LACE

1. Product design and Process Selection

2. What is a product?
• Product is anything that can be offered to the market
that can satisfy a want or need.
• There are 2 concepts for a product- narrow concept and
wide concept
• That is why it is defined as a bundle of utilities
• Typology of the product may be divided into 2 namely---
• Tangible and intangible

3. • Design is the conversion of ideas and concepts into a
physical form
• Design means the determination of shape, pattern, size,
the functional aspect etc of the product which is offered
to the customer in the form of the output of the company
• “Product design in its broadest sense includes the whole
development of the product through all preliminary
stages until the actual manufacturing begins”---
C.S.Deverell
Product design
What is a design?

4. • Reverse engineering is the process of
carefully dismantling the competitors
product to understand its unique
features and concepts
• Manufacturability – designing a product
in a such a way that its assembling is
done easily; type of machines, skilled
workers etc. are considered.
Elements in product design
R&D
Reverse
Engineering
Manufacturability
Standardization
Modular design
Robust Design
Concurrent
Engineering
CAD
PLC

5. • Modular design: is another type of standardization
where the product is designed in parts or
modules. Each module will become the sub
assembly of another product
• Robust design: means designing a product that is
operational in varying environmental conditions.
• Eg:- Jeep & Car
• Concurrent engineering is the involvement of
members from all the departments in the product
designing; saves time compared to sequential
approach.

6. Objectives of product design
• To create attention in product for increasing
its sales potential
• To enlarge the importance of the product
from customers point of view
• To make the product more effective and
create more utility
• To produce better quality at lowest cost

7. • The factors influencing the product design are
based on two perspectives- customer and the
organisation
Factors influencing product design
Customer’s
perspective
Functions
Aesthetics
User friendly
Esteem
associated with
possession
Organisation’s
Perspective
Cost of material
Cost of labour
Replacement,
exchange,
disposal

8. • Function properly
• Reliability
• Easy to operate
• Accessibility of
servicing
• Ruggedness
• Appearance
• Space utilisation
Requirements of a good product design
• Easy to manufacture
• Utilisation of the available
resources
• Use of standard
components where ever
possible
• Minimum number of parts
• Minimum number of
operations
• Easy to pack and distribute
In order to achieve
customer satisfaction
Making adequate
profit means

9. Issuesinproductdesign
• Product liability
• Intellectual property which is the property of the mind or
the intellect is legally protected which a designer has to
keep in mind
• Product design and customer
• Protection of intellectual property
• Exposure to undesirable ( Internet)
• Advertising of designs (Coke)
• Testing of the design( Human testing)
– Global warming, deforestation, pollution, waste management,
Legal issues
Ethical issues
Environmental
Issues

10. • It is that part of the organisation that transforms input
into output
• The objective of the process is to provide maximum
overall value to the customer
• It is concerned with the sequence of activities or
operations required to achieve the product specification
• It is the complete definition and description of the steps
in the production process and the linkage between
different steps
Processdesign
Process
Process Design

11. • In this type of production system, the production
department is organized according to the type of
product or service being produced
• All the production operations required to produce one
product is grouped into one production
department/work centre
• The flow of the item being processed is dictated by
individual product requirements, so the routes through
the system are variable.
• It is also called Line flow production/ Continuous
production
Typesofprocessdesign Product focused system

12. Typesofprocessdesign Process focused system
• It is the system where production operation are
grouped according to the type of process
• All production operations having similar
technological processes are grouped together to
form the production department.
• The individual processes are arranged in a sequence
so that the entire system is integrated for a single
purpose like one giant machine
• The nature of demand determines the demand on
the production system and each component flows
from one process to the other intermittently

13. Typesofprocessdesign Repetitive focus system
• It is the type of focus that falls between the product
and the process systems
• Repetitive focus works on modules which are
components previously produced through continuous
process like spares of automobiles
• These modules are used for customizing the product
thereby getting the economic advantage of
continuous model and the custom advantage of
process model like high variety, low volume
• Eg: Automobiles, fast food chains etc

14. • Rapid low cost production of goods & services that
fulfill increasingly unique customer desire.
• Products are customized for individual customers
or for niche markets.
• 4 Approaches to Mass Customization:-
Mass Customization Focus

15. Repeat again
(Transparent
Customization)
Either – Or
(Collaborative
Customization)
Sort-through
(Adaptive
Customization)
Form – Of
(Cosmetic
Customization)
Product
No
change
Change
RepresentationNo
Change
Change

16. • Machines are grouped into cells & cells
function like a product layout within a
large process layout.
Cellular Manufacturing / Group
Technology System

