Product Process Matrix free essay sample

Product Process Matrix A common classification of production process structures We often classify processes based on their physical configuration, material and product flow, flexibility, and volume expectation. There are four different process types, which a manager can choose, keeping in mind the relative importance of the following attributes:- Quality, Time, Flexibility, and Cost. These are: 1. Job process 2. Batch process 3. Line process, and 4. Continuous process Job process Machining precision parts Batch process Producing a batch of textbooks Line process Auto assembly Continuous process Oil-refining process Figure 4. 7 Processes at manufacturing organizations Job process A job process creates the flexibility needed to produce a variety of products or services in significant quantities. Customization is relatively high and volume for any one product or service is low. A job process primarily organizes all like resources around itself; equipment and workers capable of certain types of work are located together. These resources process all jobs requiring that type of work. We will write a custom essay sample on Product Process Matrix or any similar topic specifically for you Do Not WasteYour Time HIRE WRITER Only 13.90 / page This process choice creates jumbled flows hrough the operations as customization is high and most jobs have a different sequence of processing steps. A typical example would be a machine shop which makes components for the aerospace industry. Most parts on airplanes are made in relatively small quantities compared to iPods. Other types of common job shops are grinding, honing, jig-boring, and gear manufacturing shops. Batch process A batch process (disconnected flow processes) differs from the job process with respect to volume, variety, and quantity. The primary difference is that volumes are higher because the same or similar products or services are provided repeatedly. Another difference is that a narrower range of products and services is provided. Batch production is popular in bakeries and in the manufacture of text books, sports shoes, pharmaceutical ingredients, inks, paints and adhesives. In the manufacture of inks and paints, a technique called a colour-run is used. A colour-run is where one manufactures the lightest color first, such as light yellow followed by the next increasingly darker colour such as orange, then red and so on until reaching black and then starts over again. This minimizes the cleanup and reconfiguring of the machinery between each batch. White (by which is meant opaque paint, not transparent ink) is the only colour that cannot be used in a colour run due to the fact that a small amount of white pigment can adversely affect the medium colours. There are inefficiencies associated with batch production. The production equipment must be stopped, re-configured, and its output tested before the next batch can be produced. Time between batches is known as down time. There are several advantages of batch production; it can reduce initial capital outlay because a single production line can be used to produce several products. As shown in the example, batch production can be useful for small businesses who cannot afford to run continuous production lines Line process A line process (repetitive or discrete flow process) lies between the batch and continuous processes on the continuum; volumes are high, and products or services are standardized, which allows resources to be organized around a product or service. There are line flows, with little inventory held between perations. Each operation performs the same process over and over, with little variability in the products or services provided. The example for this process is the famous Ford Assembly Line. Continuous process A continuous process is the extreme end of high-volume, standardized production with rigid line flows. Its name derives from the way materials move through the process. Usually, the primary material, such as liquid, gas, or powder, moves without stopping through the facility. The processes seem more like separate entities than a series of connected operations. The process is often capital-intensive and operated round the clock to maximize utilization and to avoid expensive shutdowns and start-ups. This process is followed in most of the float glass industry, where glass of different thickness is processed in a continuous manner. Once the molten glass flows out of the furnace, machines work on the glass from both side, and either compress or expand it. Controlling the speed of rotation of those machines and varying them in numbers produces a glass ribbon of varying width and thickness. Continuous production presents possibilities for enhancing automation. By employing Programmable logic controllers (PLCs) and other automated controls, we can reduce chances of error (thereby delays and downtime) due to human intervention. This is due to the fact that most of the jobs are routine enough and can be easily automated. So there is a lot of scope for conveyors, elevators, feeders, etc. for transporting raw materials, in process materials etc. in continuous process industries. The most important difference between batch production and continuous production is that any changes in the products properties such as color, dimensions, or quality needs to be done online. And whenever it is affected, the results can be seen only after a fixed period which can extend from a few hours to days. Machinery maintenance in case of continuous process plants calls for online maintenance which requires very high alertness and quick response times from dedicated technicians. Process Analysis: Milk Processing Example System Performance= f (System Parameters)