March 17, 2016

Manufacturing Process Selection and Design - Review Notes

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.



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Chapter Outline

Process Selection
Types of Processes
Job 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 Selection

Manufacturing Process Flow Design

Conclusion

Case: Circuit Board Fabricators, Inc.

Source:
http://highered.mcgraw-hill.com/sites/0072983906/student_view0/chapter6/
Process Design - Slack's Book Chapter summary



Summaries of all Chapters of Operation Management

MBA Core Management Knowledge - One Year Revision Schedule

Updated 17 Mar 2016, 7 Dec 2014

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