Production Processes and Diagrams Quiz
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Questions and Answers

What is a key difference between continuous manufacturing and batch process?

  • Batch process requires ongoing tool changes during production.
  • Continuous manufacturing processes starting materials in fixed sizes.
  • Batch process involves a cleaning phase after each production run. (correct)
  • Continuous manufacturing requires a setup phase.

    • Which of the following statements about costs in processes is correct?

  • All costs can be classified as either variable or fixed.
  • Activity-based costing allocates operational services to products based on the actual use of resources. (correct)
  • Fixed costs fluctuate based on the production output.
  • Variable costs remain constant irrespective of production volume.

    • What encompasses the capacity of a production process?

  • The total number of machines available for use.
  • The minimum number of workers required to operate machinery.
  • The maximum output achievable regardless of time.
  • The range of production units over a defined time period. (correct)

    • Which scenario illustrates a reduction of capacity?

    <p>Personnel take vacation days impacting production shifts.</p> Signup and view all the answers

    In a batch process, what does the batch duration refer to?

    <p>The time taken for processing a completed batch, including interruptions.</p> Signup and view all the answers

    What is the primary focus of event-driven process chain (Ereignisorientierte Prozesskette) diagrams?

    <p>Modeling business processes</p> Signup and view all the answers

    Which diagram is typically used to show the allocation of responsibilities and time for tasks?

    <p>Gantt chart</p> Signup and view all the answers

    What is a key feature of BPMN (Business Process Modelling Notation)?

    <p>It standardizes the notation for business processes.</p> Signup and view all the answers

    Which of the following best characterizes a swimlane diagram?

    <p>It delineates roles and responsibilities between different participants.</p> Signup and view all the answers

    Which elements are typically included in a material flow diagram?

    <p>Production stages and transportation routes</p> Signup and view all the answers

    What role do colors play in process diagrams?

    <p>They provide additional information about different elements.</p> Signup and view all the answers

    In what context are transport route plans primarily used?

    <p>For designing efficient material movement between locations</p> Signup and view all the answers

    Which of the following best describes the purpose of a flowchart?

    <p>To illustrate the steps in a process logically</p> Signup and view all the answers

    What is a key consideration for inventory management modeling when selecting vehicles for an online bookstore?

    <p>The transport capacity and lifting height</p> Signup and view all the answers

    Which type of model would be best suited for planning the introductory program for trainees at different stations?

    <p>Simulation model</p> Signup and view all the answers

    What constraint must be observed during station assignments in the trainee program?

    <p>No more than 2 people can work at the same station at the same time</p> Signup and view all the answers

    What challenge arises during weeks 3 and 4 of the introductory program?

    <p>All trainees must be assigned to sales activities</p> Signup and view all the answers

    What implication does the special sales campaign have on the deployment of trainees?

    <p>Original program progression may be disrupted</p> Signup and view all the answers

    Which of the following is NOT a requirement that needs to be considered in the planning?

    <p>Flexible scheduling for trainees at their discretion</p> Signup and view all the answers

    What is a necessary component of the model for deployment planning?

    <p>The total number of available trainees</p> Signup and view all the answers

    What requirement becomes difficult to maintain during the sales campaign in weeks 3 and 4?

    <p>Ensuring 2 trainees in C-E departments at the same time</p> Signup and view all the answers

    What is the main utilization time (HNZ) defined as?

    <p>Time during which a capacity location generates direct value added.</p> Signup and view all the answers

    What does the setup time (Rüstzeit) entail?

    <p>Time for preparation before executing an order.</p> Signup and view all the answers

    Which of the following is included in lead time (Durchlaufzeit)?

    <p>Occupation time, transport time, and laytime.</p> Signup and view all the answers

    What does occupation time (Belegungszeit) measure?

    <p>Time for which a capacity location is used for order processing.</p> Signup and view all the answers

    Interruptions due to disruptions (SU) refer to which scenario?

    <p>Unplanned disruptions delaying order processing.</p> Signup and view all the answers

    What is NOT considered an instrument of production management?

    <p>Quality Assurance</p> Signup and view all the answers

    Which dimension is NOT part of the process optimization dimensions?

    <p>Cost Reduction</p> Signup and view all the answers

    What is considered a conflict of objectives in production economy?

    <p>Minimizing delivery times</p> Signup and view all the answers

    Which of these is a key activity in process design?

    <p>Transformation of input</p> Signup and view all the answers

    Which element is NOT part of the St.Gallen Management Model?

    <p>Employee Engagement</p> Signup and view all the answers

    What does NOT contribute to customer satisfaction according to operational goals?

    <p>Fast customer support</p> Signup and view all the answers

    Which of the following is primarily concerned with sequencing?

    <p>Supply Chain Management</p> Signup and view all the answers

    What is a primary focus of production planning?

