This document discusses manufacturing and process selection design. It covers topics such as process analysis, process flowcharting, types of processes, process performance metrics, and manufacturing process flow design. Process flowcharting uses diagrams to present the major elements of a process, including tasks, flows of materials, decision points, and storage areas. Common process types include single-stage, multi-stage, make-to-order, and make-to-stock. Process performance is evaluated using metrics like cycle time, utilization, and bottlenecks. Manufacturing process flow design maps how raw materials move through a plant.

1. Manufacturing and Process Selection Design

2. Process Analysis
Process Analysis
Process Flowcharting
Process Flowcharting
OBJECTIVES
Process Flowcharting
Process Flowcharting
Types of Processes
Types of Processes
Process Performance Metrics
Process Performance Metrics

3. Process Analysis Terms
Process Analysis Terms
Process
Process:
: Is
Is any
any part
part of
of an
an organization
organization that
that
takes
takes inputs
inputs and
and transforms
transforms them
them into
into outputs
outputs
Cycle
Cycle Time
Time:
: Is
Is the
the average
average successive
successive time
time
between
between completions
completions of
of successive
successive units
units
Utilization
Utilization:
: Is
Is the
the ratio
ratio of
of the
the time
time that
that a
a
resource
resource is
is actually
actually activated
activated relative
relative to
to the
the
time
time that
that it
it is
is available
available for
for use
use

4. Process Flowcharting Defined
Process Flowcharting Defined
Process
Process flowcharting
flowcharting is
is the
the use
use of
of a
a diagram
diagram to
to
present
present the
the major
major elements
elements of
of a
a process
process
The
The basic
basic elements
elements can
can include
include tasks
tasks or
or
operations,
operations, flows
flows of
of materials
materials or
or customers,
customers,
decision
decision points,
points, and
and storage
storage areas
areas or
or queues
queues
It
It is
is an
an ideal
ideal methodology
methodology by
by which
which to
to begin
begin
analyzing
analyzing a
a process
process

5. Flowchart Symbols
Tasks or operations Examples: Giving an
admission ticket to a
customer, installing a engine
Purpose and Examples
customer, installing a engine
in a car, etc.
Decision Points Examples: How much change
should be given to a
customer, which wrench
should be used, etc.

6. Purpose and Examples
Flowchart Symbols
Examples: Sheds, lines of
people waiting for a service,
etc.
Examples: Customers moving
to a seat, mechanic getting a
tool, etc.
Storage areas or
queues
Flows of materials or
customers

7. Types of Processes
Types of Processes
Single-stage Process
Stage 1
Stage 1 Stage 2 Stage 3
Multi-stage Process

8. Types of Processes (Continued)
Types of Processes (Continued)
A
A buffer
buffer refers
refers to
to a
a storage
storage area
area between
between
stages
stages where
where the
the output
output of
of a
a stage
stage is
is placed
placed
prior
prior to
to being
being used
used in
in a
a downstream
downstream stage
stage
Stage 1 Stage 2
Buffer
Multi-stage Process with Buffer
prior
prior to
to being
being used
used in
in a
a downstream
downstream stage
stage

9. Other Process Terminology
Other Process Terminology
Blocking
Blocking
Occurs
Occurs when
when the
the activities
activities in
in a
a stage
stage must
must stop
stop because
because
there
there is
is no
no place
place to
to deposit
deposit the
the item
item just
just completed
completed
If
If there
there is
is no
no room
room for
for an
an employee
employee to
to place
place a
a unit
unit of
of work
work
If
If there
there is
is no
no room
room for
for an
an employee
employee to
to place
place a
a unit
unit of
of work
work
down,
down, the
the employee
employee will
will hold
hold on
on to
to it
it not
not able
able to
to continue
continue
working
working on
on the
the next
next unit
unit
Starving
Starving
Occurs
Occurs when
when the
the activities
activities in
in a
a stage
stage must
must stop
stop because
because
there
there is
is no
no work
work
If
If an
an employee
employee is
is waiting
waiting at
at a
a work
work station
station and
and no
no work
work is
is
coming
coming to
to the
the employee
employee to
to process,
process, the
the employee
employee will
will
remain
remain idle
idle until
until the
the next
next unit
unit of
of work
work comes
comes

