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What are the different Process Selections?
- Job Shop
- Batch
- Repetitive
- Continuous
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What are the different Layouts?
- Product
- Process - JB, Batch, Repetitive, Continuous
- Fixed-Position
- Hybrid/Combination - Cellular, Flexible Manufacturing
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Product Layout AKA Serial Layout (Sequential) - Definition and which process or processes does it include? Give an example
- Layout that uses standardized processingn operations to achieve smooth, rapid, high volume flow
- Includes: Repetitive or Continuous Processing
- Ex: Cafeteria - Workflow in order. Station 1->2->3
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Advantages of Product Layout
- Routine accounting, purchasing & Inventory
- Low unit & material handling cost (cuz high volume)
- High rate of output & utilization of labor & equipment
- Labor Specialization
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Disadvantages of Product Layout
- Repetitive job--> Low morale & opp for advancement, repetitive stress injuries
- Poorly skilled workers --> Low maintenance of equipment & quality of output
- Fairly inflexible to changes in volume & product/process design
- Highly susceptible to shutdowns
- Needs preventive maintenance, quick repairs, spare-parts inventories
- No individual incentive plans
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U-Shaped Production Line
- Half the length of a straight production line
- Permits communication among workers
- Minimize material handling - Materials enter the plant at the same point that finished products leave
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Process Layout AKA Functional Layout
- Layout that can handle varied processing requirements
- Used for Intermittent Processing
- Includes: Job Shop & Batch Processing
- Ex: Hometown Buffet, Emergency floor in a hospital
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Advantages of Process Layout
- Can handle a variety of processing requirements.Ex: Hospitals, colleges, banks, auto-repair shops
- Equipment not vulnerable to failures and less costly
- Individual incentive plans possible
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Disadvantages of Process Layouts
- Accounting, purchasing & Inventory control more involved
- submit
- High In-process inventory
- Higher Unit Cost - Inefficient
- Challenging routing and scheduling
- Low equipment utilization (less than 50%)
- Low supervision - cuz of complexities
- Slow material handling
- Special attention for each product or customer
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Fixed Position Layout
- Layout where projects remain stationary and workers, materials and equipment are moved as needed
- Ex: Caterpillar (Large industrial Machines/Projects), Airplanes, Dams, Navy Ships, Power Plants, Buildings.
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What nature of the product dictates a fixed position layout
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Fixed position layout info
**** Slide info***
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Combination / Hybrid Layout
- Mixture of Process & Production Layout
- Ex: Super Market - Market (Process Layout), Stockroom & cash registers conveyor belts (Product Layout)
- Ex: Hospital - Hospital (Process Layout), doctors, meds, nurses, special equip work around a stationed patient (Fixed Position Layout)
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Cellular Layout
*** look up book and slide for info*** and look at the example layout of cellular layout
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Group Technology
The grouping into part families of items with similar design (all circular, square, etc.) or manufacturing characteristics
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You choose a process by considering these 3 factors.
- Variety in products
- Flexibility
- Volume in Demand
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Variety in products
- How much variety in products will the system need to handle?
- How much a product changes from one customer to the next
Ex: Gas (Standardized) , Glasses (Custom Made)
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Volume in Demand
- What is the expected volume of output.
- Ex: Gas (made fast), Glasses (Not made in advance)
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Flexibility in equipment: how is it determined?
Determined by Variety in product & Volume in demand
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Job Shop
- Ex: Eye Glasses (AED), Emergency Room, Appliance Repair
- A manufacturing facility that generates a variety of products
- High Variety & Flexibility
- Low Volume - small jobs
- Intermittent Processing - Producing several different products on the same production line
- General purpose equipment
- Highly skilled workers
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Batch
- Ex: Bakery, Classroom Lecture
- Moderate Variety, Volume, Flexibility
- Intermittent processing & Skilled workers not as high as Job Shop.
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Repetitive AKA Assembly Line
- Ex: Honda America, Automatic Carwash
- High Volume - of standardized goods/services
- Low Flexiblity & Variety
- Low Skilled workers
- Repetitive processing
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Continuous
- Ex: Salt, Flour, Petroleum, Steel Production, Water Purification
- High Volume - Highly standarized products (non-discrete items)
- No Variety or Flexibility (Specialized equipment)
- Range - Worker skill depends on system complexity Ex: Highly specialized equip = low skill
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What are the Process Characteristics?
***Put in chart from slide***
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Product/Service life cycle: Different types of processes will be needed for different stages, what are they?
- Introduction: Job Shop, Low Volume
- Growth: Batch or Repetitive, may need to switch from Job Shop depending on the product type
- Maturity: Continuous, Could be required
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Advantages / Disadvantages of the different Process Layouts.
*** Add in chart from slide***
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Product - Processes Matrix
*** Add in chart from slide***
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Definition of Automation
Machinery that has sensing and control devices that enables it to operate
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CAD
Computer Aided *****(Automated) Design
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CAM
Computer Aided ***(Automated) Manufacturing
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FMS
- Flexible Manufacturing Systems
- Grouping machines that include supervisory computer control, automatic material handling, & robots to produce a variety of similiar products.
- Ex: Video for FORD. switch car models in days versus months without changing the entire process layout cuz machines can adjust to the similiar car design for different Ford models.
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CIM
Computer Intergrated Manufacturing
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Functional vs. Cellular Layouts
**** Chart ****
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What are the different Service Layouts?
- Warehouse & Storage
- Retail
- Office- computers = layout dif than before cuz ppl don't have to physically move to transfer paperwork to dif dept.
- (They must be aesthetically pleasing as well as functional)
pg. 260
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What is one way to improve productivity and reduce costs in services?
Remove customer from the process as much as possible.
- Ex: Automation in services. ATM, Electronic rsvp (travel)
- --> less customization & risk of customer dissatisfaction
- --> reduce costs & increase productivity
pg. 260
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What is line balancing?
Process of assigning tasks to workstations in such a way that the workstations have approx equal time requirements.
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Unbalanced lines can create...
create morale problems @ the slower stations for workers who must work continuously.
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Cycle Time
is the maximum time allowed at each workstation to complete its set of tasks on a unit.
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Max output equation
- output = OT / CT
- OT - Operating Time
- CT - Cycle Time
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Cycle Time equation
CT = OT / Output
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Determine the Minimum Number
of Workstations Required
Nmin = Sum of task time / CT
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Idle Time AKA Balance Delay
% of idle time = total idle time per cycle / Nactual x CT
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Efficiency of the line equation
= 100% - Idle time
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Preceding Tasks
Alls tasks you encounter working backwards
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what is positional weight
sum of the task times for itself and all its following tasks.
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Line Balancing Rules
- Some Heuristic (intuitive) Rules:
- Assign tasks in order of most following tasks.
- Count the number of tasks that follow
- Assign tasks in order of greatest positional weight.
- Positional weight is the sum of each task’s time and the times of all following tasks.
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