Session 1 - Important Slides

Question 1

What are characteristics and the important part of Job Shops?

Answer 1

• Volume-Independent Planning
• Parts travel between workshops
• Work Centres are grouped by the type of process (welding, drilling, painting…)

• The important part is the ORDER of jobs

•	Important:
High Transport Costs
High Waiting Times
High Inventory Costs
High Labour Costs

Question 2

What are characteristics of Batch-Flow?

What is the important idea of it?

Answer 2

• Maximise the RUNNING TIME of the production
• Volume is the key factor
• Changeovers between products = Changeover time is important
• High Inventory costs
• Lot-Sizing is very important

• The idea is to BALANCE maximising production with inventory costs

=Maximise Utilisation
=Minimise Costs

Question 3

What are characteristics of Line Production and what is the important limitation of it?

Answer 3

• Volume justifies dedicated lines!
• Cycle-Time is set to pace entire factory
• Limited Flexibility regarding Volume & New Models

Limitation: there has to be a levelled schedule = the volume needs to be stable!
A lot of workers can’t change the workload every day. You must have a fixed amount of workers.

Question 4

What are characteristics of Continuous Processing and what is an example for it?

Answer 4

Flow Process: Continuous Production
• Often driven by chemical / physical needs
• Individual product is sometimes not an entity (e.g. Petrol)

Example: Battery Cell production or Chemicals Production

Question 5

Visualise the Product-Process Matrix! What is top left and what is bottom right? What is the elements of process pattern downwards? Give examples =6

Answer 5

• Up left on the matrix: 1 of the product is made, unique products = Project
• Low right on the matrix: high volume production, less product diversification = Continuous flow

1) Project = F1 Car
2) Job Shop = Aeropsace
3) Batch-Flow = Industrial Machinery
4) Worker Paced Line Flow = Automotive
5) Machine Paced Line Flow = Electronic Goods
6) Continuous Flow = Chemicals

Question 6

What are the 5 Generic forms of Manufacturing and their features? Give examples

Answer 6

1) Project
> Simple tools used flexibly by skilled personnel
> F1 Car
2) Job-Shop
> General purpose equipment requiring high skill
> One-off specialised product like Spaceship
3) Batch
> Complex standalone machines with long setups and process-based layout
> Industrial Machinery
4) Line
> Complex system of machines linked with automation, modest skilled workers
> Automotive, electronics
5) Continuous
> Capital intensive production of homogenous products
> Chemicals

Question 7

What determines the design of a Manufacturing System?

Answer 7

1) Product Variety
2) Equipment Flexibility
3) Production Volume

Question 8

What are the 5 steps of traditional manufacturing modes in Automotive Industry?

Answer 8

1) Press Shop: Batch production
• Volume Key Factor (Automation & Batches)
• Low Variety and High Investment
• Changeovers between products = time important
• Lot-Sizing Important
2) Body Shop: Machine-Paced Line Flow
• Volume Key Factor (Automation)
• Medium Product Variety (approx. 20-50 Body in white variants)
• Variations of model, roof, steering etc here
• Cycle Time is set to pace entire factory means here the machines dictate the workload
3) Paint Shop: Machine-Paced Line Flow
• Used on all car models on the production site
• High investment in Tech
4) Drivetrain Pre-Assembly: Worker-Paced Line Flow
• Types of Drivetrains: ICE, BEV, HEV, PHEV
• E-Motor, suspensions and battery manually assembled
• Low product variety for BEV, high for ICE
5) Final Assembly: Worker-Paced Line Flow
• Volume justifies dedicated lines
• Cycle Time is set to pace entire factory means here the machines dictate the workload
• Multi-Model Lines
• Limited Flexibility regarding Volume and New Models