HIGH VOLUME PRODUCTION ACTIVITY CONTROL

DO WE KNOW THE ANSWER FOR THE FOLLOWING QUESTIONS?

1. What will be the production quantity ? 2. Characteristics of the products to be manufactured

3. The availability of the equipment and what kind of equipment are to be purchased?
4. What kinds of labor are required? 5. What should be the level of automation? 6. Make or buy the components required If the answer to the above questions are known, then the next step in the process of conversion of raw materials in to finished products is to decide on how each component is to be manufactured and the sequence of operations to be performed

on it.

PRODUCTION ENVIRONMENT
1.
2.

MAKE TO STOCK
ASSEMBLE TO ORDER

3.

MAKE TO ORDER

PRODUCTION METHODS/SHOP FLOOR TYPES

Mass Production creates a homogeneous product through a continuous series of standard procedures. Batch Production produces discrete groups (batches) of products. Each item in the batch is similar. Job shop Production involves the fabrication of discrete products in accordance with customer specifications.

INTRODUCTION-ELEMENTS OF THE FLOW SHOP Flow shop: Each of the n jobs must be processed through the m machines in the same order. Each job is processed exactly once on each machine.

An assembly line is a classic example of flow shop

Every cars go through all the stations one by one in the same sequences; Same tasks are performed on each car in each station; Its operations scheduling is simplified as assembly line balancing; An assembly balancing problem is to determine the number of stations and to allocate tasks to each station.

INTRODUCTION-JOB SHOP
Turnning Center Drilling Center

Grinding Center

Milling Center

A job shop is organized by machines which are grouped according to their functions.

Job Shop:
Vol.

- low Skilled labor are required Layout - product is moved to various work centers Production usually does not begin before an order, materials purchased after an order Production scheduling - intensive scheduling and routing on the shop floor

I.

Shop Type
a.

(Flow Shop : Uni-direction)

M1 M2 M3 M4

b.

(Job Shop : Multi-direction)

M4
M1 M3 M2

c.

(Open Shop: No direction)

Batch Production

Flow Shop

Volume
Batch Productio n

Job Shop

Variety

The major problem is to attain the desired production rate. To this the problems to be addressed are: 1. Sequencing of operations 2. Ordering of stations 3. Number of stations required

Process planning helps in doing this.

Process planning:

Factors effecting Process planning:

Some definitions:
Workstation: A workstation is a location on assembly line where given amount of work is done Cycle time : It is the amount of time the product (In - process) spends at each workstation. Cycle time (CT) = Available Time period / Output units required per period Task: The smallest grouping of work that can be assigned to a workstation Predecessor Task: A task that must be performed before performing another task.

Balance delay: Percentage of total idle time on the line to total time spent by the product from the beginning to end of line

Balance Delay BD = (Total idle time for all workstations)/ (Total available working time on all stations) = (n.CT - ti ) * 100/ (n.CT) n = Number of workstations ti = station time of specific workstation ti = Total standard station time BD indicates the inefficiency of the system, which is induced by the idle time

The problem of line balancing arises due to the following factors:

1. The finished product is the result of many sequential operations 2. There is a difference in production capacities of different machines (The /p from different machines is not identical)

Line Balancing: It is the apportionment of sequential work activities in to workstations in order to gain a high utilization of labor and equipment so as to minimize the idle time.

Heuristic methods of line balancing: This method tries to reach an acceptable solution rather than an optimal solution . Used where optimal solutions are not feasible or are too costly

Procedure: 1. Draw the precedence diagram Numbers are assigned to each operation to denote how many predessors it

has
Operations showing the lowest predecessor number are taken first on the workstation 2. Select feasible cycle time 3. Assign work elements to work stations sum of elemental times should not exceed cycle time If it does identify the WE due to which this happens and carry it forward to next

station

1. Make a precedence diagram for the following problem and calculate Balance dela if the Cycle time is 8 min.

Work elements 1 2 3 4 5 6

precedence process 0 1 2 1 2 5

Time 4 2 3 2 5 4