Operation & material management-line balancing & capacity planning decision
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This document discusses line balancing and capacity planning. It defines line balancing as balancing the workload across assembly line stations to optimize output, reduce costs, and identify bottlenecks. Three types of assembly line models are described: single-model, mixed-model, and multi-model. Capacity planning is defined as determining short and long-term needs by estimating requirements for machines, labor, resources and analyzing processes. It helps make strategic, tactical and operational decisions about system availability and sizing capacity.
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Production-line balancing & capacity planning decision
This document discusses line balancing and capacity planning techniques. It describes line balancing as a tool to increase assembly line output and reduce costs by optimizing work distribution across stations. Three types of assembly line models are described: single model, mixed model, and multi-model. The purpose of line balancing is outlined as equalizing workloads, identifying bottlenecks, setting line speed, determining station and labor costs. Capacity planning is defined as determining short and long term needs by analyzing current capacity, utilization rates, and estimating resource and labor requirements. The document provides examples of how these techniques can help operations planning.
Types of manufacturing_systems
This document provides an overview of different production systems, including job shops, batch production, and mass production. It also discusses flexible manufacturing systems (FMS) and how they provide increased flexibility over mass production while still enabling higher volumes than a job shop. Programmable automation, specifically computer numerical control (CNC), is also introduced as a way to increase flexibility through computer-controlled machine tools. CNC has allowed for numerical control of machining processes like milling, drilling, boring, turning, grinding, sawing, and electrical discharge machining (EDM).
Tools for capacity planning, measurement of capacity, capacity planning process
Southwest Airlines is known for its efficient capacity planning process. They carefully forecast demand and calculate the optimal fleet size to meet demand. They use simulation models to determine the ideal capacity cushion to account for variability in demand. If simulations show demand will exceed capacity, Southwest will lease additional planes on a short-term basis to avoid turning customers away. This flexible approach has allowed Southwest to consistently meet demand while maximizing efficiency.
Capacity Planning
This document discusses capacity planning and identifies key aspects of evaluating capacity requirements and plans. It describes measuring customer demand through forecasts and measuring current organizational capacity levels. It then evaluates three approaches to capacity planning: level capacity which fixes capacity at a constant level; chase demand which adjusts capacity to match fluctuating demand; and demand management which attempts to adjust demand to meet available capacity through strategies like varying price, marketing efforts, or an appointment system.
4.types of manufacturing system and layouts
Mass production involves breaking tasks down into their simplest elements and grouping them according to production norms. It uses assembly lines where material moves continuously between work stations to complete portions of the process. It is suitable for large quantities of standardized products with less variety produced continuously over time. Batch production uses general machines to produce different products in batches when volumes do not warrant dedicated lines for each. Economic lot size balances carrying costs of inventory with ordering costs to minimize total costs.
capacity planning om
Capacity planning is the process of determining the production capacity needed to meet changing demand. It involves assessing existing capacity, forecasting future needs, identifying options to modify capacity, evaluating alternatives, and selecting the best option. Measures of capacity include design capacity which is the maximum output rate, and effective capacity which accounts for downtime. Capacity planning considers options over different time horizons and aims to balance utilization and efficiency.
Capacity planning
1. Capacity planning involves estimating current capacity, forecasting future capacity needs, identifying options to meet needs, and selecting sources of additional capacity.
2. Capacity can be measured using output rate, input rate, capacity utilization percentage, or capacity cushion and is important for meeting demands, costs, competitiveness, and planning.
3. The document discusses definitions of capacity, the capacity planning process, measurements of capacity, forecasting demands, and considerations for evaluating capacity alternatives.
Advanced manufacturing systems
The document discusses advanced manufacturing systems and compares conventional and advanced manufacturing. It describes types of advanced manufacturing systems like JIT, CIM, and FMS. JIT focuses on producing only what is needed when it is needed to reduce inventory. CIM uses computers to control manufacturing processes to increase speed and reduce errors. FMS allows flexibility to react to changes in production. The document concludes that advanced manufacturing uses computer technologies and skilled workers to efficiently produce a variety of products in both small and large volumes.
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Production-line balancing & capacity planning decision
This document discusses line balancing and capacity planning techniques. It describes line balancing as a tool to increase assembly line output and reduce costs by optimizing work distribution across stations. Three types of assembly line models are described: single model, mixed model, and multi-model. The purpose of line balancing is outlined as equalizing workloads, identifying bottlenecks, setting line speed, determining station and labor costs. Capacity planning is defined as determining short and long term needs by analyzing current capacity, utilization rates, and estimating resource and labor requirements. The document provides examples of how these techniques can help operations planning.
Types of manufacturing_systems
This document provides an overview of different production systems, including job shops, batch production, and mass production. It also discusses flexible manufacturing systems (FMS) and how they provide increased flexibility over mass production while still enabling higher volumes than a job shop. Programmable automation, specifically computer numerical control (CNC), is also introduced as a way to increase flexibility through computer-controlled machine tools. CNC has allowed for numerical control of machining processes like milling, drilling, boring, turning, grinding, sawing, and electrical discharge machining (EDM).
Tools for capacity planning, measurement of capacity, capacity planning process
Southwest Airlines is known for its efficient capacity planning process. They carefully forecast demand and calculate the optimal fleet size to meet demand. They use simulation models to determine the ideal capacity cushion to account for variability in demand. If simulations show demand will exceed capacity, Southwest will lease additional planes on a short-term basis to avoid turning customers away. This flexible approach has allowed Southwest to consistently meet demand while maximizing efficiency.
Capacity Planning
This document discusses capacity planning and identifies key aspects of evaluating capacity requirements and plans. It describes measuring customer demand through forecasts and measuring current organizational capacity levels. It then evaluates three approaches to capacity planning: level capacity which fixes capacity at a constant level; chase demand which adjusts capacity to match fluctuating demand; and demand management which attempts to adjust demand to meet available capacity through strategies like varying price, marketing efforts, or an appointment system.
