m2 Process Engineering

INDUSTRIAL ENGINEERING JTM 3023
Lecturer Mohd Norhasni Mohd Asaad KOLEJ PERNIAGAAN ROOM FPT : 3050 TEL: 4974 H/P: 019-5478634 Email: mnorhasni@uum.edu.my
PROCESS ENGINEERING
JTM3023-M2-Mohd Norhasni
LECTURE SCOPE

What is Process Engineering? Process Engineering 6 step sequence.
What is Process Engineering?
Process engineering is also called: manufacturing planning, production engineering, process planning, material processing and machine routing.
Responsible of developing a plan for the manufacture of the new or modified product.
What is Process Engineering?
Concern with the design of the actual process to be used in the manufacture of the product
Process Engineering 6 step sequence
Defining the product structure and specification Assessing each components manufacturability Process selection Cost evaluation Determining the sequence in which the operation are to be performed Documenting the process
Defining the product structure and specification
1. Defining the product structure and specification

Product structure are often shown in a hierarchical chart that shows all of the subassemblies, sub-subassemblies, components and raw materials that comprise the product.
1. Defining the product structure and specification

Product structure
Shows sequence in which components are assembled How and when the subassemblies are put together to make the final product.
Product
EXERCISE 1
Given the following diagram for a product, determine the quantity of each component required to assemble one unit of the finished product.
F (2)
J (2)
L (2)
A (4)
D (4)
J (2)
D (2)
EXERCISE 2
ITEM COMPONENTS
Draw a tree diagram for the stapler:
Stapler
Top assembly, base assembly
Top assembly Cover, spring, slide assembly Cover spring Slide assembly Slide, spring
Slide Spring
Base assembly Base, strike plate, rubber Base pad (2) Strike plate Rubber pad (2) JTM3023-M2-Mohd Norhasni
Defining the product structure and specification
Bills of Materials (BOM)
List of all components needed to produce the product Contains:

Number and name of all the parts The source of each part (purchase or manufacture) Number and name of the completed product
Example of bill of materials

Assessing each components manufacturability
2. Assessing each components manufacturability

Manufacturability:
A measure of the relative ease or difficulty of producing the item within tolerance
The tighter the tolerances, in general, the more expensive the item will be to produce.
Process Selection
A process is a method of doing something, generally involving a number of steps or operations.

Process design is the developing and designing of the steps.
Factors influencing process design
Product design and quality level. Demand patterns and flexibility needed. Quantity/capacity considerations. Customer involvement. Make or buy decision
PRODUCT DESIGN
what to produce?
CUSTOMER
PROCESS DESIGN
how to produce?
CAPACITY
How much to produce?
Make or buy decision
Reasons to make in-house

Can produce for less cost than a supplier To utilise existing equipment to the fullest extend To keep confidential processes within control of the firm. To maintain quality. To maintain workforce.
Reasons to buy out

Requires less capital investment. Uses specialised expertise of suppliers. Allows the firm to concentrate on its own area of specialisation. Provides known and competitive prices.

Cost Capacity Quality Speed Expertise
Manufacturing processes Casting

Expendable mould Permanent mould
Forming & shaping
Machining
Joining
Finishing
Bulk metal forming Sheet metal forming
Cutting
Welding Adhesive bonding Mechanical fastening
Abrasive
Burnishing Hardening Deposition Implantation Coatings Cleaning
Advanced
Metal casting Bulk metal forming
Forming & shaping Sheet metal forming
Expendable mould
Permanent mould
Sand Shell Expandable pattern Plaster Ceramic Investment
Slush Pressure Die Centrifugal Squeeze semisolid
Rolling Forging Extrusion Drawing Powder metallurgy
Punching Blanking Stamping Bending Deep drawing Spinning Stretch forming
Machining Cutting Circular shapes Turning Boring Drilling Various shape Milling Planing Shaping Broaching Sawing Gear forming Ultrasonic machining Abrasive Grinding Honing Coated abrasive Advanced
Lapping
Polishing Buffing
Joining
Welding Adhesive Bonding Mechanical fastening Fastening Seaming Crimping Sttching
Fusion
Solid state
Brazing & soldering
Oxyfuel gas Thermit Arc Resistence Electron beam Laser beam
Resistance Diffusion Explosion Cold Friction ultrasonic
Process Selection
Process types: Job shop Batch Mass production Continuous production Project
Low
Project
(customer job shop; customer tailoring; construction)
Intermittent operations
Batch process
(education classes; bakery; printing shop)
Line process
(assembly lines; cafeteria)
Repetitive operations
Continuous process
(oil refinery; water treatment plant)
High High Low

