Process Strategies
Summary
TLDRThe video script explores various manufacturing processes, highlighting how companies like BP and Honda select processes based on product variety and volume demand. It discusses continuous processes for standardized products, assembly lines for mass production, batch processing for lower volume products, and job shops for highly customized items. The goal is to balance efficiency and flexibility for high-quality, cost-effective production.
Takeaways
- 😀 Manufacturing processes are chosen based on product variety and volume of demand.
- 🔍 Gasoline is a standardized product with little variety, suitable for continuous production processes.
- 👓 Eyeglasses are custom-made, requiring a job shop process with high flexibility and individual customization.
- 🏭 BP refines crude oil into various products using continuous processes, operating 24/7 to meet constant demand.
- 🚗 Honda uses an assembly line (mass production) for making cars, allowing some customization within a repetitive process.
- 🏗️ Caterpillar employs batch processing for producing a variety of construction and agricultural equipment in lower volumes.
- 🛠️ The product process matrix helps manufacturers find the most efficient production methods based on variety and volume.
- 🌐 Continuous processes are highly automated and require specialized equipment, making them ideal for high-volume, standardized products.
- 🏗️ Batch processing allows for flexibility in equipment and production, suitable for lower-volume, varied products.
- 👨🏫 Skilled workers using general-purpose tools are crucial in job shops, where each product is unique and requires customization.
- 🔄 Hybrid manufacturing processes are becoming common, combining elements of continuous, batch, and job shop methods to meet diverse product needs.
Q & A
What are the two main considerations for selecting a manufacturing process?
-The two main considerations for selecting a manufacturing process are the variety of the product and the volume of demand. Variety refers to how much the product changes from customer to customer, while volume refers to the amount of product needed by consumers.
Why is gasoline considered a standardized product?
-Gasoline is considered a standardized product because, although there may be a small variety between different blends, the product remains consistent within each blend.
What is the significance of the product process matrix?
-The product process matrix is a graphical representation that helps in determining the most efficient production or manufacturing processes. It uses variety and volume as the vertical and horizontal axes, respectively, and the most efficient processes are found along the diagonal points on the graph.
Why is a continuous process the best manufacturing choice for a very standardized product needed in large volumes?
-A continuous process is the best manufacturing choice for a very standardized product needed in large volumes because it uses highly specialized equipment with very little flexibility and is almost completely automated, ensuring cost-effectiveness and high output.
How does BP's refinery process impact its profitability and cost-effectiveness?
-BP's refineries operate 24/7 to maintain cost-effectiveness and match output to demand. Stopping production for just a few days can undermine a plant's profitability for an entire year due to the large capacity and high cost of shutdown.
What is the role of chemical engineers in the refining process at BP's refineries?
-Chemical engineers determine the mix of products added during the conversion and treatment stages of the refining process. They also monitor elements such as the water used in the refinery to ensure it's safe to return to the environment.
How does Honda of America's assembly line process differ from a continuous process?
-Honda's assembly line process, also known as mass production, involves a connected workflow where the product moves along a conveyor system past a series of workstations. Unlike a continuous process, workers interact with tools more and much of the work such as welding is performed through automation.
What is the advantage of using batch processing in manufacturing?
-Batch processing allows for the creation of products in small lots or batches, which is suitable for manufacturing a variety of products at relatively low volume with flexible equipment. It is ideal for situations where a high degree of customization is required.
How does the job shop process differ from other manufacturing processes?
-The job shop process is characterized by creating highly specialized products in very low volumes based on individual customer orders. It involves using general-purpose tools in a variety of ways, with a focus on customization and flexibility.
What are the challenges faced by manufacturers in achieving mass customization?
-Achieving mass customization involves creating high-quality products with the efficiency of a continuous process while building in as much flexibility as possible to allow for more customization. Manufacturers must understand the dynamics of the product process matrix to balance these requirements.
Why is flexibility important in manufacturing processes?
-Flexibility in manufacturing processes allows manufacturers to adapt to varying product requirements and customer demands. It enables the production of a variety of products, customization, and the ability to respond quickly to changes in the market.
Outlines
🛠️ Selecting the Right Manufacturing Process
Consumers purchase a wide variety of products, from standardized commodities like gasoline to custom-made items like eyeglasses. Companies must choose a manufacturing process that best matches the product based on two main considerations: variety and volume. Gasoline, a standardized product, is continuously produced in large volumes, while eyeglasses are custom-made to order. The flexibility of the equipment used is also important. The product process matrix shows the relationship between variety and volume, indicating the most efficient manufacturing processes. Continuous processes are ideal for standardized products in large volumes, exemplified by BP's gasoline production, which operates 24/7 and refines crude oil into various consumer products.
🚗 Mass Production and Assembly Lines
Manufacturers often use assembly lines to produce large volumes of consumer goods with some customization. Honda's Marysville, Ohio plant exemplifies this, producing about 20,000 Civic cars monthly. The assembly line process involves a connected workflow where the product moves along a conveyor, with parts added at each station. Workers are trained in multiple tasks to avoid fatigue and maintain quality. The process includes some flexibility for different model options. Honda aims to further enhance flexibility, while Caterpillar's Aurora, Illinois plant already produces multiple models in smaller volumes using batch processing, which involves a disconnected workflow and flexible equipment.