4.types of manufacturing system and layouts
Mass production involves breaking tasks down into their simplest elements and grouping them according to production norms. It uses assembly lines where material moves continuously between work stations to complete portions of the process. It is suitable for large quantities of standardized products with less variety produced continuously over time. Batch production uses general machines to produce different products in batches when volumes do not warrant dedicated lines for each. Economic lot size balances carrying costs of inventory with ordering costs to minimize total costs.
capacity planning om
Capacity planning is the process of determining the production capacity needed to meet changing demand. It involves assessing existing capacity, forecasting future needs, identifying options to modify capacity, evaluating alternatives, and selecting the best option. Measures of capacity include design capacity which is the maximum output rate, and effective capacity which accounts for downtime. Capacity planning considers options over different time horizons and aims to balance utilization and efficiency.
Capacity planning
1. Capacity planning involves estimating current capacity, forecasting future capacity needs, identifying options to meet needs, and selecting sources of additional capacity.
2. Capacity can be measured using output rate, input rate, capacity utilization percentage, or capacity cushion and is important for meeting demands, costs, competitiveness, and planning.
3. The document discusses definitions of capacity, the capacity planning process, measurements of capacity, forecasting demands, and considerations for evaluating capacity alternatives.
Advanced manufacturing systems
The document discusses advanced manufacturing systems and compares conventional and advanced manufacturing. It describes types of advanced manufacturing systems like JIT, CIM, and FMS. JIT focuses on producing only what is needed when it is needed to reduce inventory. CIM uses computers to control manufacturing processes to increase speed and reduce errors. FMS allows flexibility to react to changes in production. The document concludes that advanced manufacturing uses computer technologies and skilled workers to efficiently produce a variety of products in both small and large volumes.
6. process selection and facility layout
The document discusses process selection and facility layout. It describes different types of processes - job shop, batch, repetitive, continuous flow, and project - and factors like volume, variety, and flexibility that determine which type is suitable. It also covers automation levels from fixed to programmable to flexible. Facility layout depends on the process and aims to optimize efficiency, flow, and safety. Product and process layouts are introduced.
Capacity planning ppt
The document discusses capacity planning for products and services. It explains key concepts like capacity, effective capacity, and utilization. It also outlines factors to consider when developing capacity alternatives and approaches for evaluating alternatives, including cost-volume analysis, break-even analysis, financial analysis, and waiting-line analysis. The goal of capacity planning is to determine the appropriate level and timing of capacity to meet future demand in a cost-effective manner.
Process selection and capacity planning
The document discusses capacity planning and outlines the key steps involved which are: defining capacity, determining capacity requirements, developing capacity alternatives, and evaluating capacity alternatives. It defines different types of capacity and how to measure it. Factors that determine effective capacity are also examined. Demand patterns and fluctuations are important to consider when determining short and long-term capacity requirements. Quantitative techniques like cost-volume analysis can be used to evaluate capacity alternatives from an economic standpoint.
Capacity planning
Capacity planning is the process of determining the production capacity needed by an organization to meet changing demands. It involves assessing existing capacity, forecasting future needs, identifying options to modify capacity, evaluating financial and technological alternatives, and selecting the most suitable option. Capacity planning can be classified as long term or short term based on time horizon and finite or infinite based on resources employed. Long term planning accommodates major changes like new products or facilities while short term addresses intermediate fluctuations through overtime or subcontracting. Factors affecting capacity planning include controllable aspects like labor and facilities as well as less controllable issues like absenteeism or machine breakdowns.
Strategic capacity planning for products and services
This document discusses strategic capacity planning for products and services. It defines key capacity planning terms like design capacity, effective capacity, and actual output. It discusses factors that determine effective capacity such as facilities, products, processes, human factors, and external factors. The document outlines the capacity planning process, including estimating future capacity needs, evaluating existing capacity, identifying alternatives, and implementing solutions. It also discusses challenges in planning service capacity and tools for analysis like cost-volume analysis and financial analysis.
Capacity planning
Capacity planning is a long-term decision that establishes a firm's overall level of resources. Capacity decisions affect the production lead time, customer responsiveness, operating cost and company ability to compete. Inadequate capacity planning can lead to the loss of the customer and business. Excess capacity can drain the company's resources and prevent investments into more lucrative ventures. The question of when capacity should be increased and by how much are the critical decisions. Failure to make these decisions correctly can be especially damaging to the overall performance when time delays are present in the system.
Capacity planning
Capacity planning is the process of determining a company's production capacity needed to meet changing demands. It involves determining the type, amount, and timing of capacity required. Key decisions include selecting the appropriate level and flexibility of facilities while maintaining balance. The process includes estimating future needs, evaluating existing capacity, identifying alternatives, analyzing costs, assessing qualitative factors, selecting an alternative, and monitoring results. Efficiency and utilization are measured by comparing actual output to effective and design capacities. Economies and diseconomies of scale affect costs based on output levels. Cost-volume analysis examines the relationships between costs, revenues, and profits at different volumes.
Capacity planning
Capacity planning is the process of determining the production capacity needed by an organization to meet changing demands for its products
2. scope of operations management
Operations management involves product selection and design, process selection and planning, location of facilities, layout and material handling, and capacity planning. It helps companies select the right products and designs to be competitive, optimize outputs from processes, select locations that minimize costs, arrange layouts for smooth production flow, and plan appropriate capacities using tools like marginal costing and linear programming. It also aids in making short term operational decisions around production planning, control, inventory control, quality control, and cost reduction. There are different types of production systems like mass, batch, job shop and project production.
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This document discusses production and operations management. It begins with definitions of production management and operations management. It then provides a historical overview of the evolution of the field from Adam Smith's specialization of labor to more modern contributions. The rest of the document defines concepts related to production systems including inputs, transformation processes, outputs, and classifications like job shop, batch, mass, and continuous production.
