Processes and Technology

BITS Pilani
Pilani Campus

06/10/2020 Production Planning Control 1

 Process Plans
• Set of documents that detail manufacturing and
service delivery specifications.
– Assembly Charts (Showing the parts and materials
needed and how they are to be assembled together)
– Operations Sheets (listing the operations to be
performed with details on equipment, tools, skills
etc.)
– Quality-control check-sheets (Specifying quality
standards and quality data to be recorded)

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Assembly Chart

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Operations or Routing Sheet for Plastic Part

Part name Crevice Tool

Part No. 52074
Usage Hand-Vac
Assembly No. 520

Oper. No. Description Dept. Machine/Tools Time

10 Pour in plastic bits 041 Injection molding 2 min
20 Insert mold 041 #076 2 min
30 Check settings 041 113, 67, 650 20 min
& start machine
40 Collect parts & lay flat 051 Plastics finishing 10 min
50 Remove & clean mold 042 Parts washer 15 min
60 Break off rough edges 051 Plastics finishing 10 min

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 Process Analysis
• Systematic study of all aspects of a process
– make it faster
– more efficient
– less costly
– more responsive

• Basic tools
– process flowcharts
– diagrams
– maps
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 Process Flowcharts
• Look at manufacture of product or delivery of
service from broad perspective.
• Processes are analyzed to reduce cost, speed time
to completion, increase customer satisfaction and
for environmental reasons (to reduce energy
consumption or increase sustainability)
• Incorporate
– nonproductive activities (inspection,
transportation, delay, storage)
– productive activities (operations) 6-6
Process Flowchart Symbols

Operation
Inspection
Transportation
Delay
Storage

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Process Flowchart of Apple Processing

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 Process
Map or
Swimlane
Chart of
Restaurant
Service

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 Process Innovation

Difference between TQM and BPR

Total redesign of a process for breakthrough improvements
Continuous
improvement refines
the breakthrough

Breakthrough
Improvement

Continuous improvement
activities peak; time to
reengineer process

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 Process Innovation

• Performance improvement will be around 50%

to 100% in a year.
• Innovation team should be encouraged to start
with a clean sheet and rethink all aspects of a
process (i.e. outputs, structure, tasks and
technology).
• The ability to learn faster, reconfigure
processes faster and execute processes faster
is a competitive advantage.

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 Process Innovation
Strategic
Directives

Baseline Data
Customer Goals for Process Benchmark
Requirements Performance
Data

High - level Innovative

Process map Ideas Design
Principles

Detailed Model
Process Map Validation Key
Performance
Measures
Pilot Study
of New Design

Goals Full Scale

No Met? Yes Implementation
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 High-Level Process Map
• It contains only essential building blocks of a
process.
• It is prepared by focusing on the performance
goal and working backward through the
desired output, sub-processes and initial
requirements.
• Design principles, such as performing sub-
processes parallel whenever possible help to
structure map efficiently.
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High-Level Process Map

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 Principles for Redesigning Processes

• Remove waste, simplify, and consolidate similar

activities.
• Link processes to create value.
• Let the swiftest and most capable enterprise
execute the process.
• Flex process for any time, any place, any way.
• Capture information digitally at the source and
propagate it through process.

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 Principles for Redesigning Processes

• Provide visibility through fresher and richer

information about process status
• Fit process with sensors and feedback loops
that can prompt action
• Add analytic capabilities to the process
• Connect, collect, and create knowledge around
process through all who touch it
• Personalize process with preferences and
habits of participants
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 Techniques for Generating
Innovative Ideas
• Vary the entry point to a problem
– in trying to untangle fishing lines, it’s best to start
from the fish, not the poles
• Draw analogies
– a previous solution to an old problem might work
• Change your perspective
– think like a customer
– bring in persons who have no knowledge of process

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 Techniques for Generating
Innovative Ideas
• Try inverse brainstorming
– what would increase cost
– what would displease the customer
• Chain forward as far as possible
– if I solve this problem, what is the next problem
• Use attribute brainstorming
– how would this process operate if. . .
• our workers were mobile and flexible
• there were no monetary constraints
• we had perfect knowledge