👓 Job Shops for Custom Products
Highly specialized, low-volume products like eyeglasses are produced using job shops. Each pair of glasses is custom-made, with steps such as selecting the correct lens strength, cutting lenses to fit frames, and adjusting frames to fit the customer's head. The process involves flexible, general-purpose tools and skilled workers. This customization requires equipment that can adapt to each new task. While job shops focus on producing unique items, some products, like eyeglasses, involve multiple processes. The product process matrix helps manufacturers balance efficiency and customization, striving for mass customization where high-quality, flexible production meets market demands.
Mindmap
Keywords
💡Manufacturing Process
💡Variety
💡Volume of Demand
💡Product Process Matrix
💡Continuous Process
💡Assembly Line
💡Batch Processing
💡Job Shop
💡Mass Customization
💡Hybrid Processes
💡Centralized Control Room
Highlights
The importance of selecting a manufacturing process that matches the product for efficiency and cost-effectiveness.
Two main considerations for process selection: product variety and volume of demand.
Gasoline as an example of a standardized product with consistent demand.
Eyeglasses as an example of a custom-made product with high variety.
The concept of the product process matrix with variety and volume as axes.
Continuous process as the best manufacturing choice for standardized products in large volumes.
BP's refineries as an example of continuous production for gasoline.
The cost implications of shutting down large-scale continuous production plants.
The role of chemical engineers in determining product mix during conversion and treatment stages.
Mass production or assembly line process for consumer goods with some customization.
Honda's use of a repetitive process in their car manufacturing plant.
The benefits of worker rotation in assembly lines to maintain quality and avoid fatigue.
Batch processing for low-volume, high-variety products like Caterpillar's machinery.
Job shop process for creating highly specialized, low-volume products like eyeglasses.
The use of general-purpose tools in job shops for custom-made products.
The challenges of fitting products neatly into one process and the rise of hybrid processes.
The goal of manufacturers to combine efficiency with flexibility for mass customization.
Understanding the dynamics of the product process matrix for effective manufacturing strategies.
Transcripts
everyday consumers around the world
purchase a variety of products these
Goods range from standardized
commodities such as gasoline and motor
oil all the way to items which are made
to order like eyeglasses and many
services in order to create a high
quality product while being efficient
and cost effective any company must
select a manufacturing process that best
matches the product as a rule the
product being created determines the
appropriate process process selection is
based on two considerations the first
consideration is variety or how much the
product changes from customer to
customer gasoline is a very standardized
product although there may be a small
variety between different blends within
each blend the product remains
consistent eyeglasses on the other hand
must be custom-made for every individual
user the second consideration is volume
of demand there is a large and constant
need for gasoline so operators refine
and distribute it as quickly as possible
glasses are custom-made to order
matching a prescription and cannot be
made in advance a third consideration
the flexibility of the equipment used to
create the product is determined by the
product being created and is often
determined by the first two these two
main factors variety and volume may be
seen as the vertical and horizontal axes
of a graph
the result is called the product process
matrix the most efficient production or
manufacturing processes are found along
the diagonal points on the graph when a
very standardized product is needed in
very large volumes a continuous process
is the best manufacturing choice this
process uses highly specialized
equipment with very little flexibility
and is almost completely automated
gasoline manufacturer BP refines crude
oil into premium fuel in refineries
across the globe there is a constant
need for its product so production is
continuous in fact it's refineries in
the United States process 1.5 million
barrels of crude oil every day these
plants operate 24 hours a day 365 days a
year in order to maintain
cost-effectiveness and match output to
demand from consumers because of the
large capacity of the operations it is
very expensive to shut down such a plant
stopping production for just a few days
can undermine a plant's profitability
for an entire year
bp's facilities refine crude oil into a
number of consumer products each barrel
of oil contains 42 US gallons which is
refined into nineteen point four gallons
of gasoline nine point seven gallons of
heating oil and diesel fuel four point
three gallons of jet fuel and a host of
other products
the first step in refining is separating
the crude oil into these various
components refineries have the
flexibility to manufacture both gasoline
and heating oil but within the plant
each piece of equipment performs a very
specific function the process is
automated so operators spend much of
their time monitoring and adjusting
processes from a centralized control
room chemical engineers determine the
mix of products added during the
conversion and treatment stages of the
process
others monitors such elements as the
water used in the refinery to ensure
that it's safe to return to the
environment the workers at the plant
represent a wide range of specialized
skills without much overlap for a global
petroleum producer like BP continuous
production is the most effective process
choice in many cases though consumers
demand some degree of customization in
order to deliver a high volume of output
and still offer some variety
manufacturers turn to a repetitive
process called an assembly line this is
also referred to as mass production most
consumer goods are mass-produced Honda
of America uses a repetitive process in
their operating plant in Marysville Ohio
at this plant
