Professional Documents
Culture Documents
Contents - Continued
Process Focus Repetitive Focus Product Focus Mass Customization Focus Comparison of Process Choices Flow Diagrams Time-Function Mapping Process Charts Service Blueprinting
Machine Technology Automatic Identification System (AIS) Process Control Vision Systems Robots Automated Storage and Retrieval System (ASRS) Automated Guided Vehicle (AGV) Flexible Manufacturing System (FMS) Computer-Integrated Manufacturing (CIM)
Askar Choudhury
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Process Strategies
Process Strategy : Organizations approach to transform resources into goods and services. Objective
Meet or exceed customer requirements Meet cost & managerial goals efficiency & production flexibility, costs & quality of products
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Process-Focused Strategy
Facilities are organized by process Similar processes are together
High Variety One or few units per run, high variety (allows customization) Changes in modules Modest runs, standardized modules Low Variety Changes in attributes (such as grade, quality, size, thickness, etc.) Long runs only
Askar Choudhury
Process focus projects, job shops,(machine, print, carpentry) Standard Register Repetitive (autos, motorcycles) Harley Davidson
Mass Customization (difficult to achieve, but huge rewards) Dell Computer Co.
Askar Choudhury
Operation 1 1
Product A 2 2 3 3
Product B
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7-5
Greater product flexibility More general purpose equipment Lower initial capital investment (Fixed cost) More highly trained personnel More difficult production planning & control Low equipment utilization (5% to 25%)
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Disadvantages
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Fast Food
Truck
.
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2006
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Product-Focused Strategy
Product-Focused (or continuous process ) facilities are organized by product High volume, low variety products Production:
Discrete unit manufacturing (e.g., lightbulbs) Continuous process manufacturing (e.g., rolls of paper)
Lower variable cost per unit Lower but more specialized labor skills Easier production planning and control Higher equipment utilization (70% to 90%) Lower product flexibility More specialized equipment Usually higher capital investment (Fixed cost)
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Other names
Line flow production Continuous production
Askar Choudhury
Disadvantages
3 3
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2006
Product-Focused Examples
Soft Drinks (Continuous, then Discrete)
Mass Customization
Using technology and imagination to rapidly mass-produce products that cater to unique customer desires, but keeping the cost low. Under mass customization the three process models become so flexible that distinctions between them blur, making variety and volume issues less significant.
2006
Askar Choudhury
Paper (Continuous)
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ta To
os lc
High variety, low volume Low utilization (5%-25%) general purpose equipment
Continuous Process Low variety, high volume High utilization (70%-90%) Specialized equipment
Process A Process B
For comparison of characteristics of four types of processes, see Table 7.2, PP-262. 2006 7-17
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Process C
volume
2006
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Receive product
Wait
Order
Print
WIP
Wait
Wait
WIP
Product
Wait
Product
WIP
WIP
Extrude
Move
1 day 10 days 1 day 9 days
1 day
2006
Product
Move
Askar Choudhury
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Strategy
Separation Self-service
Technique
Structure service so customers must go where service is offered Self-service so customers examine, compare and evaluate at their own pace Customizing at delivery Restricting the offerings
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Postponement Focus
Askar Choudhury
7-26
2006
Production Technology
1. Machine technology 2. Automatic identification systems (AIS) 3. Process control 4. Vision system 5. Robot 6. Automated storage and retrieval systems (ASRS) 7. Automated Guided Vehicles (AGV) 8. Flexible manufacturing systems (FMS) 9. Computer-integrated manufacturing (CIM)
2006
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1. Machine Technology
Increased precision Increased productivity Increased flexibility Decreased pollution Decreased size Decreased power requirements
CNC: Computer Numerical Control.
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3. Process Control
Increased process stability Increased process precision Real-time provision of information for process evaluation Multi-mode information presentation
4. Vision Systems
Particular aid to inspection (e.g., French fries) Consistently accurate Never bored Modest cost Superior to individuals performing the same tasks
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2006
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5. Robots
Perform monotonous, or dangerous tasks, or those requiring significant strength or endurance Enhanced consistency, accuracy, speed strength, power when substituted for human effort
e.g., Welding done by robots in automobile industry
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Computer controls both the workstation and the material handling equipment Computer control enhance flexibility Can economically produce low volume but high variety Reduced costs of changeover and low utilization Stringent communication requirement between components within it
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Reducing the distinction between lowvolume/high-variety, and high-volume/lowvariety production Heavy reliance on information technology
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Process Reengineering
The fundamental rethinking and radical redesign of business processes to bring about dramatic improvements in performance Relies on reevaluating the purpose of the process and questioning both the purpose and the underlying assumptions Requires reexamination of the basic process and its objectives Focuses on activities that cross boundaries
Askar Choudhury
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