Process and Product Design

Process

how to transform input into output

Classification of product

• type of product flow

• approach to customer orders

• amount of customization

• focus - demand volume vs product standardization

Type of product flow

• fixed position

• jumbled flow

• line flow

• continuous flow

Approach to customer orders

• make to order

• make to stock

• assemble to order

Project

• one at a time product exactly to customer specifications

• low volume, low standardization

Batch

• small quantity of products in batches based on actual or expected customer orders

Mass

• large volume of a standardized product, assembly line format

Continuous

• continually produce a very high volume of a fully standardized product

intermittent operations

• work is performed in distinct separate runs with frequent stops, changeovers, adjustments

• Volume and Standardization (Low): Batch process + Project

• Process Type and Tech Adoption (Low): General Purpose + Group technology

Repetitive Operations

• production processes that run nonstop with a constant standardized flow of output

• Volume and Standardization (High): Mass process + Continuous process

• Process Type and Tech Adoption (High): FMS, Focused automation, dedicated automation

Intermittent vs Repetitive

• Product Variety - I: Great R: Small

• Approach to orders - I: Make to Order R: Make to stock

• Product flow - I: Jumbled R: Line

• Equipment Type: I:Gen purpose R: Specialized

Intermittent vs Repetitive PT2

• automation: I: low R: high

• Critical resources - I: Labour R: Capital

• Throughput time: I: Longer R: Shorter

• WIP Inv: I: More R: Less

Process Type Intermittent

• Process Layout: Groups resources based on similar processes

• warehouse/office

Process Type Repetitive

• Product layout: groups resources based on products

• arranges resources in sequence (assembly line)

Hybrid between process and product layouts

• Cell Layout - grouping of products based on similar requirements (processes)

Fixed position layout

• used when the product is too big and cannot be easily moved (bridge)

Retail layout

• allocates space based on customer behaviour

Group technology

• grouping of dissimilar automated machines to produce a family of parts (similar components)

Flexible Manufacturing System (FMS)

• consists of numerous programmable machine tools connected by an automated material handling system

Robotics

• controlled by a computer, performs complex tasks

Computer aided manufacturing CAM

• controlling manufacturing through computers

Computer integrated manufacturing CIM

• integration of product design, process planning, and manufacturing through computers

Process Selection Factors

• cost

• volume

• product maturity level

• labour/tech availability

Corporate Strategy and process

• Corporate Strategy: I: Customized products R: Mass market

• Operations Strategy I: Low volume, customized service R: high volume

• Competitive priorities: I: volume flexibility, customization R: low cost

Product Design

• process of defining all of the product’s characteristics

• matching process and product

Steps in product design

1. idea development (customer driven, reverse engineering, R and D)

2. Product screening (feasibility study)

3. preliminary design and testing

4. final design

Faster intro of new products

• concurrent engineering

• computer aided design

• 3d printing

concurrent engineering

• multifunctional team approach to simultaneously design the product and the process

computer aided design CAD

• use of computer graphics to design new products

3D printing

• method of making an object by adding thin layers of materials layer by layer based on CAD