Design of production system

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Chapter 3

• Design of production system

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Contents

• 1 Product and service design
• 2 Process design
• 3 Production technology selection
• 4 Location
• 5 Layout

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1 Product and service design
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1.1  Objectives of product and service design

• To bring new or revised products or services to
  the market as quickly as possible
• To design products and/or services that have
  customer appeal.
• To increase the level of customer satisfaction.
• To increase quality
• To reduce costs

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1.2  Design for customers

• It is too difficult to fix-up
• Too much functions
• Too complicated to operation, etc.

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1.3  Design for manufacturing and assembly

• (DFMA)

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1.3.1     Objectives

• To reduce the number of parts and simplify the
  product.
• To make easy to manufacture and assembly
• Reduce the costs

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1.3.2 Principles and methods

• Standardization
• Minimize parts and operation
• Modular design
• Design for ease of jointing and separating and
  ease of coupling/uncoupling
• Design for one-way assembly, one- way travel
• Avoid special fasteners and connectors
• CAD--Computed- aided design

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Modular design

• A form of standardization in which component
  parts are subdivided into modules that are easily
  replaced or interchanged.

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Advantages of Modular design

• Fewer parts to deal with inventory and in
  manufacturing
• Reduce training costs and time.
• More routine purchasing, handing, and inspection
  procedures.
• Opportunities for long production runs and
  automation.
• Need for fewer parts and improve quality.

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Disadvantages of Modular design

• Designs may be frozen with too many imperfections
  remaining.
• High cost of design changes increases resistance
  to improvements.
• Decreased variety results in less consumer
  appeal.

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1.4  Design for reliability

• Reliability is the probability that an item will
  function as planned over a given time period. It
  may be calculated as follows
• (?--a constant failure rate)

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1.5 Designing and Developing new services
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Three dimensions of service design

• The degree of standardization of a service.
• The degree of customer contact in delivering the
  service.
• The mix of physical goods and intangible services

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Three service-ways

• Way of Line
• Automatic way
• Individual way

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2. Process design
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2.1 Types of processing

• Continuous processing
• Intermittent processing
• Projects

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Continuous processing

• Highly specialized system producing large
  volumes of one or a few standardized items.
• Repetitive manufacturing (Typically, these
  products are produced in discrete units.)

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Intermittent processing

• System that produces lower volumes of items or
  services with a greater variety of processing
  requirements
• Batches / lots
• Job shop

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2.2 The contents of the process design

• P 125, Figure 4.3

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2.3 Major factors affecting process design
decisions

• Nature of product/service demand
• Degree of vertical integration forward and
  backward integration
• Production flexibility---product flexibility/
  volume flexibility
• Degree of automation
• Product/service quality

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2.4 types of process designs

• Product-focused
• Process-focused
• Group technology/
• Cellular Manufacturing

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Product-focused

• A form of production processing organization
  in which production departments are organized
  according to the type of product/service being
  produced.
• (See Figure 4.4, P.128)

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Process-focused

• A form of production in which production
  operations are grouped according to type of
  processes.
• (See Figure 4.5, P.129)

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Group technology/cellular manufacturing (GT/CM)

• Form of production based on a coding system
  for parts that allows families of parts to be
  assigned to manufacturing cells for production.
• (P.130-131)

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3. Production technology selection

• NC--numerically controlled machines
• Robots
• Automated quality control inspection
• AIS--automated identification systems
• Automated production systems
• FMS---Flexible manufacturing systems
• CAD/CAM
• CIMS (see Figure 5.3 P.185)

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Characteristics of factories of the future

• (P.186)

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4. Location

• 4.1 General factors affecting location decision
• Figure 7.4 (p.254)
• Table 7.2 (p.257

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4.2 Analyzing retailing and other service
location

• Table 7.3 (p.260)

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5. Layout

• 5.1 Objectives of facility layouts
• Table 8.1 (p.281)

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5.2 Four basic types of layouts for manufacturing
facilities

• Process layouts
• Product layouts
• Cellular manufacturing layouts
• Fixed position layout

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5.2.1   Process layouts

• Functional layouts, job shop
• The layouts are designed to accommodate variety
  in product designs and processing steps.
• A variety of products in relatively small batches

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Product layouts

• They are designed to accommodate only a few
  product designs.
• The volume is large

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Cellular manufacturing layouts

• Machines are grouped into cells, and the cells
  function somewhat like a product layout island
  within a larger job shop or process layout.
• (Table p.285)

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Fixed position layout

• Figure 8.1 (p.286)
• The layouts are used when a product is very
  bulky, large, heavy

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Hybrid layouts
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5.3 New trends in manufacturing layout

• Cellular manufacturing layouts within larger
  process layouts
• Automated material-handling equipment
• U-shaped production lines
• More open work areas
• Smaller and more compact factory layouts
• Less space provided for storage of inventories

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5.4 Service facility layouts