Design of production systems and production technology
- 1. Design of production system and production technology Production and Operations Management Unit -2 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 1
- 2. Learning Objectives • Definition of “Product design”, “Process design”, and “Production design” • Objectives of production design • Factors influencing product design • Characteristics of a good product design 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 2
- 3. Product design • It is detailed specification of a manufactured item’s parts and their relationship. • A product design takes into account how that product will perform in an efficient and safe and reliable manner. • It is a way to gain customer satisfaction and gain differential advantage 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 3
- 4. • Functional design – The product should effectively perform the function for which it is developed. • Example: Television – the picture quality (video) sound quality (audio) is more important. • FORM DESIGN – It is concerned with appearance and aesthetic consideration and also size, volume an weight of the product. These are secondary factors. 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 4
- 5. PROCESS DESIGN 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 5
- 6. PROCESS DESIGN • Concerned with the overall sequences of operations required to achieve the design specification of product. • Specifies types of work station used, machines & equipments etc.. • Choice of process of technology - Manual, mechanized or automated technology. • Process must be capable to achieve product quality. 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 6
- 7. PRODUCTION DESIGN • The concept of designing products from the point of view of producibility. • It is a conscious effort to design for producibility and low manufacturing cost. 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 7
- 8. Importance of product design • All detailed characteristics of each product are established. • Distinctive design differentiate the product from others. • Example: Apple iPhone is differentiated from a Samsung smartphone on the basis of its product design. • An excellent design includes the following: Usability aesthetics reliability functionality innovation appropriateness (quality, cost, features) 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 8
- 9. Importance of product design • A good product design can improve its MARKETABILITY. • Product design directly affects: • Quality • Product cost • Customer satisfaction 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 9
- 10. OBJECTIVES OF PRODUCT DESIGN 1. Profit generation in the long run. 2. To achieve the desired product quality. 3. To reduce the development time and cost to the minimum. 4. To reduce the cost of the product. 5. To ensure producibility/manufacturability 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 10
- 11. Factors influencing product design •Customers requirements •Convenience of the user •Types of materials to be used •Work methods and equipment 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 11
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- 14. Factors influencing product design •Cost/Price ratio •Product quality •Process capability •Effect of existing product •Packaging 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 14
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- 16. Characteristics of Good Design •Function or performance •Appearance or aesthetic •Reliability • Refers to length of time a product can be used before it fails. •Maintainability • Restoration of a product once it has failed. Serviceability. •Availability 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 16
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- 18. Characteristics of Good Design •Producibility • Ease of manufacture with min. cost •Simplification • Elimination of complex features •Standardization • Design activity to reduce variety among group of products or parts. •Specification • Detailed description of material, part, volume, weight etc… •Safety : Product should not cause any accidents 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 18
- 19. What is a process? • A process is a sequence of activities done to achieve certain results. • It is to create added value for customers 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 19
- 20. • Process converts inputs into outputs in a production system. Process: • Is any part of an organization which takes a set of input resources which are then used to transform something into outputs of products or services. • Process: • Methodology • Utilized on a continuous basis • Result in creation of good/service • Delivered to customer • Make a profit • Add maximum value at minimum cost. 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 20
- 21. A Generalized Job Shop Operation 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 21
- 22. A Generalized Flow Shop Operation 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 22
- 23. Types of Process 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 23
- 24. Types of Process I. Conversion process II. Manufacturing process III.Testing process 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 24
- 25. Conversion process • Conversion process includes operations (actual production process). Operations may be either manual or mechanical or chemical. Operations convert inputs into output. • Conversion process also includes supporting activities, which help the process of conversion. • The supporting activities include; production planning and control, purchase of raw-materials, receipt, storage and issue of materials, inspection of parts and work-in-progress, testing of products, quality control, warehousing of finished products, etc. 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 25
- 26. Manufacturing process i. Forming processes ii. Machining process iii. Assembly process 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 26
- 27. Forming processes • Forming, or metal forming, is the metalworking process of fashioning metal parts and objects through mechanical deformation. • The work piece is reshaped without adding or removing material, and its mass remains unchanged. 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 27
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- 29. Machining process 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 29
- 30. • Machining consist of forcing cutting tool with one or more edges through the excess materials on a work piece and removing this excess material in the form of chip. 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 30 Machining Milling Drilling Grinding Shaping Turning Boring
- 31. Assembly process 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 31 It is the process of joining of parts or components to produce assemblies having specific functions. Assembly process Welding Soldering Bolts and nuts Adhesives
- 32. Testing process 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 32
