OPS360: Chapter 6

Key dimensions that influence product/service profiling are...

...often related to the range of products or services that will be processed, expected order sizes, pricing strategies, expected frequency of schedule changes, and order-winning requirements.

What are the two key questions in process selection?

1. How much variety will the process need to be able to handle? 2. How much volume will the process need to be able to handle?

Layer decisions are important for what three basic reasons?

1. They require substantial investments of money and effort. 2. They require long-term commitments, which makes mistakes difficult to overcome. 3. They have a significant impact on the cost and efficiency of operations.

flexible manufacturing system (FMS)

A group of machines designed to handle intermittent processing requirements and produce a variety of similar products.

project

A nonrepetitive set of activities directed toward a unique goal within a limited time frame.

computer-integrated manufacturing (CIM)

A system for linking a broad range of manufacturing activities through an integrating computer system.

What are some of the advantages of process layouts?

Can handle a variety of processing requirements, not particularly vulnerable to equipment failures, general-purpose equipment tends to be cheaper, possible to use individual incentive systems...

How an organization approaches process selection is determined by its process strategy. Key aspects include...

Capital intensity: The mix of equipment and labor that will be used by the organization. Process flexibility: The degree to which the system can be adjusted to changes in processing requirements due to such factors as changes in product or service design, changes in volume processed, and changes in tech.

sustainable product

Creation of goods and services using processes and systems that are: non-polluting; conserving of energy and natural resources; economically efficient; safe and healthful for workers, communities, and consumers; and socially and creatively rewarding for all working people.

process selection

Deciding on the way production of goods or services will be organized.

precedence diagram

Diagram that shows elemental tasks and their precedence requirements.

What are some of the disadvantages of product layouts?

Dull jobs, inflexibility, susceptible to shutdowns, incentive plans tied to individual output are impractical...

single-minute exchange of die

Enables an organization to quickly convert a machine or process to produce a different (but similar) product type. Single cell can produce a variety of products without the time-consuming equipment changeover associated with large batch processes.

What are the three kinds of automation?

Fixed automation, programmable, and flexible.

programmable automation

High cost, general-purpose equipment controlled by a computer program that provides both the sequence of operations and specific details about each operation. Can economically produce a fairly wide variety of low-volume products in small batches.

What are some of the advantages of product layouts?

High production, low cost, reduced training cost/time, routine accounting, established routing/scheduling...

What are some of the disadvantages of process layouts?

In-process inventory costs can be high if batch processing is used in manufacturing systems, equipment utilization rates are low, special attention is necessary for each product/customer, accounting/inventory/purchasing much more involved...

What are the five basic process types?

Job shop, batch, repetitive, continuous, and project.

cellular production

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

fixed automation

Least flexible automation. High cost, specialized equipment for a fixed sequence of operations. Low cost/high volume are its primary advantages; minimal variety and the high cost of making major changes in either product or process are its primary limitations.

product or service profiling

Linking key product or service requirements to process capabilities.

automation

Machinery that has sensing and control devices that enable it to operate automatically.

numerically controlled (N/C) machines

Machines that perform operations by following mathematical processing instructions.

cycle time

Max time allowed at each workstation to complete its set of tasks on a unit.

process technology

Methods, procedures, and equipment used to produce goods and provide services.

product layouts

Most conductive to repetitive processing. Layout that uses standardized processing operations to achieve smooth, rapid, high-volume flow.

intermittent processing

Nonrepetitive processing.

balance delay

Percentage of idle time of a line.

preventative maintenance

Periodic inspection and replacement of worn parts or those with high failure rates.

line balancing

Process of assigning tasks to workstations in such a way that the workstations have approximately equal time requirements. If well-balanced, will have perfectly smooth flow of work as activities along line are synched for mass efficiency.

What are the three basic types of layouts?

Product, process, and fixed position.

What are two techniques that facilitate effective cellular layout design?

Single-minute exchange of die (SMED) and right-sized equipment.

right-sized equipment

Smaller than equipment used in traditional process layouts, and mobile, so that it can quickly be reconfigured into a different cellular layout in a different location.

assembly line

Standardized layout arranged according to a fixed sequence of assembly tasks.

production line

Standardized layout arranged according to a fixed sequence of production tasks.

technology

The application of scientific discoveries to the development and improvement of products and services and operations processes.

technological innovation

The discovery and development of new or improved products, services, or processes for producing or providing them.

group technology

The grouping into part families of items with similar design or manufacturing characteristics.

What dictates fixed-position layout?

The nature of the product. Weight, size, bulk, etc... Things that would make it difficult/undesirable to move the product. I.E. Boeing planes.

information technology

The science and use of computers and other electronic equipment to store, process, and send information.

computer-aided manufacturing (CAM)

The use of computers in process control.

process layouts

Used for intermittent processing. Layouts that can handle varied processing requirements. Functional layouts. Equipment arranged by type.

job shop process

Used when a low volume of high-variety goods or services will be needed. Processing is intermittent; work includes small jobs with diff processing requirements. Must have high flexibility/general purpose equipment and skilled workers. Ex: Veterinarian office.

repetitive process

Used when higher volume of standardized goods/services needed. Standardized output means only slight flexibility in equipment, skill of workers low. Ex: production/assembly lines.

batch process

Used when moderate volume of goods or services is desired, and can handle a moderate variety in products/services. Need moderate equipment flexibility, but processing still intermittent. Employee skill level doesn't have to be as high as job shop, b/c less variety in jobs. Ex: Bakery, movie theater, etc.

fixed-position layouts

Used when projects require layouts. Layout in which the product or project remains stationary, and workers/mats/equipment are moved as needed.

continuous process

Used when very high volume of nondiscrete, highly standardized output is desired. Almost no variety in output, no need for equipment flexibility. Worker requirements range from low to high, depending on complexity of system. Ex: Petroleum products, steel, sugar, flour, salt...