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 Technology Decisions
• Financial justification of technology
– Purchase cost
• Includes add-ons to make technology work
– Operating Costs
• Visualize how the technology will be used
– Annual Savings
• Better quality and efficiency save money
– Revenue Enhancement
• New technology can enhance revenue
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 Technology Decisions
• Financial justification of technology
– Replacement Analysis
• When to upgrade to new technology
depends on competitive environment
– Risk and Uncertainty
• It is risky to invest and risky to
– Piecemeal Analysis
• Make sure new and existing technology are
compatible
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Components of e-Manufacturing

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 Product Technology
• Computer-aided design (CAD)
– Creates and communicates designs electronically
• Group technology (GT)
– Classifies designs into families for easy retrieval and
modification
• Computer-aided engineering (CAE)
– Tests functionality of CAD designs electronically
• Collaborative product commerce (CPC)
– Facilitates electronic communication and exchange of
information among designers and suppliers
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 Product Technology
• Product data management (PDM)
– Keeps track of design specs and revisions for the life
of the product
• Product life cycle management (PLM)
– Integrates decisions of those involved in product
development, manufacturing, sales, customer
service, recycling, and disposal
• Product configuration
– Defines products “configured” by customers who
have selected among various options, usually from a
Web site
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 Process Technology
• Standard for exchange of product model data (STEP)
– Set standards for communication among different CAD
vendors; translates CAD data into requirements for
automated inspection and manufacture
• Computer-aided design and manufacture (CAD/CAM)
– Electronic link between automated design (CAD) and
automated manufacture (CAM)
• Computer aided process (CAPP)
– Generates process plans based on database of similar
requirements
• E-procurement
– Electronic purchasing of items from e-marketplaces,
auctions, or company websites
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 Manufacturing Technology
• Computer numerically control (CNC)
– Machines controlled by software to perform a range of
operations with the help of automated tool changers;
collects processing information and quality data
• Flexible manufacturing system (FMS)
– A collection of CNC machines connected by an automated
material handling system to produce a wide variety of parts
• Robots
– Programmable manipulators that can perform repetitive
tasks; more consistent than workers but less flexible
• Conveyors
– Fixed-path material handling; move items along a belt or
chain; “reads” package labels and diverts them to correct
destination 6-25
 Manufacturing Technology
• Automatic guided vehicle (AGV)
– Driverless trucks that move material along a specified path;
directed by wire or tape embedded in floor or by radio
frequencies
• Automated storage and retrieval system (ASRS)
– An automated warehouse; items placed in a storage system and
retrieved by fast-moving stacker cranes; controlled by computer
• Process Control
– Continuous monitoring of automated equipment; makes real-
time decisions on ongoing operation, maintenance, and quality
• Computer-integrated manufacturing (CIM)
– Automated manufacturing systems integrated through computer
technology; also called e-manufacturing
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 Information Technology
• Business – to –Business (B2B)
– E-transactions between businesses usually via the
Internet
• Business – to –Consumer (B2C)
– E-transactions between businesses and their
customers usually via the Internet
• Internet
– A global information system of computer networks
that facilitates communication and data transfer
• Intranet
– Communication networks internal to an organization;
can also be password (i.e., firewall) protected sites
on the Internet 6-27
 Information Technology
• Extranet
– Intranets connected to the Internet for shared access
with select suppliers, customers, and trading partners
• Bar Codes
– Series of vertical lines printed on packages that identify item
and other information
• Radio Frequency Identification tags (RFID)
– Integrated circuit embedded in a tag; can send and receive
information; a “twenty-first century bar code” with read/write
capabilities
• Electronic data interchange (EDI)
– Computer-to-computer exchange of business documents over
a proprietary network; very expensive and inflexible
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 Information Technology
• Extensible markup language (XML)
– A markup language that facilitates computer–to–computer
communication over the Internet by tagging data before its is sent
• Enterprise resource planning (ERP)
– Software for managing key functions of an enterprise, including sales,
marketing, finance, accounting, production, materials management &
human resources
• Supply chain management (SCM)
– Software to manage flow of goods and information among a network
of suppliers, manufacturers and distributors
• Customer relationship management (CRM)
– Software to manage interactions with customers; compiling and
analyzing customer data

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 Information Technology

• Decision support systems (DSS)

– Information system to help managers make decisions;
includes quantitative modeling components and interactive
components for what-if analysis
• Expert systems (ES)
– A computer system that uses the knowledge of experts to
diagnose or solve a problem
• Artificial intelligence (AI)
– Field of study replicating elements of human thought and
natural processes in software; includes expert systems,
genetic algorithms, neural networks, and fuzzy logic

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