- 33. PROCESS PLANNING • Process Design : Concerned with the overall sequences of operations required to achieve the product specifications. •Operation Design: Concerned with design of the individual manufacturing operation. It examine man-machine relationship in manufacturing operations 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 33
- 34. Framework for process design • Refer Page No: 65 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 34
- 35. Process Selection • Process selection refers to the strategic decisions of selecting the kind of production process to have in a manufacturing plant. • Refers to the way production of goods and services is organized. • Plan regarding :- Capacity planning Equipments Design of work system Plant layout 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 35
- 36. •PRIMARY QUESTION TO BE ADDRESSED: i. How much variety of products or services will the system need to handle? ii. What degree of equipment flexibility will be needed? iii. What is the expected volume of output? 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 36
- 37. Process Strategy • Strategic planning is an organization's process of defining its strategy, or direction, and making decisions on allocating its resources to pursue this strategy. • It can be utilized to guide a variety of process decisions, operations strategy, and your business' ability to obtain the resources necessary to support them. • Key aspects: Make or buy decision Capital intensity Process flexibility 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 37
- 38. Objective: • Meet or exceed customer requirements. • Achieve competitive advantage. • Has long-run effects: Product & volume flexibility. • Costs & quality 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 38
- 39. Make-or-buy decision: Is the act of choosing between manufacturing a product in-house or purchasing it from an external supplier. Capital Intensity: A business process or an industry that requires large amounts of money and other financial resources to produce a good or service. A business is considered capital intensive based on the ratio of the capital required to the amount of labor that is required. Process Flexibility: Refers to the degree to which the system can be adjusted to changes in processing requirements. Ex: volume of products changes in technology. 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 39
- 40. 3 Process strategies: • Process Focus/ Job Shops • Repetitive Focus • Product Focus 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 40
- 41. Process Focus Facilities are organized around specific activities or processes General purpose equipment and skilled personnel High degree of product flexibility Typically high costs and low equipment utilization Product flows may vary considerably making planning and scheduling a challenge 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 41
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- 43. Repetitive Focus Facilities often organized as assembly lines. Characterized by modules with parts and assemblies made previously. Modules may be combined for many output options. Less flexibility than process-focused facilities but more efficient. 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 43
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- 45. Product Focus Facilities are organized by product High volume but low variety of products Long, continuous production runs enable efficient processes Typically high fixed cost but low variable cost Generally less skilled labor Need standardization and effective quality control 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 45
- 46. Make or buy decision 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 46 Should I continue to make the part, or should I buy it? I suppose I should compare the outside purchase price with the additional costs to manufacture the part. What will I do with my idle facilities if I buy the part?
- 47. Definition •“Make-or-Buy decisions compare the cost of producing a component or providing the service internally with the cost of purchasing the component or service from an external supplier” 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 47
- 48. Outsourcing • “Outsourcing is a strategic decision to give a task or activity to an independent contractor who determines how best to do the task or activity”. • (it is a) management strategy by which an organisation outsources major non-core functions to specialised, efficient service providers 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 48
- 49. Subcontracting Outsourcing is a strategic long term decision, Subcontracting is a tactical, short term approach. “Outsourcing is nothing but delegating a particular business activity/function to another individual/entity. Sub-contracting is sharing a part of the business activity with another. ” 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 49
- 50. Examples of outsourced services • Car park management • Cleaning • Catering • Building maintenance • Security • Transport management • Waste disposal •Library •Medical/ Welfare •Pest control •Ground maintenance •Computers & information technology 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 50
- 51. Reasons for Making • Cost concerns • Desire to expand the manufacturing focus • Need of direct control over the product • Intellectual property concerns • Quality control concerns • Supplier unreliability • Lack of competent suppliers • Volume too small to get a supplier attracted • Reduction of logistic costs (shipping etc.) • To maintain a backup source • Political and environment reasons • Organizational pride 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 51
- 52. Reasons for Buying • Lack of technical experience • Supplier's expertise on the technical areas and the domain • Cost considerations • Need of small volume •Insufficient capacity to produce in-house •Brand preferences •Strategic partnerships 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 52
- 53. Four Numbers You Should Know • The volume • The fixed cost of making • Per-unit direct cost when making • Per-unit cost when buying • Cost to Buy(CTB) = Volume x Per - unit cost when buying • Cost to Make(CTM) = Fixed costs + (Per-unit direct cost x volume) 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 53
- 54. Technology •Is define to be the know how, physical things and procedures used to produce products and services. •Know – how : knowledge and judgment of how, when and why to employ equipment's , processes and procedures. •Advanced Technology: The application of the latest scientific or engineering discoveries to the design of production and operations processes 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 54
- 55. Examples • Nuclear Technology • Manufacturing Technology • Design Technology • Communication Technology • Missile Technology • Space Technology • Laser Technology 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 55
- 56. Role of Technology • Self study topic 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 56
- 57. Classification •Manual technology •Mechanized technology •Automated technology • Current technology • Appropriate technology 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 57
- 58. •State of the art technology •Advanced technology •Obsolete technology 4/28/2017 UKA TARSADIA UNIVERSITY Prepared by : Divya Paulose 58