GB 320 chapter 9
What does rapid and innovative product designing system use to achieve make-to-order product designs?
CAD ( computeraided design) and rapid prototyping
What provides a link between product design and manufacturing?
Computer-aided process planning (CAPP)
Which of the following is a tool for process analysis and redesign?
VSM (value stream mapping)
t/f The product-process matrix classifies processes in terms of their degree of customer interaction and labor intensity.
false
Oil refineries can benefit from using a ______ process
fixed automation
This type of layout works well for project-type processes such as shipbuilding and house construction in which the product produced is bulky or fragile. It requires less of time and money to move the resources to the product's location than to change the location of workstations?
fixed-position layouts
______________automation is made possible with numerically controlled machines
flexible
What is a more advance application of flexible automation is?
flexible manufacturing system
process selection
for evaluating processed in a systematic way as well as selecting among them, choosing the right technologies, and then analyzing the process and redesigning them if necessary
In an assemble-to-order process supply chain, inventory is ______ and occurs at the ______ of the supply chain
higher, end
Computer-Aided processes planning (CAPP)
involves the use of computer technology to assist in planning the process required to manuafacture a part or product
agil manufactoring
is the ability of an organization to respond quickly to market changes with a set of processes to produce high-quality products at a reasonable cost
what is the goal of layout planning?
is to arrange people, equipment, materials, and processes so that the work flows smoothly and rapidly at all times. Other goals of layout planning include: 1. achieving appropriate product or service quality 2. eliminating waste through the efficient use of workers and space 3. eliminating bottlenecks in product or service flows
is used in a doctor's office where various patients with different ailments are treated. Each treatment is unique based on the patient's specific needs?
job-shop process
what is used when the processing requirements are intermittent and different for each product because it is unique and produces in low volumes or sporadically?
job-shop process
Mass customization combines the advantages of ______ and ______ processes.
job-shop, continuous flow
What is the goal of receptive process?
low unit costs, high efficacy and high volume of production are the goal
Custom-built homes are examples of products manufactured using ______ methods
make-to-order
flexible processes are required for______________
mass customization
What allows a firm to produce customized products at the speed, volume, cost and quality of a repetitive or continuous flow process?
mass customization process
what combines the advantage of job shop and repetitive or continuous flow processes?
mass customization process
What do service operation managers prefer to reduce their firms costs?
offer standardized services
Engineer-to-order (ETO)
offer the highest degree of product customization
the ______ is the point where the supply chain is split into distinct ______ and ______ parts
point of postponing; pull, push
A ______ layout is often used in job-shop or batch production processes.
process
A hospital often uses ______ layouts.
process
a collection of interrelated tasks that convert specific inputs into specific outputs
process
the most cost-effective way to achieve this transformation in order to produce goods or services that satisfy customers' needs and achieve the firm's sustainability goals while accommodating the firm's technological and managerial constraints
process design
Job- shop
process for proceeding a low volume of customized products and services adv: high product variety, low capital investment, and high process flexibility dis: high variable cost per unit, low-capacity utilization, low production volumes, the need for highly skilled labor, careful production planning, and complex controls
project process
process for producing a single product, offend unique, and the process is of limited duration adv: unique product tailored to customers specifications Disadv: high risk of cost and schedule overruns and subsequent customer disatisfaction
Batch process
process for producing semi-standardized products and services adv: moderate product variety and process flexibility, and moderate production volumes disadvantages: proaction planning and control moderately complex
What is one of the most important benefits of recent advanced in technology?
that service processes have become more flexible
process design
the most cost-effective way to achieve this transformation in order to produce goods or services that satisfy customers' needs and achieve the firm's sustainability goals while accommodating the firm's technological and managerial constraints
fixed automation
the process of producing a product or component in a fixed sequence of operations
Flexible automation
the process of using high-cost, general- purpose machines to produce a variety of products in low volumes or in small batches
ethical companies design their processes so that ________________
the safety of workers and consumers are not compromised
What makes the design of service processes challenging?