10. Other Process Terminology
Other Process Terminology
(Continued)
(Continued)
Bottleneck
Bottleneck
Occurs
Occurs when
when the
the limited
limited capacity
capacity of
of a
a process
process causes
causes
work
work to
to pile
pile up
up or
or become
become unevenly
unevenly distributed
distributed in
in the
the flow
flow
of
of a
a process
process
of
of a
a process
process
If
If an
an employee
employee works
works too
too slow
slow in
in a
a multi
multi-
-stage
stage process,
process,
work
work will
will begin
begin to
to pile
pile up
up in
in front
front of
of that
that employee
employee.
. In
In this
this
is
is case
case the
the employee
employee represents
represents the
the limited
limited capacity
capacity
causing
causing the
the bottleneck
bottleneck.
.
Pacing
Pacing
Refers
Refers to
to the
the fixed
fixed timing
timing of
of the
the movement
movement of
of items
items
through
through the
the process
process

11. Other Types of Processes
Other Types of Processes
Make
Make-
-to
to-
-order
order
Only
Only activated
activated in
in response
response to
to an
an actual
actual order
order
Both
Both work
work-
-in
in-
-process
process and
and finished
finished goods
goods inventory
inventory
Both
Both work
work-
-in
in-
-process
process and
and finished
finished goods
goods inventory
inventory
kept
kept to
to a
a minimum
minimum
Make
Make-
-to
to-
-stock
stock
Process
Process activated
activated to
to meet
meet expected
expected or
or forecast
forecast
demand
demand
Customer
Customer orders
orders are
are served
served from
from target
target stocking
stocking level
level

12. Types of Processes
Types of Processes
Conversion (ex. Iron to steel)
Conversion (ex. Iron to steel)
Fabrication (changing raw material into some
Fabrication (changing raw material into some
specific form.
specific form.
specific form.
specific form.
(ex. Cloth to clothes)
(ex. Cloth to clothes)
Assembly (ex. Parts to components)
Assembly (ex. Parts to components)
Testing (ex. For quality of products)
Testing (ex. For quality of products)

13. Process Flow Structures
Process Flow Structures
Process
Process flow
flow structure
structure refers
refers to
to organization
organization of
of material
material flow
flow into
into the
the
factory
factory using
using one
one or
or more
more of
of the
the process
process technologies
technologies.
.
Job
Job shop
shop (production
(production of
of small
small batches
batches of
of a
a large
large no
no.
. of
of different
different product
product.
.
(ex
(ex.
. Copy
Copy center
center making
making a
a single
single copy
copy of
of a
a student
student term
term paper)
paper)
(ex
(ex.
. Copy
Copy center
center making
making a
a single
single copy
copy of
of a
a student
student term
term paper)
paper)
Batch
Batch shop
shop (employed
(employed when
when business
business has
has a
a relatively
relatively stable
stable line
line of
of
products)
products)
(ex
(ex.
. Copy
Copy center
center making
making 10
10,
,000
000 copies
copies of
of an
an ad
ad piece
piece for
for a
a business)
business)
Assembly
Assembly Line
Line (production
(production of
of discrete
discrete parts
parts moving
moving from
from workstation
workstation to
to
workstation
workstation at
at a
a controlled
controlled rate,
rate, in
in a
a particular
particular sequence
sequence.
.
(ex
(ex.
. Automobile
Automobile manufacturer)
manufacturer)
Continuous
Continuous Flow
Flow (conversion
(conversion or
or further
further processing
processing of
of undifferentiated
undifferentiated
materials
materials in
in a
a predetermined
predetermined sequence
sequence of
of steps)
steps)
(ex
(ex.
. Petroleum
Petroleum manufacturer)
manufacturer)

14. Product
Product-
-Process Matrix
Process Matrix
Relationship
Relationship between
between process
process structures
structures
and
and volume
volume requirements
requirements is
is depicted
depicted on
on
a
a product
product-
-process
process matrix
matrix.
.
a
a product
product-
-process
process matrix
matrix.
.

15. I.
Job
Shop
Low
Volume,
One of a
Kind
Multiple
Products,
Low
Volume
Few
Major
Products,
Higher
Volume
High
Volume,
High
Standard-
ization
Commercial
Printer
French
Restaurant
Flexibility (High)
Unit Cost (High)
Exhibit 6.2
These are
the major
Effective
Measures
Process
structure
Process life
cycle stage
Product Structure
Product Life cycle
IV.
Continuous
Flow
III.
Assembly
Line
II.
Batch
Restaurant
Heavy
Equipment
Automobile
Assembly
Burger King
Sugar
Refinery Flexibility (Low)
Unit Cost (Low)
the major
stages of
product
and
process
life cycles

16. Break
Break-
-Even Analysis
Even Analysis
A
A standard
standard approach
approach to
to choosing
choosing among
among
alternative
alternative processes
processes or
or equipment
equipment
Model
Model seeks
seeks to
to determine
determine the
the point
point in
in units
units
produced
produced (and
(and sold)
sold) where
where we
we will
will start
start making
making
profit
profit on
on the
the process
process or
or equipment
equipment
Model
Model seeks
seeks to
to determine
determine the
the point
point in
in units
units
produced
produced (and
(and sold)
sold) where
where total
total revenue
revenue and
and
total
total cost
cost are
are equal
equal

