1.

Identify the 5 basic processing types, give example for each and describe the
process.

a. Job-shop: The area may assemble only one version of a product, a dozen versions, or
even a couple dozen. Job-shop involves intermittent processing, high flexibility, skilled
workers, relatively large work-in-process inventories and general-purpose machinery.

Example: a tool and die shop that is able to produce a wide variety of tools.

b. Batch: Batch processing is used when a moderate volume of goods and services is
demanded. It is designed to handle a moderate variety in products. The processing is
intermittent. The flexibility of the process to produce a variety of goods, the skill of the
workers, amount of work-in-process inventories are all less than job shop.

Example: paint manufacturing.

c. Repetitive: have been defined as those involving the processing of a material or work

piece by a sequence of passes of the processing tool. The flexibility of the process to
produce a variety of goods, the skill of the workers, amount of work-in-process
inventories are all less than batch process.

Example: Fast-food firms 

d. Continuous: is a process in which the product comes out without interruption and not
in groups. The paperboard product, once formed, can be collected on a roll in
a continuous process and passed on for further processing. These systems have no
flexibility in output or equipment. Workers are generally low skilled and there is no
work-in-process inventory. The machines are dedicated to perform specified tasks.

Examples: process to make steel, salt, sugar, and flour.

e. Project: is a process to assess each project idea and select the project with the

highest priority. Projects are still just suggestions at this stage, so the selection is often
made based on only brief descriptions of the project. These activities are generally not
repeated.

Examples: construction of a dam or a bridge, conversion of the production system from

job-shop to group technology, installing and implementing a new inventory and bar
coding system.
2. Identify and discuss the three types of automation. Discuss the advantages of
automation.

 Fixed automation - also known as “hard automation,” refers to an automated

production facility in which the sequence of processing operations is fixed by the
equipment configuration. In effect, the programmed commands are contained in
the machines in the form of cams, gears, wiring, and other hardware that is not
easily changed over from one product style to another.
 Programmable automation - is a form of automation for producing products in
batches. The products are made in batch quantities ranging from several dozen
to several thousand units at a time. For each new batch, the production
equipment must be reprogrammed and changed over to accommodate the new
product style.
 Flexible automation - is when the variety of products is sufficiently limited so
that the changeover of the equipment can be done very quickly and
automatically. The reprogramming of the equipment in flexible automation is
done off-line; that is, the programming is accomplished at a computer terminal
without using the production equipment itself. 
Advantages of Automation.

The main advantages of automation are:

 Increased throughput or productivity.
 Improved quality or increased predictability of quality.
 Improved robustness (consistency), of processes or product.
 Increased consistency of output.
 Reduced direct human labor costs and expenses.
 Installation in operations reduces cycle time.
 Can complete tasks where a high degree of accuracy is required.
 Replaces human operators in tasks that involve hard physical or monotonous
work (e.g., using one forklift with a single driver instead of a team of multiple
workers to lift a heavy object)[49]
 Reduces some occupational injuries (e.g., fewer strained backs from lifting heavy
objects)
 Replaces humans in tasks done in dangerous environments (i.e. fire, space,
volcanoes, nuclear facilities, underwater, etc.)
 Performs tasks that are beyond human capabilities of size, weight, speed,
endurance, etc.
 Reduces operation time and work handling time significantly.
 Frees up workers to take on other roles.
 Provides higher level jobs in the development, deployment, maintenance and
running of the automated processes.
3. Describe the three basic layout types. Give example for each and discuss.

 Product layout - allows for the repetitive assembly of highly standardized products,

resources are arranged sequentially, based on the routing of the products. In theory,
this sequential layout allows the entire process to be laid out in a straight line, which at
times may be totally dedicated to the production of only one product or product
version. The flow of the line can then be subdivided so that labor and equipment are
utilized smoothly throughout the operation.

Examples: Turning Operations then Milling Machines then Drilling Machines then
Assembly then Inspection then Package Dispatch

For a garment manufacturer, stations for sewing cloth, sewing on buttons, inspecting
seams, wrapping finished garments and boxing them up would all be located within
close proximity for an individual clothing item, allowing individual garments to pass
from one station to another quickly

 Process layout -  is a design for the floor plan of a plant which aims to improve efficiency
by arranging equipment according to its function. The production line should ideally be
designed to eliminate waste in material flows, inventory handling and management.

Examples: drill department, paint department and sewing stations.

 Fixed-position layout -  is where the product stays stationary while workers come to the
product site to build it. Fixed-position layouts are ideal for products that are large,
heavy, or too fragile to move.

Examples: buildings, dams, and electric or nuclear power plants, shipbuilding, aircraft,
aerospace, farming, drilling for oil, home repair, and automated car washes