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Process Selection and Facility Layout

CHAPTER. 6. Process Selection and Facility Layout. Questions for Process Analysis and Design. Is the process designed to achieve competitive advantage in terms of differentiation, response, or low cost? Does the process eliminate steps that do not add value?

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Process Selection and Facility Layout

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  1. CHAPTER 6 Process Selection andFacility Layout

  2. Questions for Process Analysis and Design • Is the process designed to achieve competitive advantage in terms of differentiation, response, or low cost? • Does the process eliminate steps that do not add value? • Does the process maximize customer value as perceived by the customer? • Will the process win/keep orders?

  3. Process Selection and System Design Capacity planning Forecasting Facilities and Equipment Process selection Product and service design Layout Work design

  4. Types of Processes • Job Shops - Small runs/variety • Batch Processing - Similar groups • Repetitive/Assembly - Discrete goods • Continuous Processing - Bulk/no variety • Projects - Nonroutine jobs

  5. Repetitive Production

  6. Continuous Production

  7. Few Major Products, Higher Volume High Volume, High Standard- ization Low Volume One of a Kind Multiple Products, Low Volume Flexibility- Quality Job Shop Commercial Printer Batch Heavy Equipment Assembly Line Automobile Assembly Continuous Flow Sugar Refinery Dependability Cost Flexibility-Quality Dependability-Cost Product-Process Lifecycle Matrix

  8. Automation/Technology Decisions • Automation -- The substitution of technology for human activity • Key Question -- How does technology fit strategically (appropriateness)? • Four other questions managers must ask-- • What will new technology do and not do? • What will new technology require? • What will new technology cost (total/life cycle)? • How certain are we of the answers above?

  9. Automation • Numerically controlled machines (NC) • Robotics, Vision, Automatic ID • Computer-aided design and manufacturing systems (CAD/CAM) • Flexible manufacturing systems • Computer-integrated manufacturing (CIM)

  10. The Need for Layout Decisions Inefficient operations Changes in the design of products or services For Example: High Cost Bottlenecks Accidents The introduction of new products or services Safety hazards

  11. The Need for Layout Designs (Cont’d) Changes in environmental or other legal requirements Changes in volume of output or mix of products Morale problems Changes in methods and equipment

  12. Basic Layout Types • Product Layouts • Process Layouts • Fixed-Position • Combination Layouts • Cellular Layouts

  13. Basic Layout Types • Product Layout • Uses standardized processing operations to achieve smooth, sequential, rapid, high-volume flow (production/assembly lines) • Process Layout • By Department or Function. Flexibly handles varied processing requirements • Fixed Position Layout • Product or project stationary, and workers, materials, and equipment are moved to site as needed

  14. Cellular Layouts • Cellular Manufacturing • Group Technology • Flexible Manufacturing Systems

  15. Cellular Layouts • Cellular Manufacturing • Machines grouped into cells to make families of items with similar processing requirements • Group Technology • Grouping items into part families based on design or manufacturing similarities

  16. Flexible Manufacturing System Computer control room Tools Conveyor Machine Machine Pallet Load Unload Parts Finished goods Terminal © 1998 by Prentice-Hall Inc Russell/Taylor Oper Mgt 2/e Ch 6 - 33

  17. CAD CAE GT DFM IGES, PDES, DMIS TQM Product design CAD/CAM Bar codes, EDI CAPP MRP CIM Systems management Process planning JIT/ kanban Cellular manufacturing DSS/ES/ AI MAP, STEP Manufacture LAN, TOP, satellites NC/CNC/ DNC FMS Robotics AGV, ASRS Automated inspection Cells and centers Components Of CIM © 1998 by Prentice-Hall Inc Russell/Taylor Oper Mgt 2/e Ch 6 - 37

  18. Other Service Layouts • Warehouse and Storage • Frequency of use, item correlation • Retail • Customer needs, traffic pattern/flow • Office • Less flow dependent

  19. Tools for Process Design • Flow Diagrams • Process Charts • Time-Function/Process Mapping • Service Blueprints

  20. Production Process Flow Diagram Customer Purchasing (order inks, paper, other supplies) Customer sales representative take order Vendors Prepress Department (Prepare printing plates and negatives) Receiving Accounting Printing Department Warehousing (ink, paper, etc.) Gluing, binding, stapling, labeling Collating Department Information flow Material flow Polywrap Department Shipping

  21. Time Function Map Receive product Order Product Customer Process Order Sales Order Productioncontrol Wait Order Print Plant A Product WIP Wait Wait Wait Warehouse Product WIP Plant B Extrude Product WIP WIP Transport Move Move 12 days 13 days 1 day 4 days 1 day 10 days 9 days 1 day 1 day

  22. SUBJECT: Request tool purchase Dist (ft) Time (min) Symbol Description Ñ Write order D lðo Ñ On desk ¡ðo w Ñ 75 To buyer D ¡ o è Ñ Examine D ¡ðn ¡ = Operation; ð = Transport; o = Inspect; D = Delay; Ñ = Storage Process Chart Example

  23. Service Blueprinting

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