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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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