m2 Process Engineering

7/29/2019 m2 Process Engineering

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INDUSTRIAL

ENGINEERING

JTM 3023

Lecturer

Mohd Norhasni Mohd Asaad

KOLEJ PERNIAGAAN

ROOM FPT : 3050 TEL: 4974

H/P: 019-5478634

Email :[email protected]
mailto:[email protected]:[email protected]


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JTM3023-M2-Mohd Norhasni

PROCESS ENGINEERING


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LECTURE SCOPE

What is Process Engineering?

Process Engineering 6 step

sequence.


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Process engineering is also called:

manufacturing planning, production

engineering, process planning, materialprocessing and machine routing.

Responsible of developing a plan for themanufacture of the new or modified product.


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Concern with the design of

the actual process to beused in the manufacture of

the product


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Process Engineering 6 step

sequence

Defining the product structure andspecification

Assessing each componentsmanufacturability

Process selection

Cost evaluation

Determining the sequence in which theoperation are to be performed

Documenting the process


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Defining the product structure

and specification


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1. Defining the product

structure and specification

Product structure are often shown in a

hierarchical chart that shows all of the

subassemblies, sub-subassemblies,components and raw materials that

comprise the product.


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1. Defining the product

structure and specification

Product structure

Shows sequence in

which componentsare assembled

How and when the

subassemblies are

put together to

make the final

product.

Product


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EXERCISE 1

Given the following

diagram for a

product, determinethe quantity of each

component

required to

assemble one unitof the finished

product.

E

F (2) G H

J (2)

D (4)

L (2)

J (2)

A (4)

D (2)


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EXERCISE 2

Draw a tree

diagram for the

stapler:

ITEM COMPONENTS

Stapler Top assembly,

base assembly

Top assembly

Cover

spring

Slide assembly

Slide

Spring

Cover, spring,

slide assembly

Slide, spring

Base assembly

Base

Strike plate

Rubber pad (2)

Base, strike

plate, rubber

pad (2)


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Defining the product structure

and specification

Bills of Materials (BOM)

List of all components needed to produce

the product Contains:

Number and name of all the parts

The source of each part (purchase ormanufacture)

Number and name of the completed product


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Example of bill of materials


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Assessing each components

manufacturability


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2. Assessing each

components manufacturability

Manufacturability:

A measure of the relative ease or

difficulty of producing the item within

tolerance

The tighter the tolerances, in general, the more

expensive the item will be to produce.


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Process Selection


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A process is a method of doing

something, generally involving a

number of steps or operations.

Process design is the developingand designing of the steps.


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Factors influencing process

design

Product design and quality level.

Demand patterns and flexibility

needed.

Quantity/capacity considerations.

Customer involvement.

Make or buy decision


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PRODUCTDESIGN

what to

produce?

PROCESS

DESIGN

how to

produce?

CAPACITY

How much to

produce?

CUSTOMER


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Reasons to make in-house

Can produce for less cost than a supplier

To utilise existing equipment to the fullestextend

To keep confidential processes within

control of the firm. To maintain quality.

To maintain workforce.


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Reasons to buy out

Requires less capital investment.

Uses specialised expertise of suppliers.

Allows the firm to concentrate on its own

area of specialisation.

Provides known and competitive prices.


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Cost

Capacity

Quality

Speed

Expertise


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Manufacturing

processes

CastingForming &

shapingMachining Joining

Expendable

mould

Permanent

mould

Bulk metal

forming

Sheet metal

forming

Cutting

Abrasive

Advanced

Welding

Adhesive

bonding

Mechanical

fastening

Finishing

Burnishing

Hardening

Deposition

Implantation

Coatings

Cleaning


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Metal casting

Expendablemould

Permanentmould

Sand

Shell

Expandable pattern

PlasterCeramic

Investment

Slush

Pressure

Die

CentrifugalSqueeze

semisolid

Forming &

shaping

Bulk metalforming Sheet metalforming

Rolling

Forging

Extrusion

DrawingPowder metallurgy

Punching

Blanking

Stamping

Bending

Deep drawingSpinning

Stretch forming


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Machining

Cutting Abrasive Advanced

Circular shapes Various shape

TurningBoring

Drilling

MillingPlaning

Shaping

Broaching

Sawing

Gear forming

Grinding

Honing

Coatedabrasive

Ultrasonic

machining

Lapping

Polishing

Buffing


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Joining

WeldingAdhesive

Bonding

Mechanical

fastening

Fusion Solid stateBrazing &

soldering

Oxyfuel gas

Thermit

Arc

Resistence

Electron beamLaser beam

Resistance

Diffusion

Explosion

Cold

Frictionultrasonic

Fastening

Seaming

Crimping

Sttching


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Process Selection

Process types:

Job shop

Batch

Mass production

Continuous production

Project


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Low

Low

High

High

Project

(customer job shop;

customer tailoring;

construction)

Batch process

(education classes;

bakery; printing shop)

Line process

(assembly lines;

cafeteria)

Continuous process

(oil refinery; water

treatment plant)

Intermittent

operations

Repetitive

operations


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BATCH MASS CONTINUOUS PROJECTTypes of product Made-to-order

(customised) Made-to-stock(standardised) Commodity Unique

Type of customer Few individualcustomers Mass market Mass market One-at-a-time

Product demand Fluctuates Stable Very stable InfrequentDemand volume Low to medium High Very high Very low

No. of differentproducts Many, varied Few Very few Infinite variety

Productionsystem Discrete, job shop Repetitive,assembly line Continuous, processindustries Long-term projectEquipment General-purpose Special purpose Highly automated VariedWorker skills Wide range of skills Limited range of

skills Equipment monitors Experts,craftspersonsAdvantages Flexibility, quality Efficiency, speed,

low cost Highly efficient,large capacity, easeof control

Custom work, latesttechnology

Disadvantages Costly, slow,difficult to manage Capital investment,lack of

responsiveness Difficult to change,far-reach error,limited variety

Non-repetitive,small customerbase

Examples Machine shop,bakeries, education Automobiles,televisions, fast

foodSteel, paper, sugar,supplying electricityto homes andbusinesses

Construction,shipbuilding


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DISCUSSION 1

What kind of process is used for making

each of the following products?

