11th Edition Chase & Jacobs & Aquilano
The chapter has three major sections.
Process Selection
Types of Processes1.Conversion processes: They convert naturally available materials, called as minerals or ores into useful metals and materials in general shapes from which many different forms can be produced (fabricated).
2.Fabrication Processes: Fabrication processes convert generally available materials into useful forms. Ex.: Making components required for an automobile using sheets as the raw materials and presses as the equipment.
3.Assembly Processes: Assemble various components into a useful product, machine or equipment.
4. Testing Processes: They are not production processes, but they are essential in production processes to assure that the processes output is up to the given specification. Testing may be done by the operator himself, another production operator in the subsequent stage or stages and specially designated inspector and many times also by the customer.
2.Fabrication Processes: Fabrication processes convert generally available materials into useful forms. Ex.: Making components required for an automobile using sheets as the raw materials and presses as the equipment.
3.Assembly Processes: Assemble various components into a useful product, machine or equipment.
4. Testing Processes: They are not production processes, but they are essential in production processes to assure that the processes output is up to the given specification. Testing may be done by the operator himself, another production operator in the subsequent stage or stages and specially designated inspector and many times also by the customer.
Process Flow Structures
- Job Shop
- Batch Shop
- Assembly Line
- Continuous Flow
Break-Even Analysis
A standard approach to choosing among alternative equipment or processes (actual production processes) is break-even analysis. We can say break-even analysis is used in Specific Process Equipment Selection.Manufacturing Process Flow Design
Organization Charts of the Manufacturing Systems (The term was used Chase - Aquilano)
Assembly drawing,
assembly chart (Gozinto chart - Goes into chart)
Route Sheet
Operation Sheet
Flow process chart
Process capacity & balance analysis, involves adjusting the capacities in various stages of a multi-stage process and improving balance to maximize output and minimize costs. We do not want unused capacity in any stage. So capacity decisions are to be taken with future demand estimates as the basis.
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Dr. D.K. Dwivedia, IIT Roorkey
https://www.youtube.com/watch?v=mLakJ77O4_s
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Process selection refers to the strategic decisions of selecting the kind of production process to have in a manufacturing plant.
Chase el al. categorized production processes into four.
Conversion processes: They convert naturally available materials, called as minerals or ores into useful metals and materials in general shapes from which many different forms can be produced.
Fabrication Processes: Fabrication processes convert generally available processes materials into useful forms. Ex.:Making components required for an automobile using sheets as the raw materials and presses as the equipment.
Assembly Processes: Assemble various components into a useful product, machine or equipment.
Testing Processes: They are essential in production processes to assure that the processes output is up to the given specification. Testing may be done by the operator himself, another production operator in the subsequent stage or stages and specially designated inspector and many times also by the customer.
The process flow in an organization refers to how a factory organizes material flow using one or more of the process technologies including the job shop, batch shop, assembly line, and continuous flows. The process chosen depends on the customization of the product as well as the volume required in the market. The relationship between the process structures and volume requirements is depicted on a product-process matrix. As volume increases the product line narrows and specialized equipment and standardized material flows are come economically feasible. The evolution in the process structure is often related to the product's life cycle stage. Thus the matrix is useful in linking marketing and manufacturing strategies.
Break even analysis allows manufacturing managers to visually present alternative profits (and losses) based on the number of units produced or sold. Specific equipment selection follows the selection of the general type of process structure in an organization. The tools of break-even analysis help managers make equipment selection decisions.
Process flow designs focus on the specific processes that raw materials, parts, and subassemblies follow as they move through the plant. Charts and drawings aid in process flow design.
Simulation in design
Simulation is now being used to help the design process. This is becoming increasingly important and widespread as computing power increases. Some of the visualizations used in design work can require very powerful computers. However, they can give an insight into how a potential process or product might work in practice which cannot be gained in any other way.
__________________
Chapter Outline
Job Shop Defined
Batch Shop Defined
Assembly Line Defined
Continuous Flow Defined
Process Flow Structures
Product-Process Matrix
Product-Process Matrix Defined
Conclusion
Case: Circuit Board Fabricators, Inc.
Source:
http://highered.mcgraw-hill.com/sites/0072983906/student_view0/chapter6/
Chase el al. categorized production processes into four.
Conversion processes: They convert naturally available materials, called as minerals or ores into useful metals and materials in general shapes from which many different forms can be produced.
Fabrication Processes: Fabrication processes convert generally available processes materials into useful forms. Ex.:Making components required for an automobile using sheets as the raw materials and presses as the equipment.
Assembly Processes: Assemble various components into a useful product, machine or equipment.
