IENG 471 - Lecture 03
Product & Process Design
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Agenda


Assignments
Product Design



Process Design




Routing Sheets
Operations Process Charts
Precedence Diagram
Data for Facilities Planning Design


Reverse Engineering
Indented Bills of Material (BOM)
Project Evaluation & Review Technique (PERT)
Questions & Issues
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Product Design

Must meet the needs of the customer


QFD
Must be communicated (internally)
Product Drawings (Assembly, Detail)
 Parts List
 Part Structure


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Indented BOM covers both the parts list and part
structure
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Indented Bill of Materials

A “BOM” is a document that:
Lists all parts in an assembly
 Shows the quantity of all components
 Allows for the roll-up of costs
 Shows the sequence of assembly


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Each indentation shows the components of the
sub-assembly
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Example: Manual Juicer
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Example: Manual Juicer
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Example: Manual Juicer

Function of the product:


Obtain seed-free juice from produce
Principle(s) of operation:
Lever (Class 2) to provide pressure
 Grating to stop seeds
 Gravity to drain the juice

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Example: Manual Juicer

Materials of construction:
Aluminum (sandcast) body
 Rubber feet


Cost of the artifact:
$ 0.32 in aluminum
 $ 0.04 in rubber
 $ ??? in labor, shipping, packaging, etc.

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Example: Manual Juicer

Indented BOM & Cost Roll-up:
(1) Juicer Assembly
$ 0.36
(1) Body Sub Assembly
$ 0.18
(1) Body Casting
$ 0.14
(4) Rubber Feet
$ 0.01
These are the
$ 0.05
These are the (1) Strainer Casting number of child
number of
required to $ 0.10
(1) Lever Casting parts
child parts
make ONE of the
required to
parent part
(1) Hinge Pin
$ 0.03
make ONE of
the parent part
Total # of Rubber Feet to make (1) Juicer Assembly: (1) (1) (4) = 4
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BOM Example in Excel
Quantity Description
1
Juicer Assembly
Cost
$0.36
.
.
. 1
Body Sub-Assembly
.
$0.18
.
.
. 1
Body Casting
.
.
$0.14
.
. 4
Rubber Feet
.
.
$0.01
. 1
Strainer Casting
.
$0.05
.
. 1
. 1
Lever Casting
.
.
$0.10
$0.03
.
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Hinge Pin
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Process Design

Steps in Process Identification
1.
2.
3.
4.
5.
6.
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Define elemental operations
Identify alternative process(es) for each operation
Analyze alternative processes for each operation
Standardize processes for each operation
Evaluate alternative processes for overall
production
Select processes for overall production
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Routing Example
ROUTING
PART NAME:
Shaft, Vise
PART NUMBER:
MATERIAL:
PREPARED BY:
DATE:
DRAWING NUMBER:
GT CODE:
LABOR RATE:
TOTAL COST:
Brass
Process Parameters
Op.
No.
Speed
Operation Description
ft/min
Feed
rpm
1
Cut material from bar
150
2
Face 1st end of shaft
150
900
3
Face 2nd end of shaft
150
4
Turn diameter to length, rough
5
ipr
Estimated
Depth
ipm
in.
Machine
Labor
Setup
hrs.
hrs
Cost
Remarks
band saw
0.10
0.10
Leave extra for machining
0.005
lathe
0.20
0.05
take minimal needed for cleanup
900
0.005
lathe
0.20
0.05
cut to length per print
150
900
0.015
lathe
0.20
0.05
leave .03 for finish cut
Turn diameter to length, finish
150
900
0.005
lathe
0.10
6
Cut groove
150
900
0.005
lathe
0.20
0.05
7
Chamfer end of shaft
150
900
0.005
lathe
0.10
0.05
8
Turn diameter to length, rough
150
900
0.015
lathe
0.20
0.05
9
Turn diameter to length, finish
150
900
0.005
lathe
0.10
10
Chamfer end of shaft
150
900
0.005
lathe
0.10
0.05
11
Center drill end of shaft
150
900
0.010
lathe
0.10
0.10
12
Drill hole in end
150
900
0.010
lathe
0.10
0.05
drill extra deep
13
Tap hole
lathe
0.10
0.10
hand tap, lots of oil
14
Center drill for cross hole
200
1200
0.006
mill
0.10
0.10
15
Drill cross hole
200
1200
0.006
mill
0.10
0.05
16
Chamfer cross hole
100
600
0.005
mill
0.05
0.05
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leave .03 for finish cut
both sides
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Operation Process Chart

Circles represent operations


Number in circle represents standard operation
Prefix in circle identifies:




Circles are annotated with operation description
Boxes represent inspections



Subassemblies (SA) – child levels
Assemblies (A) – parent level in this view
Number in box represents standard operation
Boxes are annotated with inspection description
Arcs (lines) represent component(s)

