ASSEMBLY BASED ON:
Demand Forecasting.
Preparation of suitable plans for meeting the demand.
From forecasts of demand and plans for production, production schedules prepared.
From production schedules production load is derived which is translated into action.
Forecast of Demand.
Plans.
Schedulers.
Load.
Action. In PPC loading and scheduling are important steps and they go hand in hand.
Loading differs from scheduling only in terms of detail and time span.
A schedule will time table a dept. for a month or so.
A load will time table a machine or operator for a day or a week.
SCHEDULE
Representation of time taken to carry out a task.
Takes into account the time relationship between the various functions.
A route or list of work to be done would not show the overlapping of activities where as schedule would take this in to account.
LOADING
Load work assigned to a machine or an operator, evaluates, capacity volume of out put capable of being produced in a period of time.
Preparation of loading schedules for machine or operator is capable of providing substantial improvements in productivity.
GENERAL RULES FOR SCHEDULING
Schedule first those operations with the shortest first operation.
Schedule first those operations with the shortest last operations.
Schedule jobs according to their total work content.
Schedule jobs according to their dates of promises made.
Assign jobs according to the customer.
SIMPLIFYING THE SCHEDULING PROBLEM
Reduce product range.
Reduce component range.
Examine available resources.
Enlarge all jobs wherever possible.
Use sub contractors.
Separate big and small jobs.
Close liaison with marketing.
PROBLEMS AND ISSUES IN SCHEDULING
Centralized scheduling Vs Decentralized scheduling.
Availability of realistic time estimates for various jobs/operations.
What is the time span/period for which a rigid schedule is to be made?.
Feedback on the schedules and rescheduling of jobs/activities.
Change of priorities and extraneous causes that affect schedules.
Assessment of delivery schedules given by vendors/suppliers (outside source) and synchronization of internal and external schedules.
Optimization in scheduling – the role of quantitative techniques.
Compares in production scheduling and control.
Integrating production scheduling with maintenance schedules.
SCHEDULING TECHNIQUES
Run Out List for Selecting Items.
The time when inventory on hand plus production of the items already schedules will be used.
Objective is to assign available production capacity in such a way that runs out time for all items are the same.
Inventory of each item expected on hand at the end of the period being scheduled.
Inventory on hand or scheduled in production on the scheduling date scheduled production of the item.
Expected usage of the item during the period.
Inventory expected on hand (end of scheduled period).
RUN OUT TIME WITH ECONOMIC RUN LENGTHS
A run out list can be used for scheduling an operation which makes a number of stock items which are to made in economical, fixed or minimum batches or lots and where the operating length has been set.
Divide the inventory on hand (or in production) for such item by estimated usage rate. This gives the run out time if no extra production is scheduled.
Then standard lots are scheduled beginning with item with the shortest run out time until the total time scheduled equals the planned production time.
LOADING SCHEDULES WILL HELP IN…
To make maximum possible use of plant and personnel.
To establish and meet target dates.
To determine the necessities of new plant.
To improve operator’s morale.
LOAD GENERALLY EXPRESSED IN HOURS OF WORK/MONEY/WEIGHT/LENGTH/QUANTITY
Load Delivery date Schedule Load.
It is faulty to set a delivery date without due regard for the load yet this is done frequently that it can be the general practice.
IN PREPARE SCHEDULES ATTENTION MUST BE PAID TO:
Variations to schedule.
Capacities of various sections/departments.
Efficiencies of various sections/departments.
Maintenance schedules.
Holidays.
Anticipated sickness/Absenteeism.
Existing commitments.
Availability of materials.
Basic Objective of Scheduling to obtain a Smooth, Timely Flow of Product through Manufacturing Steps.
GANNT charts, network techniques, line of balance etc. Modern software technology, Help in scheduling.
LINE OF BALANCE
Just as critical path analysis cab used to schedule and controls a single project; LOB can be used to schedule and control a single batch.
LOB – PRE – REQUISITES
There must be identifiable stages in production at which managerial control can be exercised.
Manufacturing times between these stages must be known.
A delivery schedule must be available.
Resources can be varied as required.
In controlling a number of batches the computational difficulties become great.
STEPS IN LOB
Construct a CPA diagram to show the logic and timing of production.
Carry out a reverse forward pass from time ‘0’ at the final event.
Rank the activities in the descending order of ‘equivalent week Number’. (this is also reported as stages).