17. ProcessSelection • Process selection refers to the way an organisation chooses to
produce its goods and services
• It takes into account the selection of technology, capacity
planning, layout of facilities etc
• The organisations decision on process selection will be based
on strategies like make or buy, capital intensity and flexibility
• Process by market orientation
– Make to stock
– Make to order
– Assemble to order
• Process based on production system like flow or intermittent
• Process and customer involvement
– Self service like department stores
– Customized Product selection as in cars
Process categorization

18. • A common way of defining a product is by drawing or creating
its blue print.
• Assembly drawing helps to find out what are the individual
components and what is their inter relationship.
• Detailed engineering drawings help the in-house persons and
purchasing agents with the technicalities in the components for
producing/purchasing.
• A parts list is then made which give in specifications of the
parts like, name, number, dimension etc.
• Drawings and parts list together will determine the machines &
materials
PROCESS SELECTION

19. ProcessSelectionprocess Assembly Drawing and parts list
• Design document – engineering
drawings, parts list
• Material specification – material type,
grade, properties
• Manufacturing data – surface finish,
tolerances, special treatments
• Geometry – shape, size, weight,
features
• Material evaluation – shape,
properties
• Critical processing factors – correlate
data
Design document
Material
specification Geometry
Manufacturing data
Material
evaluation
Critical
Processing Data
Process Selection
table&identify
suitable process
Sequence process
Further
processi
ng req?

20. • Layout refers to the arrangement of facilities.
• A plant layout refers to the arrangement of machinery,
equipments and other facilities like the shipping
departments, tool rooms, maintenance rooms, employee
amenities and so on for the quickest and smoothest
production at the least cost
Layoutdecision Meaning- Layout
Principles of plant layout
Maximum Security
Coordination
Use of Volume
Visibility
Accessible for
maintenance
Minimum
Distance
Minimum
Discomfort
Flexibility
Efficient Process
Flow
Minimum Handling
Providing workers
own spaceInherent Safety

21. Layoutdecision Importance- Layout
• Economies of handling
• Minimization of production delays
• Minimum equipment investment
• Better production control
• Effective usage of available area
• Avoidance of bottle necks
• Better supervision
• Avoidance of unnecessary and costly changes

22. • Also called straight line layout/ line layout is the method
in which machines are arranged in one line depending on
the sequence of operations
• Materials are fed into one machine and the output comes
out of the last machine
• In between partly finished goods travel automatically
from one machine to another, the output of one becomes
the input of another
Typesoflayout Product layout

23. • Regulation of
production as it is
planned in a
sequence
• Scientific material
handling
• No bottlenecks in
the production
• Prompt production
• Low W-I-P
• Lesser supervision
• Greater possibility
of space utilisation
Productlayout
• Heavy capital
investment
• Heavy overhead
charges
• Demerits of
breakdown
• Inflexibility
• Lack of availability of
specialised supervisors
Advantages Disadvantages

24. • Also called functional layout/ Job layout is the method
in which machines are arranged on a functional basis and
the operations of the same type are performed in the
same area.
• This type of layout is used where
– Expensive machinery is needed
– Production involves a large variety of items
– Operations are not balanced in time
– The demand is small and intermittent
Typesoflayout Process layout

25. Processlayout Advantages Disadvantages
• Lower capital
investment
• Greater flexibility
• Specialisation
• Effective supervision
• No disruption in work
schedules
• Low overhead costs
• Complexity of
production planning
• Difficulty of material
handling
• Greater floor area
• Large stock of
materials in process
• Longer processing
time

26. • It is the layout in which the material or major component
remains stationary and men, machinery and tools are
brought to the location
• This is especially suitable for products that are bulky and
heavy like ships, aircrafts, locomotives, building etc
• Its advantages are
– Men and machines can be used for a wide variety of
operations
– The investment in layout is small
– The high cost and difficulty in transporting the bulk
product can be avoided
• Disadvantages are
– There involves a low content of work in progress
– It involves high equipment handling cost
Typesoflayout Fixed Position layout

27. Typesoflayout Cellular Manufacturing/ Group Technology layout
• In this layout, machines are grouped into cells and the
cells function somewhat like a product layout
• Cellular Manufacturing /Group Technology, seeks to take
full advantage of the similarity between parts, through
standardization and common processing
• Cellular Manufacturing systems machines are grouped
together according to the families of parts produced.

