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Process design
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Process Design
Design:“To design” refers to the process of originating and developing a plan for a product, service or process.
Process:Is any part of an organization which takes a set of input resources which are then used to transform something into outputs of products or services.
Process Design
Processes that Design Products
and Services
Concept Generation
Screening
Preliminary Design
Evaluation and Improvement
Prototyping and final design
Processes that Produce Products
and ServicesSupply Network Design
Layout and Flow
Process Technology
Job Design
Process design
Nature of the design activity:
1) Design is inevitable – products, services and the processes which produce them all have to be designed.
2) Product design influences process design – decisions taken during the design of a product or service will have an impact on the decisions taken during the design of the process which produces those products or services and vice versa.
Product & services design are interrelated to its process design
Decisions taken during the design of the product or service will have an impact on the process that produces them and vice versa
Products and services should be designed in such a way that they
can be created effectively
Processes should be designed so they can
create all products and services which
the operation is likely to introduce
Designing the Product or
Service
Designing the Processes that
Produce the Product or Service
Process Design and Product/Service Design are Interrelated
• To commit to the detailed design of a product or service consideration must be given to how it is to be produced.
• Design of process can constrain the design of products and services.
• The overlap is greater in the service industry:• Service industry - it is impossible to separate service
design and process design – they are the same thing.• Manufacturing industry - it is possible to separate
product design and process design but it is beneficial to consider them together because the design of products has a major effect on the cost of making them.
Process and product/service design must satisfy customer• Products/services designer customers satisfaction criteria
• Aesthetically pleasing• Reliability• Meets expectation• Inexpensive• Quality• Easy to manufacture and deliver• Speedy
• Process designer customers satisfaction achieved through:• Layout• Location• Process technology• Human skills
The design activity is itself a process Finished designs which are:
High quality: Error-free designs which fulfil their purpose in an effective and creative way
Speedily produced: Designs which have moved from concept to detailed specification in a short time
Dependably delivered: Designs which are delivered when promised
Produced flexibly: Designs which include the latest ideas to emerge during the process
Low cost: Designs produced without consuming excessive resources
TRANSFORMED RESOURCES
Technical informationMarket informationTime information
TRANSFORMING RESOURCES
Test and design equipment
Design and technical staff
THE DESIGN ACTIVITY OUTPUTINPUTS
Designing processes• Process mapping• Process mapping symbols• Improving processes• Process performance• Throughput, cycle time & work in process
Process mapping• Used to identify different types of activities.
• Shows the flow of material, people or information.
• Critical analysis of process maps can improve the process.
Process performance• Process performance can be judge against the
five key performance objective: Quality Speed Dependability Flexibility Cost
Throughput, work content, cycle time, and work in process
• Throughput – the time for a unit to move through the process
• Work content – the total amount of work required to produce a unit of output (measured in time)
• Cycle time – The average time between units of output emerging form the process
• Work in process (WIP) –unfinished items in a production process waiting for further processing e. g. when customers join a queue in a process they become WIP
throughput = work in process x cycle time
Process Types
Project Processes
• One-off, complex, large scale, high work content “products”
• Specially made, every one customized• Defined start and finish: time, quality and cost
objectives• Many different skills have to be coordinated • Fixed position layout
Project Process
Jobbing Processes• Very small quantities: “one-offs”, or only a few
required
• Specially made. High variety, low repetition.
• Skill requirements are usually very broad
• Skilled jobber, or team of jobbers complete whole product
• Fixed position or process layout (routing decided by jobbers)
Jobbing Process
Batch Processes
• Higher volumes and lower variety than for jobbing
• Standard products, repeating demand. But can make specials
• Specialized, narrower skills• Set-ups (changeovers) at each stage of
production• Process or cellular layout
Batch Process
Mass (Line) Processes
• Higher volumes than Batch• Standard, repeat products• Low and/or narrow skills• No set-ups, or almost instantaneous ones• Cell or product layout
Mass Process
Continuous Process
• Extremely high volumes and low variety: often single product
• Standard, repeat products• Highly capital-intensive and automated• Few changeovers required• Difficult and expensive to start and stop the
process• Product layout: usually flow along conveyors
or pipes
Continuous Process
VolumeLow High VolumeLow High
Var
iety
Lo
wH
igh
Var
iety
Lo
wH
igh
Project
Jobbing
Batch
Mass
Contin-uous
Professional service
Service shop
Mass service
Service process types
Manufacturing process types