Production Systems Dr. Umesh Khandey Department of Manufacturing Engg. NIFFT, Hatia, Ranchi Production System Introduction A collection of people, equipment, and procedures organized to accomplish the manufacturing operations of a company. The set of resources and procedures involved in converting raw material into products and delivering them to customers Production and delivery of products are central to the firm Functions have value only if they enhance the ability to do this profitably Two categories: • Facilities – the factory and equipment in the facility and the way the facility is organized (plant layy)out) • Manufacturing support systems – the set of procedures used by a company to manage production and to solve technical and logistics problems in ordering materials, moving work throug h the ftfactory, and ensuring tha t products meet quality standards The Production System Production System Facilities Facilities include the factory, production machines and tooling, material handling equipment, inspection equipment, and computer systems that control the manufacturing operations • Plant layout – the way the equipment is physically arranged in the factory • Manufacturing systems – logical groupings of equitipment and workers in the ftfactory – Production line – Stand‐alone workstation and worker Manufacturing Systems Three categories in terms of the human participation in the processes performed by the manufacturing system: 1. Manual work systems ‐ a worker performing one or more tasks without the aid of powered tools, btbut sometimes using hdhand tltools 2. Worker‐machine systems ‐ a worker operating powered equipment 3. Automated systems ‐ aprocessperformedbya machine without direct ppparticipation of a human Manual Work System Worker‐Machine System Automated System Manufacturing Support Systems Involves a cycle of information‐processing activities that consists of four functions: 1. Business functions ‐ sales and marketing, order entry, cost accounting, customer billing 2. Product design ‐ research and development, didesign engiiineering, prototype shop 3. Manufacturing planning ‐ process planning, production planning, MRP, capacity planning 4. Manufacturing control ‐ shop floor control, inventory control, qqyuality control Information Processing Cycle in Manufacturing Support Systems Enterprise • The task of the enterprise is economic decision‐making and optimization of objectives in all aspects (Durlik I. 1993): 9 marketing, product development, purchase of the necessary elements for the production, 9 processing organization (final product and service), 9 sales and customer service. Company’s operation comprise following areas: • Production and technical area, • Organizational and administrative area, • The financial and economic area, • LlLegal area. The company is composed of one or more production systems Implementation can be : • Long‐term • Short‐term • Repetitive • Non repetitive Production systems • Production sstemsystem – is deliberately designed and organized arrangement of material, energy and information used by humans and aimed to manufacture certain products (goods or services) in order to meet the needs of consumer (Durlik I. 1993). Production system consists of five basic elements: 1. Input vector (data input), 2. Output vector (data output), 3. Processing (input into output), 4. Management syy,stem, 5. Feedback ValueValue--AddedAdded--ProcessProcess The difference between the cost of inputs and the value or price of outttputs. Value added Inputs Outputs Land Transformation/ Goods Labor Conversion process SiServices Capital Feedback Control Feedback Feedback R1 R2 R3 M1 M1 M1 M1 M1 The M2 M1 M1 production M3 M1 M1 M5 M4 M6 system may M7 M1 M2 Offices M1 M1 M3 M4 be very M5 V M1 M1 complex M6 Operations Machines Resources Raw Materials 18 Production system Production Objectives High Profitability Low High Costs Sales Low Unit Quality High Customer Costs Product Service High High Low Fast Many Throughput Utilization Inventory Response products Less Short Low High More Variability Cycle Times Utilization Inventory Variability Production and Inventory Control‐ Introduction Activity Analysis Non‐value‐added activity Value‐added activity • Increases time spent on product or service but does • Increases worth of not increase worth product or service to a customer • Unnecessary from customer perspective • Customer is willing to pay for it • Can be reduced, redesigned or eliminated without affecting market value or quality Operation of Production Systems and Production Planning Involve • Planning and execution of the activities that use workers, energy, information, and equipment to convert raw materials into finished products • Delivering products with the desired fifunctions, aesthihetics, and quality to the customers at right time and with minimum cost 22 Production Activity and Information Flow • Production‐planning decisions typically made in a hierarc hica l manner: 1. Physical material flow from raw material through delivered product 2. Support functions and design activities preceding production 3. Operational decisions for production planning, scheduling, and control 23 Production Activity and Information Flows Raw Material Forecasting Administrative Functions Fabrication (Purchasing, Payroll, Plant Finance, Accounting) Strategic Planning Assembly Marketing Plant Aggregate Production Finished Planning Products Product Design Distribution Disaggregation Center Process Planning Production Scheduling Manufacturing Support Retailer (Facilities Planning, Tool Management, Shop Floor Control Quality Control, Customer Maintenance) a) Product Flow b) Decision Hierarchy c) Support Functions 24 Types of production systems A production system can be defined as a transformation system in which a saleable product or service is created by working upon a set of inputs. Inputs are usually in the form of men, machine, money, materials etc. Production systems are usually classified on the basis of the following: • Type of product, • Type of production line, • RtRate of prodtiduction, • Equipments used etc. They are broadly classified into three categories: • Job shop production • Batch production • Mass production The types of production system are also grouped under two categories viz., Intermittent production system, and Continuous production system. Intermittent means something that starts (in itia tes ) and stops (halt s ) at ilirregular (unfixed) intervals (time gaps). Continuous means something that operates constantly without any irregularities or frequent halts. Intermittent Production System In the intermittent production system, goods are produced based on customer's orders. These goods are produced on a small scale. The flow of production is intermittent ((girregular) .Inother words, the flow of production is not continuous. In this system, large varieties of products are produced. These products are of different sizes. The design of these products goes on changing. It keeps changing according to the design and size of the product. Therefore, this system is very flexible. Examples of Intermittent production system Features of an intermittent production system The characteristics of an intermittent production system are listed as follows: The flow of production is not continuous. It is intermittent. Wide varieties of products are produced. The volume of production is small. General purpose machines are used. These machines can be used to produce different types of products. The sequence of operation goes on changing as per the design of the product. The qqy,uantity, size, shapp,e, desigg,n, etc. of the product depends on the customer's orders. Continuous Production System Continuous means something that operates constantly without any irregularities or frequent halts. CtiContinuous PdtiProduction StSystem Inthecontinuous prodiduction system, goodsare produced constantly as per demand forecast. Goods are produced on a large scale for stocking and selling. They are not produced on customer's orders. Here, the inputs and outputs are standardized along with the production process and sequence. Examples of Continuous production system Characteristics of a continuous production system are listed as follows: The flow of production is continuous. It is not intermittent. The products are standardized. The products are produced on predetermined quality standards. The products are produced in anticipation(An expectation) of demand. Standardized routing sheets and schedules are prepared Types Continuous Production 1. Mass Production Flows Here, company produces different types of products on a large-scale and stock them in warehouses until they are demanded in the market. The goods are produced either with the help of a single operation or uses a series of operations. E.g. of mass production is the production of toothpastes, soaps, pens, etc. Characteristics Mass Production Flows There is a continuous flow of production. However, this depends on the demand in the market. Here, there is lim ite d work-in-progress. Supervision is easy because only few itinstruc tions are necessary. The material handling is done mostly by machines, i.e. conveyors and auttitomatic transfer machines. The flow of matilterials iscontinuous. There is little or no queuing at any stage of production. 2. Process PdProduct ion Flows Here, a single product is produced and stocked in warehouses until it is demanded in the market. The flexibility of these plants is almost zero because only one product can be produced. Examples of these plants