IOM PRODUCTION PLANNING

PRODUCTION PLANNING

The activity by which manufacturing ways and means are determined.

ROLES OF MANAGEMENT

1. Think

2. Dream

3. Set Goals

4. Organize

5. Initiate

6. Execute and Control

MANUFACTURING

process of changing materials by hand or machine into more useful and valuable forms.

SCOPE OF PRODUCTION PLANNING

1. Product Concept, General Idea of the Process, and Sales Forecast

2. Breakdown products into parts and materials

3. Division of the Manpower Needs, Procurement Planning for Materials and Suppliers, and Cost Accounting

TOP MANAGEMENT

coordination of all planning activities.

PRODUCTION CONTROL DEPARTMENT

• detailed planning

• Determines what has to be done to facilitate manufacturing

• Confers with those who must do something, and follows up to see that it has been done

FOR WHOM AND FOR WHAT ARE WE PLANNING?

OWNERS
EMPLOYEES

CONSUMERS

DIMENSIONS OF THE PLANNING FUNCTION

1. Planning is a philosophy.

2. Planning is integration.

3. Planning is a process.

4.Planning is a collection of procedures.

MANUFACTURING PROCESSES

process of turning raw materials or parts into finished goods through the use of tools, human labor, machinery, and chemical processing.

Four Basic Types of Processes

1. Synthetic

2. Analytic

3. Conditioning

4. Extractive

DIFFERENT MANUFACTURING PROCESSES

1. CASTING
2. FORMING
3. MACHINING

4. STAMPING
5. HEAT TREATING
6. SURFACE TREATING

CASTING

materials are melted down and poured into molds to create a solid object with a specific shape and structure.

A.PERMANENT-MOLD CASTING

1. Used for principally for irregularly shaped articles of moderate size such as automotive engine blocks.

CENTRIFUGAL CASTING

Operation where the mold is rotated as the metal is poured. Generally they are cylindrical items.

DIE-CASTING

producing by forcing molten metal under pressure into a steel die.

FORGING

1. The metal is heated and then pressed or hammered to a shape

EXTRUSION

Material made ductile by heating is caused to flow into des by the action of press.

MACHINING

Used to embrace the reduction of material to specified shape and dimensions by the action of cutting tools mounted on machinery.

ULTRASONIC MACHINING

vibrates tiny abrasive particles at ultrasonic frequencies

CHEMICAL MILLING

employs fluids to etch 3D images 

ELECTROLYTIC MACHINING

the work piece serves as the anode and the brass/stainless-steel tool serves as the cathode

4. STAMPING

Consists of pressing or drawing sheet metal into dies in a press

5. HEAT TREATING

Improves physical properties to give better fatigue life, ductility, and tensile strength to the steels and superalloys.

HARDENING

consists of heating the metal above its critical temperature and quenching suddenly in water/oil/air blast.

TEMPERING

drawing to give the desired toughness.

ANNEALING

heat-softening method for parts hardened by heat or cold working

INFRARED HEATING

involves electromagnetic radiation 

6. SURFACE TREATING

PLATING
PORCELAIN ENAMELING
METAL BLACKENING
PAINTING
PLASTIC COATING

PLATING

adding beauty, providing an anti-corrosion finish, enlarging dimensions by adding thin layer material.

PORCELAIN ENAMELING

gives a hard somewhat brittle, baked-on, highly protective finish commonly used on some household appliances

METAL BLACKENING

improving appearance and adding slight antirust protection 

PAINTING

for appearance and as preservative makes possible the use of colors.

PLASTIC COATING

applying a layer of plastic material to a surface for various purposes

MANUFACTURING CONSIDERATIONS

1. SCHEDULING
2. ESTIMATING

Serialized Manufacture (Balanced Production)

Mass production of the same products based on depletion of finished-goods inventories. 

Job-Lot Manufacture (Balanced Machine Loads)

Producing small quantity of customized orders typically specific orders from customers

Semi-serialized Manufacture (Balanced Schedules)

A hybrid system that is not producing continuously because of its flexible production lines. 

2. ESTIMATING

• crucial for job-lot manufacturing.

• It helps determine costs and delivery time for unique products.

LINEAR PROGRAMING

• is a mathematical tool in operations research for solving optimization problems.

• It represents variables numerically, optimizes one, and analyzes its impact on others.

FORMULA

TERMS OF FORMULA

EXAMPLE OF COMPUTATION

MONTE CARLO SIMULATION

• Named after the Monte Carlo roulette wheel.

• Used when direct mathematical analysis is difficult.

• Follows the law of probability

How to Perform Monte-Carlo Simulation Manually?

1. Define the Problem

2. Create a Random Number Table

3. Run Multiple Trials

4. Analyze Results

CRITICAL PATH SCHEDULING

• is a method for project planning and coordination.

• Introduced in 1958, it became widely used in project management.

Two main types of CPS

• Program Evaluation and Review Technique (PERT) for research and development projects.

• Critical Path Method (CPM) for construction projects.