Simulation Process Improvement for S/C Structures at RUAG Space
Process Structures[1]
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Process Technology
It refers to the equipment,
people and systems used toproduce a firm·s products and
services.
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Production Process Structures
Flow Processes
Job-shop Processes
Cellular Processes
Project Processes
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Selection of a process structure
Expected volume & demand pattern
for products No. of products to be made & types
of processing each requires
Made to stock or Made to order Physical characteristics & specific
technologies required
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Flow ProcessesT o structure the process according to
the ´flowµ of the products orsequence of tasks that must beperformed to make them.
1 2 3 4 5
Materials
Work StationsOut-
putProductFlow
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Flow Processes Continuous Flow Process
-- Paper manufacturing Repetitive or Discrete Flow Process
-- Automobile assembling
Disconnected or Batch Flow Process-- Book manufacturing
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Continuous Flow Process Primarily used in process industries
Designed to produce large volumes ofa small variety of uniform products
Processing subject to very strict
specifications Highly interconnected structure
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Continuous Flow Process Used for some aspects of
production process for discreteproducts
Very capital intensive
Highly automated and computerized Low: direct labor costs & per unit
production costs
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Repetitive Flow Process Often called Line process or discrete
flow process
Common version is an assembly line
Large quantities of narrow range ofproducts
Fixed sequence of productio n tasks
Us e o f sp eci ali zed equi p ment
Greater Auto matio n
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Repetitive Flow Process:
Problems Decomposing
Assigning and combining Accommodating
Adjusting to variation & uncertainties
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Advantages: Continuous &
Repetitive Flow Process Equipment can be specialized
Jobs can be specialized Material handling can be simplified
W-I-P inventories are small
Space utilization is efficient
Quality conformance is easier to
achieve
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Advantages Production scheduling and
coordination are relatively easy Costs are easy to monitor
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Disadvantages Inflexible
High initial costs Work can become tedious and boring
Production system is extremely
vulnerable
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Batch Flow Process Also called disconnected flow process
Produce a variety of products indifferent volumes
Use special equipment and jobs at each
workstation Variation in processing times & batch
sizes
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Batch Flow Process Material handling depends on
standard operations, & there is W-I-Pinventory
T rade-off between flexibility and
efficiency
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Batch Flow Process Adv: Flexibility, Low Cost, High
Capacity Utilization, Staffadvantages.
Disadv: Expensive for high volumes,
Idling of resources, Large in-processinventory, Costly material handling
equipments, Requires more space.
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Job-Shop Process Produce small quantity of a wide
variety of products
Systems divided into work centers ordepartments that are organizedaround common activities.
Products can move among workcenters in any sequence providingmaximum flexibility.
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Advantages: Job-shop Process Production Flexibility
Ability to accommodate differentprocessing times & lot sizes
Low initial costs for general purpose
equipment Greater work satisfaction because of
variety of work performed.
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Disadvantages: Job-shop
Process General purpose equipment usually less
efficient More skilled, higher paid employees
needed Less efficient but more flexible
material-handling methods W-I-P inventories are needed for
keeping work centers operating & forscheduling flexibility.
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Disadvantages: Job-Shop
Process Require more space
Quality conformance is difficult Variability makes scheduling and
coordinating very complex
Long throughput times
Difficult to determine profitability of
individual product.
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Why Job-Shop? Variety or volume of products
produced make the use of flow process
impractical. (companies competing
through product customization)
Startup costs of making new productsin small quantities are normally much
less.
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Cellular Process A mixture of mini flow processes, called
work cells, & a job-shop operation.
Dividing products that require similarprocessing steps in the same sequence.
Work cell created to perform the stepsin the designated sequence for all theproducts.
´Remainderµ job-shop subsystem (cell).
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Cellular Process Most commonly used as substitutes
for job-shop that need increasedproductivity.
Used in place of flow processes to
obtain greater flexibility. A popular way to organize service
operations.
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Advantages: Cellular Process Material handling & transport are
reduced. Setup times are reduced.
T hroughput time is reduced.
In-process inventories are smaller. Less space is needed.
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Advantages: Cellular Process T otal equipment costs often
decrease. Workers enjoy more satisfaction.
Quality improves.
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Disadvantages: Cellular
ProcessSuccessful implementation requires
considerable amount of work &expertise to:
Characterize & Classify products
Design appropriate work cells
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Project Processes Short life-cycle with a definite
beginning and a definite end.
Producing one-of-a-kind products
Likely to utilize similar skills and
equipment. T he process itself has to be
customized.
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Project Processes Manpower deployment: tricky
Matrix
form of organization is suitablewhen multiple projects are beinghandled.
Interdependent activities
Adv: Flexibility to customize theproduct.
Dis adv: Expense.
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List of Projects Setting up a Nuclear Power Plant
Launching a new product in the market
Conducting an EDP like Finance for non-finance executives
Organizing an Annual Sales Conference
Computerization of Inventory Building a modern hospital or stadium
Modernization of outdated textile mills
Community development projects
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Dominant Operations
Management Issues: How to coordinate the wide variety of
resources that are needed for thecurrent project, as well as for other
projects of the organization?
How to complete the project onschedule and within budget?
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Types of Non-Manufacturing
operations (Service)1. On the basis of process performed:
Standard Service
Custom Service
2. On the basis of product dealt: Providers of tangible products
Providers of service
3. Participation of customer in theprocess
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Challenges of Service
Operations Not easy to measure productivity
Difficult to establish qualitystandards
Service providers generally have
contact with customers Cannot maintain inventory
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C AD/C AM Systems Systems integrated with computer-
controlled machines Once a product or part design has
been completed on the CAD system, it
can be automatically encoded asmachine instructions for computer-
controlled machines.
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Advantages: C AD Systems Saves:
Considerable time Cost of hand-programming the
machine
Reduces chances of errors.
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Flexible Manufacturing
Systems (FMS) Self-contained systems of computer-
controlled machines, a tool-changingsystem, and a material-handling
system.
Vary widely in their complexity andcapabilities.
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Advantages: FMS Flexibility
Cost and time reductions
Better material handling
Minimal in-process waiting
Quicker machine setups Smaller quantities at lower cost
Firms can respond to demand
fluctuations more quickly.
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Disadvantages: FMS Expensive
Requires considerable expertiseand planning to implement
successfully.
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Computer-integrated
manufacturing (CIM) T ie all the database systems and all
the manufacturing equipment &
subsystems together into a single
integrated system.
Control and coordinate every phase ofproduction, from initial order receipt
to shipment and billing.