY

Process

• A process is a sequence of activities that is

intended to achieve some result, for example,

to create added value for the customers

Process Planning

• Concerned with planning the conversion

processes needed to convert the raw material

into finished products.

Process Design

• Concerned with the overall sequences of

operations required to achieve the product

specifications

PROCESS TYPES:

PROCESS SELECTION AND STRATEGY

• PROCESS SELECTION:– Refers to the way production of goods or services is

organized.• PROCESS STRATEGY:

– An organization's approach to selection of the process for the conversion of resource inputs into outputs.

– Key aspects in process strategy include:• Make or buy decisions• Capital intensity and• Resource flexibility

PROCESS STRATEGY

Make or Buy is the 1st step of

process planning.

Factors considered in make

or buy decisions: Available capacity

Expertise

Quality consideration

Nature of demand

Cost

Capital Intensity: is the mix

of equipment and human

skills in a production process.

Resource Flexibility: it is the

ease with which equipment

and works can handle a wide

variety of products , levels of

output, duties and function.

VERTICAL INTEGRATION

It is the amount of production and distribution chain, from suppliers

of the components to the delivery of products and services to

customers, which is brought under the ownership of the firm.

The degree to which a firm needs to be vertically integrated

determines how many production process needs to be planned and

designed to be carried out in-house or by outsourcing.

Vertical integration is based on make or buy decisions. Where make

is more integration and buy means more outsourcing

TYPESOF VERICAL INTEGRATION

• Backward integration: moving towards the

sources of raw material.

• Forward integration: the firm acquires the

channel of distribution

ADVANTAGES AND DISADVANTAGES

Process Flowcharting Defined

• Process flowcharting is the use of a diagram to

present the major elements of a process

• The basic elements can include tasks or operations,

flows of materials or customers, decision points, and

storage areas or queues

• It is an ideal methodology by which to begin analyzing

a process

Flowchart Symbols

Tasks or operationsExamples: Giving an admission ticket to a customer, installing a engine in a car, etc.

Examples: Giving an admission ticket to a customer, installing a engine in a car, etc.

Decision PointsExamples: How much change should be given to a customer, which wrench should be used, etc.

Examples: How much change should be given to a customer, which wrench should be used, etc.

Cond…

Examples: Sheds, lines of people waiting for a service, etc.

Examples: Sheds, lines of people waiting for a service, etc.

Examples: Customers moving to a seat, mechanic getting a tool, etc.

Examples: Customers moving to a seat, mechanic getting a tool, etc.

Storage areas or queues

Flows of materials or customers

Few more ProcessesSingle-stage Process

Stage 1

Stage 1 Stage 2 Stage 3

Multi-stage Process

Cond…

• A buffer refers to a storage area between stages where the output of a stage is placed prior to being used in a downstream stage

Stage 1 Stage 2

Buffer

Multi-stage Process with Buffer

Terms Used• Blocking

– Occurs when the activities in a stage must stop because there is no place to deposit the item just completed

– If there is no room for an employee to place a unit of work down, the employee will hold on to it not able to continue working on the next unit

• Starving– Occurs when the activities in a stage must stop because

there is no work – If an employee is waiting at a work station and no work is

coming to the employee to process, the employee will remain idle until the next unit of work comes

Cond…

• Bottleneck– Occurs when the limited capacity of a process causes work to pile

up or become unevenly distributed in the flow of a process

– If an employee works too slow in a multi-stage process, work will

begin to pile up in front of that employee. In this is case the

employee represents the limited capacity causing the bottleneck.

• Pacing– Refers to the fixed timing of the movement of items through the

process

Process Performance Metrics• Operation time = Setup time + Run time

• Throughput time = Average time for a unit to move through the system

• Cycle time = Average time between completion of units

• Throughput rate = 1 .

Cycle time

• Efficiency = Actual output

Standard Output

Product Analysis

FLOWCHART

PRODUCT PRODUCT DESIGN

PRODUCTION DESIGN

PRODUCT

• It is anything that can be offered in the market

for attention, acquisition, use or consumption

PRODUCT DESIGN

• Concerned with form and function of a product.

• It refers to the arrangement of elements or parts that collectively form a product.

PRODUCTION DESIGN

• Concept of designing products from the point of view of producibility.

OBJECTIVE OF PRODUCT DESIGN

• The overall objective is profit generation in the long run.

• To achieve the desired product quality.• To reduce the development time and cost to

the minimum.• To reduce the cost of the product.• To ensure producibility or manufacturability

(design for manufacturing and assembly).

