Module 1
[Link] of Production, Planning and Control
[Link] affecting site selection for industry
[Link] Location, Plant layout and Production process
[Link] Handling system in an industry
Production , Planning and Control
(PPC)
• Production - Products are manufactured in factories by the
transformation of raw materials into finished goods , this process is
called production
Steps in PPC - 1. Planning
• Planning: Planning determines what will be produced, by whom, and
how. It formulates the plan for labor, equipment, work centers, and
material requirements needed for production.
• Relevant information from various sources helps to develop a
production plan. For instance, data from sales on order quantities and
promised delivery dates. Product specifications from the engineering
department may also be needed. The planning step helps to keep a
streamlined approach to the production process.
Steps in PPC - 2. Routing
• Routing - Routing determines the path raw materials flow within the factory.
Using the sequence, raw materials are transformed into finished goods.
• Coordinating every production process and scheduling every step is
important to measure the production process duration. Routing shows the
quantity and quality of materials and resources needed. It also shows the
operations used and the place of production.
• Routing manages the “How”, “What”, “How much”, and “Where” of
production. It systematizes the process and optimizes resources for the best
results.
Steps in PPC - [Link]
• Scheduling emphasizes “when” the operation will be completed. It
aims to make the most of the time given for the completion of the
operation.
• Definition - “The determination of the time that should be required to
perform the entire series as routed, making allowance for all factors
concerned.”
Steps of PPC - 4. Loading
• Loading looks into the amount of work loaded against machines or
workers. The total time to perform new work is added to the work
already scheduled for the machine or workstation.
• If a machine or workstation has capacity available, more orders can
make up the underload. If there is a capacity overload, proactive
measures can prevent bottlenecks. Adding a shift, requesting
overtime, bringing in operators from another shop, or using a sub-
contractor are possible options.
Steps in PPC - 5. Dispatching
• Dispatching is the release of orders and their instructions. It follows
the routing and scheduling directions. This step ensures all items are
in place for the employees to do their jobs.
Steps in PPC - [Link] Up
• Also known as expediting, follow-up locates fault or defects,
bottlenecks, and loopholes in the production process.
• In this step, the team measures the actual performance from start
until the end and then compares it with the expected performance.
Benefits of PPC
• 1. To consumers
• Ensures better service to customers by delivering quality goods within
the delivery dates
• increases customers psychologial satisfaction due to longer life of
product
• Gives better quality products at reduced prices
Benefits of PPC
• 2. To Production Management
• Minimises cost of inspection
• Helps in production time predictability
• minimises labour cost
• reduces production control expenses
• Maintains industrial peace and harmony
Benefits of PPC
• 3. To workers
• Higher earnings and higher standard of living
• Employees work at maximum efficiency
• acquires process of specialisation
Benefits of PPC
• 4. To share Holders
• Gives higher divident regularly
• Reduced speculation in the share values in stock market
• Gives psychological satisfaction for their investment
Benefits of PPC
• 5. To society
• Reduces Unemployment problem
• nation progresses towards prosperity
• Government gets more revenue in the form of taxes, which helps
them in better and efficient application of welfare economics
Plant Layout
• Plant layout is a place where men, materials , money equipment,
machinery etc are brought together for manufacturing products
• Definition: “A plant layout is an arrangement of facilities and services
in the plant. It is defined as an optimum arrangement of industrial
facilities, including personnel, equipment storage place, material
handling equipment and all other supporting services in an existing or
proposed plants”
Factors influencing Plant layout
• 1. Management Policy
• 2. Manufacturing Process
• 3. Nature of product
• 4. Volume of production
• 5. Type of equipment
• 6. Type of building
• 7. Material Handling Equipment
• 8. Service facilities
• 9. Possiblity of future expansion
Management Policy
• It significantly influence plant layout.
• Some of the following things like
• volume of production
• extend of automation
• purchasing policy
• personnel policy
Manufacturing Process
• The method of manufacturing process influences plant layout
• broadly classified as
• synthetic
• analytical
• conditioning
• extractive
Nature of product
• Small and light products can be moved easily to the machines where
as in the manufacture of locomotives and in ship building, the product
remains stationary, but machines and men move to the product.