    <p>Aligning resources with demand</p> Signup and view all the answers

    What is the main purpose of a Bill of Material (BOM)?

    <p>To define the structure and components of a product.</p> Signup and view all the answers

    Which level of the product structure does 'Product A' belong to?

    <p>Level 0</p> Signup and view all the answers

    What type of item is a 'semi-finished product' classified as?

    <p>Component</p> Signup and view all the answers

    In relation to material requirements, what can be influenced at the source?

    <p>Order for supplier material.</p> Signup and view all the answers

    What does Level 2 in the product structure primarily consist of?

    <p>Components and single parts.</p> Signup and view all the answers

    What is the significance of the quantity in a multilevel bill of materials?

    <p>To outline the required quantities for components.</p> Signup and view all the answers

    Which of the following best describes 'Bg 1' within the product structure?

    <p>An assembly part.</p> Signup and view all the answers

    What is meant by 'aggregated material requirements' in the context of BOM?

    <p>Summarizing the total demand for all material types.</p> Signup and view all the answers

    Study Notes

    Production Management & Operations Management

    • Learning block 1 covers introduction and process design
    • Module instructors are Prof. Dr. Katrin Hügel and MSc Michael Schmid
    • Module contact information: [email protected] (module responsibility), [email protected]
    • Location: Institute for Modelling and Simulation at OST
    • The module organization for the autumn 2024 semester is structured
    • The semester will have an introduction & process design block from week 1-6, taught by Schmid
    • There will be a quantitative methods block, spanning from week 7-10, taught by Schmid / Tiemessen
    • A special approaches in production management block will take place during weeks 11-13, taught by Schmid
    • Students will cover summary and testing during week 14.

    Module Concept

    • Modules include discussion and homework
    • Get involved in making the contact lessons lively by asking questions. Use dialogue
    • Use self-study exercises during the semester directly after the contact lessons
    • Exercises enable independent learning
    • Students can ask clarifying questions in the forum during the lessons
    • Moodle forum for questions about administration, exercises and lecture content

    Effort

    • Contact study: 14 weeks * 2 Lessons = 28 hours
    • Accompanied self-study: 14 weeks * 3 hours = 42 hours
    • Unaccompanied self-study: 20 hours
    • Total ECTS: 90 hours

    Learning Block 1 - Introduction and Process Design

    • Clarifying general module conditions
    • Introduction to the topic (creating awareness of production management challenges)
    • Process design (analyzing and designing activities, controlling and planning material flows)

    What Characterizes a Manufacturing Company?

    • During a 15-minute video on Trumpf GmbH+Co, typical challenges of manufacturing companies and solutions will be identified:
    • Tools/methods used to address challenges
    • Key Performance Indicators (KPIs) for characterizing success

    Production Management & Operations Management

    • The objective of production management is optimizing production and service processes to meet customer requirements
    • Important instruments of production management include demand forecasts, site planning, process design, inventory management, process planning, sequencing, and supply chain management

    3 Dimensions of Process Optimization

    • Operations research
    • Technical developments
    • Process design

    Classification in the St. Gallen Management Model

    • A model shows the relationships between the various aspects (social, natural, economic) of management

    Conflict of Objectives in Production Economy

    • High utilization versus short delivery time versus small stock versus high delivery reliability versus customer satisfaction can lead to conflict

    Important Characteristics of Production Processes

    • Initialization/customer decoupling
    • Type of material utilization
    • Degree of repetition
    • Spatial organization

    Initialization: Order Processing Types after "Customer Decoupling Point"

    • Different order processing types are shown in diagram

    Process types according to type of material utilization

    • Continuous material processing (example: wire drawing mill)
    • Synthetic material processing (example: chemical industry)
    • Analytical material processing (example: coal preparation)
    • Regrouping material processing (example: chemical technological conversion)

    Degree of Repetition

    • Individual production (defined run size)
    • Multiple production (mass production, series production)
    • Variety production with lots.
    • Variety production with batches
    • No fully controlled processes

    Process Types by Type of Spatial Organisation

    • Construction site
    • Job shop
    • Group production/Islands
    • Flow production

    Job shop production

    • A process diagram shows the connections between the different production shops
    • Shops are generally spatially grouped together

    Group or island production

    • Shops (plants) grouped to make production of a family of parts possible independently
    • Decentralized, independent control of the process

    Flow Production

    • Plants are arranged in the order needed for processing
    • Steps in the process often linked with continuous time constraints

    Important characteristics of production processes

    • Initialization / customer decoupling
    • Type of material utilization
    • Degree of repetition
    • Spatial organization

    Analyze and evaluate processes, performance

    • Steps: Modeling or "getting the picture", determining process performance, improving process through alternative process design
    • Examples of performance measurement include capacity, time, costs, quality, and flexibility

    Time: key figures in processes

    • Lead time
    • Cycle time
    • Setup time
    • Processing time
    • Occupation time
    • Transport time
    • Laytime
    • Analysis, evaluation and optimization usually need quantitative mathematical models

    Process Capacity - General

    • To determine the capacity of an individual process step:
    • Calculate the occupation time for each order on each step.
    • Find the process step with the least capacity.
    • Consider resource availability (including working hours, holidays, machine service times, and any breakdowns) to fully understand capacity reduction.

