Lab Session 05

1. OBJECTIVE:

To perform process planning and generate BOM, precedence diagram using MS Visio.
2. APPARATUS

Personal Computer, Internet, Microsoft Visio

3. THEORY:

1. What Is a Process?

A process is a set of steps that result in a specific outcome. For example, a customer service
request might have the following steps:

a) Customer requests service

b) Service department enters request into a tracking system
c) The request is routed to the repair department
d) A repair technician is assigned to evaluate the request and to respond to the customer
e) A technician is dispatched, if appropriate
f) Once the response is made, a survey is sent to the customer to confirm their issue was
resolved

In this case, the process is response to customer service request, and the outcome is resolution of
the customer's problem.
2. Goal of Process Planning:

The goal of process planning is to improve and streamline the business methods of a company.
This would have results like:

a) Lower costs, due to fewer staff needed to complete the same process
b) Higher efficiency, by eliminating problematic process steps like loops and bottlenecks
c) Higher accuracy, by including checkpoints and success measures to make sure process
steps are completed accurately
d) Greater understanding by all staff of what they need to do to meet their department
objectives

3. Principles of Process Planning:

Here are some general principles to keep in mind when evaluating or improving processes:

a) First, define the outputs, and then look toward the inputs needed to achieve those outputs.
 b) Define the goals of the process and evaluate them regularly to make sure they are still
appropriate. This would include specific measures like quality scores and turnaround
times.
c) When mapped, the process should appear as a logical flow, without loops back to earlier
steps or departments.
d) Any step performed needs to be included in the documentation. If not, it should be
eliminated or documented, depending on whether or not it's necessary to the process.
e) People involved in the process should be consulted, because they often have the most
current information on what works and what does not.

4. Steps to Plan a Process:

Process planning involves the

a) Definition,
b) Documentation,
c) Review, and
d) Improvement of steps in business processes used at a company.

5. Tools:

The tools used in this lab session include:

 MAKE-OR-BUY DECISION CHART:

A make-or-buy decision is the act of choosing between manufacturing a product in-house or
purchasing it from an external supplier. In a make-or-buy decision, the most important factors to
consider are part of quantitative analysis, such as the associated costs of production and whether
the business has the capacity to produce at required levels. The depiction of the make-or-buy
decision through a flow algorithm using different simple shapes is called “Make-or-Buy decision
Chart”
 ASSEMBLE CHART:
The assembly chart shows the sequence of operations in putting together the product. It is a
graphical means of identifying how components flow into subassemblies and ultimately into a
final product.
 OPERATIONS PROCESS CHART:
This is also known as outline process chart and it provides a compact over all view of the whole
system of operations involved in the production of a product. In this chart only the main
activities (i.e. operations and inspections) carried out to complete a job are recorded in the
sequence of their occurrence but irrespective of where they are performed and who performs
them.
Thus only symbols of process chart are used in preparing it. Sometimes a brief note about the
nature each activity (may be operation or inspection) and the time allowed are mentioned by the
side of symbols. The processing to material i.e. various activities are shown vertically on the
entry or purchase of material by horizontal lines. (The operation process chart for the fabrication
of a riveted assembly.
An operation process chart has following advantages:
 To improve shop/plant layout
 Helps in specifying the basic manufacturing system.
 Helps in determining sequence of assembly and the scheduling activities regarding dates
of purchased material and completion dates for fabricated parts.
 To introduce the new technical personal with the manufacturing system.

The operations described in the operation chart are:

1. Processing and assembly operations: Processing operation such as changing in shape and
properties. On the other hand, joining two or more parts is an assembly operation.
Furthermore, these two operations are represented by this symbols, circle (○) and (O)
letter.
2. Inspection operations: Inspection operations are represented by square symbol (□) and (I)
as letter. It's done by an inspector checks the material, work part and assembly for quality
and quantity.

Difference between assembly chart and operations process chart:

Assembly chart is the check list of items to be put together and used by the quality control
people, while the operation process chart is required at each stage of production to make sure
that all elements are ready for assembly and in proper conditions.

 BILL OF MATERIAL (BOM):

A bill of materials (BOM) is an extensive list of raw materials, components and assemblies
required to construct, manufacture or repair a product or service. A bill of materials usually
appears in a hierarchical format, with the highest level displaying the finished product and the
bottom level showing individual components and materials. There are different types of bills of
materials specific to engineering used in the design process and specific to manufacturing used in
the assembling process.

What Is Included in a BOM?

Every line of the bill of materials includes the product code, part name, part number, part
revision, description, and quantity, unit of measure, size, length, weight and specifications or
features of the product.
A BOM list reduces possible issues if product repairs are required and is necessary when
ordering replacement parts. It helps plan for acquisition orders and reduces the possibility of
errors.

Engineering BOM
The engineering bill of materials defines the design of the finished product. Engineers generate a
BOM based on a computer-aided design drawing. It includes all alternative and substitute part
numbers and parts contained in the drawing notes.

Manufacturing BOM
The manufacturing bill of materials comprises all the assemblies and parts required to construct a
finished item ready to be shipped. It also incorporates the packaging materials required to send
the product to the customer. It contains processes that require execution on the product prior to
completion and stores all the information required for manufacturing activities.
4. EXAMPLE PROBLEM STATEMENT:

Consider a pen named “Orea” manufactured by Picasso, a well-known brand in stationary

manufacturing. On the analysis of different parts of a pen to be manufactured or outsourced,
following make-or-buy decisions have been made. All the metallic and liquid parts are decided
to buy, however the plastic parts have to be manufactured within the facility.

