Designing Production Systems

Question 1

Determining Production Capacities

Answer 1

1. Quantitative production capacities:

• Total capacity over the life cycle
• Capacity per period

2. Qualitative production capacities:

• Flexibility

Question 2

Available process Time

Answer 2

1. Useful life [ Running time; Setup time]

2. Down time [Due to operational procedure, Due to disturbance, Due to personal labour, due to decommissioning]

Question 3

Categorization of Production Processes Along Order Penetration Point

Answer 3

1. Make to stock (forecast driven) - mass product as cigarets.

Procurement - Manufacture - Assembly - OPP

2. Assemble to order

Part of the car are manufacture and then assembled by the customer

[Forecast driven] Procurement;Manufacture - OPP ; Assembly [Order driven]

3. Make to order

[Forecast driven] Procurement - OPP; Manufacture; Assembly [Order-driven]

4. Purchase and make to order

Procurement - Manufacture - Assembly [Order Driven]

Question 4

Production Processes

Along Production Quantities/ Lot Sizes

Answer 4

1. Job Production - Lot size 1 (-> change over),
   e. g. bridges, fitted kitchens;
2. Batch Production - Lot size N standardized,
   e. g. clothes;
3. Mass (flow) production - Undetermined lot size, e.g. cigarettes, cement
4. Mass customisation - Combination of mass production and job production - e.g. cars
   ordered by customers;

Question 5

Categorization of Production Processes

Along Organizational Types

Answer 5

1. Point manufacture and assembly. Moving in one location -> ship building
2. Job shop manufacture and assembly. Stationary in
   job shops -> Moving between job shops, e.g.
   metalworking shop
3. Flow/ line manufacture and assembly. Stationary in
   production line -> Moving, e.g. on moving car assembly line.
4. Group/cellular manufacture und assembly. Stationary in
   cells, autonomous worker groups responsible for entire
   modules -> Moving through various groups,
   i.e. combination of job shop & flow principle

Question 6

Quality Control

Answer 6

Quality is the totality of characteristics and features of a product, that
relate to the aptitude to fulfil specified requirements.

1. Method of quality inspection:

Variable inspection: Criteria that can be measured on a scale
• Attributive inspection: Criteria met or not

2. Scope of inspection:
   • Complete control
   • Sample control