Production Operations Management

1
Production Operations Management

• Process Technology
• Layout
• U. Akinc

2
Various Technologies

• Information Technology
• Product Technology
• Process Technology

3
Reasons for Technology
Some of the competitive priorities

• Improved Product and Service Quality
• Lower Cost
• Increased Responsiveness to Market
• Increased Responsiveness to Customer
• Safety

4
Barriers to Implementation of Technology

• Difficulty in Financial Justification
• Lack of Understanding by Management
• Concern for the Impact of Technology on the Human
  Resources

traditional ROI based capital budgeting cant
consider non-financial benefits
Resistance to change, having to learn another
way of doing things
Fear of loss of jobs due to automation
5
Information and Communication Technologies

• Electronic Data Interchange
• Bar Coding (UPC)
• Electronic Pagers
• Cellular Telephones
• Internet/e-Mail
• Intranet

6
Bar Code Technology

• Speeds Data Entry
• Increases Data Accuracy
• Reduces Material Handling Labor
• Easily Monitors Labor Efficiency

7
Process Technology

• Technology Manual, Automated or Mental Processes
  that are Used to Transform Inputs Into Products
  and Services
• Advanced Manufacturing Technology or Automation
  Substitution of Machines for Human Physical and
  mental work.
• Key to usage of automation Repeatability

A task that is performed in large number of
repetitions is more apt to be automated
8
Automation and Operations Focus

• Product Focus
• High Volume Standard Products imply High Degree
  of Repeatability
• Automation is natural
• Process Focus
• Low Volumes of a wide variety of product and
  services imply limited repeatability
• Automation is more challenging

Line-Flow flow-shop
In the form of fixed automation
9
Fixed Automation

• Automation of the processes and transfer of parts
  among stations. Characterized by
• High set up cost
• Rigid Capabilities
• Extreme efficiency
• Examples
• Assembly Lines
• Transfer Lines
• Process industries (e.g., petro-chemicals)

Sometimes referred to as Detroit type automation
Machines that are linked with automatic materials
handling
10
An example of fixed automation Egg processing
11
Flexible Automation

• Automatic Processes that can be easily changed
  from one task to another. Characterized by
• Low set up costs
• A range of capabilities
• Reasonably Efficient
• Example
• Job Shop

12
Group Technology

• Another Attempt to obtain the efficiency of
  product focus without giving up the flexibility
  of process focus
• Elements of Group Technology
• Part Families based on commonality of
• Processing Steps
• Part Geometry
• Manufacturing Cells Arrangement of Equipment
  best suited for a family

13
Computer Integrated Manufacturing(CIM)

• Integration of total manufacturing enterprise
  through the use of integrated systems and data
  communications coupled with new management
  philosophy that improve organizational and
  personnel efficiency. (SME)

14
CIM

• An Umbrella term to encompass the integration of
• Product Design/Engineering
• Process Planning /Development
• Manufacturing Operations
• Production/Inventory Control

15
Components of CIM

• 1. CAD
• Computer Assisted Design Use of Computers in
  interactive engineering drawing, storage and
  manipulation of existing designs.
• 2. CAM
• Computer Assisted Manufacture Use of Computers
  to program, direct and control manufacturing
  equipment in the fabrication of parts.

16
Components of CIM (contd)

• 3. CAPP
• Computer Assisted Process Planning Selecting
  operations, their sequences, tools and material
  handling systems using interactive computer
  systems
• 4. NC Machines
• Numerically Controlled Machines
• Machines which take their instructions from a
  control device that can be programmed and
  reprogrammed in software

17
Components of CIM (contd)

• 5.Robotics
• Versatile, programmable devices capable of human
  like operations.
• Used Mostly in
• Hazardous
• Repetitive tasks
• Handling Heavy Parts
• Such as
• Spot welding
• Inspection
• Circuit board Assembly
• Spray Painting

18
A Multi-Axes Robot
Merlin1
19
A Merlin robot programmed to cut carpet to
specified sizes
Merlin2
20
A Merlin Robot spot welding
Merlin3
21
Anatomy of a Merlin robot (has three degrees of
freedom or axes)
22
Gantry Robots work like Etch-a-sketch. Movement
is on 3 linear axes (x,y,z) as opposed to
rotational as in Merlin. This robot is installing
the wind shield on a car
Gantry1
23
Another Gantry robot cutting cloth
Gantry2
24
Components of CIM (contd)

• 6. AGV
• Automatically Guided Vehicles
• 7. AS/RS
• Automated Storage and Retrieval Systems

Please visit the link
25
Automatically Guided vehicle examples
26
Infrastructure of CIM

• Use of integrated computer software for
• Production Scheduling
• Inventory Control
• Capacity Planning
• Shop Floor Control

27
Layout Planning

• Selecting location for and transfer routes and
  means among work departments
• Traditional types
• Functional (Process Focus)
• Line Flow (Product focus)
• Fixed Position (Project)
• Modern
• Group Technology

28
Functional Layout
Most appropriate for process focus
Packing
Turning
Gluing
Painting
Sanding
Planing
Drilling
Cutting
Resources are organized into functional
departments
29
Line Flow Layout
Most appropriate for Product Focus
A
E
B
C
B
D
E
A
C
E
D
A
B
B
C
Product flows through processes A-E in a
sequence dictated by the assembly requirements
of the product.
D
30
Manufacturing Cells in Group Technology
Cell A
Refer back to slide number 12 Group Technology.
Here the departments are arranged to produce
families of similar parts efficiently
Cell B
Planing
Painting
Cell C
31
A Part Family
32
Manufacturing (GT) Cell
33
Product Process Matrix
Product Variety and Volume
Many Products- Low Volume
Several Products- High Volume
One Product- Very High Volume
Low Volume- Unique
No Flow
Project
Identified Process Pattern
Job Shop
Jumbled Flow
Mixed with Dominant Flows
Batch
Assembly Line
Line Flow
Continuous or Automated
Continuous Process