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CH 4 Manufacturing Processes

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16 views13 pages

CH 4 Manufacturing Processes

Uploaded by

Bhavi Agrawal
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Production / Manufacturing Processes

Types of Production
Processes

Continuous Mass Production Project


Production
Batch
Production Job Shop
Types of production System
Continuous Intermittent
• Flow of production is • Flow of production is not
continuous continuous ( intermittent)
• Products are standardized • Variety of products are produced
• Volume of production is high. • Volume of production is low
• Special-purpose equipment is • General purpose machines are
used used
• Make to Stock(Based on • Make to order(as per customer
anticipated demand) requirement)
• Standardized production • Production planning is variable
planning and schedules and complex
• Sequence of operations are • Sequence of operations may
fixed change as per Design
Continuous/Flow Production
•Used for high-volume commodity products that are very
standardized.
•The output is continuous, not discrete-meaning individual
units are measured, rather than counted.
•The system is highly automated.
•Dedicated plant and equipment.
•Product differentiation is limited.
•High Initial investment
•Companies that operate in this fashion are referred to
as process industries.
•The set-up time for starting such process is very long.
•Predetermined sequence of process.

• e.g. Steel, paper, paints, chemicals, textiles


Mass/Line Production

•Mass production is usually associated with assembly


lines.
•Standardized products with little variety
•Products are made-to-stock for a mass market
•Demand is stable, and volume is high.
•Work in Progress is low.
•Planning and scheduling is routine
•System tends to be capital-intensive and highly
repetitive, with specialized equipment and limited labor
skills.
•It result in low cost per unit
• e.g. automobiles, electronics, fast food
Advantages- Continuous & Mass production

• Standardization of product and sequence(as per


quality standards )
• Higher rate of production
• Highest capacity utilization
• Manpower with limited skills required
• Cost per unit is less due to higher volume
Batch Process
•A production system that processes items in small groups
or batches( 100 to 1000) is called Batch production.
•It characterized by fluctuating demand, short production
runs of a wide variety of products,
•Products requiring same or similar processing needs are
manufactured(same product family).
•A job may be routed through many different machine
centers in batches or lots before it is completed.
• Work on a particular product is not continuous; it
is intermittent.
• e.g. bakery, print shops, education system
Job Shop

• Handles a large variety of products


• The products have different processing requirements,
different machines, sequences and processing time
• The batches vary in size
• Job shop results in low volume of output and thus the
products are costly.
• Largest percentage of inventory is Work in progress
• Detailed production planning is essential
• Highly skilled workers
• General purpose Machine an facilities
• e.g. restaurant
Batch and Job Shop
Advantages
• Large variety
• Operators more skilled and competent
• Opportunity for innovation and creativity
• Lower investment in plant and machinery

Limitation
• Material handling
• Production planning Complicated
• High set up cost
• WIP high
Project
•Projects represent one-of-a-kind production for an individual
customer.
•Highly Flexible and low volume
•Item produced stay at one place and all resources come to it.
•Involve large sums of money and last a considerable length of time.
•Customers are few and customer involvement intense.
•Most companies do not have the resources (or time) so
subcontracting is common.
•In services , teaming of people to work on development of a service
is also called project, eg-Software development
e.g. R&D, Construction, Shipbuilding, Spacecraft etc.
7-11

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
7-12

Example: Assembly Chart (Gozinto)

From
FromExhibit
Exhibit5.14
5.14
Lockring
4
Spacer, detent spring
5
SA-2 A-2
Rivets (2)
6
Spring-detent
7
A-5
Component/Assy Operation

Inspection
7-13

Example: Process Flow Chart

No,
Material Inspect Continue…
Received
Material for
from
Supplier Defects Defects
found?

Yes

Return to
Supplier for
Credit

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