Capacity planning
Capacity planning involves determining the production capacity needed by an organization to meet demand. It considers both short-term and long-term managerial planning and control of resources. Key aspects of capacity planning include designing facilities to accommodate large changes in long-term demand, making limited adjustments for seasonal fluctuations using methods like inventory control and adjusting workforce size, and making finer short-term adjustments to meet random demand changes. Effective capacity planning requires evaluating factors like technology, costs, flexibility, and demand uncertainty when selecting optimal plant sizes and production levels.
CAPACITY PLANNING
Contents of Presentation-
Capacity Planning:
- Meaning
- Forecasting
- Reasons
- Importance
- Examples
- Capacity Terminology
- Efficiency & Utilization
- Calculation of capacity Utilization
- Determinants of Effective Capacity
- Calculating Processing Requirements
- Capacity Planning Process
- Planning Over a Time Horizon
- Economies of Scale
- Optimal Rate of Output
-Capacity Planning Alternatives Evaluating Models
Cost Volume Analysis: Break-even Analysis
Decision Theory
Financial Analysis
Waiting-Line Analysis
- PROCESS PLANNING
Methods
- INTERACTION OF PLANNING FUNCTIONS..
-
Production and Operations Management
This document discusses several production management concepts including mass production, lean production, fixed position layout, and total productive maintenance (TPM). It provides details on:
- Mass production involves making many copies of standardized products quickly using assembly line techniques. The Ford Model T exemplified this approach.
- Lean production aims to maximize value and minimize waste from the customer's perspective. Subway utilizes some lean concepts like just-in-time assembly to make sandwiches.
- Fixed position layout involves assembling large or fragile products on-site rather than moving them, bringing personnel, supplies, and equipment to the product. Shipbuilding often uses this approach.
- TPM originated in Japan to improve machine availability through operator
Types of Manufacturing system
This document discusses different types of manufacturing systems. It defines a manufacturing system as a collection of integrated equipment and human resources that perform processing and/or assembly operations to transform raw materials into a finished product. Manufacturing systems involve input, transformation, and output processes. Key factors in selecting a manufacturing system include volume, capacity, flexibility, lead time, efficiency, and environmental impact. Examples of manufacturing systems provided include single station cells, machine clusters, manual assembly lines, automated transfer lines, and flexible manufacturing systems. Components of manufacturing systems are production machines, material handling systems, computer systems, and human resources. The document further classifies manufacturing systems as intermittent or continuous production systems based on whether production flows are started and stopped irregularly or operate
PRODUCTION PLANNING AND CONTROL-Unit 3
Product planning identifies market requirements to define a product's features. It serves as the basis for pricing, distribution, and promotion decisions. Value analysis aims to increase value, defined as function over cost, by improving function or reducing cost. Lack of product planning can lead to unsatisfied customers, quality issues, and loss of brand name. Process planning involves routing, scheduling, dispatching, and follow up based on product information, processes, capacity, orders, due dates, and resources. Economic batch quantity determines the optimal batch size to minimize average costs by balancing setup costs and inventory holding costs.
Plant location & layout
The document discusses factors to consider when determining a plant's location and layout. It outlines key location factors like availability of resources, infrastructure, and labor. It also describes different types of plant layouts based on production volume and variety, including process, product, and group layouts. The objectives, costs, and advantages of different layout types are presented. Methods for analyzing relationships between activities and determining optimal layout configurations like activity relationship diagrams and Muther grids are also covered.
S ch6
The document discusses process design and facility layout. It covers types of processes like projects, job shops, batch processing, repetitive/assembly and continuous processing. The key factors in selecting a process are variety, flexibility, volume and the tradeoff between them. Layout types include product layouts that group equipment by product steps, process layouts that group by function, and combination layouts. The document provides examples of line balancing to optimize workstation times and productivity.
UNIT 3 - PRODUCTION PLANNING AND PROCESS PLANNING
This document discusses product planning, value, customer satisfaction, logistics processes, and economic batch quantity modeling. It notes that product planning identifies market requirements to define a product's features and serves as the basis for pricing, distribution, and promotion decisions. It also defines value as the ratio of function to cost, which can be increased by improving function or reducing costs. Additionally, it lists factors that can lead to customer dissatisfaction and outlines key considerations for logistics like products, processes, capacity, orders, and resources. Finally, it provides background on economic batch quantity modeling including assumptions, variables, and the formula for calculating optimal batch size.
1.4 advanced manufacturing systems
This document discusses advanced manufacturing systems used by companies to improve production levels. It describes processes like CAD/CAM, MRP, JIT, TQC, CNC, and rapid prototyping. CAD/CAM systems aid in design and control of machine tools. MRP software plans production schedules and inventory levels. JIT focuses on reducing production lead times. TQC emphasizes quality control through process management. CNC automates machine tools using programmed commands. And rapid prototyping quickly fabricates physical models using 3D printing.
Plant layout and its types
The document discusses factors affecting plant layout and different types of layouts. It describes 7 categories of factors: materials, machinery, labor, material handling, auxiliary services, the building, and future changes. It then explains different layout types like process, product, and fixed position layouts. It provides examples of companies that have implemented innovative layouts, such as McDonald's kitchen redesign that saves $100 million per year through steps like assembling sandwiches in order.
Capacity planning ppt @ bec doms
The document discusses various capacity planning concepts including defining capacity, capacity considerations, managing demand, capacity planning processes, and applying decision trees and net present value analysis to capacity decisions. It provides learning objectives on capacity related terms and explains approaches to matching capacity to demand such as adjusting staffing, equipment, production methods, or product redesign.
