Conceptual assembly plan Process Planning Presentation.pptx

Process plans for simple and complex products.
Process performance attributes.
Conclusion; activity on your own.

Processes for simple and complex products

Raw material

Finished product


How do we envision the process plan?

What are the key features of the finished product?
What processes are needed?
What materials are involved?
What are the key attributes for use?
Which attributes can be standard, and which must be customized?
Should all operations be performed in the same location, or not?

What are the key features of the finished product?
What processes are needed?
What materials are involved?
What are the key attributes for use?
Which attributes can be standard, and which must be customized?
Should all operations be performed in the same location, or not?

 What process sequence(s) make sense?

1. Process Planning and Performance MIT 2.008x Prof. John Hart

2. Agenda Process plans for simple and complex products. Process performance attributes. Conclusion; activity on your own.

3. Process Planning: Processes for simple and complex products

4. How was it made? Image from http:// www.storopack.us / en /products-solutions/flexible-protective-packaging/ airplusr -inflatable-void-fill-and- cushioning.html Raw material Finished product http://www.dailyimpact.net/2015/10/28/death-watch-in-the-oil-patch/

5. Process plan: air pack manufacturing Raw material e xtraction Plastic pellet production Film extrusion/blowing Printing Sealing, inflation , cutting Use in your package Image from http:// www.storopack.us / en /products-solutions/flexible-protective-packaging/ airplusr -inflatable-void-fill-and- cushioning.html Finished product http://www.dailyimpact.net/2015/10/28/death-watch-in-the-oil-patch/

6. Air pack manufacturing Raw material e xtraction Plastic pellet production Film extrusion/blowing Printing Sealing, inflation , cutting Use in your package https://www.youtube.com/watch?v=O7BLsexJn0c

7. Air pack manufacturing Raw material e xtraction Plastic pellet production Film extrusion/blowing Printing Sealing, inflation , cutting Use in your package https://www.youtube.com/watch?v=kUfiwgrsfhc

8. How do we envision the process plan? What are the key features of the finished product? What processes are needed? What materials are involved? What are the key attributes for use? Which attributes can be standard, and which must be customized? Should all operations be performed in the same location, or not?

9. How do we envision the process plan? What are the key features of the finished product? What processes are needed? What materials are involved? What are the key attributes for use? Which attributes can be standard, and which must be customized? Should all operations be performed in the same location, or not?

10. How do we envision the process plan? What are the key features of the finished product? What processes are needed? What materials are involved? What are the key attributes for use? Which attributes can be standard, and which must be customized? Should all operations be performed in the same location, or not?  What process sequence(s) make sense?

11. From https:// smile.amazon.com /Amazon-Fire-7-Inch-Tablet-8GB/ dp /B00TSUGXKE/ $50 Amazon Fire Tablet

12. Glass LCD display Front case Battery PCB + speaker Back case

13. Conceptual assembly plan SCREEN FRONT CASE FRONT ASSEMBLY BOARD BACK COST BACK ASSEMBLY BATTERY BUTTONS MODULES SUBASSEMBLIES

14. Amazon Fire LCD display Polarizer sheets Color filter (rotated 45 deg ) Reflector [1] [2] [3] 1 mm LCD Display LCD display Glass + touch sensors 19

15. Planning for a complex product Customer needs and preferences: size, color, price, perception of quality! Design for manufacturing Standard vs custom parts Materials R&D required? Supply chain Supplier quality control Shipping distribution Seasonal dynamics Inventory cost, support etc...

16. Process Planning: Process performance attributes

17. How do we measure the performance of a manufacturing process?

18. Rate

19. Cost General relationship between manufacturing cost per part and production volume

20. Quality Variation and defects in m&m candies Normal (Gaussian) probability density function

21. Flexibility Titanium brackets produced using conventional manufacturing (left) and additive manufacturing (right). From General Electric 3D printing challenge (http://www.gereports.com/post/77131235083/jet-engine-bracket-from-indonesia-wins-3d-printing/)

22. Flexibility http://www.conformis.com/customized-knee-implants/image-to-implant-process/ What would be ultimate flexibility? Titanium brackets produced using conventional manufacturing (left) and additive manufacturing (right). From General Electric 3D printing challenge (http://www.gereports.com/post/77131235083/jet-engine-bracket-from-indonesia-wins-3d-printing/)

23. Air packs: the four attributes Image from: http://s3.amazonaws.com/ems.wf.net.au_production/assets/16865/web_image_article/CardiaBiohybridSealedAirFill-AirR5Lo.jpg

24. Process Planning: Conclusion

25. What have we learned? Process planning : selecting and sequencing the operations needed to manufacture a product. Most products require the integration of multiple processes, often in multiple locations. Four essential and interrelated attributes : rate, cost, quality, and flexibility. We can apply the same ‘lens’ at different levels of detail, and build both a broad and deep understanding of manufacturing fundamentals.

26. Cookie manufacturing! Raw Material Extraction Material Refining Combine Ingredients Mix Ingredients Create Dough Balls Bake Cookies Cookies Cool Cookie Time! Cookie Process Plan Excerpt from: https:// www.youtube.com / watch?v =CCbWyYr82BM … Why do I have to wait so long for my cookies?

27. Cookie manufacturing! Excerpt from: https:// www.youtube.com / watch?v =CCbWyYr82BM What is the process plan for making cookies in your kitchen? How would cookies be mass-manufactured? In both cases, what influences rate, cost, quality, and flexibility? How might you improve the process? … Why do I have to wait so long for my cookies?

28. Size of cookie? Shape of cookie? Flavor of Cookie? Image from: http://henson.com/sesamestreet.php Nutrition value of cookie?!