This document outlines factors that affect manufacturing process design, including technical and business requirements. It discusses different categories of products and types of manufacturing processes, including project, jobbing, batch, line, and continuous processing. Project processes are for made-to-order, non-repeat work by a small group. Batch processes can be low-volume and require resetting or high-volume and continuous like a production line. The document also covers hybrid processes and using case studies to illustrate different process types for various product categories.

1. Alex Hill and Terry Hill

2. Lecture outline
• INTRODUCTION
• Factors affecting MANUFACTURING
PROCESS design
• DESIGNING the manufacturing process
• HYBRID processes
• Critical REFLECTIONS
• SUMMARY

3. © Alex Hill and Terry Hill

4. Factors affecting manufacturing process
design
TECHNICAL
REQUIREMENT
S
• STEPS required
to
- Turn INPUTS
- Into OUTPUTS
BUSINESS
REQUIREMENT
S
• VOLUMES
•MARKET
- ORDER-WINNERS
- QUALIFIERS
Manufacturing processes need to meet
both
TECHNICAL and BUSINESS
requirements

5. Categories of product

6. Types of manufacturing process

7. Understanding customer requirements
Developing a strategy
Process
type Product Process
Project
Jobbing
Batch
Line
Continuous
processing
• Made ON-SITE • Resources BOUGHT TO
SITE
• SPECIAL, non-repeat
• ONE PERSON or SMALL
GROUP
• STANDARD,
repeat low to high
volume
• Has to be RESET for each
batch of products made
• MASS, repeat high
volume
• DOES NOT have to be reset
for different products
• MASS, repeat very
high volume
• Process runs
CONTINUOUSLY and never
stops

8. Process choices

9. Designing the manufacturing
pProrocceessss choices
Use the words FLEXIBLE and AGILE with care as they have
many DIFFERENT MEANINGS and, therefore, can be misleading

10. CASE 5.1
OLD AND NEW
1C.WARhy P dLoAeNs TFoSrd use a
LINE manufacturing
process?
2.Why is this process
INFLEXIBLE?

11. CASE 5.1
OLD AND NEW CAR PLANTS
Question Answer
Line process
Inflexible
• MASS products
• NARROW product range
• VERY HIGH VOLUME
• NOT RESET for different products
• Narrow PRODUCT range
• Narrow VOLUME range

12. BATCH: SIX PROCESS TYPES
LAID OUT
Hybrid processes
SIX PROCESS TYPES FUCTIONALY LAID OUT

13. ADVANTAGES
• Less WAITING time
• Lower INVENTORY
• Easier to SCHEDULE
DISADVANTAGES
• Less FLEXIBLE
• Lower equipment
UTILISATION
CELLS are a commonly used
HYBRID PROCESS

14. Making
products
A Bug’s
Life
(1998)
Kia
Sportag
e
factory
producti
on line
Bird Car Restaurant
Product category and process
type
Dinner
Rush
(2000)

15. Making
pPrroodduucct tcsategory and process
type
Film clip Pit Stop
Film
Title
Director
(year)
A Bug’s Life
John Lasseter and Andrew Stanton (1998)
Clip Start
Finish
00:47:00
00:51:22
What clip shows The bugs decide that they want to build a bird
to protect their community
Key learning
objective
The characteristics of a project process
How an operation transforms inputs into
outputs

16. Making
pPrroodduucct tcsategory and process
type
Film clip Factory
Film
Title
Director
(year)
Kia Sportage factory production line
Clip Start
Finish
01:33:13
01:34:31
What clip shows Cars being manufactured on a production line
Key learning
objective
The characteristics of a high-volume batch
process
How an operation transforms inputs into
outputs

17. Making
pPrroodduucct tcsategory and process
type
Film clip Restaurant
Film
Title
Director
(year)
Dinner Rush
Bob Giraldi (2000)
Clip Start
Finish
00:58:58
01:02:44
What clip shows
The chef producing a special one-off dish for a
restaurant critic who is having dinner in the
restaurant
Key learning
objective
The characteristics of a low-volume batch
process How an operation transforms inputs
into outputs (and the difference between
services and manufacturing)

18. Product category and process
type

19. Question Bird Car Restaurant
PRODUCT
category
PROCESS type
• Made on-site
• Special
• Mass
• Standard
• Project
• Resources
moved to
site
• Line
• High
volume
• Special
• One-off
• Jobbing
• Small group
Product category and process
type

20. Critical
reflections
• MANUFACTURING PROCESSES must be:
- ALIGNED to its market ORDER-WINNERS and
QUALIFIERS
- REFLECT its internal BUSINESS requirements
• Although DEMAND CHANGES over time, most
businesses will NOT RE-INVEST in a different
process
• Choosing the RIGHT PROCESS for the life of a
product will have a significant impact on its SALES
REVENUE and PROFIT

21. Summar
y • Manufacturing processes must
SUPPORT
- Technical and business requirements
• TECHNICAL requirements
- The product specification
• BUSINESS requirements
- Volumes and market order-winners and
qualifiers
• Each process type has a different set of
TRADE-OFFS

22. © Alex Hill and Terry Hill

23. CASE FOR TUTORIAL
PRET A MANGER