Transcript 15.2 Single - Factor (One - Way) Analysis of Variance

Chapter 6
Process Planning,
Analysis,
and Reengineering
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Process Strategy
 Overall
approach to producing goods &
services
 Defines:
capital
intensity
process flexibility
vertical integration
customer involvement
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Ch 6 - 2
2
Types of Processes
 Projects
 Batch
production
 Mass production
 Continuous production
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Ch 6 - 3
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Project
Batch
Mass
Continuous
Product
Unique
Made to order
Made to stock
Commodity
Customer
Singly
Few individuals
Mass market
Mass market
Demand
Infrequent
Fluctuates
Stable
Very stable
Volume
Very low
Low to med
High
Very high
Variety
Infinite
Many, high
Low
Very low
System
Long-term
Intermittent
Flow lines
Process industry
Equipment
Varied
General-purp.
Special-purp.
Highly automated
Type of work Contracts
Fabrication
Assembly
Mix, treat, refine
Skills
Wide range
Limited range
Equipment
Experts
craftspeople
Advantages
monitors
Custom work
Flexibility
Efficiency
quality
sped, low cost
large capacity
Disadv.
Nonrepeating
Costly, slow
Capital invest.
Difficult to change
Example
Construction
Printing, bakery
Autos, TV’s
Paint, oil, food
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Ch 6 - 4
4
Process Planning
 Make-or-buy
decisions
 Process selection
 Specific equipment selection
 Process plans
 Process analysis
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Make-Or-Buy Decisions
1.
2.
3.
4.
5.
6.
Cost
Capacity
Quality
Speed
Reliability
Expertise
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Ch 6 - 13
6
Process Plans
 Blueprints
 Bill
of material
 Assembly diagram
 Assembly chart / product
structure diagram
 Operations process chart
 Routing sheet
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Bill Of Material (unstructured)
No.
1
2
3
4
5
6
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Part No.
51292
51284
52043
51576
51265
Part name
Outlet end
Handle
Switch
Electric cord
Rear housing
51268
Motor mounting plate
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Ch 6 - 16
8
Product Structure Diagram
Packaged
Hand-vac
Upholstery
tool
Crevice
tool
Forward
housing
assembly
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Hand-vac
Dusting
tool
Screw &
lock washer
assembly
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Package
Rear
housing
assembly
Ch 6 - 17
9
Operations Process Chart
Part name
Part no.
Usage
Assembly No.
Oper No.
Tools
10
20
30
40
50
Table leg
2410
Table
437
Description
Saw to rough length
Plane to size
Saw to finished length
Measure dimensions
Sand
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Dept.
Machine Time
041
043
041
051
052
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Ch 6 - 18
10
Process Flowchart Symbols
Operations
Inspection
Transportation
D
Delay
Storage
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Ch 6 - 20
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12
Continuous Improvement and Breakthroughs
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Ch 6 - 24
13
Process Reengineering
Customer
requirements
data
Strategic
directive
Benchmark
data
Goals & specifications
for process performance
Baseline
analysis
Design
principles
High-level
process map
Innovative
ideas
Key
performance
measures
Detailed
process map
Model
validation
Pilot study of
new design
Full-scale implementation
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Ch 6 - 25
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Design Principles For Reengineering
1. Organize around outcomes, not tasks
2. Capture information once, at the source
3. Centralize resources with information
technology
4. Link parallel subprocesses
5. Design to do work right the first time
6. Remove complexity
7. Identify information & technology levers
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Ch 6 - 27
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Techniques For Generating Innovative Ideas
 Vary
entry point to a problem
 Draw analogies
 Change your perspective
 Try inverse brainstorming
 Chain forward as far as possible
 Use attribute brainstorming
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Ch 6 - 28
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Information Technology
 Management
move
large amounts of data
 Decision
add
 Expert
information system (MIS)
support system (DSS)
decision making support
system
recommend
decision based on expert
knowledge
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Ch 6 - 29
17
Technology Tools for Process
Improvement
 Artificial
Intelligence
 Advanced Communication
 Manufacturing Technology
 Flexible Manufacturing System
 Robotics
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Artificial Intelligence
 Neural
networks
emulate
 Genetic
algorithms
based
 Fuzzy
interconnections in brain
on adaptive capabilities in nature
logic
simulate
human ability to deal with
ambiguity
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Advanced Communications
 Electronic
data interchange (EDI)
 Internet
 Wireless
communications
 Teleconferencing
& telecommuting
 Bar coding
 Virtual reality
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Manufacturing Technology
 Numerically
controlled
 Computer
by punched tape
numerical controlled (CNC)
controlled
 Direct
controlled (NC) machines
by attached computer
numerical control (DNC)
several
NC machines controlled by single
computer
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Automated Material Handling
 Conveyors
 Automated
guided vehicle (AGV)
 Automated storage & retrieval system
(ASRS)
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Ch 6 - 34
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Flexible Manufacturing
Systems (FMS)
 Programmable
machine tools
 Controlled by common computer
network
 Combines flexibility with efficiency
 Reduces setup & queue times
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Ch 6 - 35
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Flexible Manufacturing System
Computer
control
room
Tools
Conveyor
Machine
Machine
Pallet
Load
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Parts
Unload
Terminal
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Finished
goods
Ch 6 - 36
24
Robotics
 Programmable
manipulators
 Follow specified path
 Better than humans with respect to
hostile
environments
long hours
consistency
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Robot Parts
 Controller
hardware,
software, power source
 Manipulator
robot
arm
 End-effector
“hand”
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Computer Integrated
Manufacturing (CIM)
 Integration
of design, manufacture &
delivery via computer technology
 CAD - uses software to create & modify designs

CAM - uses programmable automation in
manufacturing
 CAE - links functional design to CAD form design

CAPP - creates processing instructions for CAM
 GT- classifies designs to benefit from prior
experience
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Ch 6 - 39
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Components Of CIM
CAD
CAE
GT
TQM
DFM
IGES,
PDES,
DMIS
Product
design
Bar codes,
EDI
CAD/CAM
CAPP
MRP
JIT/
kanban
Systems
management
Process
planning
CIM
DSS/ES/
AI
NC/CNC/
DNC
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MAP,
STEP
Manufacture
LAN, TOP,
satellites
FMS
Robotics
AGV,
ASRS
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Cellular
manufacturing
Automated
inspection
Cells
and centers
Ch 6 - 40
28
Adoption Of Technology

Technology Readiness


Technology Design


Know what to automate
Technology Selection


Need well-designed products & efficient
processes
Choose the right level
Technology Integration

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Have a strategy for incremental automation
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Ch 6 - 41
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