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PRODUCTION MANAGEMENT
LECTURE -II
• The Production Function
• Types of production system
• Elementary knowledge of manufacturing processes
• Plant Layouts
• Material Handling
• Location Problems
• Inventory management
• Scheduling
• Network Analysis
• Break Even Point Analysis
• Reliability maint & plant services
• Quality control
• Emerging Trends
• Concept of Productivity
Syllabus
• Types of Production Systems –
•Intermittent Production
•Continuous Production
• Elementary knowledge of Manufacturing process • Assembling
• Fabrication
• Forming
• Heat Treatment
• Welding
• Machining etc
CHAPTER -II
CHAPTER -III
PRODUCTION SYSTEM
CONVERSION PROCESSINPUT OUTPUT
CONTROL
DECISION MAKER
•Solid line represents movement of material through conversion system by value addition to finish goods ( Materials Management)
•Dotted Line represents flow of information / set of Instruction
• All on line data / information is continuously passed on to control tower ,control tower in terms process / Tabulate all the information in format & sends it to decision maker ( Flow of Information)
• Decision Maker Compares / Benchmark actual information with plan & generate the set of instructions for correcting the deviations & sends it to control tower (Plan Vs Actual)
• Control tower sends instructions at appropriate point for execution & bring back process under control
PRODUCTION SYSTEM
CONVERSION PROCESS
INPUT OUTPUT
CONTROL
DECISION MAKER
The system selection is sensitive because of following parameters
1 . Type of Product
• Common parameters
• Total Volume
• Varieties in total Volume
2 .Type of Company
• Automobile
• Chemical
• Pharma
3.Life Cycle of Product / Project
Life cycle phase of Project
Introduction ( Low volume ,High Variation) Growth ( High volume , Low Variation)Maturity ( High volume , Low Variation)Decline ( Volume drops , Variation High)
Life cycle phase of Project
Introduction ( Low volume ,High Variation) Growth ( High volume , Low Variation)Maturity ( High volume , Low Variation)Decline ( Volume drops , Variation High)
Conclusion :
System selection is not a static or one time
decision but “DYNAMIC” one & changes as
organization passes through I –G-M-D Phases
& changes the equation of Volume to Variety
ratio
Types of Production System
Intermittent System Continuous System
Job Type Mass Production
Printing Job
Machine Building
Batch Type
Washing Machine
Fridge / TV / CAR
Spoons / Hair Pins / Soaps / Chocolates
Process Type
Cement / Sugar / Chemical Industries
• The goods are manufactured specially to fulfill orders made by customers & not for stock
• Characteristics :
• Most products are produced in small quantities
• Machines & equipments are laid out by process
• Workloads are unbalanced
• Highly skilled operators are required for efficient use of machines & equipments
• In process inventory is very large
• Flexible to accommodate variety in production
• Example :
•Machine shops
• Hospitals
• locomotives
• Plants
• Automobiles
INTERMITTENT SYSTEM
OP1 Information & Control Decision Maker
OP3
OP2
OP4
Storage1
Storage 2
Storage 3
Storage 4
Storage 5
Ex. Paper cutting machine
INTERMITTENT SYSTEM
Intermittent system Classification :
• Job Production • Batch Production
• Job Production : 1) It is the production of single complete unit by one operator , Group of operators
2) Whole project is considered as a one operation & work is completed on each product before passing to the next
• Characteristics :• Complete project is considered as single operation• Versatile & skilled labors are required• High capital Investment• Control operations relatively simple• High unit cost of production
• Examples : • Bridge Building• Dam Construction• Ship Buiding• Heavy machines
Intermittent system Classification :
• Batch Production
• Batch Production : It is a extension of job type production
Whole project is considered as a one operation & work is
completed on each product before passing to the next
• Characteristics :• Production schedule can be formulated according to specific
orders or demand forecasts• Items are processed in lots & batches• Only one item is produced in every production run• New batch will be taken only after completion of one• High WIP• High cycle time• Complex PPC
• Examples : • Chemical Industry• Machine tools• Printing press• Electronic instruments
Continuous System :
• In this system the items are produced for the stocks & not for specific order
• Manufacturing stock is based on sales forecast
• Inputs are standardized & standard set of processes & sequence of processes can be used
OP1
Storage1
Information & Control Decision MakerInput
OP2
OP3 OP4Storage2
OP5
Out put
Ex. Bottling Plant
Fundamental characteristics of the system is standardization
• Items are produced in large quantities independent of customer orders
• i.e Production is to stock & not to order
• Standardization is w.r. to materials & machines
• Uniform & un-interrupted flow of material is maintained through predetermined sequence of operations required to produce the product
• System can produce only one type of product at one time
Example :
• Sub assemblies
• Parts / components
•Advantage :
• Economies of production because of specialization & standardization
Mass Production
It gives more stress on AUTOMATION in production process
• The volume of production is very high
• This method is used for manufacturing items with very high demand
• Ex.
• Petroleum products
• Particular brand of medicines
• Heavy chemical industries
• Plastic industries
Note : Single raw material can be transformed into different kinds pf product
at different stages of production process
Ex. Processing of crude oil will give Kerosene / Gasoline etc at diff stages
of production
Process Production
1. Manufacturing costs
2. Capital investment
3. Size of plant
4. Technical requirement
5. Organizational structure
6. Flexibility in production
7. Type of products produced
8. Security of job
Factors for Comparison of Manufacturing systems
Assembling : Welding, Brazing, Riveting, Fastening By Nuts&bolts, Adhesives Forming :In this process shape of work piece changes without necessarily removing or adding material
Ex .Casting, Forging, Extrusions, Stamping, Embossing,
Heat Treatment : Heat treatment is process of heating & cooling of metals or alloys in solid state in order to obtain certain desired properties ( Relieve internal stresses , Hardness ,toughness etc)
Machining : It involves metal removing by Turning , Drilling , Milling , grinding ,shaping ,boring ,EDM , ECM etc. Electro discharge machining : (EDM) Spark between workpiece & tool across gap removes the material using dielectric ,which also cools the metal Electro Chemical Machining (ECM) :Chemical energy combine with electrical energy is used to do the cutting operation
Elementary knowledge of Manufacturing process