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Manufacturing and Process Selection Design

. Types of Processes. Conversioniron ore into steel Fabricationforming raw material (gold into jewelry)Assemblyfastening parts together to create product (bicycle)Testing for quality of products. . Process Flow Structures. Job shop (ex. Copy center making a single copy of a student term paper)Batch (standardized job shop) (ex. Copy center making 10,000 copies of an ad piece 30713

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Manufacturing and Process Selection Design

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    1. Manufacturing and Process Selection Design Chapter 6

    2. Types of Processes Conversion iron ore into steel Fabrication forming raw material (gold into jewelry) Assembly fastening parts together to create product (bicycle) Testing for quality of products

    3. Process Flow Structures Job shop (ex. Copy center making a single copy of a student term paper) Batch (standardized job shop) (ex. Copy center making 10,000 copies of an ad piece for a business) Assembly Line Continuous Flow

    5. Process Flow Design Defined A process flow design can be defined as a mapping of the specific processes that raw materials, parts, and subassemblies follow as they move through a plant. The most common tools to conduct a process flow design include assembly drawings, assembly charts, and operation and route sheets.

    6. Process Flow Design Assembly drawing (see Exhibit 6.5) an exploded view of the product Assembly chart (Gozinto) (Exhibit 6.6) defines how parts go together Operation and route sheet (Exhibit 6.7) specifies operations and routing Flow Process Chart (see Exhibit 6.8) uses standard symbols to show what happens to product as it flows through production process

    8. Example: Assembly Chart (Gozinto)

    9. Example: Process Flow Chart

    10. Operations Technology Hardware Systems Software Systems Computer Integrated Manufacturing Technologies in Services Benefits Risks

    11. Hardware Systems Numerically controlled (NC) machines Machining centers Industrial robots Automated material handling systems Flexible manufacturing systems (FMS)

    12. Software Systems Computer-aided-design (CAD) Automated manufacturing planning and control systems (MP & CS) Enterprise Resource Systems (ERP)

    13. Computer Integrated Manufacturing Product and process design Planning and control The manufacturing process

    14. Technologies in Services Office automation Image processing systems Electronic data interchange (EDI) Decision support systems & expert systems Networked computer systems

    15. Benefits from Adopting New Technologies Labor costs Material costs Inventory costs Transportation or distribution costs Quality costs

    16. Other Benefits…. Increased product variety Improved product features and quality Shorter cycle times

    17. Risks Technological risks Organizational risks Environmental risks Market risks

    18. Global Product Design and Manufacturing Joint Ventures Strategic Suppliers Global Product Design Strategy

    19. Virtual Factory Shift from centralized production to .... .. an integrated network of capabilities local, national, global

    20. “The best engineered part is no part” NCR has achieved or overcome the following: less components less suppliers less assembly time eliminating screws and fasteners faster speed of concept to market lower costs

    21. Product Development in Japan - Benefits Employment throughout the economy easy to make design changes many small innovative companies

    22. Product Development in Japan - weaknesses Very complex structure of companies difficult to understand difficult to control a breakdown in a small company could immobilize a large company like Matsushita.

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