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Continuu
m
Process-Focused Strategy
•Facilities are organized by process
•Similar processes are together
•Example: All drills or lathes are together
•Low volume, high variety products
•‘Jumbled’ flow
Product
•Other names Operati A
on
•Intermittent process 11 22 33
•Job shop
Product
B
Process-Focused Strategy
Examples
Bank
Hospital
1995
Corel
Corp.
Machi
© 1995 Corel Corp.
ne
Shop © 1995 Corel Corp.
Process-Focused
Production
Variances of Process
Focused Production
•University
education
•Swimming pool
remodeling
-
Pros & Cons (p262)
Advantages
Greater product flexibility
Use more general purpose equipment
Suitable for customization
Disadvantages
More highly trained personnel
More difficult production planning & control
(including inventory, machine and personnel
scheduling, maintenance, quality control…)
Low equipment utilization (25% to 45%)
Process Automation and
Flexible Manufacturing
System
Production Technology
Automated Guided Vehicles (AGV)
Automated Storage and Retrieval
Systems (ASRSs)
Flexible Manufacturing Systems
(FMS)
Programmable process Control
Vision Systems and Robots
Product-Focused Strategy
•Facilities are organized to produce a small
number of products
•High volume, low variety products
•Other names
•Continuous process manufacturing
•Line flow production
•Continuous production
Products A &
B
11 22 33
Operatio
n
Product-Focused Examples
Soft Drinks
(Continuou
s, then
Discrete)
© 1995
Corel Corp.
Light Bulbs
Paper
© 1984-1994 T/Maker Co.
(Discrete)
(Continuous) © 1995 Corel Corp.
Product Focused Process
Product-Focused Strategy
Pros & Cons (p242)
Advantages
Lower variable cost per unit
Use more specialized equipments
Easier production planning and control
Higher equipment utilization (70% to 90%)
Disadvantages
Lower product flexibility
High shut-down cost
Usually higher capital investment
Repetitive Focused
Strategy
Facilities often organized by
assembly lines
Characterized by modules
Parts & assemblies made previously
Modules combined for many
output options
Other names
Assembly line
Production line
Repetitive-Focused
Strategy - Examples
Clothe Fas
s t
Dryer McDonald’s Foo
McDonald’s
d
over 95 billion served
over 95 billion served
Mass
Customization
Scheduling Rapid
techniques throughp
ut
Process focus Product focus
Intermittent Continuous
process Process
High variety, low Low variety, high
volume volume
Automated Storage and
Retrieval System (ASRS)
Provide for automatic placement and
withdrawal of parts and products into
and from designated places in a
warehouse.
Improve efficiency of material handling
and inventory management in both
production, distribution, and retail site
Automatic Guided Vehicles
(AGV)
Material handling
machines
© 1984-1994 T/Maker Co.
Producti Wait
on
control
Order
Product
Plant A Print
WIP
Product
Warehouse Wait Wait Wait
Product
WIP
Plant B Extru
WIP
WIP
de
New Capacity
Demand
Time in Years
Time in Years
Capacity lags demand with an incremental expansion
Approaches to Capacity
Expansion
Expected Demand
New Capacity
Demand
Time in Years
Attempts to have an average capacity,
with an incremental expansion
Breakeven Analysis
Technique for evaluating process & equipment
alternatives
Objective: Find the point ($ or units) at which total
cost equals total revenue
Fixed costs: costs that continue even if no units are
produced: depreciation, taxes, debt, mortgage
payments
Variable costs: costs that vary with the volume of
units produced: labor, materials, portion of utilities
Breakeven Chart
Cost in Dollars (Thousands)
Variable cost
Volume (units/period)
Crossover Chart
Process A: low volume, high variety
Process B: Repetitive
Process C: High volume, lowA variety
s s
ce
ro e ssB
P c
- Pr o
st c ost -
o al C
c Tot r o cess
t al l cost
- P
To t a
To