PARTS LIST:
Part Part Name Drawing Quantity Material Decision
Number Number
001 Head XX 1 Plastic Make
211 Spring XY 1 Metal Buy
222 Nib XZ 1 Metal Buy
002 Ink Tube YZ 1 Plastic Make
233 Ink YY 1 Liquid Buy
003 Cap ZX 1 Plastic Make
004 Casing ZZ 1 Plastic Make
005 Pusher ZX 1 Plastic Make

On the basis of the data given we construct the following using Microsoft Visio:
a) Bill of Material
b) Assembly Chart
c) Operations Process
d) Precedence Diagram

5. PROCEDURE:

STEP 1:
 Take an Orea pen, disassemble it and identify the main parts of the pen as explained in the
problem statement. The following is considered in this regard:

On disassembling, following parts are observed:

STEP 2:

Open the Microsoft Visio software.

 Figure 1 Opening Screen of Microsoft Visio

STEP 3:

a) Click on ‘Basic Diagram’ in Microsoft Visio as shown in figure 2.

Basic Diagram

STEP 4:

Figure 2 Basic Diagram Option in Microsoft Visio Opening Window

b) Select Units and Click on Create in new drawing option’s Opening window as shown in
Figure 3.

Figure 3 New drawing Option’s Opening Window

c) Click on rectangle from Basic shapes option and drag into drawing area as shown in
figure 4.

Figure 4 New drawing Basic shapes Option’s Window

d) Right Click on rectangle in drawing area and select ‘Format Shape’. Select no fill in ‘Fill’
options and change color & width of rectangle parameter line in ‘Line’ option. Then
cross the Format shape bar as shown in figure.

Figure 5 First rectangle shape formation with Format Shape Bar

e) Double click on rectangle line in drawing area to enter the name of Product. In example
case enter ‘BALL PEN’ along with code (000)’ and change the font size to 14pt and Font
color to Black.

Figure 6 First rectangle name edition.

f) Copy the rectangle and paste its copies according to requirements of your product sub
parts at Level 1. Place the copies on suitable place and edit their name to write the names
of your product sub parts at level 1.
 Figure 7 First rectangle copies on drawing

g) Connect the rectangles at level 1 to Rectangle at Level 0 using ‘Line’ in Pointer tool icon
present at top of the Visio Window.

Pointer tool Icon

Figure 8 First rectangle connection with sub parts at Level 1.

h) Follow the steps ‘f’ and ‘g’ to complete the sub parts of Level 2 and Level 3. Thus
develop bill of material showing the levels of part that in which step they are required in
production process and in which quantity. The Bill of Material is given below in figure 9.
 Figure 9 Bill of Material (BOM) diagram.

STEP 5:

Now the decision is to be made that which part is manufactured within the facility and which is
to be buy. In other words, we are going to decide whether to make or buy the parts required for
our final product as shown.
a) Click on ‘Basic Diagram’ in Microsoft Visio as shown in figure 2.
Basic Flow chart

STEP 4:

Figure10 Basic Flow Chart Option in Microsoft Visio Opening Window

b) Select Units, Decision branches Flow Chart and Click on Create in following window.

Figure 11 New drawing Option’s Opening Window for Flow chart diagram

c) By using above chart with the suitable shapes, figures and geometries, complete the
required charts. The Make-or-Buy Decision Chart is given by:

Figure 12 Make of Buy Chart

STEP 5:

The next step is to make operation process chart showing different operations and it present in
some way make/buy decision of parts. We follow steps similar to BOM chart steps. The
Operations Process Chart is given

Figure 13 Operations Process Chart

STEP 6:

To make assembly chart follow steps as made in BOM chart making. The Assembly Chart is
given by:

Figure 14 Assembly Chart

STEP 7:

Fill out the following table for input data to precedence diagram.
Table 1: Table for Precedence diagram
Sr. No. Activity Name Activity Number Precedence
and Notation
01 Ball Pen 000 (A3) --
02 Head Assemble 101 (A1) 1011,1012,1013
03 Spring 1011 (Spring) --
04 Head 1012 (001) --
05 Ink tube 1013 (002) 10131, 10132
06 Ink 10131 (Nib) --
07 Nib 10132 (Ink) --
08 Casing Assembly 102 (A2) 1021, 1022
09 Cap 1021 (004) 10211
10 Pusher 10211 (005) --
11 Casing 1022 (003) --

To make precedence diagram we follow the steps similar to steps as taken in BOM chart making.
The Precedence Diagram is given by:

Figure 15 Precedence Diagram

EXPERIMENT DOMAIN:
Domains Psychomotor (70%) Affective (20%) Cognitiv
e (10%)
Attributes Realization Conducting Data Data Discipline Team work Apply
of Experiment Collection Analysis (Respond/
(Receivin
Experiment Contribute)
(Act) (Use tool) (Perform) g)
(Awareness)
Taxonomy P1 P2 P2 P2 A1 A2 C3
Level

Student Lab report will consist of following:

 Lab Task:

To perform process planning and generate BOM, precedence diagram using MS Visio.

(Short description: Process planning by generation of BOM, operation process chart, assembly
chart, and precedence diagram of a product (ball pen, board marker, chair, glasses). MS Visio
software)

Note: Every student in a group will be assigned a different Product from the above products to
conduct this experiment.

 Objective:

 Apparatus:

 Procedure:
1. Discussion:
 What is Process Planning?

What are the types of Process Planning?

How is Process Planning related to Industrial Facility Design Subject?

2. Comments:

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EXPERIMENT DOMAIN & RUBRICS:
Domains Psychomotor (70%) Affective (20%) Cognitive
(10%)
Attributes Realization Conducting Data Data Discipline Team work Apply
of Experiment Collection Analysis (Respond/
Experiment (Receiving) Contribute)
(Awareness) (Act) (Use tool) (Perform)

Taxonomy Level P1 P2 P2 P2 A1 A2 C3
Marks distribution 3 5 3 3 2 2 2
Marks Obtained