2. Syllabus
• The Production Function
• Types of production system
• Elementary knowledge of manufacturing processes
• Plant Layouts
• Material Handling
• Location Problems
• Inventory management
• Scheduling
• Network Analysis
• Break Even Point Analysis
• Reliability maint & plant services
• Quality control
• Emerging Trends
• Concept of Productivity
3. CHAPTER -II
• Types of Production Systems –
•Intermittent Production
•Continuous Production
CHAPTER -III
• Elementary knowledge of Manufacturing process
• Assembling
• Fabrication
• Forming
• Heat Treatment
• Welding
• Machining etc
4. PRODUCTION SYSTEM
DECISION MAKER
CONTROL
CONVERSION
INPUT PROCESS OUTPUT
5. PRODUCTION SYSTEM
• Solid line represents movement of material through conversion system by value addition
to finish goods ( Materials Management)
• Dotted Line represents flow of information / set of Instruction
• All on line data / information is continuously passed on to control tower ,control
tower in terms process / Tabulate all the information in format & sends it to decision
maker ( Flow of Information)
• Decision Maker Compares / Benchmark actual information with plan & generate the set
of instructions for correcting the deviations & sends it to control tower (Plan Vs Actual)
• Control tower sends instructions at appropriate point for execution & bring back process
under control
DECISION
CONTROL
MAKER
INPUT CONVERSION OUTPUT
PROCESS
6. The system selection is sensitive because of following
parameters
1 . Type of Product
• Common parameters
• Total Volume
• Varieties in total Volume
2 .Type of Company
• Automobile
• Chemical
• Pharma
3.Life Cycle of Product / Project
7. Life cycle phase of Project Conclusion :
Introduction ( Low volume ,High System selection is not a static or one time
Variation)
Growth ( High volume , Low decision but “DYNAMIC” one & changes as
Variation) organization passes through I –G-M-D Phases
Maturity ( High volume , Low
Variation) & changes the equation of Volume to Variety
Decline ( Volume drops , Variation
ratio
High)
8. Types of Production System
Intermittent System Continuous System
Job Type Mass Production
Printing Job
Spoons / Hair Pins /
Machine Building Soaps / Chocolates
Batch Type Process Type
Washing Machine Cement / Sugar /
Chemical Industries
Fridge / TV / CAR
9. INTERMITTENT SYSTEM
• The goods are manufactured specially to fulfill orders made by customers & not for
stock
• Characteristics :
• Most products are produced in small quantities
• Machines & equipments are laid out by process
• Workloads are unbalanced
• Highly skilled operators are required for efficient use of machines & equipments
• In process inventory is very large
• Flexible to accommodate variety in production
• Example :
•Machine shops
• Hospitals
• locomotives
• Plants
• Automobiles
10. INTERMITTENT SYSTEM
OP1 Information & Control Decision Maker
Storage1
OP2
Storage 2 Storage 4
OP4
Storage 3
OP3 Storage 5
Ex. Paper cutting machine
11. Intermittent system Classification :
• Job Production • Batch Production
• Job Production : 1) It is the production of single complete unit by one operator ,
Group of operators
2) Whole project is considered as a one operation & work is
completed on each product before passing to the next
• Characteristics :
• Complete project is considered as single operation
• Versatile & skilled labors are required
• High capital Investment
• Control operations relatively simple
• High unit cost of production
• Examples :
• Bridge Building
• Dam Construction
• Ship Buiding
• Heavy machines
12. Intermittent system Classification :
• Batch Production
• Batch
Production : It is
a extension of
job type
production
Whole project is considered as a one operation & work is
completed on
each product
before passing
to the next
• Characteristics :
• Production schedule can be formulated according to specific
orders or demand forecasts
• Items are processed in lots & batches
• Only one item is produced in every production run
• New batch will be taken only after completion of one
• High WIP
13. Continuous System :
• In this system the items are produced for the stocks & not for specific order
• Manufacturing stock is based on sales forecast
• Inputs are standardized & standard set of processes & sequence of processes can be
used
Input
OP1 Information & Control Decision Maker
Storage1
OP2
Storage2
OP3 OP4 OP5
Ex. Bottling Plant
Out put
14. Mass Production
Fundamental characteristics of the system is standardization
• Items are produced in large quantities independent of customer orders
• i.e Production is to stock & not to order
• Standardization is w.r. to materials & machines
• Uniform & un-interrupted flow of material is maintained through predetermined sequence
of operations required to produce the product
• System can produce only one type of product at one time
Example :
• Sub assemblies
• Parts / components
•Advantage :
• Economies of production because of specialization & standardization
15. Process Production
It gives more stress on AUTOMATION in production process
• The volume of production is very high
• This method is used for manufacturing items with very high demand
• Ex.
• Petroleum products
• Particular brand of medicines
• Heavy chemical industries
• Plastic industries
Note : Single raw material can be transformed into different kinds pf product
at different stages of production process
Ex. Processing of crude oil will give Kerosene / Gasoline etc at diff stages
of production
16. Factors for Comparison of Manufacturing systems
1. Manufacturing costs
2. Capital investment
3. Size of plant
4. Technical requirement
5. Organizational structure
6. Flexibility in production
7. Type of products produced
8. Security of job
17. Elementary knowledge of Manufacturing process
Assembling :
Welding, Brazing, Riveting, Fastening By Nuts&bolts, Adhesives
Forming :
In this process shape of work piece changes without necessarily removing or
adding material
Ex .Casting, Forging, Extrusions, Stamping, Embossing,
Heat Treatment :
Heat treatment is process of heating & cooling of metals or alloys in solid state in
order to obtain certain desired properties ( Relieve internal stresses , Hardness
,toughness etc)
Machining : It involves metal removing by Turning , Drilling , Milling , grinding
,shaping ,boring ,EDM , ECM etc.
Electro discharge machining : (EDM)
Spark between workpiece & tool across gap removes the material using
dielectric ,which also cools the metal
Electro Chemical Machining (ECM) :
Chemical energy combine with electrical energy is used to do the cutting operation
