Production Operations
Management
Process Technology &
Layout
U. Akinc
Bus 241
1
Various Technologies
 Information
Technology
 Product
Technology
 Process
Technology
Bus 241
2
Reasons for Technology
Some of the competitive priorities
Improved Product and Service Quality
 Lower Cost
 Increased Responsiveness to Market
 Increased Responsiveness to Customer
 Safety

Bus 241
3
Barriers to Implementation of
Technology

Difficulty in Financial Justification
traditional ROI based capital budgeting can’t consider non-financial benefits

Lack of Understanding by Management
Resistance to change, having to learn “another way” of doing things

Concern for the Impact of Technology on
the Human Resources
Fear of loss of jobs due to automation
Bus 241
4
Information and
Communication Technologies
Electronic Data Interchange
 Bar Coding (UPC)
 Electronic Pagers
 Cellular Telephones
 Internet/e-Mail
 Intranet

Bus 241
5
Bar Code Technology

Speeds Data Entry

Increases Data Accuracy

Reduces Material Handling Labor

Easily Monitors Labor Efficiency
Bus 241
6
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
Bus 241
7
Automation and Operations Focus
Product Focus: Line-Flow = flow-shop
High Volume Standard Products imply High
Degree of Repeatability
 Automation is natural In the form of fixed automation
 Process Focus:
Low Volumes of a wide variety of product
and services imply limited repeatability
 Automation is more challenging

Bus 241
8
Fixed Automation
Automation of the processes and transfer
of parts among stations. Characterized by:
High set up cost
 Rigid Capabilities
 Extreme efficiency
Sometimes referred to as Detroit type automation
Examples:
 Assembly Lines
 Transfer Lines Machines that are linked with automatic materials handling
 Process industries (e.g., petro-chemicals)

Bus 241
9
An example of fixed automation: Egg processing
Bus 241
10
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
Bus 241
11
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
Bus 241
12
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)
Bus 241
13
CIM
An Umbrella term to encompass the
integration of:

Product Design/Engineering

Process Planning /Development

Manufacturing Operations

Production/Inventory Control
Bus 241
14
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.

Bus 241
15
Components of CIM (cont’d)
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

Bus 241
16
Components of CIM (cont’d)
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
Bus 241
17
A Multi-Axes Robot
Merlin1
Bus 241
18
A Merlin robot programmed to cut carpet to specified sizes
Merlin2
Bus 241
19
A Merlin Robot spot welding
Merlin3
Bus 241
20
Anatomy of a Merlin robot (has
three degrees of freedom or axes)
Bus 241
21
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
Bus 241
22
Another Gantry robot: cutting cloth
Gantry2
Bus 241
23
Components of CIM (cont’d)
Please visit the link
6. AGV
Automatically Guided Vehicles
 7. AS/RS
Automated Storage and Retrieval Systems

Bus 241
24
Automatically Guided vehicle examples
Bus 241
25
Infrastructure of CIM
Use of integrated computer software for

Production Scheduling

Inventory Control

Capacity Planning

Shop Floor Control
Bus 241
26
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
Bus 241
27
Functional Layout
Most appropriate for process focus
Turning
Packing
Gluing
Painting
Sanding
Planing
Drilling
Cutting
Resources are organized into functional departments
Bus 241
28
Line Flow Layout
Most appropriate for Product Focus
A
E
E
A
B
D
A
D
B
C
C
D
B
E
B
C
Product flows through processes A-E
in a sequence dictated by the assembly
requirements of the product.
Bus 241
29
Manufacturing Cells in
Group Technology
Refer back to
slide number 12:
Group
Technology.
Here the
departments are
arranged to
produce families
of similar parts
efficiently
Cell A
Cell B
Planing
Painting
Cell C
Bus 241
30
A Part Family
Bus 241
31
Manufacturing (GT) Cell
Bus 241
32
Identified Process Pattern
Product
Process
Matrix
No Flow
Jumbled Flow
Product Variety and Volume
Low
VolumeUnique
Many
ProductsLow
Volume
Several
ProductsHigh
Volume
One
ProductVery High
Volume
Project
Job Shop
Mixed with
Dominant Flows
Batch
Assembly
Line
Line Flow
Continuous
or Automated
Continuous
Process
Bus 241
33