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MODULE 1 > 2 - Introduction to prod. syst > Flashcards

2 - Introduction to prod. syst Flashcards

1
Q

Production system?
production process?
production plant?

A
  • Production system = a subsystem of the company. It uses resources as inputs – raw materials, semi-finished goods, energy, information, knowledge, etc. – to provide products and services in order to satisfy the customer needs and the objectives established by the company’s strategy
  • Production (process) = set of activities (process) required to produce goods or services delivered to the market by a company
  • Production plant = physical plant where the production system is established
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2
Q

What is production ?

Diagram where PRODUCTION is located at the middle in the process.

A
  • top part: NEW PRODUCT DEVELOPMENT
  • Market analysis
  • product desing
  • product industrialization
  • on the left hand side: PRODUCTION & LOGISTICS
  • purchasing

PRODUCTION !!!

  • On the right hand side:
  • sales
  • distribution
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3
Q

What is production from these two points of view?:

  • Technological
  • Economical
A

Production is technologically the application of physical and chemical processes to alter geometry, properties and/or appearance of a given starting material to make products

Economically, production is the transformation of materials into items of greater values by means of one or more operations

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4
Q

types of transformation processes?

A 
physical (e.g. machining)
 chemical (e.g. pharmaceutics)
 location (e.g. transport)
 exchange (e.g. retail)
 storage (e.g. warehousing)
 physiological (e.g. health care)
 informational (e.g. telecom.)
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5
Q

By means of what is it possible to define a Production System?

A

*Production process
– ASME Diagram & Value Added Diagram

  • Product structure, drawings, parts list, Bill of Materials
  • Cycle times / Production programs
  • Flow sheet
  • Layout
  • Classifications
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6
Q

Production Process - ASME?

Tyope of set of data used to describe the sequence of operations?

A

Production processes are multistage processes: it means that a sequence of operations are required to realize the process that allows to obtain a product from a raw material

The set of data that describes the sequence of such operations is called

  • technology cycle or technology routing.
  • Technology diagram.
(circle )- > Opertion
reversed triangle -> store
square -> inspect
 (mix of sqauer and circle) -> wait 
row (->) means transfer
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7
Q

What is the Value Added?

What is not- Value added?

A

Value-Added is the difference between the cost of inputs and the value or price of outputs

Value-added activity
Increases worth of product or service to a customer
and therefore, the customer is willing to pay for it

–
Non-value-added activity
Increases time spent on product or service but does not increase worth
Unnecessary from customer perspective
Can be reduced, redesigned or eliminated without affecting market value or quality

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8
Q

Product Strucure? (diagram)

A

Desing -> Industrialization -> Production

b/w Design & Industrialization there are:

  • Engineering drawings
  • BOM

b/w industrialization &production

  • processing techonlogical routings
  • drawings
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9
Q

What is a Layout Diagram?

A

Layout diagrams show the physical location of equipment, staff, inventories, facilities, transport paths, etc.

drawback: It is difficult to show the material flow.

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10
Q

*** Classification of Production Systems (3-axis diagram) ?

A

X : VOLUME: How the production is managed to make the required production volume).

Y: DEMAND: How the company fulfills the demand from the market

Z: PROCESS: How the product is made through the production process.

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11
Q

*** Classification of Production Systems (3-axis diagram with the sub-categories in each axis) ?

A

X : VOLUME: How the production is managed to make the required production volume).
- single production
- batch (intermittent) production
- continous production
—————————
Y: DEMAND: How the company fulfills the demand from the market
- single ->
Production to order
- Repeatd ->

  • Production to stock

Z: PROCESS: How the product is made through the production process.

  • Discrete (manufacturing) -> Fabrication
    - > Assembly
  • Process production (process plant)
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12
Q

Classification by PROCESS?

A
  • Discrete (manufacturing)
  • Individual items are produced and can be tracked
  • Volumes can be high
  • Low levels of automation
  • there can be the fabrication of individual products and / or the assembly of several components
  • Examples of products: cars, machine tools, electronic goods
  • Process production (process plant)

-Often concerned with liquids, powders, gases
-High level of automation
Examples of products: cement, oil, sugar, paint, metals,

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13
Q

Z: PROCESS.. Process production (process plant). General features?

A
  • techonlogy
  • Not-reversible chemical-physical transformation of raw materials
  • No felixibility (Fixed technological route and mainly flow type)
  • Relevance and sensitivity of process technological parameters
  • High level of automation
  • Process flow can be: analytical, synthetic or linear

*management
Slight relevance of management parameters (as WIP, lead time, phase synch, …)

  • cost structure
  • High investments for infrastructure, machinery and automation
  • Low labour cost
  • High energy and maintenance costs
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14
Q

Z: PROCESS. Discrete production (manufacturing). Features?:

A

*Discrete production (manufacturing) typically has a closer relationship to end customers; often Process industries act as suppliers.

