Factors that affect Process Selection?
1. Forecasting2. Products & Service design3. Technological change4. Capacity planning5. Facilities & Equipment6. Layout7. Work design
Factors to consider when deciding to make or buy components?
1. Available capacity2. Expertise3. Quality consideration4. The nature of demand5. Cost
List 5 Process types?
1. Job Shops (small runs)2. Batch Processing3. Repetitive/Assembly (semicontinuous)4. Continuous Process5. Projects (nonroutine jobs)
This process type is low volume, high variety, high flexibility?
Job Shop
This process is moderate volume, moderate variety, moderate flexibility?
Batch
This process is High Volume, Low Variety, Low Flexibility?
Repetitive Assembly
This process is very high volume, very low variety, very low flexibility?
Continuous Flow
Describe Job Shop? Examples of Process? Examples of Goods & Services? Competitive Advantages?
Customized good or servicesMachine Shop, Beauty ShopSpecialty tools, Hair StylingQuality (performance) & Flexibilty
Describe Batch? Examples of Process? Examples of Goods & Services? Competitive Advantages?
Semi-standard goods or servicesBakery, ClassroomCookies, educationModerate cost & flexibility
Describe Repetitive/Assembly? Examples of Process? Examples of Goods & Services? Competitive Advantages?
Standardized goods or servicesAssembly line, cafeteria lineAutomotive line, car washLow unit cost, Dependability
Describe Continuous? Examples of Process? Examples of Goods & Services? Competitive Advantages?
Highly standardized goods or servicesSteel Mill, Sugar refinerySteel, Paper, PowerLow Price, Quality (conformance)
Describe Layout?
Layout is the configuration of departments, work centers, and equipment, with particular emphasis on movement of work (customers or materials) through the system.
Three basic layout types?
1. Product Layouts2. Process Layouts3. Fixed-Position
Describe Product Layout and which processes use it?
Product Layout uses standardized processing operation to achieve smooth, rapid, high volume flow.Line
Describe Process Layout and which processes use it?
Process layout can handle varied processing requirements.Job Shop or Batch (ex: hospital)
Describe Fixed-Position Layout and process that uses it?
Fixed Position is a layout in which the product or project remains stationary, and workers, materials, and equipment are moved as needed.Project! Ex: Building or freeway
Importance of Layout Decisions?
1. Requires substantial investments of money and effort2. Involves long-term commitments3. Has significant impact on cost and efficiency of short-term operations
Eight things that cause a need for layout decisions?
1. Inefficient operations2. Changes in the design of products or services3. The introduction of new products or services4. Accidents/Safety hazards5. Changes in environmental or other legal requirements6. Changes in volume of output or mix of products7. Changes in methods and equipment8. Morale problems
Layout Formats?
1. Group Technology Layout2. Just-In-Time Layouts-May be assembly-line or -Group Technology formats3. Fixed Position Layout-eg Shipbuilding
Cellular Layouts include?
1. Cellular Manufacturing2. Group Technology3. Flexible Manufacturing Systems
The advantage of Cellular Layouts?
They retain flexibility in the process and gain economies of scale.Ex: Lazyboy Case
Explain Cellular Manufacturing?
Layout in which machines are grouped into a cell that can process items that have similar processing requirements.
Explain Group Technology Layout?
The grouping into part families of items with similar design or manufacturing characteristics.
Adavantages of U-Shaped Production Line?
1. Shorter distance2. Workers can alternate tasks3. Shipping & Receiving can be in 1 place
Describe Process Layout?
Departmentalized process where work travels to dedicated process centers
Cellular Manufacturing Layout?
Part families are based on Group Technology-minimizes material movement-efficient, but still flexible
Line Balancing?
is the process of assigning tasks to workstations in such a way that the workstations have approximately equal time requirements.
Cycle Time?
is the maximum time allowed at each workstation to complete its set of tasks on a unit.