    Process Capacity - Continuous manufacturing

    • Preparation of the plant
    • Continuous processing of starting materials
    • Interruptions in machining (often for tool changes)
    • Tidying up the plant
    • Production units per time (e.g., pieces/hour)

    Process Capacity - Batch process

    • Preparation of vessel and filling with starting materials,
    • Processing/conversion of starting materials,
    • Emptying of the vessel and transferring products,
    • Resetting reaction vessel

    Costs in Processes

    • Variable costs (increase proportionally with production volume)
    • Fixed costs (do not change with production quantity)
    • Activity-based costing ("Process costing") allocates operational services to products based on the activities required to produce them.

    Quality in Processes

    • First-pass yield: Percentage of products produced without defects in the first process run.
    • Defect rate: Percentage of defective products.

    Flexibility in Processes

    • Ability of a system to adapt to dynamic demands.
    • Example: Stochastic analysis methods or Gantt diagrams.

    Combination of ABC and XYZ Analysis

    • Categorization of material based on value and demand predictability (X, Y, Z) to determine which provisioning principle best suits each category.

    Provisioning Principle Depending on Product Importance and Predictability, ABC/XYZ analysis

    • Integration of suppliers for X-goods
    • Managed warehouse for Y-goods, order-referred
    • Individual procurement for Z-goods

    Decision Material Provision Principle

    • Perform ABC analysis on provided list of items which defines the type of provisioning principle choice that should be selected
    • Consider predictability when making material supply choices.

    Homework

    • Process flow analysis for gear production
    • Clarify questions using discussion or forum on Moodle

    Modeling - Introduction to the Use of Models, Examples

    • Various types and representations of modeling are discussed along with suitable examples

    Modeling - Comprehensive Definition

    • A model is a simplified, purposeful representation of the original. It is an idealized or real-world system that reflects an object of study, specific properties, and relations that enable a person to acquire new knowledge and develop a thorough understanding of a topic.

    General Purpose of Models

    • Models serve aiding in tasks such as understanding, describing, deciding, and implementing changes, and they also help in scenarios like simulation and forecasting.

    Application Area Process Models

    • Top-down (strategic-organizational) level models include customer needs, processes, and customer satisfaction with a focus on a broad spectrum of process ideas.
    • Bottom-up (operational-technical) models include process input, process, and output, focusing on a narrower range of detailed process ideas

    Form & Content of Representational Process Models

    • Models use flowcharts, Material flow diagrams, factory layouts, and transport route plans to show the processes.
    • The methods for the representation of processes are bar charts, Gantt charts, and other graphical representations.
    • An example is presented of the relationship of people and activities for different departments (e.g., Accounting manager, hiring resources).

    Process models: WHAT, WHERE, WHEN

    • Simulation models of a warehouse show the activities involved in the warehouse, and the questions that can be answered through simulation
    • This includes the steps such as receiving, storing, processing ,and shipping goods and services. Examples include possible time-based scenarios

    Model Processes (Troubleshooting)

    • Example: An insurance company that has partially automated handling claims is used.
    • Kind of process model for problem analysis: Discuss different kinds
    • Procedure for solving the problem of 'lost' claims: steps to be taken by the insurance company.

    Model Processes (Investment Decision)

    • Online bookstore renewing their fleet of transport equipment.
    • Aspects to model for successful inventory management to make sure appropriate vehicles are purchased, covering dimensions, radius of turn, lifting height, capacity, speed, etc.

    Model Processes (Deployment Planning)

    • Wholesale nursery "zum Grünen Daumen" for implementing an introductory programme for trainees.
    • Weeks of station assignments for each trainee are given, limiting two people at a time on a station.
    • Type of model suitable for such task assignment (planning/scheduling) is discussed and the essential elements for such a model.
    • Operating plans for the introductory period are developed.
    • Scenarios include special sales campaigns where additional employees are needed in specific weeks for the introduction programs.

    Conclusion: Graphical Process Models

    • Process models represent the key aspects of a process, making use of different model types depending on the associated issues.
    • Graphical models (often very descriptive) may not include quantitative aspects. Therefore, process metrics (e.g., performance indicators) need to be recorded separately for optimization purposes.
    • Process models are helpful but generally need quantitative models (mathematical models) for analysis, evaluation, and optimization.

