Process Design

Design: To design refers to the process of originating and developing a plan for a product, service or process. Or The purposeful or inventive arrangement of parts or details. Process: A series of operations performed in the making or treatment of a product.

Process Design

Process design Processes that Design Products and Services

Concept Generation Screening Preliminary Design Evaluation and Improvement Prototyping and final design Layout and Flow

Processes that Produce Products and Services

Supply Network Design

Process Technology

Job Design

Nature of the design activity:

1) Design is inevitable/ Predictable products, services and the processes which produce them, all have to be designed. 2) Product design influences process design decisions taken during the design of a product or service will have an impact on the decisions taken during the design of the process which produces those products or services and vice versa.

Product & services design are interrelated to its process design

Designing the Product or Service
Designing the Processes that Produce the Product or Service Processes should be designed so they can create all products and services which the operation is likely to introduce

Products and services should be designed in such a way that they can be created effectively

Decisions taken during the design of the product or service will have an impact on the process that produces them and vice versa

Process Design and Product/Service Design are Interrelated To commit to the detailed design of a product or service consideration must be given to how it is to be produced. Design of process can constrain the design of products and services. The overlap is greater in the service industry: Service industry - it is impossible to separate service design and process design they are the same thing. Manufacturing industry - it is possible to separate product design and process design but it is beneficial to consider them together because the design of products has a major effect on the cost of making them.

Process and product/service design must satisfy customer Products/services designer & customers satisfaction criteria Reliability Meets expectation Inexpensive Quality Easy to manufacture and deliver Speedy Process designer & customers satisfaction achieved through: Layout Location Process technology Human skills

The design activity is itself a process

Finished designs which are:
TRANSFORMED RESOURCES Technical information Market information Time information High quality: Error-free designs which fulfil their purpose in an effective and creative way Speedily produced: Designs which have moved from concept to detailed specification in a short time

INPUTS

THE DESIGN ACTIVITY

OUTPUT

Timely delivered: Designs which are delivered when promised

Produced flexibly: Designs which include the latest ideas to emerge during the process Low cost: Designs produced without consuming excessive resources

Test and design equipment Design and technical staff TRANSFORMED RESOURCES

Designing processes
Process mapping Process mapping symbols Improving processes Process performance Throughput, cycle time & work in process

Process mapping
Used to identify different types of activities. Shows the flow of material, people or information. Critical analysis of process maps can improve the process.

Process mapping symbols

Operation (an activity that directly adds value)
Inspection (a check of some sort)

Beginning or end of process Activity Input or Output from the process

Transport (a movement of some thing) Delay (a wait, e.g. for materials) Storage (deliberate storage, as opposed to a delay) Process mapping symbols derived from Scientific Management

Direction of flow
Decision (exercising discretion) Process mapping symbols derived from Systems Analysis

Raw Materials

Assembly

Stored Sandwiches

Move to Outlets

Stored Sandwiches

Sell

Take Payment

Standard sandwich process Customer Request Raw Materials Assembly Take Payment

Customer Request

Customized sandwich old process

Two handed process chart

Left hand Wait Right hand Pick up base plate Insert into fixture Hold base plate Pick up two supports Locate back plate Pick up screws Locate screws

Pick up air driver

Fasten screws Wait Replace air driver Pick up centre assembly Inspect centre assembly Hold centre assembly Locate and fix Switch on timer Wait to end test Inspect Transfer grasp Inspect Transfer grasp

Wait

Put aside

Process performance
Process performance can be judge against the five key performance objective: Quality Speed Dependability Flexibility Cost

Throughput, work content, cycle time, and work in process

Throughput the time for a unit to move through the process Work content the total amount of work required to produce a unit of output (measured in time)

Cycle time The average time between units of output emerging form the process
Work in process (WIP) unfinished items in a production process waiting for further processing e. g. when customers join a queue in a process they become WIP

throughput = work in process x cycle time

Production System

Production System

Production systems or manufacturing systems convert

inputs into goods that have a physical form;

Depending on the kind of manufacturing process

adopted for converting the input into output, system can be classified as : Classification of a Production System
PRODUCTION SYSTEM CONTINUOUS