Capacity Planning
The document discusses capacity planning, which involves determining the production capacity needed by an organization to meet changing demand. It covers determining current and future capacity needs, identifying options to modify capacity, and addressing imbalances between demand and capacity. Short-term adjustments and long-term responses are discussed. Models like present value analysis, aggregate planning, and decision trees can be useful for capacity planning. Economies of scale and concepts like efficiency and utilization are also summarized.
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6. process selection and facility layout
The document discusses process selection and facility layout. It describes different types of processes - job shop, batch, repetitive, continuous flow, and project - and factors like volume, variety, and flexibility that determine which type is suitable. It also covers automation levels from fixed to programmable to flexible. Facility layout depends on the process and aims to optimize efficiency, flow, and safety. Product and process layouts are introduced.
Capacity planning ppt
The document discusses capacity planning for products and services. It explains key concepts like capacity, effective capacity, and utilization. It also outlines factors to consider when developing capacity alternatives and approaches for evaluating alternatives, including cost-volume analysis, break-even analysis, financial analysis, and waiting-line analysis. The goal of capacity planning is to determine the appropriate level and timing of capacity to meet future demand in a cost-effective manner.
Process selection and capacity planning
The document discusses capacity planning and outlines the key steps involved which are: defining capacity, determining capacity requirements, developing capacity alternatives, and evaluating capacity alternatives. It defines different types of capacity and how to measure it. Factors that determine effective capacity are also examined. Demand patterns and fluctuations are important to consider when determining short and long-term capacity requirements. Quantitative techniques like cost-volume analysis can be used to evaluate capacity alternatives from an economic standpoint.
Capacity planning
Capacity planning is the process of determining the production capacity needed by an organization to meet changing demands. It involves assessing existing capacity, forecasting future needs, identifying options to modify capacity, evaluating financial and technological alternatives, and selecting the most suitable option. Capacity planning can be classified as long term or short term based on time horizon and finite or infinite based on resources employed. Long term planning accommodates major changes like new products or facilities while short term addresses intermediate fluctuations through overtime or subcontracting. Factors affecting capacity planning include controllable aspects like labor and facilities as well as less controllable issues like absenteeism or machine breakdowns.
Strategic capacity planning for products and services
This document discusses strategic capacity planning for products and services. It defines key capacity planning terms like design capacity, effective capacity, and actual output. It discusses factors that determine effective capacity such as facilities, products, processes, human factors, and external factors. The document outlines the capacity planning process, including estimating future capacity needs, evaluating existing capacity, identifying alternatives, and implementing solutions. It also discusses challenges in planning service capacity and tools for analysis like cost-volume analysis and financial analysis.
Capacity planning
Capacity planning is a long-term decision that establishes a firm's overall level of resources. Capacity decisions affect the production lead time, customer responsiveness, operating cost and company ability to compete. Inadequate capacity planning can lead to the loss of the customer and business. Excess capacity can drain the company's resources and prevent investments into more lucrative ventures. The question of when capacity should be increased and by how much are the critical decisions. Failure to make these decisions correctly can be especially damaging to the overall performance when time delays are present in the system.
Capacity planning
Capacity planning is the process of determining a company's production capacity needed to meet changing demands. It involves determining the type, amount, and timing of capacity required. Key decisions include selecting the appropriate level and flexibility of facilities while maintaining balance. The process includes estimating future needs, evaluating existing capacity, identifying alternatives, analyzing costs, assessing qualitative factors, selecting an alternative, and monitoring results. Efficiency and utilization are measured by comparing actual output to effective and design capacities. Economies and diseconomies of scale affect costs based on output levels. Cost-volume analysis examines the relationships between costs, revenues, and profits at different volumes.
Capacity planning
Capacity planning is the process of determining the production capacity needed by an organization to meet changing demands for its products
2. scope of operations management
Operations management involves product selection and design, process selection and planning, location of facilities, layout and material handling, and capacity planning. It helps companies select the right products and designs to be competitive, optimize outputs from processes, select locations that minimize costs, arrange layouts for smooth production flow, and plan appropriate capacities using tools like marginal costing and linear programming. It also aids in making short term operational decisions around production planning, control, inventory control, quality control, and cost reduction. There are different types of production systems like mass, batch, job shop and project production.
Production and Operation Management
This document discusses production and operations management. It begins with definitions of production management and operations management. It then provides a historical overview of the evolution of the field from Adam Smith's specialization of labor to more modern contributions. The rest of the document defines concepts related to production systems including inputs, transformation processes, outputs, and classifications like job shop, batch, mass, and continuous production.
Capacity planning
Capacity planning involves determining the production capacity needed by an organization to meet demand. It considers both short-term and long-term managerial planning and control of resources. Key aspects of capacity planning include designing facilities to accommodate large changes in long-term demand, making limited adjustments for seasonal fluctuations using methods like inventory control and adjusting workforce size, and making finer short-term adjustments to meet random demand changes. Effective capacity planning requires evaluating factors like technology, costs, flexibility, and demand uncertainty when selecting optimal plant sizes and production levels.
CAPACITY PLANNING
Contents of Presentation-
Capacity Planning:
- Meaning
- Forecasting
- Reasons
- Importance
- Examples
- Capacity Terminology
- Efficiency & Utilization
- Calculation of capacity Utilization
- Determinants of Effective Capacity
- Calculating Processing Requirements
- Capacity Planning Process
- Planning Over a Time Horizon
- Economies of Scale
- Optimal Rate of Output
-Capacity Planning Alternatives Evaluating Models
Cost Volume Analysis: Break-even Analysis
Decision Theory
Financial Analysis
Waiting-Line Analysis
- PROCESS PLANNING
Methods
- INTERACTION OF PLANNING FUNCTIONS..
-
Production and Operations Management
This document discusses several production management concepts including mass production, lean production, fixed position layout, and total productive maintenance (TPM). It provides details on:
- Mass production involves making many copies of standardized products quickly using assembly line techniques. The Ford Model T exemplified this approach.
