Process Selection

Process Selection It refers to the way production of goods or services is organised.It is the basis for decision regarding capacity planning,facilittes layout and design of work system. It is necessary when a firm take sup production of new products or services to be offered to the customers. Three primary questions to be addressed before deciding on process selection: 1.How much variety of products or services will the system need to handle. 2.What degree of equipment flexibility will be needed. 3.What is the expected volume of output.
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Introduction
Process selection and capacity planning influence system design

Capital intensity Process flexibility

Technology
Refers to applications of scientific discoveries to the development and improvement of goods and services and/or the processes that produce or provide them. Three kinds of technology (impact on costs, productivity, and competitiveness): Product and service technology is the discovery and development of new products and
services.

Process technology includes methods, procedures, and equipment used to produce

goods and provide services.

Information technology (IT) is the science and use of computers and other electronic
equipment to store, process, and send information.

Technology as a Competitive Advantage

Technoly Acquisition

Process Selection
Variety How much Flexibility What degree Volume Expected output

Batch Job Shop Repetitive

Continuous

Process Selection

Two process selection: 1. Intermittent system a.Job production b.Batch production

2.Contionus system a.Mass production b. Process selection.

Process Selection
How much variety in products or services will the system need to handle? What degree of equipment flexibility will be needed? What is the expected volume of output?

Process Types:
Job Shop Batch Repetitive Continuous (Project)

Process Types
Job shop Small scale Batch Moderate volume Repetitive/assembly line High volumes of standardized goods or services Continuous Very high volumes of non-discrete goods

Job Shop Job shop production are characterised by manufacturing of one or few quantity of products designed and produced as per the specification of customers within prefixed time and cost. The distinguishing feature of this is low volume and high variety of products. A job shop comprises of general purpose machines arranged into different departments. Each job demands unique technological requirements, demands processing on machines in ascertain sequence

Jobbing Processes Very small quantities: one-offs, or only a few required Specially made. High variety, low repetition. Skill requirements are usually very broad

Skilled jobber, or team of jobbers complete whole product

Fixed position or process layout (routing decided by jobbers)

Jobbing Process

Job Shop
It is used in job shops when a low volume of high variety goods are needed. Processing is intermittent ,each job requires somewhat different processing requirements . It is charactererised by high customization ,high flexibility of equipment and skilled labor and low volume.

Relatively small scale Low volume of high-variety goods or services Processing is intermittent High flexibility of equipment

Manufacturing example: A tool and die shop that is able to produce one-of-a-kind tools. Service example: A veterinarians office, which is able to process a variety of animals and a variety of injuries and diseases.

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Characteristics

The Job-shop production system is followed when there is: 1. High variety of products and low volume. 2. Use of general purpose machines and facilities. 3. Highly skilled operators who can take up each job as a challenge because of uniqueness. 4. Large inventory of materials, tools, parts. 5. Detailed planning is essential for sequencing the requirements of each product, capacities for each work centre and order priorities.

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Advantages Following are the advantages of job shop production: 1. Because of general purpose machines and facilities variety of products can be produced. 2. Operators will become more skilled and competent, as each job gives them learning opportunities. 3. Full potential of operators can be utilised. 4. Opportunity exists for creative methods and innovative ideas. Limitations Following are the limitations of job shop production: 1. Higher cost due to frequent set up changes. 2. Higher level of inventory at all levels and hence higher inventory cost. 3. Production planning is complicated. 4. Larger space requirements.
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Project Processes One-off, complex, large scale, high work content products Specially made, every one customized Defined start and finish: time, quality and cost objectives Many different skills have to be coordinated Fixed position layout

Project Process

Batch

Batch production is defined by American Production and Inventory Control Society (APICS) asa form of manufacturing in which the job passes through the functional departments in lotsor batches and each lot may have a different routing. It is characterised by the manufactureof limited number of products produced at regular intervals and stocked awaiting sales.

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Batch Processes Higher volumes and lower variety than for jobbing Standard products, repeating demand. But can make specials Specialized, narrower skills Set-ups (changeovers) at each stage of production Process or cellular layout

Batch Process

Batch
Moderate volume of moderate variety products or services. The equipment need not be as flexible as in a job shop, but processing is still intermittent. The skill level of workers doesnt need to be as high as in a job shop because there is less variety in the jobs being processed. In Batch processing ,volumes are higher because same or similar products or services are repeatedly provided , examples of product produced in batches include paint,icecream,softdrinks,books etc.

