Module 1 bu pom notes

8/6/2019 Module 1 bu pom notes

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A plant is a place where men, materials,

money, machinery etc are brought together for

manufacturing product.

Plant location decisions are crucial becaz theycommit orgns to long lasting financial,

employment, & a distribution pattern.

Location planning: is must to avoid following

reasons like non availability of RM easily,power supply problems, problems from local

people, problems of waste disposal etc.


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a) National

decision

b) Selection of

region

c) Selection of

community

d) Selection of

site

i. Political

stability export

& importii. Currency and

exchange rates

iii. Cultural and

economic

peculiarities

iv. Naturalenvironment

i. Availability of

raw materials

ii. Nearness to

market

iii. Availability of

power

iv. Transportfacilities

v. Suitability of

climate

vi. Government

policy

vii. Competition

among states

i. Availability of

labor

ii. Civic amenities

for workers

iii. Existence of

complementary

and competing

industriesiv. Finance

facilities

v. Availability of

water and fire

fighting

facilitiesvi. Local taxes and

restrictions

vii. Personal factors

i. Soil, size and

topography

ii. Disposal of

waste

F

AC

T

OR

S

inS

E

L

E

C

TI

ON

ofL

OC

AT

ION


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FACTORS UNIMPORTANT

%

NEUTRAL

%

IMPORTANT

%

Personal business contacts in aparticular region

Good communication and/or

transport facilities

Availability of sufficient

infrastructure

Market research indicating sizeor other benefits of local market

availability of skilled labor

Region promotion efforts

particular local/regional

policies to attract business

Lack of information on otherpotential areas

24

53

47

58

70

83

81

78

11

21

20

16

15

13

09

14

65

26

33

26

15

04

10

08


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Fixed position layout

Product layout

Process layout

Layout based on group technology

(combination)


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Some products are too big to be moved, so

the product remains fixed and the layout is

based on the product size and shape.

Examples large airplanes, ships and rockets. A project layout is similar in concept to the

FPL. (commercial building, bridges)


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In product layout or product flow layoutmachines are organized to conform(comply withrules) to the sequence of the operationsrequired to produce the product.

An assembly line is a product layout, becazassembly facilities are organized according tothe sequence of the steps reqd to produce theitem.

If one part of line stops, the entire line mayhave to remain idle until the problem iscorrected.

Transfer lines are expensive & inflexible.


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A process layout groups a similar machines

having similar functions.

A typical process layout would group into

lathes(shaping metal) in one area, drills inone area, & so on.

Process layouts are most effective when

there is a wide variation in product

mix.(biscuit-Parle-G, car-Tata) Each product has a different routing

sequence associated with it.


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To implement a group technology layout

parts must be identified and grouped based

on similarities in manufacturing function or

design. Ex: manufacturing airplane which may

include thousands of parts which might be

grouped into 50 or so part families.


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Line balancing is an analysis process that tries to

equally divide the work to be done among

workstations so that the no. of workers/workstations

required on a production line is reduced.

Cycle time: the time in minutes the products comingoff the end of a production line.

cycle time = Productive time/hr = 54 min/hr

Demand/hr 540 calc/hr

= 0.1 min/calc

Min No. of workstations = sum of all task times

Cycle time


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Determine which tasks must be performed tocomplete one unit of a particular product.

Determine the sequence in which the tasks must be

performed.

Draw a precedence diagram. [it is a flowchartwherein circles represent tasks and connecting

arrows represents precedence]

Estimate task times.

Calculate the cycle time. Calculate the min. number of workstations.

Use one of the heuristics to assign tasks to

workstations so that the production line is balanced.


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Researchers have used linear programming,dynamic programming, & other mathematical

models to study line-balancing problems. But

these methods are beyond the scope.

Heuristic methods are based on simple rules,have been used to develop good solutions.

Incremental utilization heuristic

IUH simply adds tasks to a workstation in order of

task precedence one at a time until utilization is

100% or is observed to fall.


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Longest-tasks-time heuristic

The LTT heuristic adds tasks to a workstation one

at a time in the order of task precedence. If a

choice must be made b/n two/more tasks the

one with the longest task time is added. Taskswith shorter times are then saved for fine tuning

the solution.


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Aproduct is anything that is capable of satisfying a

felt need. A new product is the one which is truly

innovative & is significantly different from other

existing products.