17. Break
Break-
-Even Analysis (Continued)
Even Analysis (Continued)
Break-even Demand=
Purchase cost of process or equipment
Price per unit - Cost per unit
or
Total fixed costs of process or equipment
Unit price to customer - Variable costs per unit
This
This formula
formula can
can be
be used
used to
to find
find any
any of
of its
its
components
components algebraically
algebraically if
if the
the other
other
parameters
parameters are
are known
known

18. Break
Break-
-Even Analysis (Continued)
Even Analysis (Continued)
Example
Example:
: Suppose
Suppose you
you want
want to
to purchase
purchase a
a new
new
computer
computer that
that will
will cost
cost Rs
Rs 30000
30000.
. It
It will
will be
be used
used to
to
process
process written
written orders
orders from
from customers
customers who
who will
will pay
pay
Rs
Rs 100
100 each
each for
for the
the service
service.
. The
The cost
cost of
of labor,
labor,
electricity
electricity and
and the
the form
form used
used to
to place
place the
the order
order is
is Rs
Rs50
50
per
per customer
customer.
. How
How many
many customers
customers will
will we
we need
need to
to
serve
serve to
to permit
permit the
the total
total revenue
revenue to
to break
break-
-even
even with
with
serve
serve to
to permit
permit the
the total
total revenue
revenue to
to break
break-
-even
even with
with
our
our costs?
costs?
Break
Break-
-even Demand:
even Demand:
=
= Total fixed costs of process or equip
Total fixed costs of process or equip.
.
Unit price to customer
Unit price to customer –
– Variable costs
Variable costs
=30,000/(100
=30,000/(100-
-50)
50)
=600 customers
=600 customers

19. Manufacturing Process Flow Design
Manufacturing Process Flow Design
A process flow design can be defined as
a mapping of the specific processes that
raw materials, parts, and subassemblies
raw materials, parts, and subassemblies
follow as they move through a plant
The most common tools to conduct a
process flow design include assembly
drawings, assembly charts, and
operation and route sheets

20. Example: Assembly Chart (Gozinto)
Example: Assembly Chart (Gozinto)
A-2
SA-2
4
5
6
Lockring
Spacer, detent spring
Rivets (2)
From Exhibit 6.6
6
7
Rivets (2)
Spring-detent
A-5
Component/Assy Operation
Inspection

21. Example: Process Flow Chart
Example: Process Flow Chart
Material
Received
from
Supplier
Inspect
Material for
Defects Defects
found?
No,
Continue…
Return to
Supplier for
Credit
Yes

22. Question Bowl
Question Bowl
What
What is
is the
the break
break-
-even
even in
in demand
demand for
for a
a new
new process
process that
that costs
costs
Rs
Rs25
25,
,000
000 to
to install,
install, will
will generate
generate a
a service
service product
product that
that
customers
customers are
are willing
willing to
to pay
pay Rs
Rs500
500 per
per unit
unit for,
for, and
and whose
whose
customers
customers are
are willing
willing to
to pay
pay Rs
Rs500
500 per
per unit
unit for,
for, and
and whose
whose
labor
labor and
and material
material costs
costs for
for each
each unit
unit is
is Rs
Rs100
100?
?
a.
a. 400
400 units
units
b.
b. 250
250 units
units
c.
c. 100
100 units
units
d.
d. 62
62.
.5
5 units
units
e.
e. None
None of
of the
the above
above
Answer: d. 62.5
units (25,000/(500-
100)=62.5)

23. Question Bowl
Question Bowl
Which
Which of
of the
the following
following is
is an
an example
example of
of a
a Continuous
Continuous
Flow
Flow type
type of
of process
process flow
flow structure?
structure?
a.
a. Fast
Fast food
food
b.
b. Grocery
Grocery
c.
c. Hospitals
Hospitals
d.
d. Chemical
Chemical company
company
e.
e. None
None of
of the
the above
above
Answer: d. Chemical company

24. Question Bowl
Question Bowl
Which
Which type
type of
of process
process is
is by
by changing
changing of
of raw
raw materials
materials
into
into some
some specific
specific form
form (such
(such as
as sheet
sheet metal
metal into
into a
a
car
car fender)?
fender)?
a.
a. Conversion
Conversion
b.
b. Fabrication
Fabrication
c.
c. Assembly
Assembly
d.
d. Testing
Testing
e.
e. None
None of
of the
the above
above
Answer: b.
Fabrication