Volume of production
• In large scale organisations, production volumes will be drastically
different from that of a small scale production company
Type of equipment
• The use of single purpose machines and multi purpose machines
affect the plant layout.
Types of Plant Layout
• 1. Process layout or functional layout
• 2. Product layout or line layout
• 3. Mixed layout or combined layout
• 4. static layout or fixed position layout
Process Layout AND
Product Layout
• Called as functional layout • Called as line layout
• Similar machines are grouped • machines are arranged in the
together sequence of operations
• used in batch production • used in mass production
• non-repetitive type of work • Repetitive type of work
Process layout example
• Restaurant process layout
billing section chef
waiter store room
Advantages
• Flexibility of manpower/equipment
• inital investment is low
• better utilization of available equipment
• maintenance is easy
• over head cost is less
• workers not affected by nature of work in other sections
• can handle different products in different volumes
Disadvantages of Process Layout
• more space is occupied by machines
• handling time of material is high, so slow production
• cannot be automated easily
• more material in process remains in queue for further operations
• work in process inventory is large
Product Layout
• production system where the work stations and equipment are
located along the line of production, as with assembly lines
Assignment
• Write about Process Layout, Product Layout and their advantages and
disadvantages with suitable examples
Mixed Layout
• It is a combination of Product and Process Layout , where the
advantage of both are taken into account.
Static or Fixed Position Layout
• When workpiece is very big or too heavy to move from one position
to other, then men move to the place of work and perform the
required operations on it as it remains in one place.
• These are useful in construction work, ship building , fabrication of
large tanks , locomotives etc.
Advantages - Static Layout
• Possible to assign one or more skilled workers to a project from start
to finish, to ensure continuity of work
• Material Movement is reduced
• There is maximum flexibility for all sorts of changes in production
process
• capital investment is less
• Different projects can be taken up with the same layout
Disadvantages - Static Layout
• Highly skilled workers are required
• Machine and tools etc take more time to reach the place of work
• It involves high equipment handling costs
• Low utilization of labour and equipment
video explanation of all the layouts
• [Link]
Material handling System in Industry
• Material handling is the art and science involving movement ,
packaging and storing of materials in any form by means of gravity
manual effort or power activated machinery
• Principles: safety, reduction in time, use of gravity , avoid interference
with production line
Types of Material Handling Devices
• Material Handling devices are of three types,
• 1. Lifting and lowering devices
• 2. Transport Devices
• 3. Devices which lift and transport
[Link] and Lowering Devices
winches block and
tackle overhead bridge crane
pillar crane
2. Transportation Devices
(Horizontal Movement)
tractor and wheel hydraulic tripping
2 wheeled hand 4 wheeled hand truck trailer
truck
3. Devices, which Lift and Transport
chain conveyor belt conveyor
Fork-Lift truck
crane truck
Plant Maintainance
• Why is it important?
• Equipment breakdown leads to an inevitable loss of production.
• If a piece of equipment goes out of order in a flow production factory,
the whole line will soon come to a halt. Other production lines may
also stop unless the initial fault is cleared
Types of Plant Maintenance:
• (a) Corrective or breakdown maintenance,
• (b) Scheduled maintenance,
• (c) Preventive maintenance,
• (d) Predictive maintenance.
(a) Corrective or Breakdown
Maintenance
• Corrective or breakdown maintenance implies that repairs are made
after the equipment is out of order and it cannot perform its normal
function any longer
• e.g., an electric motor will not start, a belt is broken, etc. Under such
conditions, production department calls on the maintenance
department to rectify the defect
(b) Scheduled Maintenance:
• Scheduled maintenance is a stich-in-time procedure aimed at avoiding
breakdowns.
• Scheduled maintenance practice incorporates (in it), inspection,
lubrication, repair and overhaul of certain equipment which if
neglected can result in breakdown.
(c) Preventive Maintenance:
• A system of scheduled, planned or preventive maintenance tries to
minimize the problems of breakdown maintenance.
• The underlying principle of preventive maintenance is that
prevention is better than cure.
(d) Predictive Maintenance:
• It is comparatively a newer maintenance technique.
• It makes use of human senses or other sensitive instruments such as:
• Audio gauges,
• Vibration analyzers,
• Amplitude meters,
• Pressure, temperature and resistance strain gauges, etc., to predict
troubles before the equipment fails.
Thank you