1. Manufacturing and Process
Selection Design

2. Types of Processes
• Conversion
– iron ore into steel
• Fabrication
– forming raw material (gold into jewelry)
• Assembly
– fastening parts together to create product (bicycle)
• Testing
– for quality of products

3. Process Selection

4. Process Flow Structures
• Job Shop
– One of a kind
– Made to order
• Batch
– Low volume, many products
– Bakery
• Assembly Line
– High volume, few products
– Maruti assembly line
• Continuous Flow
– High volume, high standardization
– Refinery

5. 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.
• Drawings, charts

7. Assembly Chart
4
5
6
7
Lock-ring
Spacer, detent spring
SA-2
Rivets (2)
A-2
Spring-detent
A-5
Component/Assembly Operation
Inspection

8. Process Flow Chart
Material
Received
from
Supplier
Inspect
Material for
Defects
No,
Continue…
Defects
found?
Return to
Supplier for
Credit

9. • Designing the product = art
• Building the product = science
• Moving from design to customer =
management

10. Product – Process Matrix
Product Structure - Product lifecycle --------------------------------------------->
Process Structure Low Volume Multiple
Few major
High Volume - Process
low
products - Low products - High High
Effectiveness
Lifecyclr Stage standardization volume
Volume
Standardization measures
Job Shop
Batch
Assembly Line
Continuous
High flexibility /
Unit Cost
French restaurant
Coffee Shop
Burger King
Sugar refinary
Low flexibility /
unit cost

11. Breakeven Analysis

12. Operations Technology
• Hardware
• Software
• Computer Integrated manufacturing

13. Hardware
•
•
•
•
•
Numerically controlled (NC) machines
Machining centers
Industrial robots
Automated material handling systems
Flexible manufacturing systems (FMS)
– BMW example
– Machine, material handling, Operations, Volume,
expansion, routing, process, product, market

14. Software
• Computer-aided-design (CAD)
• Automated manufacturing planning and
control systems (MP & CS)
• Enterprise Resource Systems (ERP)

15. Technologies in Service
• Office automation
• Image processing systems
• Electronic data interchange (EDI)
• Decision support systems & expert systems
• Networked computer systems