BATCH Types of product Type of customer Product demand Demand volume No. of different products Production system Equipment Worker skills Advantages Made-to-order (customised) Few individual customers Fluctuates Low to medium Many, varied Discrete, job shop General-purpose Wide range of skills Flexibility, quality
MASS Made-to-stock (standardised) Mass market Stable High Few Repetitive, assembly line Special purpose Limited range of skills Efficiency, speed, low cost Capital investment, lack of responsiveness Automobiles, televisions, fast food
CONTINUOUS Commodity Mass market Very stable Very high Very few Continuous, process industries Highly automated Equipment monitors Highly efficient, large capacity, ease of control Difficult to change, far-reach error, limited variety Steel, paper, sugar, supplying electricity to homes and businesses
PROJECT Unique One-at-a-time Infrequent Very low Infinite variety Long-term project Varied Experts, craftspersons Custom work, latest technology Non-repetitive, small customer base Construction, shipbuilding
Disadvantages
Costly, slow, difficult to manage Machine shop, bakeries, education
Examples
DISCUSSION 1
What kind of process is used for making each of the following products?
1. 2. 3. 4. 5. 6.
Soft drinks Wedding invitations Automobiles Paper Custom homes Motorcycles

Cost evaluation
4. Evaluating the cost of each process

A new model was designed
Design drawing and part documentation
Established production process
Calculate labour and overhead cost for each planned operation
Sum the cost of individual operations

Cost evaluation
Fixed costs

Not vary with the volume produced Eg: purchase costs of machinery and tools, setup costs.
Cost evaluation
Variable costs
Costs that vary with the quantity produced. Eg: direct labour, direct material.
Total cost = Fixed cost + (Variable cost per unit)(number of units produced) Then, TC = FC + VCx unit cost = Total cost number of units produced
= TC x
Example
A process designer has a choice of two methods for making an item. Method A has a fixed cost of RM2000 for tooling and jigs and a variable costs of RM3 per unit. Method B requires a special machine costing RM20 000 and the variable costs are RM1 per unit.
RM2000 Variable unit cost 3 Total cost 2000 + 3x Unit (average cost) 2000 + 3x x
Fixed cost
RM20 000 1 20 000 + 1x 20 000 + 1x x
Volume (units) 2000 4000 6000 8000 10 000 12 000 14 000
Total cost (RM

Method A Method B
Unit cost (RM)

Method A Method B
8000 14 000 20 000 26 000 32 000 38 000 44 000
22 000 24 000 26 000 28 000 30 000 32 000 34 000

4.00 3.50 3.33 3.25 3.20 3.17 3.14
11.00 6.00 4.33 3.50 3.00 2.97 2.43
16 000
50 000
36 000
3.13
2.25
Cost
(RM1000)
Method A
Method B
Cost equalisation point
Volume (1000 units)
Evaluating the cost of each process

Activity/ Function
Cost estimation Cost per unit Batch Mass Continuous Project Difficult to routine High to moderate Low to moderate High to moderate Promote capabilities, semi-standard goods and services Routine Routine Complex
Low
Low
Very high
Fixed costs
High
Very high
Varied
Variable costs Marketing
Low
Very low
High
Promote standardised goods and services
Promote standardised goods and services
Promote capabilities
Determining the sequence of operations
5. Determining the sequence of operations
Operations that will be used to transform the material into its desired final shape.
The sequence usually developed based on:
Minimization of part handling (shortest path from machine to machine) Assuring that no succeeding operation adversely affects previous operations
Process documentation
Schematic of a process
ENVIRONMENT
Internal
External INPUT (Suppliers)
PROCESS (work steps)
OUTPUT (Customers)
COMPONENTS People Methods Equipment

Documenting the process
Flow chart
A diagram that traces the flow of information, customers, equipment, or materials through the various steps of a process. An organized way of documenting all of the activities performed by a person, by a machine, at a workstation, with a customer or on materials.
Process chart
Flow charts
Tasks or operations
Storage areas or queues
Decision points
Flow of material/ customers

