PRODUCTION ENGINEERING
Fundamental Concepts
PRODUCTION ENGINEERING
Introduction
What is Engineering?
What is Production?
What is production Engineering?
What is a product?
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Production Engineering
What is Engineering?
Combines the fields of Science and
Mathematics to solve real world problems
that improve the world around us.
An engineer has to have an ability to
implement ideas in a cost effective and
practical approach i.e. take a thought or
abstract idea and translate into reality.
This ability is what separates engineers from other
fields of science and mathematics
[Link]
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Production Engineering
What is production?- definition 01
the processes and methods used to transform
tangible Inputs(raw materials, semi finished
goods, subassemblies) and intangible
inputs(idea, information, knowledge) into
goods or services
Resources are used in this process to create an
output that is suitable for use or has exchange
value.
[Link] [Link]/definition/[Link]
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Production Engineering
What is production? definition 02
To Convert/Transform some inputs like men,
material, money, energy, information, etc, into
useful outputs like finished products and services
in required quantity and quality.
NB. The transformation of the inputs into pre specified
outputs is achieved through production process.
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Production Engineering
What is a Product?
Anything that can be offered to the market that might satisfy
a need or want
i.e.
▫ Physical goods (paper, glass , food, beverage, oil , gas , automobile
etc)
▫ Services (hospital, office, restaurant, library, consultancy )
▫ Persons (trained person; student, footballer, an experts)
▫ Information(archives, museum, library , massmedia)
etc
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Various Types of Engineering Company
• Textile • Chemical • Paper • Printing & · Tyre
• Machine • Steel processing package • Rubber,
tools industry industry industry
• Plastic
industry • Dairy and • Pharmaceutic •Automobile industry
• Cement food al · Fertilizer • Mining
• Software • Petroleum
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What is Production Engineering?
Production engineering is mostly about the
study of products and various ways of its
manufacture i.e. problem solving
Concerned with:
How the products/commodities are going to be
fabricated or created:
What machines /processes are going to be used to get the
products fabricated
What are the safest and most efficient procedures for
manufacturing the product.
Optimization of performance of the system
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What is Production Engineering?
Improve what is done and how is done
designs, processes/methods
Work with different groups:
Purchasing
Sales
Marketing
Manufacturing
Design
Maintenance
etc
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What is Production Engineering?
Production engineering is a combination of
manufacturing technology with management
science.
A production engineer typically has a wide
knowledge of engineering practices and is aware of
the management challenges related to production.
The goal is to accomplish the production process in the
smoothest, most-judicious and most-economic way.
From Wikipedia, the free encyclopedia
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Cont....
Production engineering includes the
application of:
casting, machining processing, joining processes,
metal cutting & tool design, metrology, machine
tools, machining systems, automation, jigs and
fixtures, and die and mould design and material
science and design of parts and machines
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Cont.....
Production engineering also overlaps
substantially with manufacturing
engineering, industrial engineering and
operations management
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What is Production Engineering?
Production engineering deals with the
planning and control of the mechanical
means of changing the shape, condition,
and relationship of materials within an
industry towards greater effectiveness and
value (By [Link]);
Sci-Tech Dictionary: production engineering
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What is Production Engineering?
A branch of engineering that involves the
design, control, inspection, assembly and
handling and continuous improvement of
integrated systems in order to provide
customers with high-quality goods and services
in a timely, cost-effective manner.
Sci-Tech Encyclopedia: Production Engineering
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WHAT IS INDUSTRIAL ENGINEERING?
It is concerned with the development,
improvement, implementation and
evaluation of integrated systems of people,
money, knowledge, information,
equipment, energy, materials and/or
processes.
It also deals with designing new product
prototypes more efficiently.
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Cont…
Industrial Engineering draws upon the
principles and methods of engineering
analysis and synthesis, as well as the
mathematical, physical and social sciences
together with the principles and methods of
engineering design to specify, predict, and
evaluate the results to be obtained from
such systems or processes.
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Operations Management
Systematic direction, control, and evaluation
of the entire range of processes that
transform inputs into finished goods or
services.
• Refers to the management of the production system
that transforms inputs into finished goods and
services.
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Operations Management
Operations/production Manager/Engineer:
responsible for the transformation process from
inputs to outputs.
Operations Management seeks to increase the
quality, efficiency, and responsiveness of the firm.
Seeks to provide a competitive advantage.
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Main Objective of an
Enterprise/a Company
The objective of an enterprise or a company
is to provide goods or services, and to earn
profits.
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Production System
The way an enterprise/ a Firm or a
Company acquires inputs then converts
into outputs.
Production System are those activities of
an organization where resources flowing
within a defined system are combined and
transformed in a controlled manner to add
value in accordance to the policies
communicated by the management.
