PRODUCTION MANAGEMENT

Maintenance Planning
Planning of maintenance jobs basically deals with answering two questions, what and How of the job; what activities are to be done? and how those jobs and activities are to be done?

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Steps of Job Planning

1. Knowledge base: It includes knowledge about equipment, job, available techniques, materials and facilities. 2. Job investigation at site: It gives a clear perception of the total jobs. 3. Identify and document the work: Knowing the earlier two steps and knowing the needs of preventive, predictive and other maintenance jobs. 4. Development of repair plan: Preparation of step by step procedures which would accomplish the work with the most economical use of time, manpower and material.

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5. Preparation tools and facilities list indicating the needs of special tools, tackles and facilities needed. 6. Estimation of time required to do the job with work measurement technique and critical path analysis.

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REASONS FOR GENERATION AND ACCUMULATION OF OBSOLETE, SURPLUS AND SCRAP ITEMS.

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1. 2. 3. 4. 5.

Changes in product design Cannibalization Faulty planning and forecasting Faulty purchase practices Other causes

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IDENTIFICATION AND CONTROL OF WASTE

The combining process of combining the stock records and movement analysis has been found very effective in locating such stocks in the total inventory.
Sl. No. Part description A B C Date of issue Stock on hand Value

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Whenever changes in production programme, design and product lines are contemplated, a senior executive from materials management must definitely be kept in the picture. This helps in several ways. He is in a position to inform top management of the amount of stock of materials on hand that are likely to be rendered obsolete if and when the changes are introduced.

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DISPOSAL OF SCRAP
Disposal of scrap when handled in an imaginative manner can result in handsome returns to the organization. An effective disposal requires a compact disposal organization reporting to the materials manager, continuous market survey on the prices of various categories of scrap generated in the plant and constant touch with the industries which generate similar scrap and with the endusers.

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AUTOMATION
Automation is a technology concerned with the application of mechanical, electronic, and computer based systems to operate and control production.

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TYPES OF AUTOMATION 1. Fixed automation, 2. Programmable automation, and 3. Flexible automation.

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1. FIXED AUTOMATION The typical features of fixed automation are:

(a) High initial investment for customEngineered equipment. (b) High production rates. (c) Relatively inflexible in accommodating product changes.

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2. PROGRAMMABLE AUTOMATION

(a) High investment in general-purpose equipment. (b) Low production rates relative to fixed automation. (c) Flexibility to deal with changes in product configuration. (d) Most suitable for batch production.

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3. FLEXIBLE AUTOMATION
(a) High investment for a custom-engineered system. (b) Continuous production of variable mixtures of products. (c) Medium production rates. (d) Flexibility to deal with product design variations.

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REASONS FOR AUTOMATION

1. 2. 3. 4. 5. 6.

Increased productivity High cost of labour Labour shortages Trend of labour toward the service sector Safety High cost of raw materials

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7. Improved product quality 8. Reduced manufacturing lead time 9. Reduction of in-process inventory 10. High cost of not automating

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AUTOMATION STRATEGIES

1. 2. 3. 4. 5.

Specialization of operations. Combined operations. Simultaneous operations. Increased flexibility. Improved material handling and storage systems.

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7. On-line inspection. 8. Process control and optimization. 9. Plant operations control. 10. Computer integrated manufacturing (CIM).

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COMPUTER INTEGRATED MANUFACTURING

The computers had done a dramatic impact on the development of production automation technologies. Nearly all modern production systems are implemented today using computer systems. The term computer integrated manufacturing (CIM) has been coined to denote the pervasive use of computers to design the products, plan the production, control the operations, and perform the various business related functions needed in a manufacturing firm. Computer Aided Design and Computer Aided Manufacturing (CAD/CAM) in another term that is used synonymously with CIM.

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AUTOMATED FLOW LINES An automated flow line consists of several machines or workstations which are linked together by work handling devices that transfer parts between the stations.

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Production Auto 1

Production Auto 2

Production Auto 3

Production Auto 4

Production Auto 5

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The objectives of the use of flow line automation are:

1. To reduce labor costs. 2. To increase production rates. 3. To reduce work-in-process. 4. To minimize distances moved between operations. 5. To achieve specialization of operations. 6. To achieve integration of operations.

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There are two general forms that the workflow can take. In-line Type Rotary Type

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AUTOMATED GUIDED VEHICLES SYSTEMS An automated or automatic guided vehicle system (AGVS) is a materials handling system that uses independently operated, self-propelled vehicles that are guided along defined pathways in the floor.

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Types of AGVS 1. Driverless trains: The type consists of a towing vehicle (which is the AGV) that pulls one or more trailers to form a train.

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2. AGVS pallet trucks: Automated guided pallet trucks are used to move palletized loads along predetermined routes. In the typical application the vehicle is backed into the loaded pallet by a human worker who steers the truck and uses its forks to elevate the load slightly.

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3. AGVS unit load carriers: This type of AGVS is used to move unit loads from one station to another station. They are often equipped for automatic loading and unloading by means of powered rollers, moving belts, mechanized lift platforms, or other devices.

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END