  • Products are made of discrete parts that are produced in great number of variants
  • Significant use of human resources
  • Significant inventory levels at all levels of production
  • Lead time is not as predictable as in Process Production
  • Typically flexible technological route (options)
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15
Q

Z: PROCESS. Discrete production (manufacturing).

- Fabrication….general features?:

A

*Technology

  • Not reversible physical/shape transformations of raw materials and components
  • Flexibility. Not fixed technology route, with options and variants, with variable level of flexibility
  • Not particular relevance of process technology parameters, relevance of product technology parameters
  • Management
  • Relevance of management parameters (WIP, lead time, delays, synchronizations, …)
  • Cost structure
  • Relevance of fixed assets
  • Labour intensity depending from automation and characteristics of machinery
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16
Q

Z: PROCESS. Discrete production (manufacturing).

- Assembly….general features?:

A

*Technology

  • Components assembly to make groups, sub-groups and finished products. Operation can be reversible (and also irreversible, e.g., welding)
  • Flexible. Free technology route, with degrees of freedom
  • Low relevance of process technology parameters
  • Management
  • (High) relevance of management parameters (WIP, synchronization, lead time, delay, …)
  • Cost structure
  • Low relevance of fixed assets, depending on utilization and customization of machinery
  • A lot of manual operations cause relevance of workforce utilization
17
Q

Classification by VOLUME (production method)?

A
  • single production
  • Product request (demand) from the market is not repetitive o not forecastable
  • production is performed unit by unit
  • The exact quantity requested by the customer is produced.
  • high variability of products produced.
    therefore the production cycles changes from product to product.
  • Entails relevant setup times.
Product examples: 
Special machinery or product
Special lot of chemical/pharmaceutical product
Ships
Industrial plants
  • Batch (intermittent) production:
  • demand for different types of products requires production in batches (and thus set-up costs)
  • Exceeded quantity is sent to stock for future orders
  • Demand may be repetitive
  • Volume range from low to medium
  • trade-off b/w production costs ans storage costs.
Product examples:
Tints (pigments, paintings, ...) 
Textile
Receipt based production (pharmaceutical, food, chemical, …)
Mid scale production (machine tools)

*Continous:
- Mono- product production
(low variety of product types)
- Mass production
- Stable demand
- Due to the nature of production (continous), products usually do not need to be stored in a planned way.

Product examples:
low-cost mechanical parts (screws, nuts and bolts, …)
High volume process production (cement, polymers, oil)
Food production

18
Q

Wortmann Classification? (diagram)

A

(Top part in the followuin sequence):

  • Engineering
  • Purchasing
  • Manufacturing
  • Assembly
  • Distribution

(left hand side ..vertical-way written): Suppliers
(right hand side.. vertical-way wirtten ): Customers

(now: The sequence!!)
- ETO
- PTO
- MTO
- ATO
- MTS

19
Q

ETO?

A

Engineer-to-Order(ETO):
Here, the product is designed and built to customer specifications.
this approach is most common for large construction projects and one-off products, such asFormula 1cars.

Engineer-to-Order (ETO)

  • New product, complex product, unique designs produced in single units (examples - construction)
  • Long manufacturing lead times
20
Q

PTO?

A

Purchase-to-Order (PTO):
Here the product is already designed, but materials for production are still not in inventory, then they should be ordered. It is then like MTO.

21
Q

MTO?

A

Make-to-Order (MTO):
Here, the product is based on a standard design, but components for production and manufacture of the final product are linked to the order placed by the final customer’s specifications; this strategy is typical for high-endmotor vehiclesandaircraft.

MTO:

  • Only produce items after they have been ordered
  • Existing designs (standard products) with proven production processes
  • Production system must respond quickly
  • Unpredictable demand (examples - special spec computer)
22
Q

ATO?

A

Assemble-to-Order(ATO):
Here, the product is built to customer specifications from a stock of existing components. This assumes amodular productarchitecture (the customer can customize its product) that allows for the final product to be configured in this way; a typical example for this
approach isDell’s approach to customizing its
computers.

ATO:

  • Customer lead time less than manufacturing lead time
  • Customers have influence on the design (customization is possible by customer)
  • They can select various options from predesigned subassemblies
  • Forecasts of product mixes certain or response to customer orders
23
Q

MTS?

A

Make-to-Stock(MTS);
Here, the product is built against a sales forecast, and sold to the customer from finished goods in stock (customer cannot customize the product); this approach is common in thegroceryandretailsectors.

-Customer lead time less than manufacturing lead time
- stock the products so the manufacturing lead time is minimized
Product has few options but good demand
Number of units of each product are kept on hand at all times
-Quick delivery to customers upon receipt of an order
-When delivery response time is a key competitive factor
-Allows to schedule production in advance

24
Q

On what is the Wortmann Classification based?

A
  • customer lead time - time span between the issue of an order and the delivery of the product
  • manufacturing lead time - time span between the acceptance of an order and the delivery of the product

NOTE: It is needed to match manufacturing lead time with customer lead time and therefore, different strategies can be applied to achieve this match.

MODULE 1 (3 decks)

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