Final - Process and Product Design

Question 1

What are the different ways that process can be classified as?

Answer 1

type of product flow, approach to customer orders, amount of customization, or volume and standardization

Question 2

types of product flows

Answer 2

fixed position: ex. airplane is very big so it stays stationary while production moves around it

jumbled flow: ex. assembling furniture

line flow: ex. production line (car manufacturing)

continuous flow: ex. similar to line flows, but product is uncountable i.e. sugar

Question 3

approaches to customer orders

Answer 3

make-to-order, make-to-stock, assemble-to-order

Question 4

what are two types of operations that products can be classified as, and what process types do they include?

Answer 4

intermittent operations: project, batch process (lowest and low volume + standardization)

repetitive operations: mass process, continuous process (high and higher volume + standardization)

Question 5

What are the 4 process types as classified by product volume and standardization?

Answer 5

Project: one-at-a-time product exactly to customer specifications

Batch: small quantity of products in batches based on actual or expected customer orders

Mass: large volume of a standardized product, assembly line format

Continuous: continually produce a very high volume of a fully standardized product

Question 6

throughput time

Answer 6

how long it takes to move through the production line

Question 7

What does a shorter throughput time mean?

Answer 7

If one process is slower than another, you can alternate when it comes to batches

ex. making bread (?) to rice - instead of getting another oven, as one batch is in the oven, the other is rising. therefore the oven will always be cold

Question 8

t or f: in intermittent operations, there is a lot of product variety

Answer 8

true, as opposed to little variety in repetitive ops

Question 9

t or f: in repetitive ops, customer orders are make-to-order

Answer 9

false; make-to-stock

Question 10

t or f: jumbled product flows are a feature of repetitive ops

Answer 10

false; jumbled is common in intermittent as opposed to product lines in repetitive ops

Question 11

t or f: general purpose equipment is used in intermittent ops

Answer 11

true; repetitive uses specialized

Question 12

t or f: labour is a critical resource in repetitive ops

Answer 12

false; capital is.

Question 13

t or f: automation is low in intermittent ops

Answer 13

true; high in repetitive

Question 14

t or f: throughput time is shorter in repetitive ops

Answer 14

true; longer in intermittent

Question 15

t or f: WIP inventory is more in repetitive ops

Answer 15

false; less

Question 16

process layout

Answer 16

for intermittent ops; groups resources based on similar processes

warehouse layout, office layout

Question 17

product layout

Answer 17

groups resources based on products

arranges resources in sequence (assembly lines)

Question 18

cell layout

Answer 18

hybrid between product and process layouts; grouping of products based on similar requirements (processes)

Question 19

fixed-position layout

Answer 19

used when the product is too big and cannot easily be moved ex. bridge construction

Question 20

retail layout

Answer 20

allocates space based on customer behaviour

Question 21

process layouts are designed to produce products such as…

Answer 21

fabric storage/inventory i.e. cutting, sewing, ironing

Question 22

which manufacturing technologies are designed to increase production speed of intermittent operations?

Answer 22

general purpose, group technology

Question 23

which manufacturing technologies are designed to increase production speed of repetitive operations?

Answer 23

flexible manufacturing system (FMS), focused automation, dedicated automation

Question 24

group technology

Answer 24

grouping of dissimilar automated machines to produce a family of parts

Question 25

flexible manufacturing system 9FMS)

Answer 25

consists of numerous programmable machine tools connected by an automated material handling system

Question 26

robotics

Answer 26

controlled by a computer; can perform complex tasks

Question 27

computer-aided manufacturing (CAM)

Answer 27

controlling manufacturing through computers

Question 28

CIM

Answer 28

computer-integrated manufacturing; integration of product design, process planning, and manufacturing through computers

Question 29

process selection depends on…

Answer 29

cost, volume, product maturity level, labour/technology availability

Question 30

a company’s production process needs to match its ___ strategy and ___

Answer 30

corporate; process

Question 31

what does a corporate strategy look like in intermittent vs. repetitive ops?

Answer 31

customized products vs. mass market

Question 32

what does an ops strategy look like in intermittent vs. repetitive ops?

Answer 32

low volume, customized service vs. high volume

Question 33

what do competitive priorities look like in intermittent vs. repetitive ops?

Answer 33

volume flexibility, customization vs. low cost

Question 34

product design

Answer 34

the process of defining all of the product’s characteristics: appearance, materials used, dimensions, durability, performance standard

Question 35

general steps in product design

Answer 35

1. idea development (customer drive, reverse engineering, R&D)
2. product screening (feasibility study) -> most products stay here
3. preliminary design and testing
4. final design

Question 36

concurrent engineering

Answer 36

multifunctional team approach to simultaneously design the product and the process

Question 37

CAD

Answer 37

computer-aided design: use of computer graphics to design new products