    Process Performance: Capacity, Time & Cost

    • Process derivation takes place in a class based on a printing plant's process flow analysis, including aspects of capacity, utilization, time (occupation, cycle), and costs.

    Process Performance: Quality

    • Examples like order fulfilment, formatting, printing, and binding are considered in a printing plant's process flow analysis to identify potential quality issues.

    Process Performance: Flexibility

    • Assessing the impact of non-continuous demand on a process (e.g., a printing plant) is analyzed using Gantt charts and the determination of minimum throughput time.

    Homework

    • Completing a process flow analysis.

    Material Requirement Planning (MRP)

    • MRP is a detailed planning process. Key factors include the order backlog, the primary demand for end products, the production programming, the necessary parts lists, and the estimation of net requirements
    • Material requirements are determined by reconciling requirements with stock levels. The determination of material needs involves ordering parts from suppliers, deciding whether to use third-party or in-house production, and determining inventory levels.

    Basis for Determining Primary Requirement

    • Make-to-Order: Customer-oriented based on orders that are made in the warehouse
    • Make-to-Stock: Market expectations of standardized products to meet the demand efficiently.

    Types of Articles

    • Categorization of items (e.g., final product, semi-finished product)
    • Includes parts, components, raw material

    Product structure

    • A hierarchical representation of the product constituents.
    • Includes level 0 (product A), level 1 (Bg1, T1, T2, Bg2) and level 2 (T1, T3, Bg3, T4).

    Bill of Material (BOM) - Multilevel and Quantity

    • Includes a hierarchical breakdown of the material components needed for a product Numerical quantities for material requirements are specified with a process illustration for each assembly

    Product structure, example assembly cabinet

    • A detailed illustration of the structure of a cabinet which includes all the parts, materials, and assembly elements.

    Quantity and structured BOM for variant 1/2

    • Specific quantities for different product variants (1 or 2) are outlined in a table format for better understanding.

    Homework-Production planning

    • The task of production planning “Heimätli” is specified

    Megatrend: Individualization

    • A discussion point about material flow when the number of product variants increases

    Increase in Variants

    • This illustrates a rising trend in the number of product variants and a declining trend in the average number of vehicles sold since 1980
    • A chart displays the average number of vehicle variants and the average number of vehicles sold per series

    Analysis of the sales structure by means of ABC analysis

    • Categorization of items based on sales, such as identifying the important components and optimizing inventory efficiency by implementing prioritization.

    Variety of Variants

    • A diagram showing a typical distribution of product quantity from the standardized products to the exotics.

    Variety of Variants - Need for Action in Variant Management

    • Diagram showing the trade-off between economic optimization and resulting loss (cost/price issues)

    Vicious circle of variant diversity

    • Shows how increased variant diversity leads to rising costs, loss of competitiveness, and a further increase in variant diversity.
    • Also illustrates the relationship between maturity/decline of the market with variant diversity.

    Internal and external causes - Different measures taken

    • Internal and external causes of increased variant diversity. Possible actions to take:
    • Saturation of sales markets
    • Increasing competition
    • Customer expectations, social norms, and values
    • Technological advancements

    Approaches to dealing with variant diversity

    • Reducing variant diversity to ease material inventory and production
    • A comprehensive approach to achieve economic variant diversity
    • Limiting article variety for purchased components
    • Modularization

    Modular constrictor B2C - IKEA

    • Advantages of modular design

    Material Requirement Planning (MRP)

    • Steps for Material Requirement planning (MRP)

    Principles of material supply

    • Synchronous delivery (JIT)
    • Stockpiling
    • Advantages and disadvantages, preconditions, and drivers

    ABC analysis for classification of material

    • Deployment of resources and important items from an ABC perspective
    • Classify raw materials and goods into categories (A, B, C) based on their relative importance and sales volume.

    XYZ analysis for classification according to demand forecasts

    • Categorization of material based on the predictability of demand.

    Combination of ABC and XYZ analysis

    • A combined analysis method is used to consider both value and predictability of demands

    Provisioning principle depending on importance of products and predictability of consumption

    • Different provisioning principles for items with different combinations of importance and predictability.

    Decision Material Provision Principle

    • Specific case for performing ABC analysis on the given list of items to make decisions on which materials supply principle is suitable

    Process flow analysis - Introduction by example

    • Detailed analysis on the process flow of a printing plant and their performance in capacity, time and cost aspects

    Homework

    • Task of process flow analysis on gear production

    Process design - Analyze and Design Processes, Material Flows

    • Explains methods to categorize production activities in terms of their characteristics, and illustrates the importance of material flow analysis

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    Description

    Test your knowledge on various production processes, including continuous manufacturing vs. batch processes, as well as different types of process diagrams such as BPMN and swimlane diagrams. This quiz also covers concepts related to capacity, costs, and inventory management in production settings.

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