2. Production Systems
Plant Location & Layout
Production Planning & Control
Maintenance Management
Inspection
Work Study
Lean Production Systems
Nishant Wasatkar MOM
3. Production can be defined as the process of
converting inputs into desired output thereby
adding value to some entity.
Production function brings together people,
machines & materials to provide goods &
services satisfying the wants of people.
Nishant Wasatkar MOM
4. Adjustments Monitor
Needed Output
INPUTS Conversion
Process Outputs
Labour
Materials Goods &
Equipment Services
Capital Comparison
Actual Vs
Planned
Nishant Wasatkar MOM
5. Manufacturing Cycle Time/ Lead Time
Inventory
Work in progress (WIP)
Material Handling (Manual/Automated)
General Purpose Machines (GPM)
Special Purpose Machines (SPM)
Product Layout
Process Layout
Nishant Wasatkar MOM
10. Milling
Assembly
& Test Grinding
Drilling Plating
Process Layout - work travels
to dedicated process centers
Nishant Wasatkar MOM
11. Primary Objective:
To produce goods & services of quality
accepted by customer, in desired quantities,
according to time schedules & at minimum
cost.
Nishant Wasatkar MOM
12. Effectiveness:
Producing right kind of goods & services
that satisfy customers needs.
Efficiency :
Maximizing output of goods & services
with minimum resource inputs.
Quality:
Ensuring that goods & services produced
conform to pre-set quality specifications.
Nishant Wasatkar MOM
13. Lead Time:
Minimizing mfg. cycle time by reducing
delays, waiting time and idle time.
Capacity Utilization:
Maximizing utilization of manpower,
machines and rest of resources.
Cost:
Minimizing cost of producing goods or
services.
Nishant Wasatkar MOM
15. Organizing
Work study & job design
Controlling
◦ Production control
◦ Inventory control
◦ Quality control
◦ Maintenance & replacement
◦ Cost reduction & cost Control
Nishant Wasatkar MOM
16. The factory system was a method
of manufacturing first adopted in England at
the beginning of the Industrial Revolution in
the 1750s and later spread abroad.
Traditionally, each worker used to create a
separate part of the total assembly of a
product. In factory system all resources of
productions were bring together under one
roof.
Nishant Wasatkar MOM
17. Manufacturing system need to interact with both
internal & external environment.
Internal External
Environment: Environment:
◦ Engineering ◦ Customers
◦ Marketing ◦ Competitors
◦ Personnel ◦ Suppliers
◦ Accounts/Finance ◦ Labor Unions
Nishant Wasatkar MOM
18. The selection of manufacturing system is a
strategic decision. The system selected
should ensure
◦ Desired output
◦ Required Quality
◦ Cost effectiveness
Nishant Wasatkar MOM
19. TYPES OF MANUFACTURING
SYSTEMS
INTERMITTENT CONTINUOUS
PRIDUCTION PRODUCTION
PROJECT JOBBING BATCH MASS/FLOW PROCESS
PRODUCTION PRODUCTION PRODUCTION PRODUCTION PRODUCTION
Nishant Wasatkar MOM
20. Definite beginning and definite end.
Non uniform requirement of resources
Involvement of different agencies
Fixed Position layout
◦ E.g. production of ships, aircrafts, construction of
buildings, bridge etc.
High cost overruns
◦ Often delays takes place in projects which are very
expensive due to cost of factors of production &
penalties.
Nishant Wasatkar MOM
21. Personnel Problems
◦ If labor are borrowed from outside for short
duration, involvement in project will be limited.
◦ Since project has a limited period, the staff starts
spending more time for getting prepared for next
project.
◦ Generally sites of project are in underdeveloped region &
it may change from project to project which causes
dislocation of the normal life.
Scheduling & Control
◦ As large number of activities involve in project
completion by different agencies with strict
precedence, scheduling & control becomes complex &
very important.
Nishant Wasatkar MOM
22. Small production runs.
Discontinuous flow of materials
◦ Imbalance in operation wise work content leads to
discontinuity in materials flow.
Disproportionate manufacturing cycle time
◦ Lack of materials/components, imbalanced work
flow, design changes, design errors detected during
manufacture, inaccurate work measurements etc
will lead to extended mfg cycle time.
General purpose machines & process layout.
Nishant Wasatkar MOM
23. Highly skilled labor
Highly competent knowledgeable supervision
Large work in progress
Limited functions of production planning &
control
◦ Materials are indented & purchased on receipt of orders.
◦ Tools control function is simple. Standard tools are
stocked while special tools are either made or purchased
on request.
◦ Process planning activity is almost absent.
◦ The scheduling activity is decentralized. A schedule is
prepared to show the start and completion date of each
major component of the product.
Nishant Wasatkar MOM
24. Short runs
Skilled labor in specific trades
Supervisor to possess knowledge of a specific
process.
General purpose machines & process type
layout.
Manual material handling
Mfg cycle time affected due to queues
Large work in progress
Flexibility of production schedules
Need to have production planning & control.
Nishant Wasatkar MOM
25. Continuous flow of materials
Special purpose machines & product type
layout
Mechanized materials material handling
Low skilled labor
Short manufacturing cycle time
Easy supervision
Limited work in progress
Lesser flexibility in production schedules.
Nishant Wasatkar MOM
26. Process production is characterized by
manufacture of a single product produced
and stocked.
Special purpose machines with built in
controls
Highly mechanized materials handling
Virtually zero manufacturing cycle time
Low skilled labor
Supervisor to be process specialist
Negligible work in progress
Nishant Wasatkar MOM
28. High product variety require highly skilled
labor, general purpose machinery, detailed &
sophisticated production planning & control
systems.
Low product variety enables the use of low
skilled labor, highly automated mass
production processes using special purpose
machinery and simple production planning &
control systems
Nishant Wasatkar MOM
29. JOBBING
BATCH
MASS
PROCESS
ONE DEGREE OF REPETITIVENESS MANY
Nishant Wasatkar MOM
30. Fixed cost are high for continuous process &
low for intermittent process
While variable costs are more for intermittent
process & less for continuous process.
Intermittent process therefore will be cheaper
to install and operate at low volumes &
continuous process will be economical to use
at high volumes.
Nishant Wasatkar MOM
31. Total Cost (Intermittent) Total Cost
(Continuous)
Variable Cost
(Intermittent)
Variable Cost
(Continuous)
Fixed Cost
Cost
(Continuous)
Fixed Cost
(Intermittent)
Intermittent Continuous
Manufacturing Manufacturing Range
Range Volume Nishant Wasatkar MOM
32. Flexibility implies ability of manufacturing
system to manufacture variety of products.
Greater flexibility will be achieved in
intermittent production which also results in
higher inventories, long mfg lead times &
complex planning & control.
Nishant Wasatkar MOM
33. Efficiency measures the speed and the cost of
manufacturing system.
Depending on sales volume & product variety
process has to be considered which will give
the best efficiency in terms of machines &
manpower utilization.
Environment brings new technologies, as
market preferences change the
manufacturing system has to be changed
accordingly. E.g. Furniture manufacturer.
Nishant Wasatkar MOM