INTERMITENT PROJECT

JOB Shop

BATCH

MASS

PROCESS

Project Process
Many civil engineering projects for construction or military related activities are project production. In this, complex and large manufacturing tasks are undertaken. Generally, work is carried out at the site of the work rather than in a factory. All resources such as tools, material, labor, etc, reach the site themselves. Ship building activity is an example of project production. A fixed position plant layout is recommended for this variety of production system. Characteristics: Complex, large scale, high work content products Specially made, every one customized Defined start and finish: time, quality and cost objectives Many different skills have to be coordinated Fixed position layout

Project Process

Intermittent production systems are those where the production facilities are flexible enough to handle a wide variety of products and sizes. These can be used to manufacture those products where the basic nature of inputs changes with the change in the design of the product and the production process requires continuous adjustments. Considerable storage between operation is required, so that individual operations can be carried out independently for further utilization of men and machines. Examples of intermittent system are: machine shops, hospitals, general office etc.

Characteristics of intermittent system are:

- Most products are produced in small quantities. - Machines and equipment are laid out by process. - Workloads are generally unbalanced. - Highly skilled operators are required for efficient use of machines and equipment. - In-process inventory is large. - Flexible to suit production varieties.

Manufacturing process types

High Project High

Service process types

Professional service

Jobbing
Variety Variety Service shop

Batch

Mass Low Low Continuous Low Volume High Mass service

Low

Volume

High

Job Shop Process

In this system Products are manufactured to meet the requirements of a specific order. The quality involved is small and the manufacturing of the product will take place as per the specifications given by the customer.
Characteristics :
Very small quantities: one-offs, or only a few required Specially made. High variety, low repetition. Skill requirements are usually very broad Skilled jobber, or team of jobbers complete whole product

Fixed position or process layout (routing decided by jobbers)

Example: hairdressers; tailoring, Book Printing etc.

Jobbing Process

Batch Process
Batch Production is the manufacture of number of identical products either to meet the specific order or to satisfy the demand. When the Production of plant and equipment is terminated, the plant and equipment can be used for producing similar products. Characteristics: Higher volumes and lower variety than for jobbing Standard products, repeating demand. But can make specials Specialized, narrower skills Set-ups (changeovers) at each stage of production Process or cellular layout Example: Medicine Production.

Batch Process

Continuous Production: Continuous Production

system is the specialized manufacture of identical products on which the machinery and equipment is fully engaged. The continuous production is normally associated with large quantities and with high rate of demand.

This system is classified as

(i) Mass Production (ii) Flow Production

Characteristics
Extremely high volumes and low variety: often single product Standard, repeat products Highly capital-intensive and automated Few changeovers required Difficult and expensive to start and stop the process Product layout: usually flow along conveyors or pipes

Continuous Process

Mass (Line) Process

Here same type of product is produced to meet the demand of an assembly line or the market. This system needs good planning for material, process, maintenance of machines and instruction to operators. Purchases of materials in bulk quantities is advisable.

Characteristic: Higher volumes than Batch Standard, repeat products Low and/or narrow skills No set-ups, or almost instantaneous ones Cell or product layout

Mass Process

Process or Flow production:

The difference between Mass and Flow Production is the type of product and its relation to the plant. In Mass Production identical products are produced in large numbers. If the demand falls or ceases, the machinery and equipment, after slight modification be used for manufacturing products of similar nature. In flow production, the plant and equipment is designed for a specified product. Hence if the demand falls for the product or ceases, the plant cannot be used for manufacturing other products.

Product characteristics
Types Characteristics Examples Similar service examples

Job Shop
Batch Mass Process Project

Short duration activities to Industrial hard provide customs goods or wares, printing services personalized stationary etc.

Custom service Charter bus travel, providing health care, etc. Processing of groups of In batches like Standard service in similar standard items medicines, hand groups tools, etc. Schedule air or bus travel etc. High volume processing Light bulbs ,TVs, Std. Services of standard goods or some other Fast food, services. consumer Insurance, dry goods,etc. cleaning, etc. High volume processing Chemicals, No equivalent of unit goods, that flow refining of oils, together in bulk. milling flower, etc. Long duration activities of Building a Project a team of a low volume bridge/ dam / Developing a goods or services. ship / house, etc. software, preparing for a banquet, etc.