Manufacturing example: Bakeries, which make bread, cakes, or cookies in batches Service example: Movie theaters, which show movies to groups (batches) of people, and airlines, which carry planeloads (batches) of people from airport to airport.

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Characteristics

Batch production system is used under the following circumstances: 1. When there is shorter production runs. 2. When plant and machinery are flexible. 3. When plant and machinery set up is used for the production of item in a batch and change of set up is required for processing the next batch. 4. When manufacturing lead time and cost are lower as compared to job order production.
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Advantages 1. Better utilisation of plant and machinery. 2. Promotes functional specialisation. 3. Cost per unit is lower as compared to job order production. 4. Lower investment in plant and machinery. 5. Flexibility to accommodate and process number of products. 6. Job satisfaction exists for operators. Limitations 1. Material handling is complex because of irregular and longer flows. 2. Production planning and control is complex. Work in process inventory is higher compared to continuous production. 4. Higher set up costs due to frequent changes in set up.
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Repetitive/Mass production system

Manufacture of discrete parts or assemblies using a continuous process are called mass production. This production system is justified by very large volume of production. The machines are arranged in a line or product layout. Product and process standardization exists and all outputs follow the same path.
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Mass (Line) Processes Higher volumes than Batch Standard, repeat products Low and/or narrow skills No set-ups, or almost instantaneous ones Cell or product layout

Mass Process

Characteristics
Mass production is used under the following circumstances: 1. Standardisation of product and process sequence. 2. Dedicated special purpose machines having higher production capacities and output rates. 3. Large volume of products. 4. Shorter cycle time of production. 5. Lower in process inventory. 6. Perfectly balanced production lines. 7. Flow of materials, components and parts is continuous and without any back tracking. 8. Production planning and control is easy. 9. Material handling can be completely automatic.
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Advantages Following are the advantages of mass production: 1. Higher rate of production with reduced cycle time. 2. Higher capacity utilisation due to line balancing. 3. Less skilled operators are required. 4. Low process inventory. 5. Manufacturing cost per unit is low. Limitations Following are the limitations of mass production: 1. Breakdown of one machine will stop an entire production line. 2. Line layout needs major change with the changes in the product design. 3. High investment in production facilities. 4. The cycle time is determined by the slowest operation.
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Repetitive
Higher volumes of more standardized goods or services Slight flexibility of equipment Skill of workers is generally low.

Manufacturing example: Automobiles, television sets, pencils, and computers. Service example: Automatic carwash, cafeteria lines and ticket collectors at sports events and concerts.

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Continuous Process Extremely high volumes and low variety: often single product Standard, repeat products Highly capital-intensive and automated Few changeovers required Difficult and expensive to start and stop the process Product layout: usually flow along conveyors or pipes

Continuous
Production facilities are arranged as per the sequence of production operations from the firstoperations to the finished product. The items are made to flow through the sequence of operationsthrough material handling devices such as conveyors, transfer devices, etc

Very high volume of nondiscrete, highly standardized output is desired No variety in output No need for equipment flexibility.

Manufacturing example: Petroleum products, steel, sugar, flour, and salt.

Service example: Air monitoring, supplying electricity to homes and businesses, and the Internet.

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Continuous Process

Characteristics Continuous production is used under the following circumstances: 1. Dedicated plant and equipment with zero flexibility. Material handling is fully automated. 3. Process follows a predetermined sequence of operations. 4. Component materials cannot be readily identified with final product. 5. Planning and scheduling is a routine action.

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Advantages Following are the advantages of continuous production: 1. Standardisation of product and process sequence. 2. Higher rate of production with reduced cycle time. 3. Higher capacity utilisation due to line balancing. 4. Manpower is not required for material handling as it is completely automatic. 5. Person with limited skills can be used on the production line. 6. Unit cost is lower due to high volume of production. Limitations Following are the limitations of continuous production: 1. Flexibility to accommodate and process number of products does not exist. 2. Very high investment for setting flow lines. 3. Product differentiation is limited
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Project
Nonroutine work Unique set of objectives Limited time frame Equipment flexibility and worker skills can range from low to high.

Example: Consulting, making a motion picture, launching a new product or service, publishing a book, building a dam, and building a bridge.

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Product Process Matrix

Figure 6.2
Process Type

Job Shop Batch

Appliance repair Emergency room Commercial bakery Classroom Lecture

Not feasible

Repetitive

Automotive assembly Automatic carwash

Continuous (flow)

Not feasible

Oil refinery Water purification

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