The document discusses process planning and performance for manufacturing simple and complex products, focusing on air pack manufacturing as a case study. It highlights the key features of products, necessary processes, materials, and performance attributes such as rate, cost, quality, and flexibility. The conclusion emphasizes the importance of selecting and sequencing operations and understanding manufacturing fundamentals across different levels of detail.

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Process Planning
and Performance
MIT 2.008x
Prof. John Hart

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Agenda
 Process plans for simple
and complex products.
 Process performance
attributes.
 Conclusion; activity on
your own.

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Process Planning:
Processes for simple
and complex products

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How was it made?
Image from http://www.storopack.us/en/products-solutions/flexible-protective-
packaging/airplusr-inflatable-void-fill-and-cushioning.html
Raw material
Finished
product
http://www.dailyimpact.net/2015/10/28/death-watch-in-the-
oil-patch/

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Process plan: air pack manufacturing
Raw material extraction
Plastic pellet production
Film extrusion/blowing
Printing
Sealing, inflation, cutting
Use in your package
Image from http://www.storopack.us/en/products-solutions/flexible-protective-
packaging/airplusr-inflatable-void-fill-and-cushioning.html
Finished
product
http://www.dailyimpact.net/2015/10/28/death-watch-in-the-
oil-patch/

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Air pack manufacturing
Raw material extraction
Plastic pellet production
Film extrusion/blowing
Printing
Sealing, inflation, cutting
Use in your package
https://www.youtube.com/watch?v=O7BLsexJn0c

7. 2.008x
Air pack manufacturing
Raw material extraction
Plastic pellet production
Film extrusion/blowing
Printing
Sealing, inflation, cutting
Use in your package
https://www.youtube.com/watch?v=kUfiwgrsfhc

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How do we envision
the process plan?
 What are the key features of the
finished product?
 What processes are needed?
 What materials are involved?
 What are the key attributes for
use?
 Which attributes can be standard,
and which must be customized?
 Should all operations be
performed in the same location,
or not?

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How do we envision
the process plan?
 What are the key features of the
finished product?
 What processes are needed?
 What materials are involved?
 What are the key attributes for
use?
 Which attributes can be standard,
and which must be customized?
 Should all operations be
performed in the same location,
or not?

10. 2.008x
How do we envision
the process plan?
 What are the key features of the
finished product?
 What processes are needed?
 What materials are involved?
 What are the key attributes for
use?
 Which attributes can be standard,
and which must be customized?
 Should all operations be
performed in the same location,
or not?
 What process sequence(s)
make sense?

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From https://smile.amazon.com/Amazon-Fire-7-Inch-Tablet-8GB/dp/B00TSUGXKE/
$50 Amazon Fire Tablet

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Glass LCD display
Front case
Battery
PCB + speaker
Back case

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Conceptual assembly plan
SCREEN
FRONT CASE FRONT ASSEMBLY
BOARD
BACK COST
BACK ASSEMBLY
BATTERY
BUTTONS
MODULES SUBASSEMBLIES

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Amazon Fire LCD display
Color filter
(rotated 45 deg)
1 mm
LCD
Display
LCD display
Glass + touch sensors
19

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Planning for a complex
product
 Customer needs and
preferences: size, color, price,
perception of quality!
 Design for manufacturing
 Standard vs custom parts
 Materials
 R&D required?
 Supply chain
 Supplier quality control
 Shipping distribution
 Seasonal dynamics
 Inventory cost, support
 etc...

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Process Planning:
Process performance
attributes

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How do we measure the performance of a
manufacturing process?

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Rate

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Cost
General relationship between manufacturing cost per part and production volume

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Quality
Variation and defects in m&m candies
Normal (Gaussian) probability density function

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Flexibility
Titanium brackets produced using conventional manufacturing (left) and
additive manufacturing (right). From General Electric 3D printing challenge
(http://www.gereports.com/post/77131235083/jet-engine-bracket-from-indonesia-wins-3d-printing/)

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Flexibility
http://www.conformis.com/customized-knee-implants/image-to-
implant-process/
What would be
ultimate flexibility?
Titanium brackets produced using conventional manufacturing (left) and
additive manufacturing (right). From General Electric 3D printing challenge
(http://www.gereports.com/post/77131235083/jet-engine-bracket-from-indonesia-wins-3d-printing/)

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Air packs: the four attributes
Image from: http://s3.amazonaws.com/ems.wf.net.au_production/assets/16865/web_image_article/CardiaBiohybridSealedAirFill-
AirR5Lo.jpg

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Process Planning:
Conclusion

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What have we
learned?
 Process planning: selecting and
sequencing the operations needed
to manufacture a product.
 Most products require the
integration of multiple processes,
often in multiple locations.
 Four essential and interrelated
attributes: rate, cost, quality, and
flexibility.
 We can apply the same ‘lens’ at
different levels of detail, and build
both a broad and deep
understanding of manufacturing
fundamentals.

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Cookie manufacturing!
Excerpt from: https://www.youtube.com/watch?v=CCbWyYr82BM
…Why do I have to wait so long for my cookies?

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Cookie manufacturing!
Excerpt from: https://www.youtube.com/watch?v=CCbWyYr82BM
 What is the process plan
for making cookies in
your kitchen?
 How would cookies be
mass-manufactured?
 In both cases, what
influences rate, cost,
quality, and flexibility?
 How might you improve
the process?
…Why do I have to wait so long for my cookies?

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Size of
cookie?
Shape of
cookie?
Flavor of
Cookie?
Image from: http://henson.com/sesamestreet.php
Nutrition value
of cookie?!