CH2: PRODUCT, PROCESS,
AND SCHEDULE
DESIGN
Dr. Ruba Alamad
Outlines
➢Introduction
➢Product Design
➢Process Design
Review: Facilities Planning Process
The Facilities Planning Process Phase 1 Phase 2 Phase 3
for manufacturing and
assembly facilities: Specify the required manufacturing
Define the products to be
and/or assembly processes and Implement the facilities plan.
manufactured and/or assembled.
related activities.
Determine the interrelationships Maintain and adapt the facilities
among all activities. plan.
Determine the space requirements Update the products to be
for all activities. manufactured and/or assembled
and redefine the objective
Generate alternative facilities plans.
Evaluate the alternative facilities
plans.
Relationship between product, process, and schedule (PP&S)
design and facilities planning (1 of 2)
• In this chapter, we focus on the product, process, and schedule
(PP&S) design functions.
• The success of a firm is dependent on having an efficient
production system.
• Product designs, process selections, production schedules, and
facilities plans need to be mutually supportive.
• The more specific the inputs from product, process, and
schedule designs, the greater the likelihood of optimizing
the facility and meeting the needs of manufacturing
Relationship between product, process, and
schedule (PP&S) design and facilities
planning (2 of 2)
▪ Product, process, schedule, and facilities design decisions are
not made independently and sequentially.
▪ A clear vision is needed of what to do and how to do it
▪ Including concepts, techniques, and technologies to consider.
▪ Either a new facility or a major expansion/modification to an
existing facility is being planned
PP&S Design bracket chart
PP&S Design
Product Process Schedule
Design Design Design
Identify
What product Production
required
to produce requirement
processes
Detailed Select the
Machines
design of each required
requirement
product processes
Exploded Sequencing
assembly the required
drawing processes
Part 1
Product Design
1- Product Design (1/4)
▪ Product design involves both
▪ The determination of which products are to be
produced
▪ Detailed design of individual products.
▪ Decisions regarding the products to be produced are
generally made by upper-level management based on
input from
▪ Marketing,
▪ Manufacturing, and
▪ Finance
1- Product Design (2/4)
▪ The design of the product is influenced by aesthetics,
function, materials, and manufacturing considerations.
▪ Marketing, purchasing, industrial engineering,
manufacturing engineering, product engineering, and
quality control, among other factors, will influence the
design of the product.
▪ In the final analysis, the product must meet the needs
of the customer.
1- Product Design (3/4)
▪ Exploded assembly drawings are useful in
designing the layout and handling system.
▪ These drawings generally omit
specifications and dimensions, although
they are drawn to scale.
1- Product Design (4/4)
▪ Detailed component part drawings are needed for each
component part.
▪ The drawings should provide part specifications and
dimensions in sufficient detail to allow part fabrication.
▪ The combination of exploded assembly drawings and
component part
drawings fully documents the design of the products.
Example:
Manufacture skateboards:
What we need to know and do?
Make or Buy? Demand Layout
[Link] parts needed • Needed processes? • Based on the demand • Workstation space
[Link] assembly • Sequence of processes? • And the future expectations • Equipment space
• For each component decide to • Assembly chart • How many we should produce • How many workstations? • Personnel space
make or to buy to meet the demand • Departments
• Make or Buy decision chart • Are we going to expand in • Activity relationship
future? • Which layout to use between
• Consider defects and rework workstation?
• Between Departments?
For parts we are Machines needed?
What components making: Space requirement
How many?
Manufacture
skateboards:
▪Exploded assembly
drawings are useful in
designing the layout and
handling system.
▪ Skateboard parts
(components)
Process Design
2- Process Design
▪ The process designer is responsible for both determining
▪ How the product is to be produced
▪ Who should do the processing.
▪ This involves identifying, selecting, and sequencing the required
processes.
a- Identifying Required Processes
o The extremes for a manufacturing facility range from
▪ Vertically integrated firm to
▪ Horizontally integrated firm
o Involve “make-or-buy” decisions or “sourcing” decision
a- Identifying Required Processes
▪ A bill of materials is often referred to as a structured parts list, as it contains information of the
parts and information on the structure of the product.
▪ Typically, the product structure is a hierarchy referring to the level of product assembly.
▪ Level 0 usually indicates the final product;
▪ Level 1 applies to subassemblies and components that feed directly into the final product
▪ Level 2 refers to the subassemblies and components that feed directly into the first level, and so on.
What to Include in an Effective Bill of
Materials
1. BOM Level — To help everyone understand what is required during the manufacturing process.
2. Part number — To further identify all the individual parts.
3. Name of part — Provide a special name to each part to help prevent confusion down the line.
4. Phase —The importance of this part is that it allows you to stay track of what is being done.
5. Description —This also serves to distinguish it from other parts and makes it easy to identify.
6. Quantity — Take note of the number of all the parts involved at every phase of production.
7. Make/ buy— Take note of how every part is bought or created.
[Link] Notes — other additional information.
Bill of materials chart
Bill of materials bracket chart
Skateboard Components
Activity 1
Bill of material
b- Selecting the Required Processes
▪ After deciding which products to make in-house, decisions are needed as to how the products will
be made.
▪ Decisions are based on previous experiences, related requirements, available equipment,
production rates, and future expectations.
▪ The process selection procedure involves the following steps:
1. Define elemental operations
2. Identify alternative processes for each operation
3. Analyze alternative processes
4. Standardize process
5. Evaluate alternative processes
6. Select processes
b- Selecting the Required Processes continued
c- Sequencing the
Required Processes
▪ The easiest method of constructing an Assembly Chart
is:
▪ To begin with the completed product
▪ To trace the product disassembly back to its basic
components.
▪ Disassemble:
▪ Start from unpack the air flow regulator (A-4)
▪ Inspection : (I-1)
▪ (A-3) → (A-1) which is the assembly of (SA-1) & the body.
▪ Last 7 components.
Assembly chart: Skateboard
c- Sequencing the Required
Processes Continued
▪Notes:
▪ Circles and squares represent time
▪ Horizontal connections represent sequential steps in the assembly of the product.
▪ Components have been identified with a four-digit code starting with 1, 2, 3, and 4.
▪ Subassemblies (SA) and assemblies (A) have been identified with letters and numbers.
Operation process chart
Route Sheet + the
assembly chart =
Operation Process chart
