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PRODUCTION MANAGEMENT                 LECTURE -II
Syllabus•   The Production Function•   Types of production system•   Elementary knowledge of manufacturing processes•   Pl...
CHAPTER -II  • Types of Production Systems –      •Intermittent Production      •Continuous Production                    ...
PRODUCTION SYSTEM                         DECISION MAKER             CONTROL            CONVERSIONINPUT        PROCESS    ...
PRODUCTION SYSTEM• Solid line represents movement of material through conversion system by value addition to finish goods ...
The system selection is sensitive because of following                      parameters1 . Type of Product     • Common par...
Life cycle phase of Project              Conclusion :    Introduction ( Low volume ,High      System selection is not a st...
Types of Production SystemIntermittent System         Continuous System     Job Type                Mass Production    Pri...
INTERMITTENT SYSTEM• The goods are manufactured specially to fulfill orders made by customers & not for  stock• Characteri...
INTERMITTENT SYSTEM      OP1                   Information & Control               Decision Maker    Storage1             ...
Intermittent system Classification :    • Job Production                  • Batch Production•    Job Production : 1) It is...
Intermittent system Classification :• Batch Production•                                                                   ...
Continuous System :    • In this system the items are produced for the stocks & not for specific order    • Manufacturing ...
Mass ProductionFundamental characteristics of the system is standardization• Items are produced in large quantities indepe...
Process ProductionIt gives more stress on AUTOMATION in production process• The volume of production is very high• This me...
Factors for Comparison of Manufacturing systems1. Manufacturing costs2. Capital investment3. Size of plant4. Technical req...
Elementary knowledge of Manufacturing process Assembling : Welding, Brazing, Riveting, Fastening By Nuts&bolts, AdhesivesF...
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production management

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production management

  1. 1. PRODUCTION MANAGEMENT LECTURE -II
  2. 2. Syllabus• The Production Function• Types of production system• Elementary knowledge of manufacturing processes• Plant Layouts• Material Handling• Location Problems• Inventory management• Scheduling• Network Analysis• Break Even Point Analysis• Reliability maint & plant services• Quality control• Emerging Trends• Concept of Productivity
  3. 3. CHAPTER -II • Types of Production Systems – •Intermittent Production •Continuous Production CHAPTER -III• Elementary knowledge of Manufacturing process • Assembling • Fabrication • Forming • Heat Treatment • Welding • Machining etc
  4. 4. PRODUCTION SYSTEM DECISION MAKER CONTROL CONVERSIONINPUT PROCESS OUTPUT
  5. 5. PRODUCTION SYSTEM• Solid line represents movement of material through conversion system by value addition to finish goods ( Materials Management)• Dotted Line represents flow of information / set of Instruction • All on line data / information is continuously passed on to control tower ,control tower in terms process / Tabulate all the information in format & sends it to decision maker ( Flow of Information)• Decision Maker Compares / Benchmark actual information with plan & generate the set of instructions for correcting the deviations & sends it to control tower (Plan Vs Actual)• Control tower sends instructions at appropriate point for execution & bring back process under control DECISION CONTROL MAKER INPUT CONVERSION OUTPUT PROCESS
  6. 6. The system selection is sensitive because of following parameters1 . Type of Product • Common parameters • Total Volume • Varieties in total Volume 2 .Type of Company • Automobile • Chemical • Pharma 3.Life Cycle of Product / Project
  7. 7. Life cycle phase of Project Conclusion : Introduction ( Low volume ,High System selection is not a static or one time Variation) Growth ( High volume , Low decision but “DYNAMIC” one & changes as Variation) organization passes through I –G-M-D Phases Maturity ( High volume , Low Variation) & changes the equation of Volume to Variety Decline ( Volume drops , Variation ratio High)
  8. 8. Types of Production SystemIntermittent System Continuous System Job Type Mass Production Printing Job Spoons / Hair Pins / Machine Building Soaps / Chocolates Batch Type Process TypeWashing Machine Cement / Sugar / Chemical IndustriesFridge / TV / CAR
  9. 9. INTERMITTENT SYSTEM• The goods are manufactured specially to fulfill orders made by customers & not for stock• Characteristics : • Most products are produced in small quantities • Machines & equipments are laid out by process • Workloads are unbalanced • Highly skilled operators are required for efficient use of machines & equipments • In process inventory is very large • Flexible to accommodate variety in production• Example : •Machine shops • Hospitals • locomotives • Plants • Automobiles
  10. 10. INTERMITTENT SYSTEM OP1 Information & Control Decision Maker Storage1 OP2 Storage 2 Storage 4 OP4 Storage 3 OP3 Storage 5Ex. Paper cutting machine
  11. 11. Intermittent system Classification : • Job Production • Batch Production• Job Production : 1) It is the production of single complete unit by one operator , Group of operators 2) Whole project is considered as a one operation & work is completed on each product before passing to the next• Characteristics : • Complete project is considered as single operation • Versatile & skilled labors are required • High capital Investment • Control operations relatively simple • High unit cost of production• Examples : • Bridge Building • Dam Construction • Ship Buiding • Heavy machines
  12. 12. Intermittent system Classification :• Batch Production• Batch Production : It is a extension of job type production Whole project is considered as a one operation & work is completed on each product before passing to the next• Characteristics : • Production schedule can be formulated according to specific orders or demand forecasts • Items are processed in lots & batches • Only one item is produced in every production run • New batch will be taken only after completion of one • High WIP
  13. 13. Continuous System : • In this system the items are produced for the stocks & not for specific order • Manufacturing stock is based on sales forecast • Inputs are standardized & standard set of processes & sequence of processes can be usedInput OP1 Information & Control Decision Maker Storage1 OP2 Storage2 OP3 OP4 OP5 Ex. Bottling Plant Out put
  14. 14. Mass ProductionFundamental characteristics of the system is standardization• Items are produced in large quantities independent of customer orders• i.e Production is to stock & not to order• Standardization is w.r. to materials & machines• Uniform & un-interrupted flow of material is maintained through predetermined sequence of operations required to produce the product• System can produce only one type of product at one time Example : • Sub assemblies • Parts / components •Advantage : • Economies of production because of specialization & standardization
  15. 15. Process ProductionIt gives more stress on AUTOMATION in production process• The volume of production is very high• This method is used for manufacturing items with very high demand• Ex. • Petroleum products • Particular brand of medicines • Heavy chemical industries • Plastic industriesNote : Single raw material can be transformed into different kinds pf product at different stages of production process Ex. Processing of crude oil will give Kerosene / Gasoline etc at diff stages of production
  16. 16. Factors for Comparison of Manufacturing systems1. Manufacturing costs2. Capital investment3. Size of plant4. Technical requirement5. Organizational structure6. Flexibility in production7. Type of products produced8. Security of job
  17. 17. Elementary knowledge of Manufacturing process Assembling : Welding, Brazing, Riveting, Fastening By Nuts&bolts, AdhesivesForming :In this process shape of work piece changes without necessarily removing oradding material Ex .Casting, Forging, Extrusions, Stamping, Embossing, Heat Treatment : Heat treatment is process of heating & cooling of metals or alloys in solid state inorder to obtain certain desired properties ( Relieve internal stresses , Hardness,toughness etc) Machining : It involves metal removing by Turning , Drilling , Milling , grinding,shaping ,boring ,EDM , ECM etc.Electro discharge machining : (EDM)Spark between workpiece & tool across gap removes the material usingdielectric ,which also cools the metalElectro Chemical Machining (ECM) :Chemical energy combine with electrical energy is used to do the cutting operation

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