FACTORS INFLUENCING PRODUCT DESIGN

i. Customer requirements

ii. Convenience of the operator or user

iii. Trade off between function and form

iv. Types of materials used

v. Work methods and equipment's

vi. Cost/Price ratio

vii. Product quality

viii. Process capability

ix. Effect on existing products

x. Packaging

Characteristics of Good Product Design

i. Function or performance

ii. Appearance or aesthetics

iii. Reliability

iv. Maintainability

v. Availability

vi. Producibility

vii. Simplification

viii. Standardization

ix. Specification

x. Safety

TECHNOLOGY USED IN DESIGN

• CAD -Computer Aided Design

– Assists in creating and modifying designs

• CAE -Computer Aided Engineering

– Tests & analyzes designs on computer screen

• CAD/CAM -Design & Manufacturing

– Automatically converts CAD data into processing

instructions for computer

Benefit of CAD

• Produces better designs faster• Builds database of designs and creates

documentation to support them• Shortens time to market• Reduces time to manufacture• Enlarges design possibilities• Enhances communication and promotes

innovation in design teams

BASIC CONSIDERATION IN DESIGN

• Form Design: how a product looks like

• Function Design : how a product performs

– Based on Reliability and Maintainability

– Reliability

Design for Manufacturability

• Traditional Approach

– “We design it, you build it” or “Over the wall”

• Concurrent Design/ Engineering

– “Let’s work together simultaneously”

– Merits of Concurrent Design:• Improves quality of early design decisions• Decentralized -suppliers complete detailed design • Incorporates production process• Often uses a price-minus system• Scheduling and management can be complex as tasks are

done in parallel

Designing for the Customer

1. QFD- a process that helps a company determine the

products characteristics important to the customer and

to evaluate its own products in relation to others.

2. HOUSE OF QUALITY- a matrix that helps a product

design team translate customer requirement into

operating and engineering goals.

3. VALUE ANALYSIS- analysis with the purpose of

simplifying products and process by achieving a

equivalent or better performance at a lower cost.

PRODUCT PLANNING AND DEVELOPMENT

Meaning of product planning and development

• It is the process of finding out new ideas for

producing new products and then introducing

them in the market.

• It also includes improving the existing

products

OBJECTIVE

Characteristics of product development

• Product Quality

• Product Cost

• Development Time

• Development Cost

• Development Capability

8 STEPS OR 6 STAGES OF PROUCT DEVELOPMENT

Idea generation

Idea screening

Concept development

Marketing Strategy

Business analysis

Product design and

development

Test marketing

Commercialization

STAGE-1

STAGE-2

STAGE-6STAGE-5

STAGE-3

STAGE-4

6 stages of product development

• STAGE-1 Planning

• STAGE-2 Concept Development

• STAGE-3 System-Level design

• STAGE-4 Design Detail

• STAGE-5Testing and Refinement

• STAGE-6 Production Ramp-up

Challenges of product development

• Trade offs

• Details

• Time pressure

• Creation

• Satisfaction of needs

• Team spirit

Measuring Product Development Performance

Measures•Freq. Of new products introduced•Time to market introduction•Number stated and number completed•Actual versus plan

•Freq. Of new products introduced•Time to market introduction•Number stated and number completed•Actual versus plan

Time-to-marketTime-to-market

ProductivityProductivity

QualityQuality

•Cost of materials and tooling per project•Engineering hours per project•Actual versus plan

•Cost of materials and tooling per project•Engineering hours per project•Actual versus plan

•Design-performance and customer satisfaction•Conformance-reliability in use

•Design-performance and customer satisfaction•Conformance-reliability in use

Performance Dimension

Key Terms:1. CONTRACT MANUFACTURERS-

Companies that specialize in manufacturing products for other companies and have become successful . These companies are called contract manufacturers. Thus simply we can put that as a contract manufacturer is an organization capable of manufacturing or purchasing all the components needed to produce a finished product or services.

2. CORE COMPETENCY-a company’s core competency is the one thing that it can do better than its competitors. Core competency gives a long term competitive Advantage to the company

3. Concurrent engineering- emphasizes cross functional integration and concurrent development of a product and its associated processes

Project Assignment

Visit a nearby branch of a bank and observe

the various inputs and outputs in the

transformation process. Make a schematic

diagram to represent the transformation

process including the random disturbances

and the feedback mechanism. Find out the

quality monitors for monitoring the quality of

inputs to the process. What type of process

design is followed by the bank.