MDP4330

Production Systems Design

Lecture #2
Process Design
 Today’s lecture
• Process design tools & Production charts
• Process/Technology selection
• Machine Selection

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 Process design
• Process design determines the specific
equipment types required to produce the
product.
• It also involves the determination of
manufacturing/assembly sequence as
required by the product design.
• There are some tools that are quite helpful
and handy in that process.

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 Product Drawing
• Any facilities planning project starts with
engineering drawings for the part to be
produced.
• Product drawings include other specifications
for the material used, standard parts and
fits/tolerances.

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Teakettle example

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Teakettle example

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Airflow regulator example

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 Product assembly
• Product assembly is represented by a list of
parts and components that constitute the
product.
• They are represented by:
– Product structure tree
– Bill of Material (BOM)

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Product Structure Tree

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Bill of Materials

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 Production Charts
• Production charts are standardized way of
representing the sequence and steps of
manufacturing/assembly processes.
• They are drawn using symbols standardized by
the American Society of Mechanical Engineers
(ASME) in 1947.

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 Production Charts
• Production charts can be used in:
– Designing the production system
– Analyzing an existing production system to guide
improvement decisions.
• They include:
– Assembly chart
– operation process chart
– Precedence chart

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Standard symbols used in production charts

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Teakettle assembly chart

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Teakettle operation process chart

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Assembly
Chart for
airflow
regulator

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Operation Process Chart

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Precedence Chart

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 Time estimates
• Methods of estimating operation time:
– Standard machine formulas obtained from any
handbook on manufacturing.
– Experience and historical records
– Mechanics of the process in case of automated
systems
– Time study for manual operations

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Sample of time estimation of a manual
operation

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 Routing sheet
• The next step in planning is to draw a routing
sheet (sometimes called route sheet or
production routing).
• It shows how a part is to be produced, which
machines are needed, the tools to use,
estimated setup times for the machines, and
production in terms of the number of units
expected per hour from each machine.

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Routing sheet example

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Routing sheet example

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What are routing sheets used for?
Determining the number and types of machines
to be purchased to produce certain output rates,
the number and skill of the employees needed,
the production system to use, and indeed how
the entire plant should be laid out. Routing
sheets and the bill of materials form the major
database for current and future facilities
planning.

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 Other charts
• Left-Hand, Right-Hand Chart
• Gang Chart
• Gantt Chart
• Flow Process Chart

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Left-hand, Right-hand Chart

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Gang Chart

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Gantt Chart

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Flow process chart

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 Process Requirements
• Specification of process requirements typically
occurs in three phases:
– Determining the quantity of components that
must be produced, including scrap allowance, in
order to meet the market estimate.
– Determining the equipment requirements for each
operation.
– Combining operations requirements to obtain
overall equipment requirements.

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 Process/Technology selection
• The selected technology must be able to support the quality
standards set by the corporate / manufacturing strategy
• This decision must take into consideration future expansion
plans of the company in terms of
– production capacity (i.e., support volume flexibility)
– product portfolio (i.e., support product flexibility)
• It must also consider the overall technological trends in the
industry, as well as additional issues (e.g., environmental
and other legal concerns, operational safety etc.) that might
affect the viability of certain choices
• For the candidates satisfying the above concerns, the final
objective is the minimization of the total (i.e., deployment
plus operational) cost

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 Types of manufacturing processes
• Change material shape
• Machining part to a fixed dimension
• Obtain surface finish
• Join parts
• Change physical properties
• Plastic processing

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Material shape change

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Traditional Machining

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Non-Traditional Machining

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Surface finishing

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Joining

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 Plastic Process (molding)
• Compression molding
• Injection molding
• Rotary molding
• Blow molding
• Extrusion
• Thermoforming

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 Machine Selection
• To select machines, we need to know:
– Types of machines available for the required
manufacturing operations.
– Names of machine tool suppliers/sellers
– Range of costs
– Machine throughput and other technical data.
• Where can we obtain this information?
• How can we use it?

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 Online Equipment Sellers
• WWW is full of technical data provided by
equipment manufacturers.
• www.machinetools.com
• www.Alibaba.com
• www.haco.com/en
• …

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