Flowchart of the Sales Process for a Consulting Company
Figure 4.3
Flowchart of Telephone Ordering Process
Figure 4.16
Process Charts
Process: Subject: Beginning: Ending: Emergency room admission Ankle injury patient Enter emergency room Leave hospital
Insert Step Append Step Remove Step
Step no. Time (min) Distance (ft)
Summary
Activity
Operation Transport Inspect Delay Store
Number of steps 5 9 2 3
Time (min) 23 11 8 8
Distance (ft) 815
Step description
1 2 3 4 5
6 7 8 9 10 11 12 13 14 15 16 17 18 19
0.50 10.0 0.75 3.00 0.75

1.00 1.00 4.00 5.00 2.00 3.00 2.00 3.00 2.00 1.00 4.00 2.00 4.00 1.00
15 40 40
60 200 200 60 180 20
X
X X X X X X X X
Enter emergency room, approach patient window Sit down and fill out patient history Nurse escorts patient to ER triage room Nurse inspects injury Return to waiting room
Wait for available bed Go to ER bed Wait for doctor Doctor inspects injury and questions patient Nurse takes patient to radiology Technician x-rays patient Return to bed in ER Wait for doctor to return Doctor provides diagnosis and advice Return to emergency entrance area
X
X X X X X X X X
Figure 4.8
Check out Walk to pharmacy Pick up prescription X JTM3023-M2-Mohd LeaveNorhasni the building
Process chart
Operation
Changes, created or adds something. Moves the studys subject from one place to another Can be a person, a material, a tool or a piece of equipment.
Transportation
Process chart
Inspection
Checks or verifies something but does not change it. Occurs when the subject is held up awaiting further action. Occurs when something is put away until a later time.
Delay
Storage
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INDUSTRIAL ENGINEERING JTM 3023

What is Process Engineering? Process Engineering 6 step sequence.

What is Process Engineering?

What is Process Engineering?

Process Engineering 6 step sequence

Defining the product structure and specification

1. Defining the product structure and specification

1. Defining the product structure and specification

Draw a tree diagram for the stapler:

Top assembly, base assembly

Defining the product structure and specification

Bills of Materials (BOM)

List of all components needed to produce the product Contains:

Example of bill of materials

Assessing each components manufacturability

2. Assessing each components manufacturability

A process is a method of doing something, generally involving a number of steps or operations.

Factors influencing process design

Make or buy decision

Reasons to make in-house

Make or buy decision

Reasons to buy out

Make or buy decision

Cost Capacity Quality Speed Expertise

Manufacturing processes Casting

Forming & shaping

Bulk metal forming Sheet metal forming

Welding Adhesive bonding Mechanical fastening

Burnishing Hardening Deposition Implantation Coatings Cleaning

Metal casting Bulk metal forming

Forming & shaping Sheet metal forming

Sand Shell Expandable pattern Plaster Ceramic Investment

Slush Pressure Die Centrifugal Squeeze semisolid

Rolling Forging Extrusion Drawing Powder metallurgy

Punching Blanking Stamping Bending Deep drawing Spinning Stretch forming

Brazing & soldering

Oxyfuel gas Thermit Arc Resistence Electron beam Laser beam

Resistance Diffusion Explosion Cold Friction ultrasonic

High High Low

Costly, slow, difficult to manage Machine shop, bakeries, education

Soft drinks Wedding invitations Automobiles Paper Custom homes Motorcycles

4. Evaluating the cost of each process

Design drawing and part documentation

Established production process

Calculate labour and overhead cost for each planned operation

Sum the cost of individual operations

RM20 000 1 20 000 + 1x 20 000 + 1x x

Volume (units) 2000 4000 6000 8000 10 000 12 000 14 000

Total cost (RM

Unit cost (RM)

8000 14 000 20 000 26 000 32 000 38 000 44 000

22 000 24 000 26 000 28 000 30 000 32 000 34 000

4.00 3.50 3.33 3.25 3.20 3.17 3.14

11.00 6.00 4.33 3.50 3.00 2.97 2.43

Cost equalisation point

Volume (1000 units)

Evaluating the cost of each process

Variable costs Marketing

Promote standardised goods and services

Promote standardised goods and services

Determining the sequence of operations

5. Determining the sequence of operations

The sequence usually developed based on: