DESIGNING AND MANAGING

PRODUCTION PROCESS
LESSON1: PROCESS TECHNOLOGY AND
DESIGN
LESSON2: FACILITY LAYOUT AND
WORKPLACE DESIGN
LESSON3: PROCESS MANAGEMENT
PROCESS TECHNOLOGY AND
DESIGN
PROCESS a specific combination of
machines, operators, work methods,
materials, tools, and environmental
factors that together convert inputs to
outputs
PROCESS TECHNOLOGY methods
and equipment used to manufacture a
product or deliver a service
HARD TECHNOLOGY involves the
application of computers, sensors,
robots, & other mechanical & electronic
aids
SOFT TECHNOLOGY application of
computer software
CLASSIFICATION OF PRODUCTION
SYSTEMS AND PROCESSES
MAKE-TO-ORDER produce only in
response to order
- produce a larger variety of
products in smaller quantities
MAKE-TO-STOCK build inventories
for future sales
TYPES OF PRODUCTION
PROCESS
CONTINUOUS
FLOW
- Are characterized
by high production
volume and a high
degree of product
standardization
MASS,OR
ASSEMBLY-LINE
- Are used for high-
volume production
of discrete parts
TYPES OF PRODUCTION
PROCESS
BATCH, OR
INTERMITTENT
- Production process
are used for
producing lots of
similar products
- Labor skills are
necessary to set up
machines and
perform a wider
variety of tasks
during production
JOB-SHOP
- Production process
produce a wide
variety and small
quantity of
specialized products
TYPES OF PRODUCTION
PROCESS
PROJECT
- Production process is one in which a
unique and usually large and complex
item is produced
THREE TYPES OF PROCESS
TECHNOLOGY
MANUAL TECHNOLOGY uses no
machinery to perform manufacturing
or assembly tasks
MECHANIZED TECHNOLOGY
utilizes machines that are under
human control
AUTOMATED TECHNOLOGY uses
computers to control the process
Automation and Advanced
Technology
NUMERICAL
CONTROLLED
- Enable the
machinists skills to
be duplicated by a
computer program
that is stored on a
computer
ROBOTICS
- A programmable
machine designed
to handle materials
or tools in the
performance of a
variety of stock
Automation and Advanced
Technology
MACHINE VISION
SYSTEMS
- Automatically
receive and
interpret an image
of a real scene to
obtain information
&/or control
machine
processrss
INFORMATION-
BASED
TECHNOLOGY
- bar-code
technology
eliminates the need
for people to
keyboard
information into a
computer, greatly
speeding
processing and
reducing errors
PROCESS PLANNING AND
DESIGN
To design a process, several activities must be
performed
1. identify the individual components of the product
and their order of assembly (PRODUCT
ANALYSIS)
2. Identify the sequence of production steps
required to fabricate each component (PROCESS
ANALYSIS)
3. Select the appropriate technology and
equipment to accomplish each processing step (
PROCESS SELECTION)
4. Design work methods for each
FACILITY LAYOUT AND
WORKPLACE DESIGN
FACILITY LAYOUT
Refers to the specific arrangement of
physical facilities
It is necessary whenever:
1. a new facility is constructed
2. there is a significant change in
production or throughout volume
3. a new product is introduced
4. different process and equipment are
installed

LAYOUT PATTERN
PRODUCT
LAYOUT
continuous-flow,
mass-production,
and batch
processing
production process
are usually
physically
organized by
product layout
PROCESS
LAYOUT
consists of a
functional grouping
of machines or
activities that do
similar work

Examples of product layout
Service organization that provide
highly standardized services
Course registration in a college or
university

Note: whenever little variety and
personalization of services is offered
and the volume of demand is high, a
product layout is used.
LAYOUT PATTERN
GROUP LAYOUT
- Process layouts, which
dominate batch-
production facilities,
result in a large
number of setups for
different parts, as well
as high materials-
handling costs and
high work-in process
inventory
- Example: offices
FIXED-POSITION
LAYOUT
- The construction of
large items, such as
heavy machine tools,
airplanes, locomotives
is usually
accomplished in one
place rather than
moving from one work
center to another tools
and components are
brought to one place
for assembly.

DESIGN OF PRODUCT
LAYOUT
Continuous flow, assembly line, and
many batch-processing production
processes are all forms of product line
which can be defined as a fixed
sequence of production stages, each
consisting of one or more machines or
workstations
DESIGN OF PROCESS
LAYOUTS
In designing process layouts, we are
concerned with the arrangement of
departments relative to each other
DESIGN OF GROUP
LAYOUTS
Involves three steps:
1. selection of part families
2. selection of machine groupings or
cells
3. detailed arrangement of the cells
PROCESS
MANAGEMENT
PROCESS MANAGEMENT
Control planning and administering the
activities necessary to sustain a high
level of performance in a process
Improvement, identifying opportunities
for achieving continuously higher
levels of quality in operational
performance
Focused on preventing defects and
errors, eliminating waste as non-
value-added processing steps,
waiting, and redundancy
PROCESS CONTROL
CONTROL the continuing process of
evaluating performance and taking
corrective action when necessary
THREE COMPONENTS
1. a standard goal
2. a means of measurement of
accomplishment
3. a means of comparing actual
results with the standard along with
feedback to form the basis for
corrective action
QUALITY CONTROL
POKA-YOKE a device that permanently
prevents the recurrence of the defect it is
designed to eliminate
SUCCESSIVE CHECKING design of
process that are physically impossible if
preceding processes have produced
defective parts
AUTOMATION involves equipping
machines with automatic stopping devices
and other features that eliminate the
possibility that large quantities of defectives
will be produced.