1

Manufacturing Process Selection and Design

Overall development of
processing plans
Design specifications

Sales forecasts, Customer orders

Product design

Functional design
Production design, setting minimum possible costs
Drawings and specifications of what to make

Make or Buy decisions

Make

Process decisions, selection from alternative processes

Route sheets and Operation sheets

Modifications of process plans due to layout, Quality

preferences and machine availability

Workplace design
and Tool Design
Manufact
uring

Buy

Process planning

Product analysis, Assembly charts, Flow charts etc.

Product-Flow Characteristics
Types of Product Flow
Line Flow
Batch Flow
Project Flow

Characteristics of Flows

4-3
4-3

Line Flow

cut

drill

bend

Task or work station

Product flow

paint

Batch Flow
Bend
BatchA
Paint

Cut
Drill
Task or work station

BatchB
BatchC
Product flows

Classification by Type of
Customer Order
Make to Stock (MTS)
Make to Order (MTO)
Assemble to Order (ATO)

Process Selection Decisions

Process characteristics matrix
Factors affecting process choice

Factors Affecting Process Choice

Market conditions and competition
Capital requirements
Labor supply and cost
State of technology

Process Manufacturing
System- A Layout in a
Cement Plant
Limestone

Crusher

Hopper 1

Feeder 1

Iron One

Hopper 2

Feeder 2

Clay

Hopper 3

Feeder 3

Gympsum

Blending Silo

Firing Kiln

Hopper 4
Feeder

Dispatch Silo

Raw
Mill

Hopper 5
Cement Mill

Feeder

10

Types of Processes

Conversion (ex. Iron to steel)

Fabrication (ex. Cloth to clothes)

Assembly (ex. Parts to components)

Testing (ex. For quality of products)

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Process Flow Structures

Job shop (Ex. Tailoring Shop )

Batch shop (Ex. Garment Manufacturer /

Pharmaceutical Products)

Assembly Line (ex. Automobile manufacturer)

Continuous Flow (ex. Petroleum Products

manufacturer)

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I.
Job
Shop
II.
Batch
III.
Assembly
Line
IV.
Continuous
Flow

Few
High
Low
Multiple Major Volume,
Volume, Products, Products, High
One of a
Low
Higher StandardKind
Volume Volume ization
Commercial
Printer
French
Restaurant

Flexibility (High)
Unit Cost (High)

These
Theseare
are
the
themajor
major
stages
stagesof
of
product
product
and
and
process
process
life
lifecycles
cycles

Heavy
Equipment
Automobile
Assembly
Burger King
Sugar
Refinery

Flexibility (Low)
Unit Cost (Low)

13

Manufacturing Process Flow

Design

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

Example: Assembly Chart

(Gozinto)
4
5
6
7

14

From
FromExhibit
Exhibit5.14
5.14

Lockring
Spacer, detent spring

SA-2

Rivets (2)

A-2

Spring-detent
A-5
Component/Assy Operation
Inspection