28. Typesoflayout Cellular Manufacturing/ Group Technology layout
• The major advantage is that material flow is significantly
improved, which reduces the distance travelled by
materials, inventory and cumulative lead times.
• Cellular Manufacturing employs setup reduction and gives
the workers the tools to be multi process, operating
multiple processes, and multifunctional, owning quality
improvements, waste reduction, and simple machine
maintenance.
• This allows workers to easily self-balance within the cell
while reducing lead times, resulting in the ability for
companies to manufacture high quality products at a low
cost, on time, and in a flexible way

30. LeanManufacturingSystem Meaning of Lean Production
• The term lean defines a system that utilizes less, in
terms of all inputs, to create the same output as the
mass production while contributing more to the
customers
• The basic idea behind Lean is the abolition on “Muda”
(Waste), Cost reduction and Employee empowerment
• It has enabled the companies to gain in productivity,
which results in customer satisfaction through superior
quality and prompt delivery
• The under lying concept is to make problems visible,
when and where they occur and take corrective measures
to prevent recurrence

31. LeanManufacturingSystem Steps in Lean Production
There are 5 essential steps in Lean
• Identify value: value is related to how the specific
product meets the customers requirements at a specified
price and time
– Identifying the features that create value to the
customers is the first step
• Identify the value stream: which is identifying the
activities that contribute to value
– Necessary activities are defined as prerequisite and
others are reduced or avoided

32. LeanManufacturingSystem Steps in Lean Production
• Improve Flow: flow is the uninterrupted movement of
product through the system to the consumer
– Major hurdles/buffers for the smooth flow are work in
queue, batch process and transportation
– Streamlining them will help in smooth flow
• Allow customer pull: which is to make the process
responsive to providing the product or service only when
the customer needs it- not before or after
• Work towards perfection: which means to continue the
above steps to remove waste, improve flow thereby
improving quality
– When the product spends less time in process,
damages or obsolescence is reduced
– Simplification of processes reduces variation

33. LeanManufacturingSystem Advantages of Lean Production
• Reducing the manufacturing time
• Helps to reduce the floor space
• Helps to increase manufacturing
productivity
• Helps to boost profits
• Helps to achieve good customer relations
• Cultures are standardized

34. LeanManufacturingSystem Lean Production- Tools and techniques
• Cellular Manufacturing: cell consists of equipment &
workstations arranged in order to maintain smooth flow of
materials; assigned with skilled, qualified workers.
• Kaizen( Continuous Improvement): is a concept whereby
organisations undergo a systematic, gradual, orderly and
continuous endeavor for improvement
– Improvement may take place in the form of reduced
inventory, cycle time, defective parts, thereby increased
productivity and profit
• Just in time: is the concept that attempts to eliminate the
sources of waste by putting the right part at the right time at
the right place
– It tries to eliminate the waste due to WIP inventory, defects
and poor scheduling of the parts delivered
– Customer demand is the driving force
– It helps the internal processes of the company to meet
sudden changes in the demand

35. LeanManufacturingSystem Lean Production- Tools and techniques
• 5S system: which details the actions required in the organisation and
housekeeping of the work areas through 5 S’s which are:
– Seiri (SORT): what is not needed, using a red tag system to
identify items that are not needed
– Seiton(STRAIGHTEN/Set in order): what must be kept or making
things visible. “A place for everything and everything in its
place”. It focuses on effective storage methods
– Seiso(SCRUB/ Shine): which focuses on keeping the work place
clean and clutter free by taking care of the facility
• Proper Ventilation ,air, leakages of oil, coolant,
contamination, breakage, misalignments etc are checked
– Seiketsu(Standardize): which is to standardize the work practice
which can be followed by all.
• Focuses on employee participation in work improvement
– Shitsuke(SPREAD/Sustain): focuses on defining a new status quo
and standard of work place
• Through employee training and time to improve their area

36. LeanManufacturingSystem Lean Production- Tools and techniques
• Heijunka( Production smoothing): is a concept which focuses on
keeping the production cost to the minimum by keeping the
production level constant
– It is one of the important concept adopted from Toyota
Production system which says that manufacture only what can be
sold
• Standardization of work: means that each job is organized and is
carried out in an effective manner.
– No matter who does the job, the same quality should be achieved
– Standardization includes time needed to finish the job, the steps
in the job and the parts in hand
– It aims in reducing WIP inventory, non value added activity and
achieving proper line balancing
– A tool used for standardizing work is the “Takt time” which refers
to how often the parts are to be produced based on actual
demand
Takt time= Available work time per day/ Customer demand per day