- Lean production aims to maximize value and minimize waste from the customer's perspective. Subway utilizes some lean concepts like just-in-time assembly to make sandwiches.
- Fixed position layout involves assembling large or fragile products on-site rather than moving them, bringing personnel, supplies, and equipment to the product. Shipbuilding often uses this approach.
- TPM originated in Japan to improve machine availability through operator
Types of Manufacturing system
This document discusses different types of manufacturing systems. It defines a manufacturing system as a collection of integrated equipment and human resources that perform processing and/or assembly operations to transform raw materials into a finished product. Manufacturing systems involve input, transformation, and output processes. Key factors in selecting a manufacturing system include volume, capacity, flexibility, lead time, efficiency, and environmental impact. Examples of manufacturing systems provided include single station cells, machine clusters, manual assembly lines, automated transfer lines, and flexible manufacturing systems. Components of manufacturing systems are production machines, material handling systems, computer systems, and human resources. The document further classifies manufacturing systems as intermittent or continuous production systems based on whether production flows are started and stopped irregularly or operate
PRODUCTION PLANNING AND CONTROL-Unit 3
Product planning identifies market requirements to define a product's features. It serves as the basis for pricing, distribution, and promotion decisions. Value analysis aims to increase value, defined as function over cost, by improving function or reducing cost. Lack of product planning can lead to unsatisfied customers, quality issues, and loss of brand name. Process planning involves routing, scheduling, dispatching, and follow up based on product information, processes, capacity, orders, due dates, and resources. Economic batch quantity determines the optimal batch size to minimize average costs by balancing setup costs and inventory holding costs.
Plant location & layout
The document discusses factors to consider when determining a plant's location and layout. It outlines key location factors like availability of resources, infrastructure, and labor. It also describes different types of plant layouts based on production volume and variety, including process, product, and group layouts. The objectives, costs, and advantages of different layout types are presented. Methods for analyzing relationships between activities and determining optimal layout configurations like activity relationship diagrams and Muther grids are also covered.
S ch6
The document discusses process design and facility layout. It covers types of processes like projects, job shops, batch processing, repetitive/assembly and continuous processing. The key factors in selecting a process are variety, flexibility, volume and the tradeoff between them. Layout types include product layouts that group equipment by product steps, process layouts that group by function, and combination layouts. The document provides examples of line balancing to optimize workstation times and productivity.
UNIT 3 - PRODUCTION PLANNING AND PROCESS PLANNING
This document discusses product planning, value, customer satisfaction, logistics processes, and economic batch quantity modeling. It notes that product planning identifies market requirements to define a product's features and serves as the basis for pricing, distribution, and promotion decisions. It also defines value as the ratio of function to cost, which can be increased by improving function or reducing costs. Additionally, it lists factors that can lead to customer dissatisfaction and outlines key considerations for logistics like products, processes, capacity, orders, and resources. Finally, it provides background on economic batch quantity modeling including assumptions, variables, and the formula for calculating optimal batch size.
1.4 advanced manufacturing systems
This document discusses advanced manufacturing systems used by companies to improve production levels. It describes processes like CAD/CAM, MRP, JIT, TQC, CNC, and rapid prototyping. CAD/CAM systems aid in design and control of machine tools. MRP software plans production schedules and inventory levels. JIT focuses on reducing production lead times. TQC emphasizes quality control through process management. CNC automates machine tools using programmed commands. And rapid prototyping quickly fabricates physical models using 3D printing.
Plant layout and its types
The document discusses factors affecting plant layout and different types of layouts. It describes 7 categories of factors: materials, machinery, labor, material handling, auxiliary services, the building, and future changes. It then explains different layout types like process, product, and fixed position layouts. It provides examples of companies that have implemented innovative layouts, such as McDonald's kitchen redesign that saves $100 million per year through steps like assembling sandwiches in order.
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Strategic capacity planning for products and services
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Capacity Planning
The document discusses capacity planning, which involves determining the production capacity needed by an organization to meet changing demand. It covers determining current and future capacity needs, identifying options to modify capacity, and addressing imbalances between demand and capacity. Short-term adjustments and long-term responses are discussed. Models like present value analysis, aggregate planning, and decision trees can be useful for capacity planning. Economies of scale and concepts like efficiency and utilization are also summarized.
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Kingfisher Airlines- A Case Study
1) Kingfisher Airlines is an Indian airline based in Mumbai that began operations in 2005. It aimed to provide high-quality national and international service but struggled with financial losses.
2) The airline industry in India was dominated by state-owned carriers until the 1990s when private airlines entered the market. Kingfisher grew rapidly after acquiring Air Deccan in 2007 but soon faced severe financial troubles.
3) By 2009, Kingfisher was India's largest airline in terms of passengers carried but continued incurring large losses, which eventually led to the airline ceasing operations in 2012 due to insurmountable debt.
Process Strategies and Capacity Planning
The document discusses process strategy and capacity planning. It begins by defining process strategy as an organization's approach to transforming resources into goods and services. It then describes four main types of process strategies: process focus, repetitive focus, product focus, and mass customization focus. Each strategy is characterized based on factors like product variety, equipment use, and employee skills. The document also covers tools for analyzing and designing processes like flow diagrams, process charts, and time-function mapping.
Meaning Of Business Finance
Financial management deals with acquiring and allocating capital funds to meet a business' financial needs and objectives. It involves making decisions around how large and fast a firm should grow, what assets it should hold, and how it should structure its financing. The traditional approach to financial management focused on raising and administering funds, while the modern approach views it as integral to overall management, involving investment, financing, dividend, and funds requirement decisions aimed at profit maximization, wealth maximization, or stakeholder value.
Flexible manufacturing system(FMS).
