Professional Documents
Culture Documents
Devaki Nadkarni
PRODUCTION SYSTEM
A system whose function is to convert set of input into set of desired output.
FACTORS TO BE CONSIDERED
Machined Parts
Casting
Forging
Machines
Welding process
Painting
PROCESS DESIGN
Process design means the complete delineation and description of specific steps in the production process and the linkages among the steps that will enable the production system to produce products of the desired quality, in the required quantity, at the time, customers want them and at the budgeted cost.
Nature of Demand Degree of vertical integration Flexibility Degree of automation Quality level and degree of customer contact
Nature of Product
The operations management has to design the production systems to produce products/ services of the kind the customers want, when they want them and at a cost that allows the firm to be profitable. Demand Forecast seasonality of demand, growth trends and other patterns of demand to determine the future production capacity.
a)
b)
Flexibility
Ability to respond fast to the customers needs is known as flexibility. Two forms of flexibility are product/service flexibility & volume flexibility. Ability of the production system to change quickly from production of one product/service to another is known as product/service flexibility. Ability to quickly increase or reduce the volume of products/services produced is known as volume flexibility.
Three aspects of Flexibility: (1) How quickly a process can convert from one product to another (2) Accommodate large volume (Service operations like restaurant, retail stores, health clinic etc.) at the time of need. (3) Produce more than one product simultaneously (Dell computer assembly process build customized computer )
Degree of automation
The degree of automation to be adopted and integrated into the production system is a key issue in process design, because of the high expenses involved in automation and also the difficulty involved in integrating automation into existing operations.
The choice of design of production process affects the level of product quality to a considerable extent. The extent to which customers get involved in the production system has important implications for the design of production processes.
Process Selection
There are hundreds of processes involved in different organizations
Choice of process provides a source of competitive advantage Therefore, processes vary among organisations
Common to all is the flow of product or the sequence of tasks that must be performed
Product volume (more numbers but less variety) Product variety (More variety but less number) Customer order type
made to stock (products are made in advance of customer order) made to order (Product is made on receiving a customer order)
Process Selection
Variety
How much Batch Job Shop Repetitive
Flexibility
What degree
Volume
Expected output
Continuous
Process Types
Job shop
Small scale
Batch
Moderate volume
Repetitive/assembly line
High volumes of standardized goods or services
Continuous
Very high volumes of non-discrete goods
Job-Shop Process
A job shop is a functional organization whose departments or work centers are organized around particular processes that consists of specific types of equipment or operations. Eg. Hospital (blood test, X-Ray, etc.) A variety of products are worked in the same workstations or machines. One machine completes partly and the product moves to the other machines for subsequent processing. The product has to be moved from one machine to another until it is completed.
Production flexibility: the processing requirements, the no. of machines required and, the order they are to be processed in, etc. are possible. Low initial costs for general purpose machinery Greater worker satisfaction
Less efficiency (general purpose m/cs are less efficient in processing) Skilled labor required for set-up and operation of these machines Less efficient material handling Higher work-in-process inventory Larger space requirements for in-process inventory Quality conformance harder to achieve Complex scheduling & coordination (long throughput time) Harder to assign costs & measure profitability of individual products
Batch Production
Batch processes are used to produce small quantities of products in groups or batches based on customer order or specification. A batch process produces the same product again and again - repetitive or discrete flow process.
Eg. McDonald produces hamburger in batches University accepts students in batches Shoes manufactured in batches for same size/design.
and ability to use special equipment and jobs at each work station. It is efficient to process a large batch at one stage and send the entire batch for processing - next stage.
(ii) Flexibility to produce variety of products in different volumes
(iii) It accommodates variability in processing time which cannot be synchronized by other processes.
(iii) (iv)
Assembly lines are designed to produce a large volume of a standardized product for mass production.
Assembly Line
Continuous Process
Operates continually to produce a very high volume of a fully standardized product.
(i) Takes care of high volume of a standardized product: equipment can be specialized to perform a narrow range of functions very efficiently.
(ii) Jobs can be specialized: workers can benefit from repetition of narrow range of work. Less skilled and lower wage workers can be used (iii) Material handling can be improved by the use of conveyor belts, gravity slides, robots, etc.
Inflexible systems - only products that require same processing and sequencing Initial costs are high (because of the specialized equipment used) Work can be tedious & boring (no job rotation and cross training) System is vulnerable to breakdowns causing stoppage of work.
Product-Focused
Job shop
Continuum
Job A Job B 1
Drilling Turning
Bank
Fast Food
Truck
Product-Focused Strategy
Raw Material
2
Components
4
Assemblies
1 3 5 7
Fin. Goods
Raw Material
Components
1 Product/Material Flow
Production Operation
Paper (Continuous)
Process Continuum
Process Focused (intermittent process)
Repetitive Focus (assembly line)
Continuum
High variety, low volume Modular Low utilization (5% - 25%) Flexible equipment General-purpose equipment Low variety, high volume High utilization (70% - 90%) Specialized equipment
High Variety One or few units per run, high variety (allows customization) Changes in modules Modest runs, standardized modules Changes in attributes (such as grade, quality, size, thickness, etc.) Long runs only
Process focus projects, job shops,(machine, print, carpentry) Standard Register Repetitive (automobiles)
Poor strategy (Variable costs are high)
Mass Customization (difficult to achieve, but huge rewards) Dell Computer Co.