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Process SelectionProcess Selection
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Process and Process Selection
ProcessProcess:: Any set of activities performed by an organization that takes inputs and transforms them into outputs ideally of greater value to the organization than the original inputs.
Process selectionProcess selection refers to the strategic decision of selecting with which kind of production processes to have in the manufacturing plant.
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Process Selection
Three primary questions:
How much variety in products or services will the system need to handle?
What degree of equipment flexibility will be needed?
What is the expected volume of output?
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Types of Processes
Based on what they do Conversion process
Iron ore steel sheets, ingredients of toothpaste toothpaste
Fabrication process: changing raw materials into some specific form Sheet metal car fender, gold a crown for a tooth,
cloth clothes Assembly process
Assemble parts to components, put toothpaste tubes into a box, fasten a dental crown into someone’s mouth
Testing process For quality of products
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Process Types
A process flow structureprocess flow structure refers to how a factory organizes material flow using one or more of the process technologies.
Job shop
Batch shop
Assembly Line
Continuous Flow
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Job Shop
Job shop:Job shop: A process structure suited for low-volume production of a great variety of nonstandard products.
Each job may require a different set or sequence of processing steps
High flexibility of equipment (General-purpose equipment )
Skilled workers
Examples: commercial printing firms, copy center making a single copy of a student term paper, airplane manufacturers, machine tool shops, American Chopper
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Batch Shop
Batch shop:Batch shop: A process structure that produces a moderate variety of standard products at relatively low volumes. A somewhat standardized job shop
Employed when a business has a relatively stable line of products
The products are produced periodically in batches to reduce the impact of setup time on equipment
The equipment need NOT be as flexible as in a job shop
The skill level of workers need NOT to be as high as in a job shop
Examples:
Bakeries: make bread, cakes, cookies in batches;
Movie theatre: shows movies to groups (batches) of people;
Airlines: carry batches of people from airport to airport;
Other examples: production of beer, book, magazine, etc
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Assembly Line
Assembly line Assembly line (Repetitive processing):
A process structure designed to make discrete parts moving through a set of specially designed workstations at a controlled rate. High volume
Standardized products
Slight flexibility of equipment
Skill of workers is usually low
Examples: manual assembly of toys and appliances, automatic assembly of components on a printed circuit board, production line (automobiles, computers, etc.)
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Example: Production Line
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Continuous Flow
Continuous flow:Continuous flow: An often automated process structure that converts raw materials into finished product in one continuous process. Highly standardized products, no variety
Special-purpose equipment (no need for equipment flexibility)
Skill of workers is low
Examples: petroleum, steel, sugar, flour, and salt
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Example: Continuous Flow
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Product-Process Matrix
Choice of process flow structure is based on two main considerations: Variety—how much the product changes from
customer to customer;
Volume of demand.
Product-process matrix:Product-process matrix: Shows the relationship between process structures and product volume and variety characteristics.
As volume increases and the product line narrows, specialized equipment and standardized material flows become economically feasible. (see next slide)
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Product-Process Matrix
Volume
Variety
HighLow
High
Low
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