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Chapter 7. Manufacturing Processes

Chapter 7. Manufacturing Processes. Process Flow Structures: Job shop (ex. Copy center making a single copy of a student term paper) Batch shop (ex. Copy center making 10,000 copies of an ad piece for a business) Assembly Line (ex. Automobile manufacturer)

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Chapter 7. Manufacturing Processes

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  1. Chapter 7. Manufacturing Processes Process Flow Structures: • Job shop (ex. Copy center making a single copy of a student term paper) • Batch shop (ex. Copy center making 10,000 copies of an ad piece for a business) • Assembly Line (ex. Automobile manufacturer) • Continuous Flow (ex. Petroleum manufacturer)

  2. 7-2 Basic work flow structures • Project layout • Workcenter • Manufacturing cell • Assembly Line • Continuous process

  3. 7-3 Product-Process Matrix

  4. Few Major Products, Higher Volume High Volume, High Standard- ization Exhibit 6.10 Low Volume, One of a Kind Multiple Products, Low Volume Flexibility (High) Unit Cost (High) I. Job Shop Commercial Printer French Restaurant These are the major stages of product and process life cycles II. Batch Heavy Equipment III. Assembly Line Automobile Assembly Burger King IV. Continuous Flow Sugar Refinery Flexibility (Low) Unit Cost (Low)

  5. Break-Even Analysis: • A standard approach to choosing among alternative processes or equipment • Model seeks to determine the point in units produced (and sold) where we will start making profit on the process or equipment • Model seeks to determine the point in units produced (and sold) where total revenue and total cost are equal This formula can be used to find any of its components algebraically if the other parameters are known Break-even Demand= Purchase cost of process or equipment Price per unit - Cost per unit or Total fixed costs of process or equipment Unit price to customer - Variable costs per unit

  6. Break-Even Analysis (Continued): • Example: Suppose you want to purchase a new computer that will cost $5,000. It will be used to process written orders from customers who will pay $25 each for the service. The cost of labor, electricity and the form used to place the order is $5 per customer. How many customers will we need to serve to permit the total revenue to break-even with our costs? • Break-even Demand: = Total fixed costs of process or equip. Unit price to customer – Variable costs =5,000/(25-5) =250 customers

  7. Manufacturing Process Flow Design: • A process flow design can be defined as a mapping of the specific processes that raw materials, parts, and subassemblies follow as they move through a plant • The most common tools to conduct a process flow design include assembly drawings, assembly charts, and operation and route sheets

  8. Lockring 4 Spacer, detent spring 5 SA-2 A-2 Rivets (2) 6 Spring-detent 7 A-5 Component/Assy Operation Inspection Example: Assembly Chart (Gozinto) From Exhibit 5.14

  9. Example: Process Flow Chart No, Continue… Material Received from Supplier Inspect Material for Defects Defects found? Yes Return to Supplier for Credit

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