The development of a new product passes thru seven

distinct stages.

Needs Identification Advance product planning

Advance Design Detailed Engineering Design

Production process design & development Product

Evaluation & Improvement Product use & Support.


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Needs Identification

New product development starts with an idea. Ideasemanate from customers, top management, staff ofthe mktg, production dept or from the engg section.

Advance Product Planning

Includes preliminary mkt analysis, clarifyingoperational requirements, establishing design

criteria. Estimating logistics requirements for producing,

distributing & maintaining the product in the mkt.

Conceptual design for pen would articulate itslength, weight, strength, shape, color, price etc.


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Advance Design

In this stage it involves detailed investigation by

basic & applied researchers into technical feasibility.

Detailed Engineering Design

It involves analysis, experimentation, & data

collection to find designs that meet several design

objectives such as reliability, safety, maintainability,producibility.


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Production Process Design & Development

Armed with the detailed product design, engineers &

manufacturing specialists prepare plans for material

acquisitions, production, warehousing, transportation& distribution.

This also involves planning for other supporting

systems such as controls, info & human resources.


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Product Evaluation & Improvement

Field performance & failure data, technical

breakthroughs in materials & equipment and formal

research are used to monitor, analyze & if necessaryredesign.

Product use & support

Support systems might educate users on specificapplication of the product, provide warranty & repair

services, distribute replacement parts, upgrade the

product with design improvements.


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Production It is a conversion of raw materials into the end

product by using processes, machines, men, tools

etc.

It is a process by which goods & services are created. Production Management

PM is means application of mgmt principles to the

production function in a factory. It involves the

application of planning, organizing, directing &controlling to the production process.

5 Ps of P&OM

Product, process, plant, programmes & people.


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Process It is asystematic series of actions directed to the

achievement of a goal.

It should be goal oriented, systematic, capable one.

Flowprocess chart

Flow process chart is a graphic representation of all:

Operations

Transportations

Inspections

Delays

Storages


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It seeks to increase the productivity by improvingways & means of doing work.

It is an analysis of a specific job in order to find most

efficient method in terms of cost, time & effort.

Work study

Method study

Time Study (Work

measurement)

Improved

planning

Higher

productivity


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To save the time & cost To analyse the present method & develop a new

improved method of production.

To increase the productivity

To improve the efficiency of work so that resourcescan be used efficiently used.


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Reduce the cost & time for manufacturing of theproduct.

Leads to production of more qualitative product in

turn more profits.

Improved layout Better working conditions to employees

Basis of rewards.

Provide better control and performance.


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It is a process of subjecting work to systematic,critical scrutinizing in order to make it more

effective & efficient.

The systematic recording & critical examination of

ways of doing things in order to make improvementsis known as Method study.


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Analyze methods of work Gain insight in how work is performed

Document methods of work

Improve methods of work

Enable planning by providing data

Disable possible hazards & dangers to safety


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Select (the work to be done) Record (all relevant info about that work)

Examine (the recorded info)

Develop (an improved way of doing things)

Implement (the new method as standard practice)

Maintain (the new standard proactive)


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Better understanding of work performed. Improved operator performance.

More safety less risks from hazards for health &

assets.

Saves the cost and time.


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It is application of techniques designed to establishthe time for a worker to carry out task at a defined

rate of working.

Objectives of Time Study

Establish standard times Rate operator performance

Gain info to calculate overall production capabilities

& data for capacity planning.

Establish the total work content of finished goods.


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Knowledge about standard times to be expected Ability to estimate total work content

Operators can be appraised on factual grounds

Some labor regulation might require standard times

on the basis of solving labor disputes.


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Stopwatch time study Using synthetic time standards

Work sampling

Stopwatch time study

This time study makes direct observations by means

of a simple stop watch measuring, generally to the

precision of 0.01 minute.

The actual performance is studied by collecting data& direct observations by means of sample.


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Synthetic time standards

In this method work is sub divided into certain

standard components for which standard times are

available from previously established times.

A predetermined motion time system (PMTS) is

frequently used to set labor rates in industry byquantifying the amount of time required to perform

specific tasks.

Work Sampling It is a work measurement technique where

observation about work are collected at discrete

time interval, either periodic or random.


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