CHAPTER
7: MANUFACTURING PROCESSES (P=
ROCESS
DESIGN)
PROCESS
DESIGN ACTUALLY INVOLVES DETERMINING THE MEANS BY WHICH
WE
WILL TRANSFORM INPUTS INTO OUTPUTS.
YOU
MUST KNOW WHAT THOSE OUTPUTS WILL BE and generally WHAT THE INPUTS WILL BE<=
/span>--Here we may =
have
many options to look at.
Inputs-->Transformed-->Outpu=
ts
TYPES
OF PROCESSES
How
they are designed
&=
nbsp; Make to stock
&nbs=
p; =
Make
to order
&nbs=
p; =
Assemble
to order
&nbs=
p; What
they do
Conversion---F=
orrest
to Logs (logging) or Logs to boards (milling)
Fabrication---=
Building
trusses (floor or roof), making air conditioning ductwork
Assembly---Fra=
ming a
house, soft drink bottling operation
Testing---A cr=
ime
lab, or quality control testing
PROCESS FLOW
STRUCTURES (refer to Product
Process Matrix and discuss ramifications)
&=
nbsp; Process-------------------=
------------------------------------------Product
&=
nbsp; Job
Shop
Batch Shop &n=
bsp; Assembly
Line Continuous=
Flow
&=
nbsp; Low
Volume &=
nbsp; &nbs=
p; &=
nbsp; &nbs=
p; &=
nbsp; High Volume
&=
nbsp; Flexible &=
nbsp; &nbs=
p; &=
nbsp; &nbs=
p; &=
nbsp; =
Inflexible
PROCESS
DESIGN IS NOT A ONE-SHOT DEAL--IT MAY BE REVISITED FROM TIME TO TIME IN
RESPONSE TO CHANGES IN THE INTERNAL ENVIRONMENT.
External Factors
a. technological change
b. market changes
c. government regulation
d. competitors actions
Internal Factors
a. change in product design
b. changes in plans and goals
c. changes in profitability
MAJOR
ISSUES:
Capital vs. Labor Intensive
Change from one to other.
Desired level of flexibility
a. product
b. volume
c. resource flexibility
1. workers
2. machines
3. other inputs
Degree of vertical integration
It is not just a question of cost, or
profits, it is a question of expertise.
1. Forward
2. Backward
Make or Buy an early
consideration, because if we buy it, we won't need to make it.
Considerations:
1. available capacity
2. expertise
3. quality
4. nature of demand
5. cost
Own or Lease
Outsourcing of services and support
functions
Customer involvement (particularly impor=
tant
in non-manufacturing operations.)
The extent to which customers are involv=
ed
with the process influences process selection.
Self-Service Customers invo=
lved
in performing process--influences process design.
Product Selection Customers may=
be
involved in developing product specifications and product and process
design. (EX: Custom home)
Time and Location Part of the p=
rocess
may involve getting to the location where customer is to be served, or gett=
ing
customer to location to get the service.
The major issues are interrelated and
interdependent.
At one time a high level of automation
(capital intensive production) was inversely related to flexibility. That is changing. EX: FMS.
&=
nbsp; &nbs=
p;