Process selection2

1 Process Selection and Facility Layout

Process Selection and Facility Layout

2 Process Selection and Facility Layout

Introduction

• Process selection– Deciding on the way production of goods or

services will be organized

• Major implications– Capacity planning– Layout of facilities– Equipment– Design of work systems

3 Process Selection and Facility Layout

Forecasting

Product andService Design

TechnologicalChange

CapacityPlanning

ProcessSelection

Facilities andEquipment

Layout

WorkDesign

Process Selection and System Design

4 Process Selection and Facility Layout

Process Selection

• Variety– How much

• Flexibility– What degree

• Volume – Expected output

Job Shop

Batch

Repetitive

Continuous

ProjectProcess Types

5 Process Selection and Facility Layout

Process Types

• Projects– Unique

• Job shop– Small scale

• Batch– Moderate volume in lots

• Repetitive/assembly line– High volumes of standardized goods or

services• Continuous

– Very high volumes, Highly standardize

6 Process Selection and Facility Layout

Product – Process Matrix

Oil refineryGenerating

Electricity

Notfeasible

Continuous(flow)

Automotiveassembly

Automaticcarwash

Repetitive

Commercialbakery

ClassroomLecture

Batch

Not feasible

Appliance repair

Emergency room

Job Shop

Process Type

Project BridgesHighways

VolumeF

lex

ibili

ty /

Mix

NotFeasible

NotFeasible

7 Process Selection and Facility Layout

Project Non-Routine, Often “One Of A Kind” OperationLimited Time Frame To Complete

Steps Involved in Project Process 1.Project initiation stage;2.Project planning or design stage;3.Project execution or production stage;4.Project monitoring and controlling systems;5.Project completion stage.

Manufacturing : Buildings, Dams, Bridges, Ships

Service : Crisis Management (Hurricane Recovery)

8 Process Selection and Facility Layout

Job Shops

Low Volume – High Variety of Goods& Services

Processes may change from job to job.

Highly flexible workforce and equipment.

Manufacturing Examples: Tool & Die Shop,Custom Car Painting

Service Examples: Beauty Solon, Hospital,Veterinarians Office(Many animals, many issues)

9 Process Selection and Facility Layout

Batch ProcessesMedium Volume having job shop flexibility

using repetitive techniques.

Easy to set-up processes.

Process runs batches using repetitive techniques. Flexible Automation

Manufacturing Examples: Small Bakery,PIP style printing

Service Examples: TV Show Production, Airline baggage handling

10 Process Selection and Facility Layout

Repetitive / Assembly Line

High Volume – Low Variety of Goods & Services

Processes are very constant with little change.

Lower skilled workers needed – Fixed Automation

Manufacturing Examples: Auto Assembly, High Volume Electronics

Service Examples – Cafeteria Lines, Ticket Takers

11 Process Selection and Facility Layout

Continuous ProcessesVery High Volume – Very Low Variety

Continuous Processes

Frequently totally automatedFixed (hard) automation

Manufacturing Examples: Making Steel, Fiberglass, Petrochemicals, Generating Electricity.

Service Examples: Internet, Air Quality Monitoring, Delivering Electricity

12 Process Selection and Facility Layout

Automation

• “Machinery or equipment with sensing devices that enable it to operate."

– ATM’s To Robots

Commonly used term with many meanings.

Fixed Automation / Hard AutomationProgrammable Automation

13 Process Selection and Facility Layout

Fixed vs. Programmable Automation

Fixed Automation – designed to do a specific task.Specialized equipment – high volume at low cost,inflexible.

Programmable Automation – may be reprogrammed to do many different tasks.General purpose equipment – lower volume/ higher variety, very flexible.

14 Process Selection and Facility Layout

Automation

Reduce Human variation Improve Quality – consistency Safety Productivity?? Others

Advantages of Automation?

15 Process Selection and Facility Layout

Automation

– Costs!– Lack of flexibility - Limitations

• People can think, feel, make decisions

– Support personnel needed– Must use to be cost effective– Other

Disadvantages of Automation?