Production

PRODUCTION:- 1 The action or process of producing or being produced.  the amount of something produced.  [as modifier] denoting a vehicle manufactured in large numbers, as opposed to a prototype or other special version. 2 a film, record, or play, viewed in terms of its making or staging. Production is any process or procedure developed to transform a set of input elements like men, materials, money, machine, information and energy into a specified set of output element like finished products and services in proper quantity and quality, thus achieving the objectives of an enterprise. PRODUCT: products are manufactured by the transformation of raw materials into finished goods. PRODUCTION SYSTEM:- • Production management • Operation management • Management science PRODUCTION MANAGEMENT:- Production management centers on two major areas:- Design of the production system (includes product, process, plant, equipment and so on). Development of the control system (to manage inventories, product quality, production schedules and productivity).

Fig: 1 The production management cycle OPERATION MANAGEMENT:- It involved the field of production or manufacturing management is concerned with the application of the basic concept and principles of management to those segments of the organization that produce the good and/or services of the organizations. Especially operation management involves designing the system of the organization that produce goods or services and with the planning and controlling of the day to day operations which takes place with in these systems. MANAGEMENT SCIENCE:- Management science can be defined as:- “A problem solving process used by interdisciplinary term to develop mathematical model that represent simple to complex functional relationship and provide management with the basis for decision making and a means of uncovering new problems for quantitative analysis”. Management science is the application of the scientific method to study of the operations of large complex organizations or activities. PRODUCTION SYSTEM:- Production system depends upon: • Characteristics of materials flow • Product process types • Customer’s ordering • Producer’s policy CLASSIFICATION OF PRODUCTION SYSTEM:- According to flow of materials the production system may be into two types. They are: 1. Discontinuous flow/intermittent flow 2. Continuous flow DISCONTINUOUS FLOW: The distinguishing characteristics for this kind of production are that job passes through the production process in lot. That is to say, a lot would stay together throughout its processing, and move from one step to the next as a group. When products are produced in group or lots or batches, the production system is also known as “Batch manufacturing”. CONTINUOUS FLOW MANUFACTURING:- In this kind of production system, materials flow continuously during production, through the production process. Generally, production equipments are organized and sequenced according to the step involved in the production process, and routings are fixed. Some example of flow manufacturing include production lines, assembly lines etc. The APICS (American Production and Inventory Control Society) definition for flow manufacturing focuses on an uninterrupted material flow, but allows for a verity of products to be produced. E.g. electronics goods, automobile parts etc. Generally production is set at a given rate, and often products are produced in bulk. This is also known as “Rate-based” production system. When quantity is huge, that is termed as “Mass” production. Continuous production system can be divided into two categories. • Mass and flow line production • Continuous or process production Mass flow production: Mass production means the production of items on large scale, employing very specialized machines and processes. Item like metal screws and plastic products are made in mass production and their cycle of manufacture involves one or more operations on the raw material on one machine. Item like air conditioners, T.V. sets and motor cycles come under flow production and are manufactured in continuous stages from process. In this type of production there is a continuous and steady flow of materials. Characteristics of mass flow production: 1. There is a scope for considerable division of labour. 2. Machinery is laid as per the sequence of production. 3. Materials handling is reduced to minimum. 4. Very little time is spent on the resetting of machines. 5. The flow of work is balanced. 6. Work cycles are short and of repetitive nature. 7. Time study can be applied, to advantage, to different operation. 8. Work-in-progress is small as compare to discontinuous production. 9. Procedures, tools and material handling need proper attention. 10. Plant lay out and facilities are designed to suit production requirement. 11. Flow production is preferred where there is a continuous and regular product demand. 12. It offers lowest production cost per unit. Characteristics of continuous production: 1. All products undergo the same process. Raw materials enter at one point and leave as a finished product at another. 2. Material handling is automatic. 3. Plant layout is as per the requirement of production. 4. Both types of worker i.e. semi-skilled and skilled are employed. 5. Outputs and inputs are respectively measured and regulated, using sophisticated control. 6. Machinery employed is one built to the need. 7. Good plant maintenance and effective quality control are the essential requirement. According to product and its associated process the production system may be classified into two types. They are: 1. Discrete manufacturing 2. Process manufacturing DISCRETE MANUFACTURING:- A discrete manufacturing system is that one where products and its parts are separately identifiable, and parts require operations individually. This may be continuous or discontinuous types. This involves typical fabrication and assembly operations. E.g. electronics parts, automobile etc. PROCESS MANUFACTURING:- A type of manufacturing that is often found in high volume production plants is process manufacturing as commonly use in food, chemical and pharmaceutical industries. Process is usually associated with component materials that are powders or liquids and processes that involve mixing, heating, and/or chemical reactions. Component materials are known as “ingredients” and generally are not identifiable once the finished good is produced. E.g. lotion, shampoo, tea etc. According to the customer’s ordering and producer’s production policy, a production system may be classified into four types. They are: 1. Make to stock (MTS) 2. Assembly to order (ATO) 3. Make to order (MTO) 4. Engineer to order (ETO) MAKE-TO-STOCK:- In these types of manufacturing environment, products are produced for storage in the stock room/ inventory room. Productions are sold from the stock room, to the customers. MTS characterizes the manufacture of products based on a well known and relatively predictable demand mix. The volume of production and thus level of storage is set through forecasting, based on statically analysis. In this environment, interaction with customer is rather distant and delivery time is generally short (ideally zero). The design of product and its operational features are not directly driven by customers. E.g. television, automobile, pen pencil etc. ASSEMBLE-TO–ORDER:- This involves having the same core sub-assemblies for most products and the ability to vary all other components of the final assembly (finished good). ATO companies try to offer a wide range of products with short customer delivery time. ATO companies produces major sub-assemblies in advance (in MTS fashion) that can be quickly7 assembled together to form the final product. Products are designed in modules. Demands for modules can be forecasted final assembly is driven by customer. E.g. computer. MAKE-IN-ORDER:- This involves having all the components available along with the engineering design. Manufacturing of the product begins with receipt of an order, and the configuration of the product is likely to change from the initial specification during the course of processing. Products are mostly customized to the specific needs of each individual customer. Customer lead time can be reduced by purchasing materials based upon forecast. Sales volumes are very difficult to forecast. Therefore procurement to forecast should be limited to long lead time items with high usage in many product variants and low probability of obsolescence. ENGINEER-TO-ORDER:- This is an extension of MTO system. The engineering design of the product is totally based on the customer specifications.

