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The branch of engineering that deals with the creation and management of
systems that integrate people, materials and energy in productive ways.
Industrial Engineering
In general engineers are concerned with the analysis and design of systems.
Like, Electrical Engineers are concerned with electrical systems, Mechanical
Engineers are concerned with mechanical systems, Chemical Engineers are
concerned with chemical systems, and so forth.
Industrial Engineers are concerned with production systems.
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Production system
Production system
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ii
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V
Function of production system
Production system
Production Planning
Production Control
Sub-function of production planning and Control
Production Planning
Production planning is usually done at the following three horizon levels:
Up to 2 years ahead
How can demand be met from existing facilities and resource inputs
Short term
Production Planning
Requirements of Production Planning:
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Production Control
Production control is a mechanism to monitor the execution of the plans. It has
several important functions.
Making sure that production operations are started at planned places and
planned time.
Observing progress of the operations and recording it properly.
Analyzing the recorded data with the plans and measuring the deviations.
Taking immediate corrective actions to minimize the negative impact of
deviations from the plans.
Feeding back the recorded information to the planning section in order to
improve future plans.
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Production Control
Control system use in manufacturing organization
Transformation process
Resources
Objectives
Input
Or
Products
output
Services
Value addition
An open loop control system
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Production Control
Quality control
Stock control
Cost control
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II
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IV
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Demand
Cumulative Demand
220
220
170
390
400
790
600
1390
380
1770
200
1970
130
2100
300
2400
Suppose that the firm estimates that it costs $100 per unit to increase the production rate, $150
to decrease the production rate, $50 per quarter to carry the items on inventory, and an
incremental cost of $80 per unit if subcontracted. Compare the cost incurred if pure strategies
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are used.
Introduction
Factors for PDD
Product analysis
Summary
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Product analysis
The first task in product analysis is to become familiar with the product!
What does it do? How does it do it? What does it look like? All these
questions, and more, need to be asked before a product can be
analysed.
Why product analysis is so important?
Design modifications are more expensive at a later stage of product life
Design modifications are unwelcome, once the product is launched
Design modifications at later stage also delay the launch of a new
product
Factors of product analysis
Its objective should be to satisfy as many functions as possible
Its objective should be keep product cost as low as possible
It is a trade-off between product functionality and product cost
It focuses on development of multiple product concepts
Additional considerations
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Product analysis
Additional considerations
It has to be manufactured and assembled minimum cost and easily
Product has to work
It has to sell
It must be profitable
Several aspects are considered
Functionality aspect
Operational aspect
Quality aspect
Reliability aspect
Durability aspect
Maintainability aspect
Aesthetic aspect: i.e., how that product look, how is the texture of that
product, what is the shape and size of that product, what are the surface
finish of that product, picketing of that product etc.
Product analysis is not just as to evaluate some product idea but it converts
the idea into useful product.
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Product analysis
Information flow
during product
analysis
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Or we can say that the value analysis is used to identify efficiently the
unnecessary cost,
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A.
B.
C.
Techniques to be used:
Blast: In this stage alternative products, materials, process, or ideas
are generated. These alternatives should, first of all, qualify for
accomplishing some important part of the function in a very
economical manner or, at least, serve as an economical base for
modifications that are likely to accomplish an important part of
function.
Create: In create phase, the technique of "Use real creativity" needs
to be employed to come out with ways by which the low cost
alternatives identified during the blast stage can be modified to
accomplish the specified function to a much greater extent with
pertinent increase in cost.
Refine: In this step, much more creativity is used and also the
techniques "Use industry experts to extend specialized knowledge"
and "Utilize and pay for vendors skills and knowledge" are used to
refine the ideas developed during the create step to come out with a
refined alternative that fully accomplishes the specified function at a
lower cost. During refine step, some more functionality is added36as
well as some additional cost.
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Disadvantages include
Batch Production
Batch production is the manufacture of a number of identical articles either
to meet a specific order or to meet a continuous demand. Batch can be
manufactured either only once
or repeatedly at irregular time intervals as and when demand arise
or repeatedly at regular time intervals to satisfy a continuous demand
Batch Production
Labor should be skilled enough to work upon different product batches.
In process inventory is usually high owing to the type of layout and
material handling policies adopted.
Semi automatic material handling systems are most appropriate in
conjunction with the semi automatic machines.
Normally production planning and control is difficult due to the odd size
and non repetitive nature of order.
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Batch Production
Advantages of batch production are :
It can reduce initial capital outlay because a single production line can be
used to produce several products.
Batch production is also useful for a factory that makes seasonal items,
products for which it is difficult to forecast demand, a trial run for
production, or products that have a high profit margin.
Labour costs are reduced so the final price is lower.
Production rate is faster
Batch production also has disadvantages.
There are inefficiencies associated with batch production as equipment
must be stopped, re-configured, and its output tested before the next
batch can be produced.
Larger stocks of raw materials must be kept.
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Mass Production
In mass production, same type of product is manufactured to meet the
continuous demand of the product. Usually demand of the product is very
high and market is going to sustain same demand for sufficiently long
time.
Mass Production
As product flows along a pre defined line, planning and control of the
system is much easier.
Cost of production is low owing to the high rate of production.
In process inventories are low as production scheduling is simple and can
be implemented with ease.
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