the trade-off between customers expectations and service providers desire for effiency
what is an improvement over the straight-line layout because it is more compact, which minimizes the handling of materials and is a compact layout in the shape of a U that allows workers to handle jobs in multiple workstations, gives workers an unobstructed view of the entire line, and allows workers to travel efficiently between workstations
u-shape layout
Computer-aided manufacturing (CAM)
uses computer software and hardware to control machine tools and other related machinery
When should continuous flow processes be used?
when very large volumes of a highly standardized product are to be produces
product layout (straight-line layout)
works well for repetitive or continuous flow processes used to produce a highly standardized product with high and constant demand.
features of mass customization process
- make or build to order - high or low volume production -use of lean, agile and synchronized manufacturing methods - continuous flow work cells -multi skilled and empowered employees
What questions do we ask to determine whether to use in house production or outsourcing?
-Do we have enough capacity to produce the component? - Do we have the core competencies to produce the component? - Are our suppliers reliable? - Does outsourcing entail significant risks? - What are the costs of outsourcing?
What are advantages of flexible automation
-reprograming machines to handle product customization - Numericall controlled(NC) machines - industrial robot - computer-aided manufacturing (CAM) - Computer-aided processing planning (CAPP)
two types of automation
1. fixed automation 2. flexible automation
Using the right technology can help firms?
1. improve quality of their services 2. provide them more quickly and efficiently 3. offer them at a lower cost
what three production strategies does mass customization combine to produce flexibility?
1. lean manufacturing 2. synchronous manufacturing 3. agil manufactoring
product customization designing process for supply chains
1. make-to-stock(MTS) 2.Make-to-order(MTO) 3. Assemble-to-order (ATO) 4.Engineer-to-order (ETO)
What do you use service process matrix for?
1. position their service relative to their competitors 2. understand the effect of a strategic change intended to reposition the firm's operations 3. many service businesses ave attempted to reposition their process in relation to the service process matrix
three basic types of layouts
1. process layouts 2. product layouts 3. fixed-position layouts
5 types of basic process types
1. project 2. job-shop 3. batch 4, repetitive 5. continuous flow
Characteristics of mass customization
1. rapid and innovative product design systems 2. flexability 3. responsive supply chains and tight inventory controls
office layouts
1. traditional layout- with walls and doors to reflect the status of employees in the organization's hierarchy, reduce noise and maintain privacy 2. cubical layout- rows of cubicles are separated by aisles to facilitate communication among the cubicles occupants 3. many office layouts now have low-rise partitions instead of walls to separate offices 4. many modern offices have adopted an open office layout design to leverage the power of modern technologies
legal, ethical and sustainability issues
1. using materials in production processes that are nontoxic, are recyclable, and require low energy 2. designing or redesigning processes - that do not waste recourses or produce harmful byproducts - that byproducts can be recycles - to maintain the physical well-being of workers and the general public
What combines the advantages of MTS and MTO methods?
Assemble to order (ATO)
Which of the following is the technology used for exchanging design- and manufacturing-related information of a product in computer-interpretable format?
STEP
make to stock (MTS)
This type of manufacturing method is used for products that typically require little or no customization, are produced in large volumes, and are stored as inventory for future use.
Cellular layout
a cellular manufactoring layout -based on the principles of group technology (GT), a parts coding and classification system in which parts or products with similar characteristics are grouped into families.
Process
a collection of interrelated tasks that convert specific inputs into specific outputs
what is process strategy influenced by?
by the degree to which customers can affect a products design specifications
fixed position layout
a layout type in which the product remains stationary in the plant. The resources such as workers, materials, machines, and tools needed to produce the product are brought to the product's location
Flexible manufacturing system
a processing method that can produce parts, allow changes to be made to products being manufactured and handle varying levels of products - can be picked up and moved
servicescape
a service is assembles and delivered and the seller and customer interact
what is a collection of processes?
a system
Industrial robots
a versatile machine that can perform routine task such as cutting and boring, welding, assembly and materials handling without any human intervention
Product profiling
a way to evaluate the alignment of the needs of a company's markets with its processes - it identifies the key product and service dimensions of a market to uncover misalignments that can occur over time
The ability to adjust the point of postponement in a global supply chain by employing techniques of all manufacturing process is a hallmark of ______ manufacturing.
