PRODUCTION PLANNING (copy)

PRODUCTION PLANNING

The activity by which manufacturing ways and means are determined.

Objectives:

1. Bring a prescribed level of profit

2. Capture a desired share of the market demand.

3. Operate the plant at the predetermined level of efficiency.

4. Utilize available plant facilities.

5. Create a specified number of jobs.

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.

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

OWNERS

profit, operate at the optimum plant capacity, and utilize available facilities

EMPLOYEES

create and maintain jobs

CONSUMERS

meet the market demand.

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 PROCESS

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.

TYPES OF CASTING

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

2. CENTRIFUGAL CASTING - Operation where the mold is rotated as the metal is poured. Generally they are cylindrical items. 

3. DIE-CASTING - producing by forcing molten metal under pressure into a steel die.

FORMING

a process that reshapes materials, typically metal, through plastic deformation, meaning the material is permanently changed without being removed or added.

TYPES OF FORMING

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

2. 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.

TYPES OF MACHINING

1. ULTRASONIC MACHINING - vibrates tiny abrasive particles at ultrasonic frequencies

2. CHEMICAL MILLING - employs fluids to etch 3D images 

3. ELECTROLYTIC MACHINING - the work piece serves as the anode and the brass/stainless-steel tool serves as the cathode

STAMPING

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

HEATING TREATING

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

TYPES OF HEAT TREATING

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

2. TEMPERING - drawing to give the desired toughness.

3. ANNEALING - heat-softening method for parts hardened by heat or cold working

4. INFRARED HEATING - involves electromagnetic radiation

SURFACE TREATING

involves modifying the outer layer of a material to enhance its properties, appearance, or functionality

TYPES OF SURFACE TREATING

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

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

3. METAL BLACKENING - improving appearance and adding slight antirust protection 

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

5. 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.

ESTIMATING

• crucial for job-lot manufacturing.

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

• Bids must be accurate to ensure profitability and competitiveness.

LINEAR PROGRAMMING

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

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

MONTE CARLO SIMULATION

• Named after the Monte Carlo roulette wheel.

• Used when direct mathematical analysis is difficult

• Relies on probability to simulate real-world scenarios

• Uses random-number generators (tables, computers, or cards)

• Repeats trials multiple times to find the optimum solution

• Follows the law of probability

CRITICAL PATH SCHEDULING

• is a method for project planning and coordination.

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

Two main types:

• Program Evaluation and Review Technique (PERT)

• Critical Path Method (CPM)

Program Evaluation and Review Technique (PERT)

for research and development projects.

Critical Path Method (CPM)

for construction projects.