Single-minute exchange of die(SMED)
___ ___ ___ ___ enables an organization to quickly convert a machine or process to produce a different (but similar) product type so a single cell can produce a variety of products without the time-consuming equipment changeover associated with large batc
process
___ layout disadvantages:
In-process inventory costs can be high if batch processing is used in manufacturing systems.
Routing and scheduling pose continual challenges.
Equipment utilization rates are low.
Material handling is slow and inefficient, and mo
Preventive
___ maintenance periodic inspection and replacement of worn parts or those with high failure rates
effort commitments
layout decisions are important for three basic reasons: (1)require substantial investments of money and ___; (2)involve long-term ___ making mistakes difficult to overcome; (3)significant impact on the cost$ and efficiency of operations.
sustainability flow
Principles/Benefits of lean design are waste reduction/___; variance reduction to achieve level production/improve process ___; reduced inventory/floor space; quicker response/shorter lead times; reduced defects, rework, and scrap; increased productivity;
Lowell
The ___ Center advocates designing and operating sustainable processes in ways that:
"Wastes and ecologically incompatible byproducts are reduced, eliminated or recycled on-site;
Hazardous chemical substances or physical agents and conditions are eliminat
Repetitive
The standardized output of this process type means only slight flexibility of equipment is needed, workers skill generally low. Can be used for mass customization. Examples include production lines and assembly lines.
product processing information
Three aspects of technology can be factors in process selection and layout: ___ tech, ___ tech, and ___ tech.
Project
A nonrepetitive set of activities directed toward a unique goal within a limited time frame
Product or service profiling
linking key product or service requirements, to process capabilities; asking what range of products or services that will be processed, expected order sizes, pricing strategies, expected frequency of schedule changes, and order-winning requirements.
Technological innovation
the discovery and development of new or improved products, services, or processes for producing or providing them
Technology
The application of scientific discoveries to the development and improvement of products and services and operations processes
Automation
machinery that has sensing and control devices that enable it to operate automatically
computer-aided manufacturing (CAM)
the use of computers in process control
Numerically Controlled (N/C) Machines
machines that perform operations by following mathematical processing instructions
Flexible Manufacturing System (FMS)
a group of machines designed to handle intermittent processing requirements and produce a variety of similar products
computer-integrated manufacturing (CIM)
a system for linking a broad range of manufacturing activities through an integrating computer system
3D printing
a process that creates a three-dimensional object by adding successive layers of material
AKA: additive manufacturing
Product layout
Layout that uses standardized processing operations to achieve smooth, rapid, high-volume flow
Production line
standardized layout arranged according to a fixed sequence of production tasks
Assembly line
standardized layout arranged according to a fixed sequence of assembly tasks
Process layouts
layouts that can handle varied processing requirements
Fixed-position layout
Layout in which the product or project remains stationary, and workers, materials, and equipment are moved as needed
Cellular production
layout in which workstations are grouped into a cell that can process items that have similar processing requirements
Group technology
the grouping into part families of items with similar design or manufacturing characteristics
Line balancing
the process of assigning tasks to workstations in such a way that the workstations have approximately equal time requirements
Cycle time
the maximum time allowed at each workstation to complete its set of tasks on a unit
Precedence diagram
a diagram that shows elemental tasks and their precedence requirements
Balance delay
percentage of idle time of an assembly line
Intermittent processing
non repetitive processing
teamwork flexibility
An advantage of a U shaped production line is that it facilitates ___ and ___ in work assignments.
Idle
Balance delay is another name for the percentage of ___ time and a product layout.
Intermittent
___ processing can take the form of batch processing or a job shop.
Job shop
High flexibility, general-purpose equipment, and skilled workers are important characteristics; used when low volume with high-variety will be needed.
Continuous
___ production systems are very efficient for high volumes of non-discrete, standardized output, but they are not very flexible and can be costly to change
Information
___ technology refers to both data and systems.
Processes
___ convert inputs into outputs.
changing
Once a process type is functioning, ___ it can be difficult, time consuming, and costly.
process
capacity and ___ selection are interrelated and affect facility and equipment choices, layout, and work design.
layout work design
capacity and process selection are interrelated and affect facility and equipment choices, ___, and ___ ___.
strategy
An organization approaches process selection by considering the organization's process ___.
