Chapter 7 Process Strategy

1
Chapter 7 Process Strategy

• Process types and selection, automation, line
  balancing

2
Process Selection

• Make or buy analysis (pp 233-237)
• QBEP FC / (p v)
• Production environment (or type of operations or
  process types)
• Project
• Job
• Batch
• Repetitive
• Continuous flow
• Volume, mix, flexibility considerations

3
Why Automate?
4
Why Automate?

• Reduce or eliminate labor cost??
• ?
• Apply only to high volume operations??
• ?
• Keep up with other CEOs at the Rotary Club??
• ?
• See ad and say Wow, Ive got to have that!??
• ?

5
Why Automate?

• Quality
• Assures consistency, low variability
• Rapid change
• Shortens setups and changeovers
• Reduces time to turnaround prototypes
• Lower tooling cost
• Eliminates specialized tools and dies
• Reduced labor cost

6
Automation Concepts - 1

• Product design
• CADD computer aided drawing and drafting
• CAD computer aided design
• Process design
• CAPP computer aided process planning
• Machine control
• NC numerical control
• CNC computerized numerical control
• DNC direct numerical control
• FMS flexible manufacturing system
• CAM computer aided manufacturing

7
Automation Concepts - 2

• Production scheduling
• CAS computer aided scheduling
• Service
• CAI computer aided instruction
• Warehousing
• AS/RS automated storage and retrieval systems

8
Automation Concepts - 3

• Robotics (Industrial robots)
• Heavy use in auto industry
• Described in terms of number of axes of motion
  (up to 6)
• Arm sweep
• Shoulder swivel
• Elbow extension
• Pitch (wrist)
• Yaw (wrist)
• Roll (wrist)

9
Automation Concepts 4

• CIM computer integrated manufacturing
• Integrates all the preceding concepts
• MAP manufacturing automation protocol
• Major development in U.S. auto industry

10
Line Balancing Definitions

• Line balancing
• Balance work among production lines, or
• Balance tasks among workstations on 1 line
• Cycle time
• Materials Management time from beginning of
  first operation until completion of last
  operation, or
• Industrial Engineering time between completion
  of 2 units of product, or
• Line Balancing Maximum time allowed at each
  workstation

11
Line Balancing Tools

• Cycle time calculation
• Output capacity ( OC OT / CT )
• Where OT Operating Time per day, CT Cycle
  Time
• Cycle time ( CT OT/D )
• Where D Desired output rate
• Precedence diagrams
• Similar to network diagram
• Measures of effectiveness
• Balance delay ( of idle time)
• Efficiency