Week 3- Chapter 6

Examples of service automation

- self serve - atm machines - online journals and databases.

What are the disadvantages of Line balancing?

Forming task bundles having the same duration

What is continuous process?

High volume highly standardized equipment high fixed costs low variable costs low WIP inventory EG. cereal

What is a job shop process?

Low volume high variety small runs intermittent processing high flexibility of equipment skilled workers high variable cost per unit low fixed cost complex scheduling high Work-In-Process inventory EG. diamond rings

What is line balancing (design product layout)?

Process of grouping and assigning tasks to workstations so that the workstations have approximately equal time requirements

What are the 8 types of facility layouts?

Product process Cellular Hospital restaurant retail warehose office

Management challenges for continuous Process

Same as in an assembly line, automated control of the flow, start and stop of production

Management challenges for Batch Process

Scheduling batches in order to meet planned production and demand while utilizing the resources at a high level. Capacity issues and technology management are more important than in job sops

What is repetitive (assembly line) process?

Semi continuous slight flexibility of the equipment skill of workers is low routine scheduling low WIP inventory EG. Cars, motor bikes

Management challenges for Job shop Process

To schedule the jobs so that the due dates are met and the resources are utilized as much as possible

What is a product layout?

arranges production resources linearly according to the progressive steps by which a product is made. Sequence emphasized - Repetitive or continuous Processing - Designed for fast flow of customer goods through the system - More common fo goods

What is a process layout?

arranges production resources together according to similarity of function. Specialization emphasized

What does CT stand for?

cycle time

What is process design?

determining the form and function of how goods or services are produced

What is process design?

identifying the activities, resources, and controls needed in the production process

What does OT stand for?

operating time per day

What is Assembly to order Production/inventory Strategy ?

producing a large variety of products after customer orders are received. •standardized sub-assemblies and components held in inventory •fast delivery as well as high variety •final assembly is postponed until an actual order for the final product is received

What is Make to order Production/inventory Strategy ?

producing a variety of products to customer specifications. •involves low-demand customized products produced with complex but flexible processes resulting in long production lead time

What is Make to stock Production/inventory Strategy ?

producing and holding items in inventory for fast delivery to customers. •reduces purchase lead time for customers •standardized products that have high predictable demand

What is mass customization Hybrid process?

producing high quantity and high variety efficiently - McD's "made for you - Dell computers custom build

What is Focused factory Hybrid process?

specialized in a high quantity, standardized product

facility layout

the arrangement of departments, work centers, equipment

What is the objective of facility layout?

to have smooth movement

What is process layout?

®Process organized by specialization ®Used for Intermittent processing ®Job Shop or Batch Processes ®Common in Services

What are the advantages of Cellular Layout?

• less material handling and work-in-process inventory • faster processing time and reduced setup times • increased capacity

What is Flexible automation?

•Customized equipment •Computer-aided design and manufacturing systems (CAD/CAM), Flexible manufacturing systems (FMS), Computer-integrated manufacturing (CIM)

What is the importance of facility layout?

•Efficiency >> Cost, Quality, Flexibility, Timeliness

What is programmable automation?

•High-cost, general purpose equipment controlled by a computer program •Numerically Controlled (N/C) Machines: CNC, DNC, robots

What is a cellular layout?

•Layout in which machines are grouped into a cell that can process items that have similar processing requirements

What are the advantages of Line balancing?

•Minimizes idle time along the line •Results in high utilization of labour and equipment.

What is Fixed automation?

•Very rigid •High cost, specialized equipment for a fixed sequence of operations

What is batch process?

Moderate volume moderate variety, less flexible equipment and less skilful workers EG. Baked goods

Management challenges for Assembly line Process

Capacity balance, technology management, quality, and materials management

What is cycle time?

Cycle time is the maximum time allowed at each workstation to complete its set of tasks on a unit.

what does D stand for ?

Desired output rate per dat

What are the three steps to "Implement" (process design)?

1. Buy machines and equipment 2. Recruit workers 3. Start trial runs

What are the 6 reasons on wether to make a part in house or buy it from another company?

1. Cost 2. Capacity 3. Expertise 4. Quality consideration 5. Nature of demand 6. Technology secrecy

What are the three steps to process design Methodology?

1. Define the Production Process (Stage 2 of stage gate model) 2. Production process development (Stage 3 of stage gate model) 3. Implement (Stage 4 of stage gate model)

What are the three types of automation?

1. Fixed 2. Programmable 3. Flexible

What are the advantages of Product layout?

1. High degree of labour & equipment utilization = lower cost per unit 2. Minimal work-in-process inventories 3. Simplified accounting, purchasing and inventory control 4. Easier training and supervision

What are the disadvantages of Product layout?

1. Higher equipment cost 2. Dull, repetitive jobs = stress, low morale 3. Lack of flexibility in product or production rates 4 .Work stoppage at any point ties up the whole operation

What are the 4 Process types?

1. Job shop 2. Batch 3. Repetitive (assembly line) 3. Continous

What are the advantages of Process layout?

1. Less vulnerable to shutdown (from mechanical failure or absenteeism) 2. Lower maintenance costs (and reduced investment in spare parts)

What are the three steps to "Define the Production Process" (process design)?

1. Make or buy decisions 2. Set objectives 3. Determine nature of process in general

What are the three Production/ Inventory Strategies?

1. Make to stock 2. Make to order 3. Assemble to order

What are the disadvantages of Process layout?

1. Scheduling can be difficult (= low equipment utilization rates) 2. Setup, material handling, and labour and costs can be high 3. Increased work-in-process inventory

What are the three steps to "Production process development" (process design)?

1. conceptualize the design 2. Make embodiment of the design 3. Create a detailed design

what are the three factors to determine the number of workstation needed in line balancing?

1. cycle time 2. sum of task time 3. ability to combine tasks into workstations.

What are the 2 types of hybrid Process?

Focused Factory and mass customization