adaptive
lean manufacturing
allows a company to achieve efficient levels of high volume, low-cost productions
Which of the following processes is best suited for products in their growth stage of the product life cycle?
batch
a service firm such as a credit card company uses a _______________________ to process bills. Instead of receiving a separate bill for each credit card transaction, the customer receives a bill each month for all of that months credit card transactions
batch process
what is used to produce a moderate variety of products in moderate volumes in groups or batches?
batch process
Why are layout decisions strategic decisions?
because they affect the cost and efficiency of operations
Hybrid layouts(also known as combination layouts)
combine the advantages of the three basic layout types
Adaptive manufactoring
combines lean and agile manufacturing with flexible manufacturing systems to adapt production in response to changing market conditions.
the complete automation of the manufacturing plant can be accomplished using _______
computer-integrated manufacturing technology (CIM) - using computers to control all processes
The service process design matrix classifies service processes in terms of their degree of ______ and ______.
customer interaction; labor intensity
What do customers prefer?
customized services that address their unique needs
Process types can be mapped to manufacturing methods according to the product's ______ and ______
demand variability; complexity
layout
describes the physical arrangement of work and storage areas, departments, or equipment, within the confines of some physical structure such as a plant, office, warehouse, or a service facility
What does CAD (computeraided design) and rapid prototyping allow?
enables a company to come up with several version of a product, sometimes in a matter of minutes
The decoupling point occurs at the ______ of a(n) ______ supply chain
end; make-to-stock
repetitive process
process for producing standardized products and services Adv: low variable cost per unit, high capacity utilization, high production volume, need for skilled labor now, production planning and control less difficult dis: limited precut variety, high capital investment and low process flexibility
continous flow process
process of producing highly standardized products and services Adv: very high volumes of productions and very high capacity utilization and efficiency Disadv: highly ridges process with no flexibility. The process is costly to redesign and is associated with high costs when the process is interrupted or down
the decision of selecting the kind of process that can give a firm a competitive advantage in terms of speed to market, responsiveness to customers, and cost savings
process selection
Banks changing their lending practices and processes to better align with new government regulations on bank operations is an example of matching ______ decisions with the ______.
process selection, market's requirements
The particular process a company selects is influenced by its
process strategy
which is the strategy a firm opts to take in producing goods and services determined by the availability and mixture of labor, equipment, and automation
process strategy
assemble to order (ATO)
process, the basic parts and components of a product are standardized, have already been manufactured, and are kept in stock. After receiving an order, these parts are quickly assembled based on the customer's requirements.
is a way to evaluate the alignment of the needs of a company's markets with its processes.
product profiling
what identifies the key product and service dimensions of a market to uncover misalignments that can occur over time?
product profiling
Make to Order (MTO)
products are manufactured only after receiving a customer's order. A combination of standard and custom-made components is used to make the product, but its final configuration is specific for the customer.
Numerically controlled Machines (NC)
programed with a specific set of instructions that tell the machines the details of the operations to be performed - used to produce products such as industrial components
What process is used when a product is unique and typically produces one at a time to the customer's specification?
project process
What type of project works best when there is low demand for a prices, non routine work, a large investment of recourses, and stringent time and budget constraints for completion?
project process
A ______ manufacturing system uses actual ______ rather than ______ to produce goods and services
pull, customer orders, demand forecast
process layout
referred to as a functional layout, is used when a firm produces low volumes of products using job-shop or batch production processes. - enables the firm to meet the different need of variety of customers
When a high volumes of standardized products need to be produced, a __________________ process should be used?
repetitive
Starbucks' effort in creating a homey, comfortable atmosphere and décor for its patrons is an example of how to consider the ______ in planning service layouts.
servicescape
an example of project process
ship building
synchronous manufacturing
synchronizing customer's orders with the task performed at the various workstations - allows the firm to produce a wide variety of products using the job-share rpcicess
