5 -making_products
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Transcript of 5 -making_products
Alex Hill and Terry Hill
Making productsAlex Hill and Terry Hill
Learning objectives
• Recognise the TECHNICAL and BUSINESS requirements to be met when making products
• Define the different TYPES of manufacturing process
• Identify the APPROPRIATE manufacturing process to use for different production volumes
• Identify the CATEGORIES of product and TYPES of manufacturing process
• Understand the business IMPLICATIONS of investing in alternative types of manufacturing process
• Explain why HYBRID processes may be introduced
Lecture outline
• INTRODUCTION
• Factors affecting MANUFACTURING PROCESS design
• DESIGNING the manufacturing process
• HYBRID processes
• Critical REFLECTIONS
• SUMMARY
© Alex Hill and Terry Hill
Factors affecting manufacturing process design
•STEPS required to
- Turn INPUTS- Into OUTPUTS
TECHNICALREQUIREMENTS
•VOLUMES•MARKET- ORDER-WINNERS- QUALIFIERS
BUSINESSREQUIREMENTS
> KEY IDEAManufacturing processes need to meet bothTECHNICAL and BUSINESS requirements
Factors affecting manufacturing process designCategories of product
Factors affecting manufacturing process designCategories of product
Factors affecting manufacturing process designTypes of manufacturing process
Developing a strategyUnderstanding customer requirements
Process type
Product Process
Project
Jobbing
Batch
Line
Continuous processing
• Made ON-SITE • Resources BOUGHT TO SITE
• SPECIAL, non-repeat
• ONE PERSON or SMALL GROUP
• STANDARD, repeat low to high volume
• Has to be RESET for each batch of products made
• MASS, repeat high volume
• DOES NOT have to be reset for different products
• MASS, repeat very high volume
• Process runs CONTINUOUSLY and never stops
Designing the manufacturing processProcess choices
Designing the manufacturing processProcess choices
Designing the manufacturing processProcess choices
> KEY IDEA
Use the words FLEXIBLE and AGILE with care as they have many DIFFERENT MEANINGS and, therefore, can be misleading
Designing the manufacturing processImplications of process design
CASE 5.1
OLD AND NEWCAR PLANTS
1.Why does Ford use a LINE manufacturing process?
2.Why is this process INFLEXIBLE?
CASE 5.1
Question Answer
Line process
Inflexible
• MASS products• NARROW product range• VERY HIGH VOLUME• NOT RESET for different products
OLD AND NEW CAR PLANTS
• Narrow PRODUCT range• Narrow VOLUME range
Hybrid processesCells
Hybrid processesCells
Hybrid processesCells
Hybrid processesCells
Hybrid processesCells
•Less WAITING time•Lower INVENTORY•Easier to
SCHEDULE
ADVANTAGES
DISADVANTAGES
•Less FLEXIBLE•Lower equipment
UTILISATION
> KEY IDEA
CELLS are a commonly usedHYBRID PROCESS
Car RestaurantBird
Making productsProduct category and process type
A Bug’s Life
(1998)
Gung Ho
(1986)
Dinner Rush
(2000)
Film clip Pit Stop
FilmTitleDirector (year)
A Bug’s LifeJohn Lasseter and Andrew Stanton (1998)
ClipStartFinish
00:47:0000:51:22
What clip showsThe bugs decide that they want to build a bird to protect their community
Key learning objective
The characteristics of a project processHow an operation transforms inputs into outputs
Making productsProduct category and process type
Film clip Factory
FilmTitleDirector (year)
Gung HoRon Howard (1986)
ClipStartFinish
01:33:1301:34:31
What clip shows Cars being manufactured on a production line
Key learning objective
The characteristics of a high-volume batch processHow an operation transforms inputs into outputs
Making productsProduct category and process type
Film clip Restaurant
FilmTitleDirector (year)
Dinner RushBob Giraldi (2000)
ClipStartFinish
00:58:5801:02:44
What clip showsThe chef producing a special one-off dish for a restaurant critic who is having dinner in the restaurant
Key learning objective
The characteristics of a low-volume batch process How an operation transforms inputs into outputs (and the difference between services and manufacturing)
Making productsProduct category and process type
Making productsProduct category and process type
Question Bird Car Restaurant
PRODUCT category
PROCESS type