Capital intensity
Key aspects or process selection include: ___ ___, Process flexibility
Process flexibility
Key aspects or process selection include: Capital intensity, ___ ___
Capital intensity
The mix of equipment and labor that will be used by the organization; key aspect of process selection
Process flexibility
The degree to which the system can be adjusted to changes in processing requirements due to such factors as changes in product or service design, changes in volume processed, and changes in technology; key aspect of process selection
demand
Process choice is ___ driven.
variety volume
The two key questions in process selection are: How much ___ and ___ will the process need to be able to handle?
inversely
Usually, volume and variety are ___ related
Batch
___ processing is used when a moderate volume of goods or services is desired, and it can handle a moderate variety in products or services.
Repetitive
This type of process is sometimes referred to as assembly.
continuous
When a very high volume of nondiscrete, highly standardized output is desired, a ___ system is used.
project
The work is often organized as a ___ when situations are not ongoing but are limited duration; Equipment flexibility and worker skills can range from low to high:
putting on a play, consulting, making a motion picture, launching a new product or service,
hybrid
It is not unusual to find ___ processes, that have elements of other process types embedded in them.
economic
___ considerations (initial cost, space, cash flow, maintenance, consultants)
integration
___ considerations (cost, time, resources)
automated
In order for ___ processing to be an option, job-processing requirements must be standardized.
Fixed
___ automation is the least flexible; High-cost, specialized equipment for a fixed sequence of operations; Low cost and high volume are its primary advantages; minimal variety and the high cost of changes are its primary limitations.
Programmable
___ automation involves the use of high-cost, general-purpose equipment controlled by a computer program that provides the sequence of operations and specific details about each operation; capability of economically producing a fairly wide variety of low-
fixed programmable flexible.
there are three kinds of automation:
computerized numerical control (CNC)
Individual machines often have their own computer; this is referred to as
direct numerical control (DNC).
One computer may control a number of N/C machines, which is referred to as
Flexible
___ automation evolved from programmable automation; equipment that is more customized than programmable automation; requires significantly less changeover time; almost continuous operation of equipment and product variety without the need to produce in b
FMS
___ also has certain limitations. One is that this type of system can handle a relatively narrow range of part variety, so it must be used for a family of similar parts, which all require similar machining; requires longer planning and development times t
extrusion
the deformation of either metal or plastic forced under pressure through a die to create a shape
sintering
using heat or pressure or both to form a solid material from powder without causing it to liquefy
best
flexibility does not always offer the ___ choice in processing decisions.
variety uncertainty
decision makers choose flexible systems for either of two reasons: Demand ___ or ___.
Layout
___ refers to the configuration of departments, work centers, and equipment, with particular emphasis on movement of work (customers or materials) through the system
product layout
___ ___advantages:
A high rate of output.
Low unit cost/high volume.
High cost of specialized equipment is spread over many units.
Labor specialization
Low material-handling cost per unit. Material handling is simplified, often automated.
High utilization
disadvantages
Product Layout ___:
Intensive division of labor usually creates dull, repetitive jobs that provide little opportunity for advancement and may lead to morale problems and to repetitive stress injuries.
Poorly skilled workers may exhibit little interest in
machine
___ shop, which has separate departments for milling, grinding, drilling, and so on.
process
___ Layout Advantages:
Can handle a variety of processing requirements.
Not particularly vulnerable to equipment failures.
General-purpose equipment is often less costly than the specialized equipment used in product layouts and is easier and less costly
...
disadvantages of process layouts include the following:
In-process inventory costs can be high if batch processing is used in manufacturing systems.
Routing and scheduling pose continual challenges.
Equipment utilization rates are low.
Material handling i
Right-sized
___ equipment is often smaller than equipment used in traditional process layouts, and mobile, so that it can quickly be reconfigured into a different cellular layout in a different location.
group
___ technology involves identifying items with similarities in either design characteristics or manufacturing characteristics, and grouping them into part families.
Output rate
#NAME?
Cycle time
#NAME?
theoretical minimum
Percentage of idle time
0
stations
N actual = Actual number of ___
parallel workstations
These are beneficial for bottleneck operations which would otherwise disrupt the flow of product as it moves down the line.
design
The ___ of process layouts requires the following information:
A list of departments or work centers to be arranged, their approximate dimensions, and the dimensions of the building or buildings that will house the departments.
A projection of future work