????(process choice)

1
???????

• ???????????????????????,?????????,????????????????
  ???,?????????????????/??????????????/??????

2
?????????
????
??
?????
?? ??
??? ????
??
????
????
3
???????

• ????(process choice)
• ????(vertical integration)
• ???????????????,?????????????
• ????(resource flexibility)
• ?????????????????????????????
• ????(customer involvement)
• ??????(capital intensity)

4
Processes at manufacturing organizations

• Project process
• Selecting location for new plant in Europe
• Installing ERP for a manufacturing firms
  business processes

• Job process
• Machining precision metal tubes
• Internal consulting team at manufacturing firm

• Batch process
• Forging process to make fittings for pressure
  vessels access
• Producing a batch of textbooks at R. R.
  Donnelleys plant

• Line process
• Auto assembly
• King Soopers bread line

• Continuous process
• Oil refining process
• Bordens pasta making process

High
Low
Volume
5
Processes at service providers

• Project process
• Real estate process for leasing and constructing
  facilities for large insurance company
• Student teams field project

• Job process
• Customer service process at financial services
  firm
• General medical practice

• Batch process
• Order fulfillment process of importer/distributor
• Placing purchase orders at public relations agency

• Line process
• Cafeteria line
• Teller line at bank

• Continuous process
• Power generation plant
• Providing telephone line access

High
Low
Volume
6
Types of Processes

• PROJECT BATCH MASS CONTINUOUS
• Product Unique Made to order Made to stock
  Commodity
• Customer One-at-a-time Few individuals Mass
  market Mass market
• Demand Infrequent Fluctuates Stable Very stable
• Volume Very low Low to med High Very high
• No. of different Infinite Many, varied Few Very
  low
• products
• Production Long-term Discrete, job Repetitive,
  Process industry
• System Project assembly lines
• Equipment Varied General-purpose Special-purpose H
  ighly automated
• Type of work Contracts Fabrication Assembly Mix,
  treat, refine
• Skills Experts, Wide range Limited
  range Equipment
• craftspeople of skills of skills monitors
• Advantages Custom work, Flexibility, Efficiency, H
  ighly efficient
• technology quality speed, low cost large
  capacity
• Dis- Nonrepetitive, Costly, slow, Capital
  investment, Difficult to
• advantages small customer difficult to lack of
  change
• base, expensive manage responsiveness

7
???????

• ????
• ??????
• ?????????????
• ??????
• ???????????

8
????

• ?????(flexible work force)
• ???????????????????????
• ???? vs. ????

9
????

• ?????(self-service)
• ????(???)
• ?????
• ?????
• ?????????????

10
??????

• ??? vs. ????
• ??????
• ?????
• ????
• ??
• ??????????,????????????

11
???????????????
Low volume, make-to-order process

• Project process
• Selecting location for new plant in Europe
• Installing ERP for a manufacturing firms
  business processes

• Less vertical integration
• More resource flexibility
• More customer involvement
• Less capital intensity/automation

• Job process
• Machining precision metal tubes
• Internal consulting team at manufacturing firm

Process design choices
High volume, make-to-stock process

• More vertical integration
• Less resource flexibility
• Less customer involvement
• More capital intensity/automation

• Line process
• Auto assembly
• King Soopers bread line

• Continuous process
• Oil refining process
• Bordens pasta making process

12
???????????????
Low volume, customized-service process

• Less vertical integration
• More resource flexibility
• More customer involvement
• Less capital intensity/automation

• Project process
• Real estate process for leasing and constructing
  facilities for large insurance company
• Student teams field project

• Job process
• Customer service process at financial services
  firm
• General medical practice

Process design choices
High volume, standardized-service process

• Batch process
• Order fulfillment process of importer/distributor
• Placing purchase orders at public relations agency

• More vertical integration
• Less resource flexibility
• Less customer involvement
• More capital intensity/automation

• Line process
• Cafeteria line
• Teller line at bank

• Continuous process
• Power generation plant
• Providing telephone line access

13
??

• Maxwell vs. Coffee shop

14
Process Selection with Break-Even Analysis
Total cost fixed cost total variable
cost TC cf vcv Total revenue volume x
price TR vp Profit total revenue - total
cost Z TR - TC vp - (cf vcv)
cf fixed cost v volume (i.e., number of units
produced and sold) cv variable cost per
unit p price per unit
15
Solving for Break-Even Volume
16
Break-Even Analysis
17
?????????

• ??? vs. ???? vs. ??
• ???120 vs. ???12000
• ????????????????????
• ?????????????

18
??????????

• ??????
• ????
• ???????
• ???????
• ????
• ???????
• ??????
• ??????

19
??????

• ?????(type)
• ?????(form)
• ?????
• ?????/????
• ??????????(????)
• ????
• ????
• ???????
• ?????
• ????