The document discusses flexible manufacturing systems (FMS). It provides a history of FMS, describing how the concept originated in the 1960s and was first implemented by companies in the US, Germany, Russia, and Japan. It defines an FMS as an automated machine cell consisting of interconnected processing workstations and automated material handling. FMS offers benefits like reduced costs, optimized cycle times, and flexibility to handle different part styles and quick changeovers. It classifies FMS based on the number of machines and describes common components and layouts of FMS. Potential applications and advantages are also outlined, along with challenges associated with implementing FMS.
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Design of Production and Service Systems - Facilities
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IRJET- Basic Study of Assembly Line Balancing
1) The document discusses assembly line balancing, which involves assigning tasks to workstations in a way that minimizes idle time while satisfying precedence constraints between tasks.
2) It provides an overview of different types of assembly lines, including single model lines, mixed model lines, multi-model lines, paced vs unpaced lines.
3) The objectives of assembly line balancing are outlined as minimizing the number of workstations, minimizing cycle time, maximizing workload smoothness, and maximizing work relatedness.
Line balancing
Line Balancing, which is the necessity of production floor in garment Industry for maximum output in minimum cost.
Modeling of assembly line balancing for optimized number of stations and time
This document summarizes research on modeling assembly line balancing to optimize the number of stations and cycle time. It begins by classifying assembly line balancing problems based on objectives and problem structure. It then presents the Buxey 29 task precedence diagram and solves the problem to find feasible solutions with minimum cycle time for different numbers of stations (8, 9, 10 stations). The results show the total time remains 324 seconds for the optimal solution as more stations are added, while the cycle time decreases from 41 to 34 seconds. Increasing stations improves flexibility but also costs, so solutions must consider objectives and constraints.
O0123190100
This document presents a mathematical model for analyzing a generic single channel, multi-phase production line. The model aims to minimize system costs by reducing idle machine times and work-in-process inventory levels between machines. The model accounts for machine cycle times and calculates the times at which products enter and exit each machine in the production line. It assumes deterministic arrival rates and develops equations to determine the optimal level of service to minimize the total expected costs of providing service and of waiting for service.
Design lean sysm
This document discusses using a queueing model to design a lean manufacturing system based on Toyota's production system. It provides an overview of Toyota's approach of using small independent line segments separated by buffers. This allows problems to be fixed in-station to reduce rework. The document then discusses key considerations for factory designers in balancing factors like capacity, variation, buffers and costs. It provides a queueing model in an Excel file for experimenting with how changes to factors like line length, variation and over-speed impact throughput. Questions are also provided to help implement and communicate insights from the model.
line balancing in garment industry
1. The document discusses improving line efficiency in a garment manufacturing plant through line balancing and layout modification.
2. It analyzes the sewing line balancing problem using the Largest Candidate Rule Algorithm and Ranked Positional Weight Method to optimally assign tasks to workstations.
3. The goal is to evenly distribute work across stations to reduce work-in-progress, waiting times, production cycle times and costs which are currently problems in the plant due to unbalanced lines.
Implementation and Selection of Optimum Layout Design in Cellular Manufacturi...
Laying out a factory involves deciding where to put all the facilities, machines, equipment and staff in the
manufacturing operation and layout determines the way in which materials and other inputs flow through the operation.
The objective of this work is to find the best layout designs with an intention of minimize the material movement and cost
to improve the over efficiency of a diligence and such extension of our work is we planned to implement this optimized
layout design in any of the industry to achieve some good results in their production. In this paper we proposed to make
a deliberate case study in a process industry to study the existing layout design. We have design the optimum layout
considering different layouts like with an aim of minimize the cost by reducing the total travelling distance of materials
and change the existing layout design for selected process industry this optimum layout design is executed using through
ARENA simulation software with different form of machine layouts.
Cellular manufacturing
This document discusses cellular manufacturing. It begins by explaining that cellular manufacturing involves grouping similar products together based on their manufacturing requirements and producing them in dedicated manufacturing cells. Each cell contains the necessary machines and resources to produce a family of similar parts. The document then discusses the advantages of cellular manufacturing, such as reduced setup times, inventory, and material handling. It also notes potential disadvantages like issues balancing cell production volumes. The remainder of the document provides details on implementing cellular manufacturing, including identifying part families, designing cell layouts, and arranging machines within each cell for efficient production flow.
Assembly line optimization to Improve Productivity
Vimal Samsingh, Deepak and Srivatsan performed a case study in optimizing the assembly line of a manufacturing industry
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This document discusses optimizing the supply chain network design for pump manufacturing companies. It involves deciding which locations to open manufacturing plants and what production capacity levels to use. The modeling framework presented formulates the problem as a linear optimization model that minimizes total costs while meeting demand across markets. Data was collected from four pump companies and their supply chain networks were analyzed in Lingo software. For each company, it was determined that a new low capacity manufacturing plant should be opened in a specific state to improve the supply chain network design.
Lean in fishing net
This document discusses applying lean principles to optimize the production system design for a fishing net manufacturing company. It identifies key controllable factors like production unit size, pacemaker process, order batching, and production sequence. Through simulation and optimization, it evaluates different scenarios and identifies an optimal future state design that increases service level from 68% to 90% while decreasing work-in-process from 63,971 kg to 42,269 kg. This future state map can help the company implement lean manufacturing practices with no additional investment needed.
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The software has become a modern asset and competitive product. The product line that has long been used in manufacturing and construction industries nowadays has attracted a lot of attention in software industry. Most importance of product line engineering approach is in cost and time issues involved in marketing. Feature model is one of the most important methods of documenting variability in product line that shows product features and their dependencies. Because of the magnitude and complexity of the product line, build and maintain feature models are complex and time-consuming work. In this article feature model importance and position in product line is discussed and feature model extraction methods are reviewed and compared.
