week 8 - product process desing & layout

Question 1

what are the 2 types of products?

Answer 1

1. made to order
2. made to stock

Question 2

what is a made to order product?

Answer 2

> a simplified design process because customer participates
demand variability (can’t forecast)
ex: local tailor suit shop, because it is custom made

Question 3

what is a made to stock product?

Answer 3

> complex design process because product are expected to satisfy a large nb of customer
simplified planning
ex: meat industry, because meat is standard

Question 4

what are the production design strategies (5)?

Answer 4

1. standardization
2. simplification
3. modular design
4. delayed differentiation
5. product design & sustainability

Question 5

what is the definition of standardization?

Answer 5

it refers to the strategy of seeking uniformity in products & in the parts comprising them (same parts, same production process, same design)

Question 6

what are the advantages and disadvantages of standardization?

Answer 6

advantages:
> fewer parts to deal with in inventory & manufacturing
> reduce training cost & time
> more routine purchasing, handling & inspection
> order can be met from inventory
> opportunities for long production runs and automation

disadvantage:
> designing a product that meets the needs of many customers requires a large investment
> high cost of design changes increases resistance to improvement
> decreased variety results in less consumer appeal
> it is difficult to address the needs of specific clients

Question 7

what’s simplification?

Answer 7

taking a product with a lot of pieces and simplifying it to create less pieces

Question 8

what’s the modular design?

Answer 8

a form of standardization & parts are subdivided into modules

Question 9

what are the advantages & disadvantages of modular design?

Answer 9

advantages:
> easier diagnosis & remedy of failure
> easier to repair & replace
> simplification of planning, procurement, inventory management, manufacturing & assembly
> lower training costs

disadvantages:
> modules must be compatible & interchangeable
> increase in replacement costs, as the whole defective module must be changed

Question 10

what are the process selection criterias (4)?

Answer 10

1. volume
2. variety
3. demand
4. flow

Question 11

what are the types of process (4)?

Answer 11

1. job shop
2. batch
3. mass production
4. continuous process

Question 12

what are the types of flow & what do they do (3)?

Answer 12

1. intermittent flow: movement of in-process products is discontinuous & multidirectional
2. semi-continuous flow : in-process products move in a regular yet intermittent, unidirectional manner
3. continuous flow: the product moves in a constant unidirectional manner

Question 13

job shop: process criteria, ideal layouts & example

Answer 13

1. volume : low
2. variety : high
3. type of demand : made to order
4. type of flow: intermittent
5. types of layouts: fixed-position, functional, cellular
   ex: cake shop

Question 14

batch: process criteria, ideal layouts & example

Answer 14

1. volume : average
2. variety : average
3. type of demand : made to stock
4. type of flow: intermittent
5. types of layouts: functional, cellular, linear
   ex: footwear

Question 15

mass production: process criteria, ideal layout & example

Answer 15

1. volume : average
2. variety : average
3. type of demand : made to stock
4. type of flow: semi-continuous
5. types of layouts: linear
   ex: maker of electronic (TV, phones, etc.)

Question 16

continuous: process criteria, ideal layout & example

Answer 16

1. volume : high
2. variety : low
3. type of demand : made to stock
4. type of flow: continuous
5. types of layouts: linear
   ex: sugar producer

Question 17

what is the fixed-position layout?

Answer 17

> layout in which the product remains fixed, equipment & workers are brought to the site as required
constant movement of workers & equipment
products that are complex or big
complex production control that requires a good coordination

Question 18

what is a functional layout?

Answer 18

> layout where the work centres & equipment are arranges in clusters based on the operation they perform (department)
flexible system with respect to workers & equipment
multidirectional & variable flows
complex quality control & supervisor
qualified workforce (specific skills)

Question 19

what is a linear layout?

Answer 19

> layout where the work centres & equipments are set up sequentially, in the order in which the product moves through all the different operations
simple, logical, unidirectional
costly & inflexible
reduce WIP inventory
one failure can stop the whole line
repetitive jobs
(think of it as a golf course, one entry, one exit, a player has to complete every whole to be done)

Question 20

what’s a cellular layout?

Answer 20

> layout in which the work centers & equipment are arranged in several groups or cells around a team of employees
flexible
general supervision required with relatively simple control
simplification of planning & scheduling activities
autonomy & versatility of workers & emplaisis on team work
a group of workers involved in a production of a good from A to Z