1. The document discusses product-process strategy and describes a product-process matrix that relates a product's life cycle stage and volume to the appropriate production process life cycle stage. 2. It also covers topics like process characteristics, product flows, process planning, manufacturing technologies, flexible manufacturing systems, and computer integrated manufacturing. 3. Finally, it discusses factors to consider for facility layouts and mass customization strategies based on volume, lead time, and cost considerations.

1. MGMT 5240
Process Design
Product-Process Strategy
Product-Process Matrix
Product Life Cycle stages
y g
Process Life Cycle stages
Product Flow Characteristics
Cross Functional Decision Making
PRODUCT-PROCESS MATRIX
PRODUCT STRUCTURE (Product Life Cycle)
I III
II III
Low volume-low High volume-high
Multiple products, Few major products
standardization, one of standardization,
low volume higher volume
a kind commodity products
PROCESS STRUCTURE (Process Life Cycle)
I
Commercial
Jumbled flow
(job shop)
printer NONE
II
Disconnected Heavy
line flow Equipment
(batch)
III
Connected
line flow Automobile
(assembly assembly
line)
IV
Continuous Sugar
flow NONE Refinery
1

2. Product Life Cycle Stages
Low volume-low standardization, one of
a kind
Multiple p
p products, low volume
,
Few major products, higher volume
High volume-high standardization,
commodity product
Process Life Cycle Stages
Project
Job Shop
Batch
Mass production
Continuous production
Process Characteristics
Project Batch Mass Continuous
Product Unique Made to order Made to stock Commodity
Variety Infinite Many, high Low Very low
Customer Singly Few individuals Mass market Mass market
Demand Infrequent Fluctuates Stable Very stable
Volume Very low Low to med High Very high
System Long-term Intermittent Flow lines Process industry
Equipment Varied General-purp. Special-purp. Highly automated
Type of work Contracts Fabrication Assembly Mix, treat, refine
Skills Experts Wide range Limited range Equipment
craftspeople monitors
Advantages Custom work Flexibility Efficiency Highly efficient
quality speed, low cost large capacity
Disadv. Nonrepeating Costly, slow Capital invest. Difficult to change
Example Construction Printing, bakery Autos, TV’s Paint, oil, food
2

3. Product-Flow Characteristics
Types of Product Flow
° Project Flow
° Batch Flow
° Line Flow
Characteristics of Flows
Project Flow
Task 2 Task 4
Start End
Task 1 Task 3
Task Task or activity
Precedence relationship
Batch Flow
WS 2 WS 4
WS 1 WS 3 WS 5
WS Task or work station
Product flows
3

4. Line Flow
WS 1 WS 2 WS 3
WS Task or work station
Product flow
Product-Flow Characteristics
Project Batch Line
Product
Order Type Single Unit Batch Continuous or Large Batch
Variety Very High High Low
Volume Single Unit Medium High
Variety Infinite Many, high Low
Labor
Skills - - - - - - High - - - - - -
g Low
Task Type - - - - Nonroutine - - - - Routine
Pay - - - - - - High - - - - - - Low
Capital
Investment Low Medium High
Equipment - - - General Purpose - - - Special Purpose
Objectives
Flexibility High Medium Low
Cost High Medium Low
Control & Planning
Production
Control - - - - - Difficult - - - - - - Easy
Process Planning
Make-or-buy decisions
Process strategy & selection decisions
Process plans
Process analysis
Specific equipment selection
4

5. Process Plans
Blueprints
Bill of material
Assembly diagram
y g
Assembly chart / product
structure diagram
Operations process chart / route sheet
Process flow chart
Bill Of Material
(unstructured)
No. Part No. Part name
1 51292 Outlet end
2 51284 Handle
3 52043 Switch
4 51576 Electric cord
5 51265 Rear housing
6 51268 Motor mounting plate
Product Structure Diagram
Packaged
Hand-vac
Upholstery Crevice Dusting
Hand-vac Package
tool tool tool
Forward Screw & Rear
housing lock washer housing
assembly assembly assembly
5

