The document discusses manufacturing process selection and design. It covers key aspects like product design, process planning, product and process flow characteristics, types of product flows including line, batch and project flows. It also discusses factors that affect process choice like market conditions, capital requirements and technology. The document provides examples of layouts in different industries like automobiles, cement plants and describes different types of processes and process flow structures.

1. 1
Manufacturing Process Selection and Design

2. Overall development of
processing plans
Design specifications
2
Sales forecasts, Customer orders
Product design
Functional design
Production design, setting minimum possible costs
Drawings and specifications of what to make
Make or Buy decisions
Make
Process decisions, selection from alternative processes
Route sheets and Operation sheets
Modifications of process plans due to layout, Quality
preferences and machine availability
Workplace design
and Tool Design
Manufact
uring
Buy
Process planning
Product analysis, Assembly charts, Flow charts etc.

3. Product-Flow Characteristics
Types of Product Flow
– Line Flow
– Batch Flow
– Project Flow
Characteristics of Flows
4-3
4-3

4. Line Flow
cut
drill
bend
Task or work station
Product flow
paint

5. Batch Flow
Bend
Paint
Cut
Drill
Task or work station
BatchA
BatchB
BatchC
Product flows

6. Classification by Type of
Customer Order
Make to Stock (MTS)
Make to Order (MTO)
Assemble to Order (ATO)

7. Process Selection Decisions
Process characteristics matrix
Factors affecting process choice

8. Factors Affecting Process Choice
Market conditions and competition
Capital requirements
Labor supply and cost
State of technology

9. 9
Schematic Layout of a
Product focused Production
System
Raw
Material
1
Components
(procured)
Components
(made)
2
Assemblies
3
Sub
Assemblies
2
Sub
Assemblies
4
Finished
Product
Assemblies
3
Procured Sub
Assemblies
3
1 - Component manufacturing
Section
2 – Sub Assembling Section
3 – Assembling Section

10. 10
How to make a car :
The production
process in a Modern Car Plant includes lots of checks on quality and Extensive
Treatment to Prevent Corrosion

11. 11
Process Manufacturing
System- A Layout in a
Cement Plant
Limestone
Crusher
Hopper 1
Feeder 1
Iron One
Hopper 2
Feeder 2
Clay
Hopper 3
Feeder 3
Gympsum
Blending Silo
Firing Kiln
Hopper 4
Feeder
Dispatch Silo
Raw
Mill
Hopper 5
Cement Mill
Feeder

12. 12
Process Focused
Production – A Schematic
Layout
Receiving
raw materials
storage
Job A
Foundry
Welding
and
soldering
Lathe
section
:
:
Job B
:
Painting
and
packaging
:
:
:
Quality
control
:
:
:
:
:
:

13. 13
Types of Processes

Conversion (ex. Iron to steel)

Fabrication (ex. Cloth to clothes)

Assembly (ex. Parts to components)

Testing (ex. For quality of products)

14. 14
Process Flow Structures

Job shop (Ex. Tailoring Shop )

Batch shop (Ex. Garment Manufacturer /
Pharmaceutical Products)

Assembly Line (ex. Automobile manufacturer)

Continuous Flow (ex. Petroleum Products
manufacturer)

15. Product-Process Strategy
Strategy must consider not only the
product or service, but also how to
produce it.
As many industries move through their
product life cycles, they also move through
a process life cycle. e.g. the traditional
bread bakery vs. the modern automated
bakery.

16. Product Life Cycle Stages
Low volume-low standardization, one of a
kind
 Multiple products, low volume
Few major products, higher volume
 High volume-high standardization,
commodity product

17. Process Life Cycle Stages
Jumbled flow (job shop)
 Disconnected line flow (batch)
Connected line flow (assembly line)
 Continuous flow

18. 18
I.
Job
Shop
II.
Batch
III.
Assembly
Line
IV.
Continuous
Flow
Few
High
Low
Multiple Major Volume,
Volume, Products, Products, High
One of a
Low
Higher StandardKind
Volume Volume ization
Commercial
Printer
French
Restaurant
Flexibility (High)
Unit Cost (High)
These are
These are
the major
the major
stages of
stages of
product
product
and
and
process
process
life cycles
life cycles
Heavy
Equipment
Automobile
Assembly
Burger King
Sugar
Refinery
Flexibility (Low)
Unit Cost (Low)

19. 19
Relationship between
Product Design and Batch
Size
Batch size
A
Product
Focused,
Dedicated
System
B
Product focused batch
system
Cellular
manufacturing
C
Process focused
job shop
D
Number of product designs

20. Manufacturing Process Flow
Design

A process flow design can be defined as
a mapping of the specific processes that
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

21. Example: Assembly Chart
(Gozinto)
4
5
6
7
From Exhibit 5.14
From Exhibit 5.14
Lockring
Spacer, detent spring
SA-2
Rivets (2)
A-2
Spring-detent
A-5
Component/Assy Operation
Inspection
21

22. Example: Process Flow
Chart
Material
Received
from
Supplier
No,
Continue…
Inspect
Material for
Defects
Defects
found?
Yes
Return to
Supplier for
Credit
22

23. 23
Question Bowl
What is the break-even in demand for a new
process that costs Rs25,000 to install, will
generate a service product that customers
are willing to pay Rs500 per unit for, and
whose labor and material costs for each unit
is Rs100?
a.
400 units
b.
250 units
c.
100 units
d.
62.5 units
e.
None of the above
Answer: d. 62.5
units (25,000/(500100)=62.5)

24. 24
Question Bowl
Which of the following is an example of a
Continuous Flow type of process flow
structure?
a.
Fast food
b.
Grocery
c.
Hospitals
d.
Chemical company
e.
None of the above
Answer: d. Chemical company

25. 25
Question Bowl
Which type of process is by changing of raw
materials into some specific form (such as
sheet metal into a car fender)?
a.
Conversion
b.
Fabrication
c.
Assembly
d.
Testing
e.
None of the above
Answer: b. Fabrication