Arcs are annotated with part number & description for
introduced components

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(See Figure 2.12 in text, p. 44)
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Example: Manual Juicer
Operations-Process Chart
Body
Casting
Rubber
Feet
Strainer
Casting
Lever
Casting
Hinge
Pin
4001
4021
4002
4003
4004
Trim,
0101 sand,
inspect
Trim,
0102 inspect
Trim,
0101 sand,
inspect
Trim,
0101 sand,
inspect
Trim,
0101 sand,
inspect
A1
SA1
I1
Plastic
Bag
A2
4031
Note: lines merge / diverge only at operations!
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Standard OPC Symbols
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Process Design Result

The result of the process design can
be a precedence diagram:
Take the OPC and turn it on its’ side.
Connect the component arcs with a single
operation (START), and you have a
Precedence Diagram
 The precedence diagram can be converted
to a PERT chart for SCHEDULE DESIGN

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Example: Manual Juicer
Precedence Diagram
0101
4004
4003
0100
4002
0101
0101
A1
I1
A2
4021
0102
SA1
4001
0101
4031
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PERT: Scheduling Terminology

Activity - A specific task or set of tasks that are
required by the project, use up resources, and take
time to complete

Event - The result of completing one or more
activities. An identifiable end state occurring at a
particular time. Events use no resources.

Network - The combination of all activities and events
define the project and the activity precedence
relationships
Meredith, J. R. &
Mantel, S. J. (2006)
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PERT: Scheduling Terminology

Path - The series of connected activities (or
intermediate events) between any two events in a
network

Critical - Activities, events, or paths which,
if delayed, will delay the completion of the project.
A project’s critical path is understood to mean that
sequence of critical activities that connect the
project’s start event to its finish event
Meredith, J. R. &
Mantel, S. J. (2006)
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PERT: Activity-on-Node Network Fundamentals
J, K, & L can all begin at
the same time, if you wish
(they need not occur
simultaneously)
M but
J
A
B
C
K
A is preceded by nothing
B is preceded by A
C is preceded by B
L
(1)
(3)
All (J, K, L) must be
completed before M can
begin
Y Y and Z are preceded by X
X
Z
Z Y and Z can begin at the
same time, if you wish
Y
AA AA is preceded by X and Y
Z is preceded by X and Y
X
(2)
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(4)
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Meredith, J. R. &
Mantel, S. J. (2006)
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PERT: Activity on Node Notation
Early Start (ES)
Early Finish (EF)
Activity
Late Start (LS)
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Duration (D)
Late Finish (LF)
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PERT: Calculating ES and EF

Forward Pass Through Network:




Move left to right, covering each simultaneous
activity in order
ES = maximum of EF for all immediate predecessor
activities (0 for START activity)
EF = ES + Duration
Critical Time = EF of the END activity
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PERT: Calculating LS and LF

Backward Pass Through Network:




Move right to left, covering each simultaneous
activity in order
LF = minimum of LS for all immediate successor
activities (Critical Time for END activity)
LS = LF – Duration
Slack (Float) Time:
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LS – ES
Note: Slack = 0 for Critical Activities
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PERT: Critical Path Example
1
4
4
5
B 3
3
0
1
F 1
6
6
1
G 1
7
7
8
4
8
1
1
4
1
3
2
9
9
H 1
8
4
D 2
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C 3
A 1
0
5
11
Z 2
9
9
11
8
E 4
4
4
8
Critical Time = 11 sec
Slack D = 1 sec
Slack B, F, G = 2 sec
Critical Path = A, C, E, H, Z
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PERT: Critical Path Management

CP are those activities where ES = LS


Any delay in these activities will delay production!
Wrong to say that these activities are the most
important, though:


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Frequently, activities with slack are put off until too late if
not monitored!
Other paths may be near-critical, and will also delay the
project if not monitored!
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Tying Critical Path to Facilities

Critical Path is connected to Makespan

If this were a repetitive operation environment:




Makespan is the total time for a single, physical unit to go
through all operations
In manufacturing, it’s the time difference between the start
and finish of a sequence of jobs or tasks Skorin-Kapov, J. & A. J. Vakharia
In health care, it is the duration of a patient’s medical
experience for the treatment of a medical episode
Quick exercise

Suppose that you had to schedule personnel to make a
mass-produced product


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What would you do to perform operations on the CP?
What might you do with non-CP operations?
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Questions & Issues

HW 2:

Hands on assignment to develop:





BOM
Operations Process Chart
Precedence Diagram
PERT Chart
Team exercise

Team members must each contribute a document



4 people per team (5 people, if necessary)
Other tools are in MIL Lab (IER 310)
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Semi-randomly assigned members
Leave the tools there, but OK to take the product parts
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