MANAGEMENT OF MACHINES MANAGEMENT OF MACHINES AND MATERIALS (MS-5)AND MATERIALS (MS-5)

UNIT 3UNIT 3PROCESS SELECTIONPROCESS SELECTION

Roshan GnyawaliRoshan Gnyawali

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Introduction Strategy Process Types

Project Intermittent Flow Continuous Flow Processing

Process Selection Break-even Analysis

ContentsContents

Technology in Process Selection

•CAD/CAM

•Flexible Manufacturing System

•Robot and Robotics

•Group Technology

•Computer Integrated Manufacturing

(CIM)

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Process selection Deciding on the way production of goods or

services will be organized Strategic Decision

Major implications Capacity planning Layout of facilities Equipment Design of work systems Human Resources

IntroductionIntroduction

Process Selection has major Impact on Cost, Productivity and Competitiveness

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Forecasting

Product andService Design

TechnologicalChange

CapacityPlanning

ProcessSelection

Facilities andEquipment

Layout

WorkDesign

Links to Process SelectionLinks to Process Selection

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• Key aspects of process strategy– Capital intensive – equipment/labor

– Process flexibility

– Volume and Variety

– Produce-to-stock / Produce-to-order

– Environment and Technological Change

Process Selection StrategyProcess Selection Strategy

Process Selection Strategy

Design Purchasing Production Assembly Delivery

Make To Stock

Assemble To Order

Make To Order

Purchase To Order

Engineering To OrderBuilding, FurnitureBuilding, Furniture

Plane Plane

Restaurant, Clothing, MoldingRestaurant, Clothing, Molding

Fast Food, ComputerFast Food, Computer

CFL LampCFL Lamp

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Process TypesProcess Types

Project Form

Intermittent Flow

Continuous Flow

Processing

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Example: Building of Ship, Aircraft; Construction of Roads, Buildings; Annual Conference; Training

Project FormProject Form

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Short Life Cycle Matrix Organization Different Functional Specialization Scheduling and Control is important

CPM/ PERT techniques Time-bound, Different functional

specialization, Immobile Product, Temporary team

Project FormProject Form

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Example: Fork Lift Trucks, Home Appliances

Intermittent FlowIntermittent Flow

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Various Standard Operations Material Handling and In-Process Inventory

High Difficulty in Management of Resources Variety at Low Cost High Capacity Utilization Highly skilled workers Complex operation planning and control

Intermittent FlowIntermittent Flow

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Computerized Production and Inventory Control Systems

Integrated CAM Manufacturing Resource Planning (MRP II) Group Technology

Techniques for Intermittent FlowTechniques for Intermittent Flow

Computer-Aided ManufacturingComputer-Aided Manufacturing

Manufacturing Systems utilizing computer software programs that control the actual machine on the shop floor.

Benefits Reliable Instructions to machines Product quality consistent Close tolerances can be obtained Lower labor costs

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Group TechnologyGroup Technology

A way of organizing and using data for components that have similar properties and manufacturing requirements.

Families of Component Parts, Machines, Equipments or People

Grouped in cells so that volumes are higher and variety smaller

Taking advantages of continuous flow Time and cost reduced Material handling reduced Shorter throughput time In-process inventory reduced

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Example: Refrigerator assembly, Car Assembly, Fast Food Restaurants, Bank Counter

Continuous FlowContinuous Flow

Continuous FlowContinuous Flow

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Continuous FlowContinuous Flow

Difficult to adapt

Problem of balancing the line

Possibility of stoppage of line

Low worker morale

Capital Intensive

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Computer Numerical Control (CNC) / Direct Numerical Control (DNC)

Robotics CAD / CAM / CAE (Computer Aided

Engineering) Flexible Manufacturing (FMS)

Techniques for Continuous FlowTechniques for Continuous Flow

Flexible Manufacturing System Flexible Manufacturing System (FMS)(FMS)

It is a computer-controlled process technology suitable for producing a moderate variety of products in moderate volumes.

It contains several automated programmable work stations.

Automated Material-handling equipment are used.

Flexible Manufacturing System Flexible Manufacturing System (FMS)(FMS)

Introduce flexibility to continuous process in

terms of component design, operation

sequence, batch sizes, production capacity

Combine advantages of continuous flow

process and intermittent flow process

Increased variety, improved response to

customer order, updated product design3-20

Flexible Manufacturing System Flexible Manufacturing System (FMS)(FMS)

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Robotics

Robot: A programmable machine capable of moving materials and performing routine, repetitive tasks. Replace humans for heavy, dirty, dangerous,

unpleasant, monotonous tasks.

Robotics: The science of selecting robots for various applications.

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Example: Fertilizer, petrochemicals, milk, drugs

Processing IndustryProcessing Industry

Processing IndustryProcessing Industry

Single Input

Analytic and Synthetic Process

Continuous Processing

Low Labor Required

Capital Intensive

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Process Selection

Combination to take advantage of more forms

Stage in Life-cycle of product Suited to the Market Competitor approach Technological Changes Environmental Changes Break-even analysis of processes

Break Even Analysis

Intermittent

Project

Volume

Cos

t

Continuous

Computer Integrated ManufacturingComputer Integrated Manufacturing

CIM is a concept of a fully automated factory, where all manufacturing processes are integrated and controlled by computers.

CIM integrates information flows in marketing, design, manufacturing, engineering, resource requirements planning, purchasing, production process, quality assurance, administration etc.

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Discussion Questions

Define FMS. What is the general field of FMS application significant in terms of potential market size for its capability? State with reference to any production unit.

Why is mass production preferred over in some types of products with large volume? Explain the key elements of mass production with some examples.

Differentiate continuous flow processes from intermittent flow processes. Give examples.

On the basis of material flow, classify production systems and give examples for each type.

End of Unit 3

UNIT 4: Facilities LocationUNIT 4: Facilities Location