AND PROCESS DESIGN
Product Design
Product Design can be defined as the idea generation, concept development,can be defined as the idea generation, concept development, testing and manufacturing or implem
testing and manufacturing or implementation of a physical object or service.entation of a physical object or service.
The development of a new product passes through
The development of a new product passes through seven distinct stages asseven distinct stages as shown in the figure below:
shown in the figure below:
N
Neeeedds s IIddeennttiiffiiccaattiioonn AAddvvaanncce e PPrroodduucct t PPllaannnniinngg Advance Design Advance Design
Detailed Engineering Design Detailed Engineering Design
Product Process Product Process
Design and Design and Development Development
Product Evaluation Product Evaluation And Improvement And Improvement
Product use and Product use and
support support
OPERATIONS MANAGEMENT-PRODUCT OPERATIONS MANAGEMENT-PRODUCT
AND PROCESS DESIGN AND PROCESS DESIGN
Process Design
Process Design is concerned with the overall sequences of operationsis concerned with the overall sequences of operations required to achieve the product specifi
required to achieve the product specification. It specifies the type of workcation. It specifies the type of work stations that are to be used, the m
stations that are to be used, the machines and equipments necessary and theachines and equipments necessary and the quantities in which each is required.
quantities in which each is required.
The sequences of operations in the manuf
The sequences of operations in the manufacturing process is determined byacturing process is determined by
The nature of product
The nature of product
The materials used.
The materials used.
The quantities being produced and
The quantities being produced and
The existing physical layout of the plant.
The existing physical layout of the plant.
Major Factors affecting Process Design Dec
Major Factors affecting Process Design Decisionsisions
Nature of product/service demand.
Nature of product/service demand.
Degree of vertical integration.
Degree of vertical integration.
Product/service and volum
Product/service and volume flexibilitye flexibility..
Degree of automation.
Degree of automation.
Level of product/service quality
Level of product/service quality
32 32
OPERATIONS MANAGEMENT-PRODUCT OPERATIONS MANAGEMENT-PRODUCT
AND PROCESS DESIGN AND PROCESS DESIGN
Interrelationship of Product and Process Design Interrelationship of Product and Process Design
Product Ideas Product Ideas
Feasibility Studies Feasibility Studies
Product Design
Product Design Process DesignProcess Design
Advance Product PlanningAdvance Product Planning
Advance DesignAdvance Design
Product Process Design andProduct Process Design and Development
Development
Product Evaluation and Product Evaluation and ImprovemImprovementent
Product Use and SupportProduct Use and Support
Organizing the process flowsOrganizing the process flows
Relation of Process Design toRelation of Process Design to Process Flow
Process Flow
Evaluating the Process DesignEvaluating the Process Design
Produce and Market New Products Produce and Market New Products
Continuous interaction Continuous interaction
OPERATIONS MANAGEMENT-PRODUCT OPERATIONS MANAGEMENT-PRODUCT
AND PROCESS DESIGN AND PROCESS DESIGN
Machines A
Machines A and B are both capable of and B are both capable of manufacturing a product. Theymanufacturing a product. They compare as follows:
compare as follows:
D
Daattaa MMaacchhiinne e AA MMaacchhiinne e BB IInnvveessttmmeenntt RRss5500000000 RRss8800000000 IInntteerreesst t oon n CCaappiittaall 1155% % ppeer r aannnnuumm 1155% % ppeer r aannnnuumm
H
HoouurrllyyWWaaggeess RRss1100 RRss88 No of pieces produced
No of pieces produced per hour
per hour
5
5 88
A
Annnnuuaal l ooppeerraattiinng g hhoouurrss 22000000 22000000
Which machine will have the lowest cost per unit of output ,if run for the wholeWhich machine will have the lowest cost per unit of output ,if run for the whole year?
year?
If only 4000 pieces are to be produced in a year, which machine would have theIf only 4000 pieces are to be produced in a year, which machine would have the lowest cost per piece?
lowest cost per piece?
Will your answer to above vary if you are informed that 12.5% of the output of Will your answer to above vary if you are informed that 12.5% of the output of machine B gets rejected at the inspection stage. If so, w
machine B gets rejected at the inspection stage. If so, w hat would be the newhat would be the new solution.
solution.
34 34
OPERATIONS MANAGEMENT-PRODUCT OPERATIONS MANAGEMENT-PRODUCT
AND PROCESS DESIGN AND PROCESS DESIGN
Methods P and Q are both capable of manufacturing a product.They compare as follows Methods P and Q are both capable of manufacturing a product.They compare as follows::
D
Daattaa MMeetthhoodd PP MeMetthhooddQQ F
Fiixxttuurree--ccoosstt RRs s 2244000000 RRs s 1166000000 --lliiffee 66mmoonntthhss 44mmoonntthhss T
Toooolliinngg--ccoosstt RRs s 22556600 RRs s 44880000 -- lliiffee 33000 0 ppiieecceess 55880 0 ppiieecceess P
Prreessssiinng g ttiimme e ppeer r ppiieeccee 66mmiinnuutteess 44mmiinnuutteess
The annual requirem
The annual requirement is ent is 1500 nos. Op1500 nos. Operating cost per hour is Rs 12erating cost per hour is Rs 128 for both the8 for both the processes. Material cost is the same in each case.
processes. Material cost is the same in each case.
Which method would you choose for production during period of one year?
Which method would you choose for production during period of one year?
OPERATIONS MANAGEMENT-PRODUCT OPERATIONS MANAGEMENT-PRODUCT
AND PROCESS DESIGN AND PROCESS DESIGN
Production manager of a unit wants to
Production manager of a unit wants to know for what quantity heknow for what quantity he can use automatic machine as against semi-automatic machine.
can use automatic machine as against semi-automatic machine.