37. LeanManufacturingSystem Lean Production- Tools and techniques
• Total productive maintenance: is a tool which is necessary to account
for machine breakdowns which is a serious concern in manufacturing
– There are 3 main components namely:
– Preventive maintenance: which is to do with regular maintenance
on all equipments which leads to improvement in through put of
each machine
– Corrective maintenance: which deals with decision as to fix or
replace an equipments which is always breaking down
– Maintenance prevention: which is to buy the right machine which
is easy to maintain on a regular basis
• Quality Function Deployment: is the concept of transforming the
voice of the customer into the product
– It is also called House of Quality where the output is identified as
required by the customer
– It is identified and traced back to the input by making changes in
the product design and manufacturing process

38. AgileManufacturingSystem Meaning
• AMS is a manufacturing system which has the ability to
manage market changes as a matter of routine
• Market changes refer not only to production volume but
also to product characteristics
• AMS is the ability to produce with in shortest lead time,
low cost, high quality, customized products in various
volumes
• A measure of agility is the time required to switch from
one set of characteristics to another
• The aim of AMS is to combine organisations, people,
technology into a single structure to manage quickly and
at low cost infinite number of demand types

39. AgileManufacturingSystem Characteristics
• Greater Product customization at low cost
• Quick response to changing market conditions
• Upgradable products- designed for modularity,
recyclability, reconfigurability
• Dynamic configuration of processes and systems to
accommodate swift changes
Advantages Disadvantages
• Greater competitive
advantage
• Innovative designs based
on customers demands
• Responds quickly to crisis
• Flexibility in production
• High investment required in
machinery and work force
• Sudden increase or
decrease in demand may
affect production leading to
over or under stock
• Continuous updating
required

40. Computerintegratedmanufacturing • It is the automated version of manufacturing process,
where the three major manufacturing function - product
and process design, planning and control and
manufacturing process itself are done by automated
technologies
• They are also known by the names of total factory
automation/ animation, factory of the future etc
• The objectives of CIM are
– Responsiveness to rapid changes in demand and
product modification
– Better use of resources and reduction in inventory
– Better control of production cost
– Manufacturing of high quality at low cost
• Issues in CIM are related to the integration of technology
with the processes as it is time consuming, data
integrity as machines react clumsily to wrong data,
extensive logic as there is no substitute for human
mind

41. Computerintegratedmanufacturing
• CAD is the use of computer systems in assisting the creation,
modification, analysis and optimization of design
• It consists of the hardware and software required to perform the
specialised function required by the particular firm
• The elements of CAD consists of
– The human factor who is the designer or the engineer with out
whom the CAD system will not be successful
– System factor which consist of hardware components namely Cad
work station, Input and output devices etc
– Computer aided synthesis is the design process which can tell you
how to improve the design. The synthesis process gives many
options to the design from which the most optimum and
profitable can be chosen
• The advantages of CAD are namely Quality improvement, better
computer- human interaction, flexibility and economy, reduced cost
of product development
Computer aided designing (CAD)

42. Productionandoperationtechnology • Machine technology
• Process control is the use of information technology to
monitor and control a physical process
– It is used for measuring thickness of paper or control
room temperature in refineries or heavy boiling plants
etc
– It operates in a number of ways like
• The sensors collect the data, which is read by
reading devices in periodic interval and are
converted into digital signals which are transmitted
to a computer which analyses the data and gives
the output in various forms like warning lights,
messages on computer consoles or printers
• Vision systems combine video cameras and computer
technology and are often used in inspection roles. They
are consistently accurate, do not get bored and are of
modest cost

43. Productionandoperationtechnology • Robots: is a machine which has the ability to hold, move
and perhaps grab the items. They are effectively used to
perform tasks that are monotonous and especially
dangerous and those that can be improved by substituting
machine with human especially when related to
consistency, accuracy and speed
– Eg: Welding of cars in car factories
• Automated storage and retrieval system ASRS: where it is
extremely difficult to handle warehouses ASRS has been
used. It is a mechanism which provides automatic
placement and withdrawal of parts or products from and
to the designated place in the warehouse
– Eg: ASRS systems used in Walmart, Tupperware etc
• Automated guided vehicles(AGS) are electronically guided
vehicles that are used to move parts and equipments

44. • It is the process of arranging the production line so that there
is even flow of production from one work station to another
without any delays and with least idle time
• The procedure for assembly line balancing may consist of:
– Determining the tasks to be completed and Drawing a
Precedence diagram
– Estimate the task time
– Determine the cycle time
– Balancing the assembly line
• Methods of assembly line balancing are :
– Heuristic method which means to “find out by
experimentation”. They break down complex problems
into simple manageable sub problems and solutions are
found for each
Assembly line balancing