1. Soft drinks

2. Wedding invitations

3. Automobiles

4. Paper

5. Custom homes

6. Motorcycles


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Cost evaluation


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4. Evaluating the cost of each

process

A new model was designed

Design drawing and part documentation

Established production process

Calculate labour and overheadcost for each planned operation

Sum the cost of individual operations


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Cost evaluation

Fixed costs

Not vary with the volume produced

Eg: purchase costs of machinery andtools, setup costs.


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Cost evaluation

Variable costs

Costs that vary with the quantity

produced. Eg: direct labour, direct material.


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Total cost = Fixed cost + (Variable cost per

unit)(number of units produced)

Then,

TC = FC + VCx

unit cost = Total cost = TC

number of units produced x


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Example

A process designer has a choice of

two methods for making an item.

Method A has a fixed cost of RM2000for tooling and jigs and a variable costs

of RM3 per unit. Method B requires a

special machine costing RM20 000and the variable costs are RM1 per

unit.


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Fixed cost RM2000 RM20 000

Variable unit cost 3 1

Total cost 2000 + 3x 20 000 + 1x

Unit (average cost) 2000 + 3x 20 000 + 1x

x x


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Volume

(units)

Total cost (RM Unit cost (RM)

Method A Method B Method A Method B

2000 8000 22 000 4.00 11.00

4000 14 000 24 000 3.50 6.00

6000 20 000 26 000 3.33 4.33

8000 26 000 28 000 3.25 3.50

10 000 32 000 30 000 3.20 3.00

12 000 38 000 32 000 3.17 2.97

14 000 44 000 34 000 3.14 2.43

16 000 50 000 36 000 3.13 2.25


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Cost equalisation

point

Method A

Method B

Volume (1000 units)

Cost

(RM1000)

9


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Evaluating the cost of each

process

Activity/Function

Batch Mass Continuous Project

Costestimation Difficult toroutine Routine Routine Complex

Cost per unit High tomoderate

Low Low Very high

Fixed costs Low tomoderate High Very high Varied

Variablecosts High tomoderate Low Very low High

Marketing Promotecapabilities,semi-standardgoods andservices

Promotestandardisedgoods andservices

Promotestandardisedgoods andservices

Promotecapabilities


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Determining the sequence of

operations


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5. Determining the sequence

of operations

Operations that will be used to

transform the material into its

desired final shape.


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The sequence usually developed

based on:

Minimization of part handling (shortest

path from machine to machine)

Assuring that no succeeding operation

adversely affects previous operations


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Process documentation


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Schematic of a process

PROCESS

(work steps)

ENVIRONMENT

Internal

External

OUTPUT

(Customers)

INPUT

(Suppliers)

COMPONENTS

People

Methods

Equipment


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Documenting the process

Flow chart

A diagram that traces the flow of information,

customers, equipment, or materials through the

various steps of a process.

Process chart

An organized way of documenting all of the

activities performed by a person, by a machine,at a workstation, with a customer or on

materials.


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Flow charts

Tasks or operations

Storage areas or queues

Decision points

Flow of material/ customers


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Flowchart of the Sales Process fora Consulting Company

Figu re 4.3


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JTM3023-M2-Mohd NorhasniFigu re 4.16

Flowchart of

TelephoneOrderingProcess


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Process Charts

Figu re 4.8

Process: Emergency room admission

Subject: Ankle injury pat ientBeginning: Enter emergency roo m

Ending: Leave hos pital

Step

no.

Time

(min)

Distance

(ft)

Summary

Numberof stepsActivity

Time(min)

Distance(ft)

Step description

Insert Step

Append Step

Remove Step

1 X Enter emergency room, approach patient window

2 X Sit down and fill out patient history

3 X Nurse escorts patient to ER triage room

4 X Nurse inspects injury

5 X Return to waiting room

6 X Wait for available bed

7 X Go to ER bed

8 X Wait for doctor

9 X Doctor inspects injury and questions patient

10 X Nurse takes patient to radiology

11 X Technician x-rays patient

12 X Return to bed in ER

13 X Wait for doctor to return

14 X Doctor provides diagnosis and advice

15 X Return to emergency entrance area

16 X Check out

17 X Walk to pharmacy

18 X Pick up prescription

19 X Leave the building

0.50 15

10.0 -

0.75 40

3.00 -

0.75 40

1.00 -

1.00 60

4.00 -

5.00 -

2.00 200

3.00 -

2.00 200

3.00 -

2.00 -

1.00 60

4.00 -

2.00 180

4.00 -

1.00 20

Transport 9 11 815

Operation 5 23

Inspect 2 8

Store

Delay 3 8


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Process chart

Operation

Changes, created or adds something.

Transportation Moves the studys subject from one place

to another

Can be a person, a material, a tool or apiece of equipment.


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Process chart

Inspection

Checks or verifies something but does

not change it.

Delay

Occurs when the subject is held up

awaiting further action.

Storage Occurs when something is put away until

a later time.


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Documents

m2 Process Engineering