Question

Q1. What are the five different types of process choices? What are some examples of each? What criteria should be used when selecting between them? What are the advantages and disadvantages of each?

Q2. What are some methods for overcoming a limiting bottleneck operation?

Q3. What is the goal of line balancing? What happens if a line is unbalanced?

Answer 1

Answer:-

There are five basic process types which are as below:-
a. Jobshop: -

This type of process is mainly used for the low volume and large variety of goods or services. intermittent processing, high flexibility, skilled workers, relatively large work-in-process inventory, and general-purpose machinery are the main requirements for job shop process. The typical example of this process is the tool and die shop which is able to produce a number of tools.

b. Batch:- This process is mainly implemented for the moderate volume of products and services is to be produced/. This process can handle an average number of variety. This process can be seen as intermittent. The skill of the workers, the flexibility of handling number of verities of goods, the amount of work in process inventory are lesser in comparison to job shop. Paint manufacturing can be the typical example of this type of process.

c. Repetitive:- In this process, high volume and relatively standardized goods or services are produced. In comparison to batch processing, this process has the limited skill of the workers, flexibility of handling number of verities of goods, the amount of work in process inventory. An example is the production of automobiles.

d. Continuous:- This process facilitates very high volume or highly standardized goods or services This process has almost zero flexibility in the production or equipment. Low skilled workers and thus no work in process inventory are the main traits of this process. Only a specific activity can be performed by the machines. Example:- steel manufacturing, and sugar manufacturing

e. Project:- This process is specially designed for the production of non-routine products, unusual tasks or activities. These are non-repetitive in nature. There can be a very high to very low requirements of skill of the workers, flexibility of handling number of verities of goods, the amount of work in process inventory. Example:- construction of a dam

Answer:-

In order to avoid the bottleneck, following methods can be adopted:-

• Bottlenecking can be avoided by adding more resources to the bottleneck operation
• Monitoring of work in process in front of the bottleneck and it must have a part to process. The will require the management of resources feeding the bottleneck in order to make sure that nothing is slowing them down.
• Making sure that bottleneck always operate on the quality parts
• If there is a process facing bottleneck every now and then, it is important to examine the schedule of the process
• Increase the time the operation is working
• Try to avoid and minimize scheduled and unscheduled downtime.

The goals of line balancing are as below:-

•The goal of line balancing is to identify tasks that can be grouped together based on the tasks time requirements.

• Synchronizing activities in such a way provides smooth workflow and maximizes equipment and labor utilization.

• Having a balance between the production rate

• Regular material flow.

• Maximum uses of man power and machine capacity.

• Minimum process time.

• Minimizing slack time.

• Minimizing workstation.

If there is a line unbalancing, it will cause the equipment and labor an idle time. The operations can becomes too fast paced or too slow which will result in work build ups between the stations and can cause lower morale among employees and will increase the operational costs to organization.

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