Chapter 7 SCMT 364: Manufacturing Processes

lean manufacturing

also called pull inventory, and use inventory only when you need it. this is a way to achieve high levels of customer service with minimal inventory investment

process characteristics of a project layout

requires flexibility, sequencing and complexity from project to project, activities often outsourced to suppliers, and typically used on engineer to order (ETO) or make to order (MTO)

output characteristics of a project layout

resources and inputs come to the product's location and is typically used for buildings, ships, or time constrained people (services like doctor's visits)

indifferent analysis

this finds the point where a company is indifferent between two processes because the total income for each is the same

manufacturing cell

this is a dedicated area where products/services with similar process characteristics are produced (furniture)

workcenter (job shop)

this is a flexible process structure for products that require different inputs and have different flows through the process. things can be more customizable and flexible

manufacturing process flow design

this is a method to evaluate the specific processes that material follow as they move through the plant. focus should be on the identification of activities that can be minimized or eliminated

assembly line

this is a process in which discrete products flow through a fixed sequence of activities or stations at a specific production rate

continuous process

this is a single flow process that converts raw materials int finished products in one continuous flow (cans, rice, chemical/oil refineries)

break-even analysis

this is a standard approach to choosing among alternative processes or equipment. it seeks to determine the point in units produced where a company will start to make a profit on the process. point in which the total revenue = the total costs

project layout

this is also called a fixed position layout and it is when the main product stays in one place and resources are moved to the product

process automation

this is the use of mechanization and information technologies to reduce the need for human involvement and decision making in a process (welding robots and bar codes)

mass customization

this uses advanced technologies to customize products quickly and at a low cost by stressing flexibility and postponement

customized, low volume (auto repair, machine shop, copy shop), grouping similar equipment or functions together

what are output characteristics of a work center (job shop)?

high variety of inputs and process flows, challenging job sequencing, high work in process inventory, high skilled/flexible workers, general purpose equipment, and typically used on engineer to order or make to order

what are process characteristics for a work center (job shop)?

high capital investment, maintenance and management of equipment requires expensive engineers, potentially decreases customers' perception of quality, no learning or innovation, and reduces process flexibility

what are some drawbacks to process automation?

standard products with limited range of options (fast food restaurants, shoes, cell phones, now cars are made like this)

what are some output characteristics for an assembly line?

typically moderate volume levels, standard products with limited or modular components: metal fabricating, furniture, computer chips

what are some output characteristics for manufacturing cells?

very high volume, high variety (customized m&ms, dell computers, t-shirts)

what are some output characteristics for mass customization?

very high volume and little variety

what are some output characteristics of a continuous process?

products follow the same sequence of activities, operations often run 24/7, highly specialized equipment, low skilled operators, high skilled technicians, line stoppages are very costly, and typically used on make to stock (MTS) process

what are some process characteristics for a continuous process?

activities in same sequence for all products, standard inputs, lower skilled workers specialize in fewer activities, and typically used un Make to stock (MTS) processes

what are some process characteristics for an assembly line?

small u-shaped production areas, used on MTO, ATO, and MTS processes. easier to communicate information to other workers how to be more efficient, and workers can help with each other in their certain job while waiting to do their job

what are some process characteristics for manufacturing cells?

products follow same sequence of activities, standard modules, flexible manufacturing systems, standard modules are produced and stocked until customer orders arrive, then customization takes place (postponement), and is typically used on Assemble to order (ATO)

what are some process characteristics for mass customization?