20
????

• ????
• ???
• ????????
• ????
• ??
• ??
• ??
• ?????
• ??????
• ????
• ???????

• ????
• ????????
• ??
• ???(accuracy)
• ??
• ??
• ????
• ???
• ??????
• ????
• ??????

21
???????

• ??
• ??
• ??
• ??
• ??
• ??
• ??
• ??

• ????????????
• ?????,??????????
• ?????,????????????
• ???????,?????????????

22
???????1

• ??????
• ????
• ????
• ??
• ????
• ?????
• ????

• ????
• ???
• ????
• ?????????
• ?????
• ??????????

23
???????2

• ???????
• ?????????????
• ????
• ????
• ??????
• ????
• ???
• ?????

• ????
• ?????????????????
• ?????(????????)?

24
???????3

• ????
• ?????
• ????????????
• ????????
• ????
• ????
• ????????

• ????????
• ??????
• ??????
• ????
• ??????
• ??????
• ??????

25
????

• Purchase cost
• Operating cost
• Annual savings
• Revenue enhancement
• Replacement analysis
• Risk and uncertainty
• Piecemeal analysis

26
????????????
27
???????

• Blueprints
• Bill of material (????)
• Assembly chart /product structure diagram
• Operations process chart
• Routing sheet

28
Assembly Chart
29
????????(computer-aided process planning, CAPP)

• CAPP is a specialize software system for process
  planning.
• Type of CAPP
• Variant system
• A variant system retrieves a standard process
  plan from a CAPP database and allows the planner
  or engineer to modify it for the new part.
• Generative system
• A generative system uses a knowledge base of
  rules gathered from expert machinists to create
  an individual process pan from scratch.

30
????

• The systematic examination of all aspects of a
  process to improve its operation
• Faster
• More efficient
• Less costly
• More responsive
• Basic tools
• Process flowchart
• Process diagrams
• Process maps

31
Process Flowchart Symbols(?????)
32
Process Flowchart
33
Process Diagram
34
Process Map
35
??(Routing)1

• ??????????????????????
• ???????????????????????????
• ??????,??????????????????????,????????????

36
??(Routing)2

• ?????????(Operation),???????????????????????
• ???????????????????????,???????????
• ??????,???????,??????????????????,????????????????
  ???,?????????????????????,????????????????????

37
???(Process Sheet)??
38
??????

• ???????????????????????????????,?????????????

39
??????

• ?????????????????,?????????????????????,??????????
  ????

40
???????1

• ??????????
• ?????????
• ???????????
• ????????????????
• ????????????????
• ???????????
• ????????????????????

41
??????2

• ???????????
• ???????????
• ????????????????
• ???????????
• ???????????
• ?????????
• ???????
• ???????

42
????????1

• ??????????????134000?,?????????????2000??,???1?5??
  ???????4?5?2?3?2?????90,????????????

43
????????2
44
????????
90
45
?????????

• ??????????????????
• ??????,?????????????????????????????
• ?????????????????
• ???????????????????
• ????????????????????

46
???????????

• Information Technology
• Artificial Intelligence
• Advanced Communications
• Manufacturing Technology

47
Information Technology

• Management Information Systems (MIS)
• Move large amounts of data
• Decision Support Systems (DSS)
• Add decision making support
• Expert System
• Recommend decision based on expert knowledge

48
Decision Support System
49
Artificial Intelligence

• Neural networks
• Emulate interconnections in brain
• Genetic algorithms
• Based on adaptive capabilities in nature
• Fuzzy logic
• Simulate human ability to deal with ambiguity

50
Advanced Communications

• Electronic data interchange (EDI)
• Internet, extranets
• Wireless communications
• Teleconferencing telecommuting
• Bar coding, RFT
• Virtual reality

51
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
• Automated Material Handling
• Robotics
• Flexible manufacturing systems (FMS)
• Includes automated material handling

52
Automated Material Handling

• Conveyors
• Automated guided vehicle (AGV)
• Automated storage retrieval system (AS/RS)

53
Flexible Manufacturing Systems (FMS)

• Programmable machine tools
• Controlled by common computer network
• Combines flexibility with efficiency
• Reduces setup queue times

54
Flexible Manufacturing System
55
Robotics

• Programmable manipulators
• Follow specified path
• Better than humans with respect to
• Hostile environments
• Long hours
• Consistency
• Adoption has been slowed by ineffective
  integration and adaptation of systems

56
e-Manufacturing

• Real-time sharing of data with trading partners
  and customers to drive collaborative decisions
• CAD - uses software to create modify designs
• GT- classifies designs to benefit from prior
  experience
• STEP - sets standards for communication
• CAPP - creates processing instructions for CAM
• CAM - uses programmable automation in
  manufacturing

57
Components of e-Manufacturing