Jumbled flow process

Chapter 4:

Process Selection

Copyright © 2018 by The McGraw-Hill Companies, Inc. All rights reserved.

McGraw-Hill Education

Copyright © 2018 by The McGraw-Hill Companies, Inc. All rights reserved.

4-*

Copyright © 2018 by The McGraw-Hill Companies, Inc. All rights reserved.

*

The purpose of this chapter is to describe the major types of processes available and the factors that should be considered in any process selection decision. Two major dimensions of process classification are considered; flow of the product, and type of customer order. The product-process matrix, formulated by Hayes and Wheelwright, provides a basis for process selection by linking product-process and corporate strategy. Focused Operations, Mass Customization and 3D Printing are also covered as part of process selection decisions.

Chapter 4 Learning Objectives

LO 4.1 Contrast and compare the five types of product-flow processes.
LO 4.2 Describe the differences among order fulfillment processes.
LO 4.3 Explain how companies should make process selection decisions.
LO 4.4 Correctly place examples of products on the diagonal of the product-process matrix.
LO 4.5 Describe the features of focused operations.
LO 4.6 Discuss the advantages and disadvantages of mass customization and 3D Printing.
LO 4.7 Contrast pollution prevention, control and practices.
Copyright © 2018 by The McGraw-Hill Companies, Inc. All rights reserved.

4-*

Copyright © 2018 by The McGraw-Hill Companies, Inc. All rights reserved.

Here are our Learning Objectives for this course. Between these videos, the textbook, supplemental readings, assignments and Discussion Boards, you will end the course with some new skills and many new insights.

*

Product-Flow Characteristics

Types of Product Flow

Continuous process
Assembly line
Batch flow
Job shop
Project
Copyright © 2018 by The McGraw-Hill Companies, Inc. All rights reserved.

4-*

Copyright © 2018 by The McGraw-Hill Companies, Inc. All rights reserved.

Process selection decisions determine the type of process used to make a product or service. The considerations required for process selection include the volume of the product and whether the product is standardized or customized. Remember that standardization refers to mass production of the same product (i.e. cookie cutter). This helps keep the unit cost down by limiting the flexibility of change the product. Customization enables manufacturers to give customers many choices. Generally speaking, high-volume products that are standardized will be made using either a continuous process or an assembly line, both where there is little to no downtime. Low-volume customized products will be made using a batch or job shop process where there’s more down time associated with producing the product.

*

Product-Flow Characteristics:
Continuous Process

Highly standardized and automated
Flexibility limited
High volumes of production
Commodity products
Low cost is the ‘Order Winner’
Process industries (sugar, paper, oil, electricity, etc.)
Copyright © 2018 by The McGraw-Hill Companies, Inc. All rights reserved.

4-*

Copyright © 2018 by The McGraw-Hill Companies, Inc. All rights reserved.

Continuous production tends to make products that are difficult to differentiate and low cost becomes the “order winner” for manufacturing to compete in very price-sensitive markets. Therefore, continuous production tends to be highly automated, operate at capacity, and minimize inventories and distribution costs to reduce the total cost of manufacturing.

*

Product-Flow Characteristics:
Assembly Line

Linear sequence of operations (often paced)
Large capital investment, use of automation
Very efficient
High-volume, standardized products
Low flexibility to product and volume changes
Discrete products (autos, appliances, computers, etc.)
Copyright © 2018 by The McGraw-Hill Companies, Inc. All rights reserved.

4-*

Copyright © 2018 by The McGraw-Hill Companies, Inc. All rights reserved.

Assembly lines make only one or a few products and use inflexible equipment and labor. The assembly-line flow is characterized by a linear sequence of operations where the product moves from one step to the next in a sequential manner from beginning to end. The example I like to reference is Subway or Chipotle fast food restaurants. You start at one end then work your way down the assembly line as your order is being finalized. The sub-assemblies of products are laid out to give the customer a modular design of options to produce a finished good.

*

Assembly Line: Metal Bracket (Figure 4.1)

paint

drill

bend

Task or work station

Product flow

cut

Copyright © 2018 by The McGraw-Hill Companies, Inc. All rights reserved.

4-*

Copyright © 2018 by The McGraw-Hill Companies, Inc. All rights reserved.

Example of how an assembly line production is set up in a linear flow.

*

Product-Flow Characteristics:
Batch Flow

Production of batches or lots
Batches flow as a unit (set) from one work center to another
Process layout of work centers (by tasks)
Flow is jumbled and intermittent
Flexible labor and equipment (general purpose)
Low to high volume, variety of products
Many types of products (furniture, dishes, boats)
Copyright © 2018 by The McGraw-Hill Companies, Inc. All rights reserved.