Process Planning Aids
Process planning is essential for designing and implementing a work system that will produce the required quantity of goods and services. It is a continuous activity, as production volumes have to be continuously adapted to the changing demand for goods and services. Managers generally use assembly charts and process charts to redesign, update and evaluate their production processes.
Assembly Charts
Assembly charts are used to obtain a general understanding of the entire process involved in producing products which involve assembly of a number of parts. They provide an overall macro view of the movement of components and sub-assemblies in the process of producing a finished product. They also show the material requirements (i.e. the list of all major components), sub-assembly operations, quality checks and assembly operations that are involved in making a mechanical assembly. In these charts, it is a standard practice to indicate operations by circles and inspections by squares. Figure 5.6 illustrates a typical assembly chart that is used for producing an electric heater.
Process Charts
Process charts are similar to assembly charts, except that they include extra information like description of the various steps involved, their frequency of occurrence, the time for each step, the distance traveled and so on. Non-productive activities like storage (D), delay (D) and transport (Þ) are also included. Figure 5.7 depicts a typical process chart used in a hypothetical manufacturing organization.
Process charts are used to compare alternative ways of performing operations. Each activity can be reviewed by examining whether it can be improved by eliminating a task, combining tasks, changing the sequence of tasks, or modifying the tasks.
Process charts can be used for process planning when new products are being planned or when existing operations have to be improved. Thus, these charts help the manager analyze the efficiency of processes.
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