Optimization_model_of the propsed kiiraEV assembly lineprstn
This document summarizes an optimization model developed for the proposed assembly line for Kiira EV electric vehicles in Uganda. It describes the background and objectives of developing an optimized assembly line layout. The methodology included developing a detailed component dictionary, preliminary task sequencing, and using simulation and mathematical modeling to develop an optimal layout. The results of the simulation showed a throughput of 5 cars per 9-hour shift was possible with a 30-minute cycle time. The mathematical model can help determine the optimal number of stations and cycle times required. Recommendations include considering automation and using the model to inform expansion decisions.
Analysis of agile manufacturing and comparison with other manufacturing systems
This document analyzes agile manufacturing systems and compares them to other manufacturing systems. It defines agile manufacturing as the ability to quickly respond to shifting customer demands through rapid production process changes. The document then discusses how agile manufacturing relies on shared data systems and up-to-date information. Decision models are presented that show agile manufacturing systems have lower costs and are more financially attractive than dedicated systems for responding to uncertainties like new product introductions or demand changes. The models indicate agile systems allow faster and lower-cost launches of new products. In conclusion, agile systems appear well-suited to the automotive industry's need for rapid, cost-effective responses to dynamic markets.
Chapter 7.pptx
1. Investment in automation and technology is replacing both American and Chinese workers, making them more efficient. One robot can replace thousands of human-hours for certain tasks.
2. Toyota invested $1.3 billion to overhaul its factory in Georgetown to build 11 vehicle types quickly through new technology like lasers that weld parts 4x faster.
3. Process choice, technology investment, and layout are critical factors that impact a firm's competitiveness through costs, delivery speed, flexibility, and ability to satisfy customer demands.
IRJET- Use of Simulation in Different Phases of Manufacturing System Life Cycle
This document discusses the use of simulation throughout the manufacturing system life cycle, from conceptual design to operations planning. It provides examples of how simulation can be used to design modular assembly systems and optimize production capacity and operations planning. The key benefits of simulation include shortened design time, improved system design quality, faster sales cycles, and better training of personnel. Simulation allows experimenting with different configurations before implementing real systems and helps identify bottlenecks and optimize performance.
Flexible manufacturing system
A flexible manufacturing system (FMS) is a set of numerically controlled machine tools and supporting workstations connected by an automated material handling system and controlled by a central computer, allowing it to process multiple product styles simultaneously. An FMS provides benefits like reduced cycle times, lower inventory levels, improved quality and quicker response to market changes. It uses elements like robotics, material handling equipment, machines, assembly cells, computers and software. Planning and optimization is important to maximize efficiency through approaches like minimizing cycle times, balancing workloads, and incorporating quality inspections.
A Comparison Of Group Technology & Process Layout (3)
This study used a computer simulation to compare a process layout to a group technology layout using the model of an actual manufacturing shop. The process layout grouped similar machines together while the group technology layout grouped machines dedicated to producing similar parts families. Ten performance metrics were examined, including setup times, move distances, throughput, utilization, queues and flow times. While the group technology layout had shorter setups and moves, the process layout had better performance overall with shorter average flow times and queues due to its flexibility to produce varying demand distributions. So the process layout was more effective even though it had longer setups and moves.
A Comparison Of Group Technology & Process Layout (3)
This study used a computer simulation to compare a process layout to a group technology layout using the model of an actual manufacturing shop. The process layout grouped similar machines together while the group technology layout grouped machines dedicated to producing similar parts families. Ten performance metrics were examined, including setup times, move distances, throughput, utilization, queues and flow times. While the group technology layout had shorter setups and moves, the process layout had better performance overall with shorter average flow times and queues due to its flexibility to produce varying demand distributions. So the process layout was more effective even though it had longer setups and moves.
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Research methodology-research process
This document outlines the 7 steps of the research process:
1. Define the research problem
2. Review relevant literature
3. Formulate testable hypotheses
4. Prepare the research design to collect evidence efficiently
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Myself Gokila digital marketing consultant located in Coimbatore other various types of digital marketing services such as SEM
SEO SMO SMM CAMPAIGNS content writing web design for all your business needs with affordable cost
Digital Marketing Services | Techvolt Software :
Digital Marketing is a latest method of Marketing techniques widely used across the Globe. Digital Marketing is an online marketing technique and methods used for all products and services through Search Engine and Social media advertisements. Previously the marketing techniques were used without using the internet via direct and indirect marketing strategies such as advertising through Telemarketing,Newspapers,Televisions,Posters etc.
List of Services offered in Digital Marketing |Techvolt Software :
Techvolt Software offers best Digital Marketing services for promoting your products and services through online platform on the below methods of Digital marketing
1. Search Engine Optimization (SEO)
2. Search Engine Marketing (SEM)
3. Social Media Optimization (SMO)
4. Social Media Marketing (SMM)
5. Campaigns
Importance | Need of Digital Marketing (Online Promotions) :
1. Quick Promotions through Online
2. Generation of More leads and Business Enquiries via Search Engine and Social Media Platform
3. Latest Technology development vs Business promotions
4. Creation of Social Branding
5. Promotion with less investment
Benefits Digital Marketing Services at Techvolt software :
1. Services offered with Affordable cost
2. Free Content writing
3. Free Dynamic Website design*
4. Best combo offers on website Hosting,design along with digital marketing services
5. Assured Lead Generation through Search Engine and Social Media
6. Online Maintenance Support
Free Website + Digital Marketing Services
Techvolt Software offers Free website design for all customer and clients who is availing the digital marketing services for a minimum period of 6 months.
With Regards
Gokila digital marketer
Coimbatore
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website = https://digitaldiscovery.institute/
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2. Lack of Results: Investing time and resources without seeing tangible results can be disheartening. The absence of immediate results often leads businesses to lose faith in their SEO strategies. It's important to remember that SEO is a long-term game that requires patience and consistent effort.