Testing Processes: They are essential in production processes to assure that the processes output is up to the given specification. Testing may be done by the operator himself, another production operator in the subsequent stage or stages and specially designated inspector and many times also by the customer.
The process flow in an organization refers to how a factory organizes material flow using one or more of the process technologies including the job shop, batch shop, assembly line, and continuous flows. The process chosen depends on the customization of the product as well as the volume required in the market. The relationship between the process structures and volume requirements is depicted on a product-process matrix. As volume increases the product line narrows and specialized equipment and standardized material flows are come economically feasible. The evolution in the process structure is often related to the product's life cycle stage. Thus the matrix is useful in linking marketing and manufacturing strategies.
Break even analysis allows manufacturing managers to visually present alternative profits (and losses) based on the number of units produced or sold. Specific equipment selection follows the selection of the general type of process structure in an organization. The tools of break-even analysis help managers make equipment selection decisions.
Process flow designs focus on the specific processes that raw materials, parts, and subassemblies follow as they move through the plant. Charts and drawings aid in process flow design.
Simulation in design
Simulation is now being used to help the design process. This is becoming increasingly important and widespread as computing power increases. Some of the visualizations used in design work can require very powerful computers. However, they can give an insight into how a potential process or product might work in practice which cannot be gained in any other way.
__________________
Chapter Outline
Process Selection
Types of ProcessesJob Shop Defined
Batch Shop Defined
Assembly Line Defined
Continuous Flow Defined
Process Flow Structures
Product-Process Matrix
Product-Process Matrix Defined
Break-Even Analysis
Specific Process Equipment SelectionManufacturing Process Flow Design
Conclusion
Case: Circuit Board Fabricators, Inc.
Source:
http://highered.mcgraw-hill.com/sites/0072983906/student_view0/chapter6/
In the link, there are powerpoint slides of the chapter.
Process Design - Slack's Book Chapter summary
Summaries of all Chapters of Operation Management
MBA Core Management Knowledge - One Year Revision Schedule
Bibliography
Books
K G Swift, J. D. Booker
Butterworth-Heinemann, 15-Feb-2013 - Technology & Engineering - 456 pages
Manufacturing Process Selection Handbook provides engineers and designers with process knowledge and the essential technological and cost data to guide the selection of manufacturing processes early in the product development cycle.
Building on content from the authors’ earlier introductory Process Selection guide, this expanded handbook begins with the challenges and benefits of identifying manufacturing processes in the design phase and appropriate strategies for process selection. The bulk of the book is then dedicated to concise coverage of different manufacturing processes, providing a quick reference guide for easy comparison and informed decision making.
For each process examined, the book considers key factors driving selection decisions, including:
Basic process descriptions with simple diagrams to illustrate
Notes on material suitability
Notes on available process variations
Economic considerations such as costs and production rates
Typical applications and product examples
Notes on design aspects and quality issues
Providing a quick and effective reference for the informed selection of manufacturing processes with suitable characteristics and capabilities, Manufacturing Process Selection Handbook is intended to quickly develop or refresh your experience of selecting optimal processes and costing design alternatives in the context of concurrent engineering. It is an ideal reference for those working in mechanical design across a variety of industries and a valuable learning resource for advanced students undertaking design modules and projects as part of broader engineering programs.
Provides manufacturing process information maps (PRIMAs) provide detailed information on the characteristics and capabilities of 65 processes in a standard format
Includes process capability charts detailing the processing tolerance ranges for key material types
Offers detailed methods for estimating costs, both at the component and assembly level
Papers
Framework of models for selecting manufacturing processes and associated parameters for surface topographies
Benoit Rosa (1)*, Maxence Bigerelle(2), Antoine Brient(1) and Serge Samper(1)
1 Institut de Physique de Rennes (IPR), UMR CNRS 6251, Rennes, France
2 Laboratoire d'Automatique de Mécanique et d'Informatique Industrielles et Humaines (LAMIH), UMR CNRS 8201, Valenciennes, France
Mechanics & Industry 20, 301 (2019)
The factors affecting selection of manufacturing process are mentioned below.
Volume of production
Type of component
Expected quality standards
Properties of component
Technical viability of the process
Economy
Rate of production
Limitations of shape and size
Surface finish and tolerance requirement
Functional requirement of the component
Let me explain each of these points.
https://knordslearning.com/factors-affecting-selection-of-manufacturing-process/
Good search results for: Manufacturing Process Selection
Updated 12.5.2022, 18.3.2022, 17 Mar 2016, 7 Dec 2014
Read on 17 March 2016.
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