Production Planng & productivity devel

Production Planning

Activity by which manufacturing ways and means are determined.

Objectives of Production Planning

1. Bring prescribe 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 Managements

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

For whome 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, labor, machinery and chemical processing,

4 basic types of processes

1. Synthethic

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 specific shape and structure

A. Permanent Mold Casting

used for principally for irregularly shaped articles of moderate size such as automotive engine blocks

B. Centrifugal Casting

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

C. Die Casting

producing by forcing molted metal underpressure into a steel die

Forming
A. Forging

metal is heated and then pressed or hammered to a shape

B. Extrusion

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

Machining

Used to embrace the reduction of material to specified shape and dimension by the action of cuttting tools mounted on machinery

A. Ultrasonic Machining

vibrates tiny abrasives particles at ultrasonic frequencies

B. Chemical Milling

employs fluid to etch 3D images

Electrolytic Machining

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

Stamping

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

Heat Treating

improves physical properties to give better fatigue life, ductility, and tensile strength to the steels and super alloys

A. Hardening

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

B. Tempering

drawing to give the desired toughness

C. Anneling

Heat softening method for parts hardened by heat or cold working

D. Infrared heating

involves electromagnetic radiation

Surface Treating
A. Plating

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

B. Porcelain enameling

gives hard somewhat brittle, baked on, highly protectice finish commonly used on some household appliances

C. Metal Blackening

Improving apperance and adding slight anti rust protection

D. Painting

For appearance and as preservative makes possible the use of colors

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 load)

Producing small quantity of customized orders typically specific orders from customers

Estimating

it helps determine cost and delivery time for unique products.

Linear Programming

mathematical tool in operations research for solving optimization problems

Monte Carlo Simulation

-used when direct mathematical analysis is difficult

-relies on probability to simulate real world scenarios

-used random-number generators

Critical Path Scheduling

method for project planning and coordination

2 types of critical path scheduling

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

Productivity

the relationship of the volume of goods and services produced to the physical inputs used in its production.
Productivity = (output/input)

Productivity Growth

driven by factors like workforce skills, technology, capital utilization, production scale, management quality, and labor relations. It requires collaborations among businesses, labor, investors, consumers, and governments, with economic expansiong playing a key roles in job creation, investments, operational effifiency.

Factors Affecting Productivity Gains

1. Tangible Capital Per Worker

2. Improvement in the quality of labor

3. More efficient use of capital and Labor

Tangible Capital per Worker (Physical Capital)

Increases in productivity and the higher income thus produced help generate capital formation

Improvement in the quality of labor

labor, which is also a form of investment is a critical factor in the equation of productivity improvement

More efficient use of capital and labor

Improvement in managerial technique as well as modifications in tools and equiment

Product Simplification

means essentially the elimination of extraneous or marginal lines, types, and models of products

Product Diversification

it is the direct opposite of simplifications. It involves the addition of lines of products, types and models

Product Engineering

process of designing, developing, and improving, products to meet customer needs and market demand while ensuring efficiency in manufacturing and functionality.

Product design

process of creating products that are functional. manufacturable and meet customer needs through a blend of creativity and technical expertise

Industrial Standardization

process of developing and implementing technical standards within an industry to ensure that products, services, and processes are compatible, safe, efficient, and of high quality

Product standard

are guidelines or specifications that define the characteristics, quality, and safety requirements for a product, ensuring consistency, safety, and compatibility

Engineering Design Standard

are documented guidelines and specifications that ensure consistency. safety, performances, and quality in the design and development of engineering products and systems

Material Standards

established criteria defining the quality, composition, propertiesm and performance requirements of materials used across various industries, ensuring consistent quality and facilitating communication and commerce.

Quantity Standards

the pre determined, acceptable amount of inputs ( like raw materials or labor hours) needed to produce a product or service, used for cost control and performance evaluation

Process Standard

establishing consistent, documented procedures and guidelines for performing specific task to enhance efficiency, reduce errors, and ensure uniformity across an organization

Equipment Standards

ensure consistency, compatibility and safety across different applications and industries by establishing and implementing technical standards for tools and equipments

Safety Standards

Standards designed to ensure the safety of products, activities, and/or processes to create a safe and healthy workspace

Administrative Practice Standards

standards designed to ensure the safety of products, activities and/or processes to create a safe and healthy workspace

Incipient period

refers to the early stage of a project, typically, at the beginning, when work is just starting, and progess is relatively slow.

Developments Period

project where actual work is progessing at a more consistent and noticeable pace after the incipient period ( early stage)

Saturations period

refers to the phase during the project when work is progressing at its maximum possible rate or output

Premature Standardization

refers to the process of establishing standards or regulations for a technology or industry before it has had a chance to fully develop of mature