week 8 - product process desing & layout Flashcards
what are the 2 types of products?
- made to order
- made to stock
what is a made to order product?
> a simplified design process because customer participates
demand variability (can’t forecast)
ex: local tailor suit shop, because it is custom made
what is a made to stock product?
> complex design process because product are expected to satisfy a large nb of customer
simplified planning
ex: meat industry, because meat is standard
what are the production design strategies (5)?
- standardization
- simplification
- modular design
- delayed differentiation
- product design & sustainability
what is the definition of standardization?
it refers to the strategy of seeking uniformity in products & in the parts comprising them (same parts, same production process, same design)
what are the advantages and disadvantages of standardization?
advantages:
> fewer parts to deal with in inventory & manufacturing
> reduce training cost & time
> more routine purchasing, handling & inspection
> order can be met from inventory
> opportunities for long production runs and automation
disadvantage:
> designing a product that meets the needs of many customers requires a large investment
> high cost of design changes increases resistance to improvement
> decreased variety results in less consumer appeal
> it is difficult to address the needs of specific clients
what’s simplification?
taking a product with a lot of pieces and simplifying it to create less pieces
what’s the modular design?
a form of standardization & parts are subdivided into modules
what are the advantages & disadvantages of modular design?
advantages:
> easier diagnosis & remedy of failure
> easier to repair & replace
> simplification of planning, procurement, inventory management, manufacturing & assembly
> lower training costs
disadvantages:
> modules must be compatible & interchangeable
> increase in replacement costs, as the whole defective module must be changed
what are the process selection criterias (4)?
- volume
- variety
- demand
- flow
what are the types of process (4)?
- job shop
- batch
- mass production
- continuous process
what are the types of flow & what do they do (3)?
- intermittent flow: movement of in-process products is discontinuous & multidirectional
- semi-continuous flow : in-process products move in a regular yet intermittent, unidirectional manner
- continuous flow: the product moves in a constant unidirectional manner
job shop: process criteria, ideal layouts & example
- volume : low
- variety : high
- type of demand : made to order
- type of flow: intermittent
- types of layouts: fixed-position, functional, cellular
ex: cake shop
batch: process criteria, ideal layouts & example
- volume : average
- variety : average
- type of demand : made to stock
- type of flow: intermittent
- types of layouts: functional, cellular, linear
ex: footwear
mass production: process criteria, ideal layout & example
- volume : average
- variety : average
- type of demand : made to stock
- type of flow: semi-continuous
- types of layouts: linear
ex: maker of electronic (TV, phones, etc.)
continuous: process criteria, ideal layout & example
- volume : high
- variety : low
- type of demand : made to stock
- type of flow: continuous
- types of layouts: linear
ex: sugar producer
what is the fixed-position layout?
> layout in which the product remains fixed, equipment & workers are brought to the site as required
constant movement of workers & equipment
products that are complex or big
complex production control that requires a good coordination
what is a functional layout?
> layout where the work centres & equipment are arranges in clusters based on the operation they perform (department)
flexible system with respect to workers & equipment
multidirectional & variable flows
complex quality control & supervisor
qualified workforce (specific skills)
what is a linear layout?
> layout where the work centres & equipments are set up sequentially, in the order in which the product moves through all the different operations
simple, logical, unidirectional
costly & inflexible
reduce WIP inventory
one failure can stop the whole line
repetitive jobs
(think of it as a golf course, one entry, one exit, a player has to complete every whole to be done)
what’s a cellular layout?
> layout in which the work centers & equipment are arranged in several groups or cells around a team of employees
flexible
general supervision required with relatively simple control
simplification of planning & scheduling activities
autonomy & versatility of workers & emplaisis on team work
a group of workers involved in a production of a good from A to Z