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5. Lack of Understanding of SEO Basics: Many businesses dive into the complex world of SEO without fully grasping the fundamental principles. This lack of understanding can lead to several issues:
Keyword Awareness: Failing to recognize the importance of keyword research and targeting the right keywords in content.
On-Page Optimization: Ignorance regarding crucial on-page elements such as meta tags, headers, and content structure.
Technical SEO Best Practices: Overlooking essential aspects like site speed, mobile responsiveness, and crawlability.
Backlinks: Not understanding the value of high-quality backlinks from reputable sources.
Analytics: Failing to track and analyze data prevents businesses from optimizing their SEO efforts effectively.
6. Unrealistic Expectations and Timeframe: Entrepreneurs often fall prey to the allure of quick fixes and overnight success. Unrealistic expectations can overshadow the reality of the time and effort needed to see tangible results in the highly competitive digital landscape. SEO is a long-term strategy, and setting realistic goals is crucial for success.
#SEO #DigitalMarketing #BusinessGrowth #OnlineVisibility #SEOChallenges #BostonSEO
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• Practical, step-by-step methodology for choosing SEO pillar topics and publishing content quickly that ranks fastMastering SEO for Google in the AI Era - Dennis Yu
Mastering SEO for Google in the AI Era - Dennis YuDigiMarCon - Digital Marketing, Media and Advertising Conferences & Exhibitions
Mastering Local SEO for Service Businesses in the AI Era is tailored specifically for local service providers like plumbers, dentists, and others seeking to dominate their local search landscape. This session delves into leveraging AI advancements to enhance your online visibility and search rankings through the Content Factory model, designed for creating high-impact, SEO-driven content. Discover the Dollar-a-Day advertising strategy, a cost-effective approach to boost your local SEO efforts and attract more customers with minimal investment. Gain practical insights on optimizing your online presence to meet the specific needs of local service seekers, ensuring your business not only appears but stands out in local searches. This concise, action-oriented workshop is your roadmap to navigating the complexities of digital marketing in the AI age, driving more leads, conversions, and ultimately, success for your local service business.
Key Takeaways:
Embrace AI for Local SEO: Learn to harness the power of AI technologies to optimize your website and content for local search. Understand the pivotal role AI plays in analyzing search trends and consumer behavior, enabling you to tailor your SEO strategies to meet the specific demands of your target local audience. Leverage the Content Factory Model: Discover the step-by-step process of creating SEO-optimized content at scale. This approach ensures a steady stream of high-quality content that engages local customers and boosts your search rankings. Get an action guide on implementing this model, complete with templates and scheduling strategies to maintain a consistent online presence. Maximize ROI with Dollar-a-Day Advertising: Dive into the cost-effective Dollar-a-Day advertising strategy that amplifies your visibility in local searches without breaking the bank. Learn how to strategically allocate your budget across platforms to target potential local customers effectively. The session includes an action guide on setting up, monitoring, and optimizing your ad campaigns to ensure maximum impact with minimal investment.Recently uploaded (20)
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Operation & material management-line balancing & capacity planning decision
- 1. Line Balancing & Capacity Planning Decision Submitted By : Rohit Raina 0613-MBA-2013
- 2. Line Balancing Balancing Of Machine An assembly line consists of several working stations at which different operations are performed.
- 3. Assembly Line Balancing Line Balancing is an effective tool to increase the output of the Assembly line and to reduce manpower and cost. Henry Ford who introduced the Assembly Line Balancing and in early times it was simple line balancing (LB) which has optimized the industrial importance, the effective difference between the optimal and sub-optimal operation can afford savings which will be million dollars every year.
- 4. Line Balancing It is a Classical Operation Research (OR) which optimizes the problem, and it has been handled by OR for many decades. Many of the algorithms have been proposed to solve this problem. Its a commercial software which is available to optimize the industry and their lines.
- 5. Models Assembly Line Balancing is dependent on 3 models and it is described that these 3 kinds of models is related to Assembly Line Balancing and they are Single-Model Assembly lines, mixed models, and multi-model Assembly lines.
- 6. Single Model Assembly Singe-Model Assembly Line: in early times assembly lines were used in high level production of a single product. But now the products will attract customers without any difference and allows the profitable utilization of Assembly Lines. An advanced technology of production which enables the automated setup of operations and it is negotiated time and money. Once the product is assembled in the same line and it won’t variant the setup or significant setup and it’s time that is used, this assembly system is called as Single Model Line.
- 7. Mixed Model Assembly In this model the setup time between the models would be decreased sufficiently and enough to be ignored. So this internal mixed model determines the assembled on the same line. And the type of assembly line in which workers work in different models of a product in the same assembly line is called Mixed Assembly Line.
- 8. Multi-Model Assembly In this model the uniformity of the assembled products and the production system is not that much sufficient to accept the enabling of the product and the production levels. To reduce the time and money this assembly is arranged in batches, and this allows the short term lot-sizing issues which made in groups of the models to batches and the result will be on the assembly levels.
- 9. Assembly Line Balancing The purpose of the assembly line balancing technique is: 1. To equalize the work load among the assemblers 2. To identify the bottleneck operation 3. To establish the speed of the assembly line 4. To determine the number of workstations 5. To determine the labor cost of assembly and pack out 6. To establish the percentage workload of each operator 7. To assist in plant layout 8. To reduce production cost
- 11. Capacity Planning Decision Capacity – What should be the output Capacity Planning – It is the process of determining short term and long term needs of the organization. Long Term Short Term
- 12. Applications It helps in estimating the total sum and requirement. Total Machine and labor requirement. System Availability Resource Availability Helps in process mapping and capacity analysis
- 13. Labor Requirement Labor requirement = (D*S) / E
- 14. System Availability System Availability = N * h
- 15. Types of Decisions Strategic Decisions Tactical Decisions Operational Decisions
- 16. Thank You !!!