Design, pageRaffo BA 339 1

Design and Technology

Design, pageRaffo BA 339 2

Scope of Operations

Support from Accounting, Finance, Human Resources, Information Systems

Marketing & Sales

Customer

Order Entry DistributionWhse & transport,by channel

Customer Requirements

Product Design

Process Design

ProductionQuality

Materials ManagementSupply Chain Management,Purchasing, Inventory Control

PlanningStrategyCapacitySchedule

Design, pageRaffo BA 339 3

Freedom to Choose

• Given a product design and forecast, now need to design the process

• Need to select processes and materials• Free to choose from a variety of sourcing options

on the spectrum: buy fully assembled to fabricate from raw materials.

• Each option has benefits and costs, depending on your business situation.

• Consider K-Bob

Design, pageRaffo BA 339 4

Process Notes

Design, pageRaffo BA 339 5

Process Flow Structures

• Continuous Processing

• Assembly Line

• Intermittent/ Batch

• FMS

• Job Shop

• Project Shop

Design, pageRaffo BA 339 6

Attributes of Production Systems

• System Inputs (Volume, Variety)

• System Outputs (Volume, Variety)

• Operator Tasks (Number, type, complexity)

• Yield

• Rework/ Cycling

• Production Volume

• Variability (Supply, Demand, Internal)

Design, pageRaffo BA 339 7

• Characteristics– Inputs and outputs (defined, high vol., low var.)

– Operator tasks (defined, few in number, simple)

– High yields, low rework, no cycling

– High volume, low variety beyond original design

– Problems with Demand variability, controlled supply and system variability (quality)

Continuous, Assembly, and Batch Operations

Design, pageRaffo BA 339 8

Flexible Manufacturing Cells

• Characteristics– Inputs and outputs (defined, medium vol., medium var.)

– Operator tasks (defined, few in number, simple)

– High yields, low rework, can have cycling

– Medium volume, medium variety

– Accommodates Demand variability, requires controlled supply and system variability (quality)

Design, pageRaffo BA 339 9

Job Shop

• Characteristics– Inputs and outputs (defined, medium to low volume,

medium to high variety)

– Operator tasks (skilled, multiple in number, variable)

– Medium yields, medium rework, can have cycling

– Medium to low volume, medium to high variety

– Accommodates variability

Design, pageRaffo BA 339 10

• Characteristics– Inputs and outputs (poorly defined, low volume, high

variety)

– Operator tasks ((highly)skilled, multiple, variable)

– possible low yields, possible high rework, cycling often

– low volume, high variety

– Designed to accommodate variability

Project Shop

Design, pageRaffo BA 339 11

Design of the Product and Process

Design, pageRaffo BA 339 12

Design Process Overview

Product Planning

Customer Requirements -> Customer Value

Design RequirementsProduct DesignPart/item characteristics

Process Planning

Process Operations

Process Control

Operations RequirementsProduction

Design forManufacturability

Design, pageRaffo BA 339 13

Effective Product/Process Design

Measures of design effectiveness

Design for operations guidelines

Customer needs, Competitor’s Capabilities

Multi-functional Design Team

Competitive Environment

Design Strategy

Design, pageRaffo BA 339 14

Impact of Technology of Product and Process

Design, pageRaffo BA 339 15

Notes on Technology

• Impact of Technology– Automating Design (Process)– Automating Production (Process)– Source of new products (Product)

• Countries consider technology research a competitive weapon

Design, pageRaffo BA 339 16

FMS/ AWMH/ CIM

AutomatedGuidedVehicle (AGV)

AGV

Automated Warehouse

Flexible Manufacturing Systems

Design, pageRaffo BA 339 17

Automated MFG. Planning and Cntl

ASM

Sub-ASM Sub-

ASM

DetroitLyon, FRSingapore

Design, pageRaffo BA 339 18

Technology Notes

• Technology Classifications– Product/ Process Technologies

– Hardware/ Software

• Motivations– Capability/ Features

– Cost

– Speed of Delivery

– Quality

– Flexibility Customizability

Design, pageRaffo BA 339 19

Production Technologies

• NC Machines/ Machining Centers/ FMS

• Robots

• CAD/ CAM/ CAE/ CA Pro Pln

• Automated Materials Handling

• Computer Integrated Manufacturing

• Automated Manufacturing Planning and Control

Design, pageRaffo BA 339 20

Service Technologies

• Office Automation

• Image Processing Systems

• Electronic Data Interchange

• Decision Support Systems

Design, pageRaffo BA 339 21

Evaluation of Technology Investments

• Labor Costs• Material Costs• Inventory Costs• Transportation and Distribution Costs• Quality Costs• Increased Product Variety• Improved Features & Quality• Shorter Cycle Times

Design, pageRaffo BA 339 22

Risks

• Technical

• Operational

• Organizational

• Environmental

• Cost