This document discusses key concepts related to production including process, efficiency, productivity, and throughput. It provides examples to illustrate these concepts and how they are calculated. Specifically, it defines production as the number of outputs from a process. Efficiency is the ratio of output to input, while productivity expresses efficiency as a ratio of output to time. Throughput is the net output after all process steps. The document also discusses factors that affect productivity and the concept of line balancing to reduce bottlenecks and idle time.

1. Production Concepts Ideas for Today and Tomorrow Keynes Austin

2. OBJECTIVE…. Process Production Efficiency Productivity Throughput How to calculate throughput? Resource planning Line Balancing

3. What is a process? INPUT OUTPUT ACTIVITY

4. Example

5. Different Manufacturing Processes Car Manufacturing Process Transaction Process ASSEMBLY PAINTING INSPECTION DOWNLOAD KEYING CONVERTER SHIPMENT

6. What is Production? Production is measured in numbers. Examples 1000 pens are produced 100 cars are produced 300 books produced 200 forms produced Production is the number of products (output) delivered from a process.

7. Efficiency Efficiency is a performance measure of a production process. It can be defined as the ratio of output and input. Example 1 - Output: 10kms - Input: 1 litre of diesel - Efficiency = 10kms per litre (referred to as mileage) Example 2 - Output: 990grams of wheat flour - Input: 1000 grams of wheat in the flour - Efficiency = 99%

8. What is Productivity? The Efficiency measure, when expressed as a ratio of output and time is called productivity. “ Productivity is the output delivered within a specified time frame using specified resources.” Example: 10 pens produced with 1 manpower 18 pens produced with 2 manpower In the above example, clearly 1 is better. 33 pens produced with 3 manpower and 9 defects. Now Which one is best among these three examples cited above?

9. Units of Productivity Measurement Pens per hour Cars per day Kilo characters per hour Forms per hour Books per man shift

10. What is Throughput? Throughput is the net output delivered after performing various (sub) process steps involved in the production process.

11. Sample Throughput Computation

12. Deriving Formula for Throughput Throughput = {1/(1/x1+1/x2+1/x3)} Where x1, x2, x3 are the productivity at each process step.

13. Resource Planning Inputs for Resource Planning Volume Time (no: of working days) Throughput Example How many manpower is required to do 10,000 pens in 25 days, if throughput is 21pens/hour? Output per day per person = 21*7 = 147 Manpower required for 10,000 pens = 10,000/(147*25) = 2.72

14. Factors Affecting Productivity Process Related Factors Complexity Instruction Interpretation effectiveness System & Software configuration (like application, hardware etc) Connectivity People & Environment Factors Ergonomics like ambience, lighting, operator’s relative position to machine, etc. Motivation level of the employee. Other external factors having psychological impact on the operators.

15. Line Balancing Line Balancing is used to schedule and control upstream processing steps in a production system - To clear any bottle neck - To reduce any idle time in the system thereby increasing the overall efficiency. See Illustration below: There are three process in the production system and the production required is 200 for the day. What would be the total manpower required and how many in each process?

16. Excercises 1. Forms processing line produces 1000 forms in 8 hours. What is the production and Productivity? 2. The following are the productivity numbers of forms processing line Downloading = 100 forms/hour Keying = 20 forms/hour Inspection = 25 forms/hour a) Compute the throughput? b) What is the manpower that is required if we need to deliver 14000 forms per month (20 working days)?

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18. Many Thanks