• Made on-site• Special
• Mass• Standard
• Project• Resources
moved to site
• Line• High volume• Don’t reset
• Special• One-off
• Jobbing• Small group
Making productsProduct category and process type
Critical reflections
• MANUFACTURING PROCESSES must be:- ALIGNED to its market ORDER-WINNERS and
QUALIFIERS- REFLECT its internal BUSINESS requirements
• Each PROCESS has a different set of TRADE-OFFS
• Although DEMAND CHANGES over time, most businesses will NOT RE-INVEST in a different process
• Choosing the RIGHT PROCESS for the life of a product will have a significant impact on its SALES REVENUE and PROFIT
Summary
• Manufacturing processes must SUPPORT
- Technical and business requirements
• TECHNICAL requirements- The product specification
• BUSINESS requirements- Volumes and market order-winners and
qualifiers
• Each process type has a different set of TRADE-OFFS
© Alex Hill and Terry Hill
Revision questions
1 Which of the following is an example of a special product:
a) Automobile
b) Oil tanker
c) Ocean-going yacht
Revision questions
1 Which of the following is an example of a special product:
a) Automobile
b) Oil tanker
c) Ocean-going yacht
Revision questions
2 The essential difference between a batch and line process is:a) A line process is always straightb) When changing from one product to
another, a batch process has to be stopped and reset whereas a line process does not
c) A batch process can be stopped, but a line process cannot be stopped
Revision questions
2 The essential difference between a batch and line process is:a) A line process is always straightb) When changing from one product to
another, a batch process has to be stopped and reset whereas a line process does not
c) A batch process can be stopped, but a line process cannot be stopped
Revision questions
3 The differentiating feature of a continuous process is: a) The processes are laid out sequentiallyb) It is another name for a line processc) It is very expensive to stop and restart
hence it runs continuously
Revision questions
3 The differentiating feature of a continuous process is: a) The processes are laid out sequentiallyb) It is another name for a line processc) It is very expensive to stop and restart
hence it runs continuously
Revision questions
4 Which of the following is a definition of flexibility:a) Handling a range of products
b) Meeting demand peaks
c) Both a) and b)
Revision questions
4 Which of the following is a definition of flexibility:a) Handling a range of products
b) Meeting demand peaks
c) Both a) and b)
Revision questions
5 Which of the following is true:a) Process investments tend to be
inexpensive to changeb) Companies choose a process with the
intention of not changing it in the near future
c) Both a) and b)
Revision questions
5 Which of the following is true:a) Process investments tend to be
inexpensive to changeb) Companies choose a process with the
intention of not changing it in the near future
c) Both a) and b)
Revision questions
6 The essential difference between cells and batch manufacturing is that:a) In cells, processes are allocated to the
sole use of a group of productsb) In cells, similar processes are grouped
togetherc) In cells, equipment utilisation tends to be
higher than in batch
Revision questions
6 The essential difference between cells and batch manufacturing is that:a) In cells, processes are allocated to the
sole use of a group of productsb) In cells, similar processes are grouped
togetherc) In cells, equipment utilisation tends to be
higher than in batch
Revision questions
7 Potential cause(s) of non-alignment between a company’s markets and its operations’ capabilities are: a) The company is trying to meet the
differing demands of several markets with a single process
b) The needs of the market have changed over time
c) Both a) and b)
Revision questions
7 Potential cause(s) of non-alignment between a company’s markets and its operations’ capabilities are: a) The company is trying to meet the
differing demands of several markets with a single process
b) The needs of the market have changed over time
c) Both a) and b)
CASE FOR TUTORIAL
PRET A MANGER