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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
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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.
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Concern with the design of the actual process to be used in the manufacture of the product
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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
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Shows sequence in which components are assembled How and when the subassemblies are put together to make the final product.
Product
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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)
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EXERCISE 2
ITEM COMPONENTS
Stapler
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
Number and name of all the parts The source of each part (purchase or manufacture) Number and name of the completed product
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Process Selection
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Product design and quality level. Demand patterns and flexibility needed. Quantity/capacity considerations. Customer involvement. Make or buy decision
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PRODUCT DESIGN
what to produce?
CUSTOMER
PROCESS DESIGN
how to produce?
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CAPACITY
How much to produce?
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.
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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.
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Machining
Joining
Finishing
Cutting
Abrasive
Advanced
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Expendable mould
Permanent mould
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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
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Joining
Welding Adhesive Bonding Mechanical fastening Fastening Seaming Crimping Sttching
Fusion
Solid state
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Process Selection
Process types: Job shop Batch Mass production Continuous production Project
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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)
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
Examples
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DISCUSSION 1
What kind of process is used for making each of the following products?
1. 2. 3. 4. 5. 6.
Cost evaluation
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Cost evaluation
Fixed costs
Not vary with the volume produced Eg: purchase costs of machinery and tools, setup costs.
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Cost evaluation
Variable costs
Costs that vary with the quantity produced. Eg: direct labour, direct material.
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Total cost = Fixed cost + (Variable cost per unit)(number of units produced) Then, TC = FC + VCx unit cost = Total cost number of units produced
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= 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.
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RM2000 Variable unit cost 3 Total cost 2000 + 3x Unit (average cost) 2000 + 3x x
Fixed cost
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16 000
50 000
36 000
3.13
2.25
Cost
(RM1000)
Method A
Method B
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Low
Low
Very high
Fixed costs
High
Very high
Varied
Low
Very low
High
Promote capabilities
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Operations that will be used to transform the material into its desired final shape.
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Minimization of part handling (shortest path from machine to machine) Assuring that no succeeding operation adversely affects previous operations
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Process documentation
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Schematic of a process
ENVIRONMENT
Internal
External INPUT (Suppliers)
OUTPUT (Customers)
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.
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Process chart
Flow charts
Tasks or operations
Decision points
Figure 4.3
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Figure 4.16
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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
Step description
1 2 3 4 5
6 7 8 9 10 11 12 13 14 15 16 17 18 19
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.
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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.
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Delay
Storage
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