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Goals of a production system
to serve the customers with the highest quality product
possible in the least amount of time
Produce the right quantity of products of the correct
standard, for the required number of customers,
To ensure that requirement of the production systems are
matched to the type of product to be produced and to the
sales i.e. to the required market at the correct price
continuous improvement and customer delight.
using the resources effectively and efficiently
i.e. Continuous search for areas of improvement in the production
system
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Production System Cont…
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Typical Examples
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Types of Production Systems
production
Systems
Intermittent Continuous/flow
Production production
system system
process
Mass production
Batch Project production
Job production flows
production production system
system
system system
Continuous Production system
Features of the System
Flow of production is continuous
products are standardized
Products are produced as per quality standards
Products are produced in anticipation of Demand
Standardized routing sheets and schedules are prepared
(A) Mass production:
In this type, a large number of identical items is
produced,
Both plant and equipment are flexible enough to
deal with other products needing the same
production processes.
For example, a highly mechanized press shop
that can be utilized to produce different types of
components or products of steel metal without
the need of major changes.
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(B) Process Flow Production
the plant, its equipment, and layout have been
chiefly designed to produce a particular type of
product.
Flexibility is limited to minor modifications in
layout or design of models.
the processing of materials is continuous and
progressive
It is very highly automated (process automation),
Some famous examples are:
Automobiles, engines, house-hold machinery,
chemical plants, steel mill, chemical plants etc.
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Process/Flow Production Cont…
If the management decides to switch over to a
different type of product, it will result in
extensive change in tooling, layout, and
equipment.
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Intermittent Production System
Features of the System
Flow of production is not continuous
Variety of products are produced
Volume of products is small
General purpose Machines are used
Sequence of operation changes as per design
Production Depends on Customer’s Order
rapid value addition
(A) Job Shop Production system
A small number of items produced only once,
A small number of items produced
intermittently when the need is felt,
A small number of items produced
periodically at known time interval.
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Advantages
Low risk of loss to the factory adopting this
type of production.
Due to flexibility, there is no chance of failure of
factory due to reduction in demand.
It can always get one or the other job orders to
keep it going.
Requires less money and is easy to start.
Less or no management problem because of
very small work force.
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Disadvantages
For handling different types of jobs, only
workers with multiple skills are needed.
This increases labor cost.
Low equipment utilization.
Raw materials are purchased in less quantity
The cost of material procurement is more
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(B) Batch Productions System
A batch of items produced only once,
A batch of items produced at irregular
intervals when a need is felt,
A batch of items produced periodically at
known intervals to satisfy the continuous
demand.
generally adopted in medium size enterprises
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Batch Productions System cont…
Material handling may be automated by robots
as in case of CNC machining centers.
A medium size lots (5 to 50) of same items is
produced in this system.
Lot may be produced once in a while or on
regular interval generally to meet the continuous
customer demands.
Plant capacity generally is higher than demand.
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Advantages
It is flexible in the sense that it can go from
one job to another with almost zero cost.
It needs general purpose machines having
high production rate.
If demand for one product decreases then
production rate for another product may be
increased, thus the risk of loss is very less.
Most suitable for computer-aided-
manufacturing (CAM).
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Disadvantages
As the raw materials to be purchased are in
smaller quantity than in case of mass
production, the benefits of discount due to
large lot purchasing is not possible.
It needs specially designed jigs and fixtures.
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(C) Project System
Inputs, resources and methods are only applied
once to produce the required product
A project is a highly flexible and low volume
type operation.
Usually the item to be produced stays in a fixed
place and all the resources come to it.
At the end of production, resources leave the
place.
Examples:
ship construction, bridge construction, buildings
and large machines, A product prototype etc
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Production Systems - Comparison
Type of Mass Process Flow Job Batch
Parameter
Prod.
System
Per unit Cost Low Low High Moderate
Size Large V. Large Small Medium
capital Invest Less High Low High
Job variety Low Very Low Very High Moderate
Flexibility No No More More
Technical Ability, Less Less High High
skills
Volume of High Very High Very low Low
output
Organization Line Staff Line Staff Functional Functional
structure
Industrial Automobile Chemical, Construction, Consumer
Application Sugar Petroleum, Bridges product,
Refinery Milk processing Machine Tools
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In terms of product variety and production volume
CONTINUOUS
FLOW
MASS
VOLUME
INTERMITTENT
BATCH
JOB SHOP
PROJECT
PRODUCT VARIETY
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Characteristics of a
Production Engineer.
A production engineer possesses a wide set of
skills, competences and attitudes such as:
Industrial engineering, Manufacturing engineering,
Product design, Marketing, Finance, management and
Corporate planning
These abilities are fundamental for the
performance of coordinating and integrating
professionals of multidisciplinary teams.
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Characteristics of a Production
Engineer.
The production engineer should be able to:
Dimension and integrate resources.
consider physical, human and financial resources at
high efficiency and low cost, yet considering the
possibility of continuous further improvement;
Make proper use of math and statistics
model production systems during decision making
process;
Design, implement and refine products,
services, processes and systems
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Characteristics of a Production
Engineer Cont …
The production engineer should be able to:
Forecast and analyse demand.
Incorporate concepts and quality
techniques
Deploy organizational standards for control
proceedings and auditing;
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Characteristics of a Production
Engineer Cont …..
The production engineer should be able to:
Stay up-to-date with technological
developments,
Understand the relation between
production systems and the environment
Manage and optimize flow
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