Honda produces a large number of only a
few different models of their popular
Civic line of cars in fact this plant
alone produces an average of 20,000 cars
every month nearly 250,000 for each
model year
the production process utilizes a
connected workflow in which the product
moves along a conveyor system past a
series of work stations
at each station parts are brought to the
line to be added or assemble until the
product is finished in traditional
assembly lines workers complete the same
task over and over at honda workers are
trained in a variety of tasks they
rotate workstations regularly to avoid
fatigue and to maintain quality because
each station is designed for a specific
task there is little need for flexible
equipment workers interact with tools
more than in a continuous process but
much of the work such as welding is
performed through automation still there
is enough flexibility at each
workstation to offer a variety of
options on the model being produced in
repetitive processing variety is created
by combining individual modules engines
for example are created separately from
the main assembly line allowing engines
with different specifications to go into
the same model body color and interior
features and plug-in items such as
stereos and accessories are examples of
other modules that create variety within
the steady repetitive flow while this
process is so structured that each line
produces only one type of product the
line that produces the Civic for example
cannot build an Acura Honda is seeking
to change that at its Ohio plant for
example workers are trained on the next
season's model of cars while they are
still building the current model
industrial engineers meanwhile are
looking for ways to redesign the
assembly line building in so much
flexibility that it could produce any
model the company makes in Aurora
Illinois caterpillar is already doing
what Honda hopes to accomplish this
plant produces twenty four different
models of wheel loaders compactors
excavators and agricultural tractors all
in the same facility caterpillar
produces four families of construction
and agricultural equipment but all in
relatively low volumes because the
volume of products they manufacture is
lower than Honda's and the variety of
machine is greater Kanna pillar makes
use of batch processing this process
creates products in small lots or
batches in much smaller volume than
Honda unlike repetitive processing which
depends on a connected workflow batch
processing involves a disconnected
production line processing is
intermittent with workers coming to the
machine rather than the product coming
to them a variety of products produced
at relatively low volume with flexible
equipment characterize a batch
manufacturing process sometimes products
are created in batches as small as one
when a highly specialized product is
needed in a very low volume based on an
individual customer order the process
which matches the product is often
referred to as a job shop eyeglasses are
made using such a job shop process
each pair is made to suit a specific
customers vision and head shape so each
pair must be created individually at AED
vision optician Jim Bracken has been
making glasses for more than 20 years he
stocks lens blanks which have already
been ground to a specific prescription
strength after choosing the proper
strength lens Jim uses a bevel edger to
custom cut the lens to the specific
frames the customer has chosen
he then uses a hand edger to grind out
any imperfections the lenses are fitted
by hand to the frames finally he
fine-tunes the fit of the frame to the
size and shape of the clients head
although many of these same steps go
into the creation of every set of
glasses fitting the lens to the frame
and the frame to the customer is unique
every time outside of the bevel edger
none of the equipment jim uses is
specific to his industry standard table
salt in a pan on a hot plate serves as a
heat source to soften plastic frames for
bending
a nearby pan of water cools the frames
standard flexible tools such as a
screwdriver and pliers are used to fit
metal frames this is typical of many job
shops where a small set of general
purpose tools are used in a variety of
ways because every product is
custom-made the equipment must be
flexible enough to change with each new
task and since volume is small the
process can be geared to providing an
exact custom product highly skilled
workers using general purpose tools to
produce a small volume of very
specialized products is typical of the
job shop production processes the
product process matrix illustrates the
general rules of manufacturing or
production processes finding and using
the appropriate process is necessary to
ensure quality and keep cost low enough
to match the market demand and volume it
is unusual however that a product will
fit so neatly into one process for
another and many products depend on
several processes for their creation
these hybrid processes are becoming more
and more common the steel which goes
into Honda's cars and caterpillars heavy
equipment for example is created through
a continuous process
if you order specialized stereo
equipment for your car it may be
produced through batch processing
although the eyeglasses created at a IDI
are built in a job shop the frames may
have been created on an assembly line
and the glass blank for the lenses
through a continuous process for many
manufacturers the goal is to create
high-quality products with the
efficiency of a continuous process while
building in as much flexibility as
possible in order to allow for more and
more customization at the same time
small volume producers search for
methods to produce greater volume of
specialized products at lower prices in
order to achieve this mass customization
manufacturers must understand the
dynamic of the product process matrix
浏览更多相关视频
THP - Mikrobiologi Industri - Prinsip Dasar Penerapan Mikroba dalam Industri (Bagian 2)
Lecture 6 Process Selection and Facility Layout
Lezione 4C - CREAZIONE VSM - Parte 3 di 4 - Lean Thinking e Toyota Producition System - Zero sprechi
Manufacturing Industry Overview - A Galco TV Tech Tip | Galco
F3. The Eight Wastes of Lean (DOWNTIME)
Artificial Intelligence and manufacturing
5.0 / 5 (0 votes)