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2 Production MGT

The document discusses various topics related to production management including types of production systems, manufacturing processes, and plant layouts. It describes two main types of production systems: intermittent and continuous. Intermittent systems include job shops and batch production, while continuous systems involve mass and process production. Some key manufacturing processes mentioned are assembling, forming, heat treatment, and various machining methods. The document also includes diagrams of production system flows and factors to consider when selecting a production system.

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65 views17 pages

2 Production MGT

The document discusses various topics related to production management including types of production systems, manufacturing processes, and plant layouts. It describes two main types of production systems: intermittent and continuous. Intermittent systems include job shops and batch production, while continuous systems involve mass and process production. Some key manufacturing processes mentioned are assembling, forming, heat treatment, and various machining methods. The document also includes diagrams of production system flows and factors to consider when selecting a production system.

Uploaded by

nsrmurthy63
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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PRODUCTION MANAGEMENT

LECTURE -II

Syllabus
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

CHAPTER -II
Types of Production Systems

Intermittent Production
Continuous Production

CHAPTER -III
Elementary knowledge of Manufacturing process Assembling Fabrication Forming Heat Treatment Welding Machining etc

PRODUCTION SYSTEM

DECISION MAKER

CONTROL

INPUT

CONVERSION PROCESS

OUTPUT

PRODUCTION SYSTEM
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
DECISION CONTROL

MAKER

INPUT

CONVERSION PROCESS

OUTPUT

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)

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 Printing Job Machine Building

Mass Production

Spoons / Hair Pins / Soaps / Chocolates

Batch Type

Process Type

Washing Machine Fridge / TV / CAR

Cement / Sugar / Chemical Industries

INTERMITTENT SYSTEM
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

Storage1

OP2
Storage 2
Storage 4

OP4

Storage 3

OP3

Storage 5

Ex. Paper cutting machine

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 Bridge Building Dam Construction Ship Buiding Heavy machines

Examples :

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 : Examples : 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

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 Input OP1

Information & Control

Decision Maker

Storage1

OP2

Storage2

Ex. Bottling Plant

OP3

OP4

OP5

Out put

Mass Production
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

Process 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

Factors for Comparison of Manufacturing systems


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

Elementary knowledge of Manufacturing process


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

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