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Tutorial. Process Design

This document provides an overview of process design for manufacturing. It discusses making make vs buy decisions and factors to consider. It then explains that process design maps parts lists to production routing. It describes assembly charts and operation process charts that visually represent manufacturing processes and sequences. Finally, it discusses analyzing process flow charts to optimize operations and determining manufacturing systems based on product volume and variety.

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Faisal Saleh Raza
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44 views10 pages

Tutorial. Process Design

This document provides an overview of process design for manufacturing. It discusses making make vs buy decisions and factors to consider. It then explains that process design maps parts lists to production routing. It describes assembly charts and operation process charts that visually represent manufacturing processes and sequences. Finally, it discusses analyzing process flow charts to optimize operations and determining manufacturing systems based on product volume and variety.

Uploaded by

Faisal Saleh Raza
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Tutorial: Process design

ISEN4821

Make / Buy decision


Some companies have complete vertical integration; they manufacture
all their parts.
Some others buy everything and just assemble them. Most companies
are somewhere between two extremes of this continuum.
Make or buy decision is made after value analysis and mostly by the
same people involved in value analysis. In the final analysis we should
know whether it is techno-economically better to make the part or buy
it.
-Is the required process compatible with other processes?
-Do we have the knowledge and expertise to run this process?
-Do we have extra capacity to allocate to this process?
-Do we have the required budget to invest in this process?
-Does the process reaches its BEP?
-Is manufacturing costs lower than sub-contracting?

Process design
At this point, we are assuming that:

• The product is identified,


• Its parts are identified
• The make / buy decision is made.

The next question is how to manufacture each part? Process design is


a transformation process.

Parts Process Production


list Design routing

It is a function which maps parts list into production routing. Parts list
has the name of the product at title, and the specifications of parts at
rows.
• Production routing has the name of a part at title, and the
operations required to make the part at its rows. A typical
Production routing is shown below.

Production Routing
Part name : 101

Operationn Description Machine Standard Machine capacity


n # time

The sequence of processes required to manufacture a part may be


determined by:
A number of methods including
• Using established processes (used by manufacturers of similar
products).
• Modifying/improving processes used in production of similar
products
• Developing totally new processes.

Pictorial tools to represent processes


-Assembly chart
-Operations process chart
-Precedence diagram (used in some cases)

In Planning the development of a production system, the layout of the


machines and the plant is not known, and we can only visualize the
operation that are needed and the sequence they must be arranged.
Assembly charts and operation process chart are graphical presentation
of the sequence of processes and possible plant layout.
Assembly Chart;
Gives a broad overview of how several parts manufactured
separately are to be assembled to make the final product.

Example: Production of a simple table.


Laminated Top

Leg

Small Rail Large Rail

Parts list for the Simple Table*


Product name : Table A

Part Descriptio No/ Unitproduct Material Remarks


# nn
101 Top 1 laminated Wood
102 Leg 4 Aluminum
103 Small rail 2 R. w
104 Large rail 1

*Each department may add its own field of interest to the common fields of the parts
list.

Assembly chart may also show a flow in reverse- How a product that is
in unit form can be disassembled and distributed in different processes,
like in chemical processing. Figure 1 below is a possible assembly chart
for the a(above) simple table.

Part #103 Part# 102 Part # 101

(2) (4) (1)


AS

(1) AS-1 AS-2 Final


Part #104 Product

Supplies Supplies Supplies

Figure 1: Assembly Chart for the Simple Table

Assembly charts are used extensively in production scheduling. To use


it for scheduling, it must be drawn to scale (time scale). In that case the
straight line shows the start and completion time for each
manufacturing, installation or assembly operation. Knowing the
delivery date for the final product, the scheduler can work backward
and determine a schedule for each operation. Another example of
Assembly Chart is shown in Figure 2.

Operation Process Chart.


This chart provide details of the assembly chart. It shows every
operation and inspection that each part needs as it progress from raw
material to the final assembly. For each activity (operation or
inspection, the operation process chart includes an estimate of time it
will take to complete the activity.
Figure 2: Another Form/Example of Assembly chart
e
(n1)

Part # ….. (n2)


A-1

Part ##.......

Part##...... ………. A-2

Part##...... ………….

.
Part##......

Part ##...... SA-1 A-3

Part##......

Part##......

Part##...... SSA-1 SA-2 A-4

Part##......

Part # xy (m)

A-1 : A part is assembled to the main part.

A-2 : Several parts are assembled together to the main assembly.

SA-1 : Several parts are sub-assembled, then assembled to main


assembly.

SSA-1 : Several parts are sub-assembled, then another part is sub-


assembled to them, then they all are assembled to the main sub-
assembly.
Operation Process Chart.
This chart provide details of the assembly chart. It shows every
operation and inspection that each part needs as it progress from raw
material to the final assembly. For each activity (operation or
inspection), the operation process chart includes an estimate of time it
will take to complete the activity.

At the initial stages it is valuable to get an overall view of the


process. This will indicate how detailed further recording need to be. An
operator process chart provides a distance eye view of the whole process
or activity. In an operations process chart all the operations and
inspections involved are recorded. The chart does not indicate where
the work takes place or who performs it. The delays, transport and
storages are not indicated. But the entry points of materials are
indicated.

An operations Process Chart is a graphic representation of the


sequence of all the operations and inspections involved in a process or
procedur Such a chart will serve as a starting point for the critical
examination. This is a very useful chart for initial analysis .. Where the
process is long and complicated, this chart provides an overall picture
and gives adequate information for critical examination. This chart is
particularly useful for recording maintenance and other indirect work.
An example of the operation process chart is given below.

Note that, the following process flow chart will be complete only if
time estimates for estimate of times required for each activity (operation
or inspection) are included in the chart.
Analyzing Process Flow Charts
The operation process chart is used to analyze the processes involved in
manufacturing of the products or delivery of services and optimize the
operations. To analyze a standard Operation Process Chart, Review the
flow of the process and do the following:

1. Look at the process inputs.

• Does the amount of input seem appropriate to the rest of the


processes.
• Is the method of input unnecessarily complicated? If so,
determine changes that can improve the process.

2. Compare process inputs to outputs.

• Are there more outputs than inputs?


• Are they necessary
• Can any be combined or eliminated?

3. Look at the process.

• Does the process contain a large number of decisions? If so, look


at improving the work flow to combine or eliminate tasks.
• Are there no decisions? If not, look at automating the task.

4. Review the process pattern.

• Looping patterns in the process flow or cycling back and forth


between the same operations or persons may indicate unnecessary
transfers.

5, Review the outputs.

• Is the process producing any unnecessary distributions of the


process output (i.e. generating a report with unnecessary copies
being made and distributed)?
Determining Manufacturing System
A first step in determining the best manufacturing system necessary to
produce a given set of products at given quantities per year, is Volume-
nariety (called P_O) chart (see below)
In most cases the P_Q chart is interpreted as a Pareto’s-chart, resulting
in somehow clear division of products each division requiring a special
production system as follows

(1)
P1 P2

(2)
P3 P4

P5 P6 P7 (3)
P8 P9 P

1). For Group (1), the high volume demand, we need to use mass
production/product layout

2). For group (1), the low volume demand group, we need to use Job-
Shop type system

3) For group 2, Medium volume and batch type operation, we need to


use process layout or combination of the systems.

4) For large products with very small “Q”, products stay stationary
and production system id build around it. In such cases we use
Project-Shop

Note that when the P_Q chart is flat (se second chart above, The
decision on production system necessary to manufacture the product is
not as straighjt forward as in the first case.

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