Chapter 6 Manufacturing Process
Chapter 6 Manufacturing Process Design and Layout
Process Flow Structures Process Design Tools Layout Design
1
1
Manufacturing Process Selection and Design
Process Flow Structures How to organize material flow based on product design and competitive dimension? Continuous flow Assembly line, Flow line Batch shop: roller coaster ride, sightseeing tour, red wine Job shop: department store Project (one-of-a-kind): movies
2
1
Continuous flow
Highly automated, integrated production
line. Shutdowns and start-ups are expensive
p.211 petroleum, chemicals, beverages
3
Flow Line
Discrete parts moving at a controlled rate, following the same sequence to build the product.
Honda assembly line 3300 ft, 20 off-line branches
Ex 6.1
4
2
Batch shop
p.210
one piece flow
5
Job Shop
Small batches of many different products, with different processing sequences
Assembly Drilling 2 2 Lathe 1 1 1 Milling A B C D Raw materials 4 4 2 3 3 3
Painting
6
3
Product-Process Matrix
Ex 6.2
Honda
specialized equipment and standardized flows become economically feasible
7
Manufacturing Process Flow Design
Record and Evaluate Tables and charts Assembly charts Operation and route sheet Flow process chart (diagnostic tools) Design principles Performance measures Analyze and improve How many orders can we process per hour? How long it will take for an order to go through the system? Where and how much capacity to expand?
8
4
Assembly Chart
Defines the order of the assembly and the overall flow pattern Ex 6.5
operation
inspection
Ex 6.6
9
Process Flow Chart
TN 5.5
Identify activities that can be minimized or eliminated
move, delays, storage
10
5
Operation and Route Sheet
Ex 6.7
Specify process routing, the type of equipment, tooling, and the content of operations
11
Design Principle: Equipment Selection
Initial Investment 價格、輔助設備、二手機型 Output Rate 實際產能 Output
Process Flow Structures Process Design Tools Layout Design
1
1
Manufacturing Process Selection and Design
Process Flow Structures How to organize material flow based on product design and competitive dimension? Continuous flow Assembly line, Flow line Batch shop: roller coaster ride, sightseeing tour, red wine Job shop: department store Project (one-of-a-kind): movies
2
1
Continuous flow
Highly automated, integrated production
line. Shutdowns and start-ups are expensive
p.211 petroleum, chemicals, beverages
3
Flow Line
Discrete parts moving at a controlled rate, following the same sequence to build the product.
Honda assembly line 3300 ft, 20 off-line branches
Ex 6.1
4
2
Batch shop
p.210
one piece flow
5
Job Shop
Small batches of many different products, with different processing sequences
Assembly Drilling 2 2 Lathe 1 1 1 Milling A B C D Raw materials 4 4 2 3 3 3
Painting
6
3
Product-Process Matrix
Ex 6.2
Honda
specialized equipment and standardized flows become economically feasible
7
Manufacturing Process Flow Design
Record and Evaluate Tables and charts Assembly charts Operation and route sheet Flow process chart (diagnostic tools) Design principles Performance measures Analyze and improve How many orders can we process per hour? How long it will take for an order to go through the system? Where and how much capacity to expand?
8
4
Assembly Chart
Defines the order of the assembly and the overall flow pattern Ex 6.5
operation
inspection
Ex 6.6
9
Process Flow Chart
TN 5.5
Identify activities that can be minimized or eliminated
move, delays, storage
10
5
Operation and Route Sheet
Ex 6.7
Specify process routing, the type of equipment, tooling, and the content of operations
11
Design Principle: Equipment Selection
Initial Investment 價格、輔助設備、二手機型 Output Rate 實際產能 Output