6. Operations Process Chart
Part name Table leg
Part no. 2410
Usage Table
Assembly No. 437
Oper No.
No Description Dept.
Dept Machine Time Tools
10 Saw to rough length 041
20 Plane to size 043
30 Saw to finished length 041
40 Measure dimensions 051
50 Sand 052
Process Flowchart
Date: 9-30-95 Location: Graves Mountain
Analyst: TLR Process: Apple Sauce
Operation
Transport
Description
Storage
(feet)
Dista
Inspect
(min)
Time
Delay
Step
of
process
1 Unload apples from truck 20
2 Move to inspection station 100 ft
3 Weigh, inspect, sort 30
4 Move to storage 50 ft
5 Wait until needed 360
6 Move to peeler 20 ft
7 Apples peeled and cored 15
8 Soak in water until needed 20
9 Place in conveyor 5
10 Move to mixing area 20 ft
11 Weigh, inspect, sort 30
Total 480 190 ft
Specific Equipment Selection
Purchase cost
Operating cost
Annual savings
Revenue enhancement
Replacement analysis
Risk and uncertainty
Piecemeal analysis
6

7. Manufacturing Technology
Numerically controlled (NC) machines
°controlled by punched tape
Computer numerical controlled (CNC)
°controlled by attached computer
Direct numerical control (DNC)
( )
°several NC machines controlled by single
computer
Robotics
°programmable manipulators
°consistency
°hostile environment
°long hours
Technology
CAM – Computer-aided manufacturing
FMS – Flexible manufacturing systems
CIM – computer-integrated manufacturing
Flexible Manufacturing
Systems (FMS)
Programmable machine tools
Controlled by common computer
network
Combines flexibility with efficiency
Reduces setup & queue times
7

8. Flexible Manufacturing System
Tools
Conveyor
Machine Machine
Pallet
Load Unload
Terminal Finished
Parts
goods
Computer Integrated
Manufacturing (CIM)
Integration of design, manufacture &
delivery via computer technology
CAD - uses software to create & modify designs
CAM - uses programmable automation in
manufacturing
CAE - links functional design to CAD form design
CAPP - creates processing instructions for CAM
GT- classifies designs to benefit from prior
experience
Components of CIM
CAD CAE GT DFM DFA
TQM
Product
design CAD/CAM
Bar codes,
EDI
MRP CAPP
Systems Process
JIT/ management CIM planning
Cellular
kanban manufacturing
DSS/ES/
AI MAP,
Manufacture STEP
LAN, TOP,
satellites
NC/CNC/ AGV, Automated Cells
FMS Robotics
DNC ASRS inspection and centers
8

9. Automated Material Handling
Conveyors
Automated guided vehicle (AGV)
g ( )
Automated storage & retrieval system
(ASRS)
Facility Layouts
Characteristics
° Product – based on equipment (assembly
line - auto assembly)
° Process – based on similarity of process
(job shop -machine shop)
° Fixed Position – item built in one place
(project – ship building)
° Hybrid – combines characteristics of other
layouts (cellular, FMS, CIM)
Process Layout
Assembly
Process A Process C
4 6 7 9
5 8
2 Process B 12
10
1 3 11
Process D
A B C Raw materials
9

10. Product Layout
IN
OUT
Process Layout
after PWP (cellular)
Assembly
9
8 10
12 11
4 Cell1 Cell 2 6 Cell 3
2 1 5 7
3
Raw materials A C B
Product Layout
after PWP
PWP # 1
High
AA B D C Volume
PWP # 2
Low
B A C D Volume
10

11. Types of Focus
Product focus
Process type
Technology
gy
Volume of sales
Make-to-stock and make-to-order
New products and mature products
Mass Customization & Strategic
Process Choices
HIGH/
LONG
Make to
Order (MTO) Psychiatric
Counseling
Internet-
based
Education
Volu
Pre-
Lead Time
ume
fabricated
f bi t d
COST/
homes
Assemble to
Order (ATO)
Subway
Dell
Computers MASS
CUSTOMIZATION
TV Customization
producer
Make to Stock
LOW/
(MTS)
SHORT
LOW
Degree of HIGH
Customization
11