∆ = Customer order decoupling point. → = Production based on forecast. ← = Production based on customer order. Fig:-2 Customer order decoupling point. Table:-1 Production planning in different manufacturing environment:- Aspect MTS ATO MTO ETO Basic for production planning Forecast (finished good) Forecast (major sub-assembly)and backlog F.A Backlog and customer orders Customer’s order only. PRODUCTION PLANNING AND CONTROL:- Production planning and control can be viewed as a hierarchical process to plan, manage and control different activities associated with production of goods. It starts with preparing a long range business plan and ends with delivering finished goods. Though there is a clearly identified stage, known as “Production plan” in the complete chain of command, professionals term the complete chain of command as production planning and control system. Apart from the core production planning function, these are several other functions, which support the complete hierarchy at different stages. Some of these functions include: quality functions (planning and control), maintenance planning and control, purchasing, sales, design engineering, accounting etc. The target of production planning and control include: • Decision regarding what to produce and when to produce. • What resources are required and how much. • Monitor and control production in the shop floor to ascertain if the production is going on as per production plan. In case of problem or derivation, decisions must be taken to control that.

Inventory planning and control is a major function that supports production planning and control. PRODUCTIVITY:- Productivity of a production system is analogous to the efficiency of a machine. Just as it is desired to increase the efficiency of machine. Productivity may be defined as the ratio between output and input. Out put means the amount produced or number of items produced and inputs are various resources employed, e.g. land and building, equipment and machinery, materials, labour etc. FACTORS AFFECTING PRODUCTIVITY:- (a) factor affecting national productivity:- • Human resources • Technology and capital investment • Government regulation (b) Factor affecting productivity in manufacturing and services:- • Product or system design • Machinery and equipment • The skill and effectiveness of the worker • Production volume WHAT IS PPC? Any manufacturing activity requires resource input term of men, materials, money and machines. In any business that products a product or service, production activity must be related to customer’s order. For maximum effectiveness, this must be done in such in way that the customer demands are satisfied, but at the same time production activities are carried on in an economic manner. The process of developing this kind of relationship between market demands and production capability is the function of production planning and control.