production management

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