Prepare a calendar and accumulated delivery quantity.
From the tables schedule the quantity of each actively which should be completed by a particularly date.
Record the actual progress on LOB chart or life table.
MANUFACTURING PROCESS AND MACHINES
Metal cutting process forms the basis of the engineering industry and is involved either directly or indirectly in the manufacture of nearly every product.
Manufacturing requires tools and machines that can produce economically as well as accurately. Economy depends to large extent on the proper selection of the machine or process that will give satisfactory finished products.
In small lot or jobbing type manufacturing, general purpose machines such as the lathe, drill press and planer may prove to be the best type, since they are adaptable, have lower initial cost, require less maintenance and process the flexibility to meet changing conditions in shop.
A special purpose machine should be considered for large quantities of a standardized product. A machine built for one type of work or operation will do the job well, quickly and at low cost with the service of a semi skilled operator.
In manufacturing any product, there are usually a number of machining operations, which are as follows:
Turning
Grinding
Broaching
Drilling
Milling
Reaming
Shaping etc
The type of different tools and machines most commonly used in the manufacturing sector:
Turning. Machines: Turning machines are more commonly known as lathes.
Centre lathes or Engine lathes.
Gap bed lathes.
Tool room lathes.
Bench lathes.
Hollow spindle lathes.
Special purpose engine lathes.
Turret lathes & Drum turret lathes.
Capstan lathes.
Vertical turret lathes.
Automatic lathes.
Copying lathes.
Numerically controlled lathes.
Chucking lathes.
Grinding and abrasive machines.
Abrasive
Machines Abrasive machining is a primary stock removal process which competes favorably with other stock removal methods. It is not a finishing operation like conventional grinding or lapping. Not limited to bonded wheel operations, it includes coated and free abrasive processes as well.
Grinding Machines-
Classification of grinding and abrasive machines:
Cylindrical grinder.
Internal grinder.
Surface grinder.
Universal grinder.
Tool grinder.
Special grinding machines.
Surface preparing.
Abrasive grinding.
Broaching-Broaching is a machining process in which a cutting tool, having multiple transverse cutting edges, is pushed or pulled through a hole or a surface to remove metal by axial force.
Broaching Machine:
Drilling.
Drilling machines.
Drilling machine size.
TYPES
Hand feed drilling machine, Radial drilling machine,
Milling-
Milling is a machining process in which metal is removed by a rotating multiple tool cutter.
Milling machines-
Milling machines are employed for machining flat surfaces, contoured surfaces, surfaces of revolution, external and internal threads and helical surfaces of various cross sections.
TYPES
Column and knee-type machines, Horizontal milling machines, vertical milling machines.
TYPES of milling cutters- There are 3 general designs of cutters Arbor cutters.
Shank cutters.
Face cutters.
The cutters most generally used are classified principally according to their general shape or the type of work they do.
Plain milling cutter, Slide milling cutter, Metal slitting saw cutter, Angle milling cutter, Form milling cutter, End milling cutters, T-slot cutters and Inserted tooth cutter.
A number of different types of machines are available for different type of operations. (Now a day’s improved version of new software technology are being used to build additional strength for the above to have more accuracy and prompt fine finished work)
The above information is a brief idea about production planning and control. It may differ slightly from an industry to industry due to improved versions of technology.
This information is an instance about the sector I have been involved with. The reader is advised to use the information according to his needs on the basis of his/her manufacturing segment.
Load.
Action. In PPC loading and scheduling are important steps and they go hand in hand.
Loading differs from scheduling only in terms of detail and time span.
A schedule will time table a dept. for a month or so.
A load will time table a machine or operator for a day or a week.
SCHEDULE
Representation of time taken to carry out a task.
Takes into account the time relationship between the various functions.
A route or list of work to be done would not show the overlapping of activities where as schedule would take this in to account.
LOADING
Load work assigned to a machine or an operator, evaluates, capacity volume of out put capable of being produced in a period of time.
Preparation of loading schedules for machine or operator is capable of providing substantial improvements in productivity.
GENERAL RULES FOR SCHEDULING
Schedule first those operations with the shortest first operation.
Schedule first those operations with the shortest last operations.
Schedule jobs according to their total work content.
Schedule jobs according to their dates of promises made.
Assign jobs according to the customer.
SIMPLIFYING THE SCHEDULING PROBLEM
Reduce product range.
Reduce component range.
Examine available resources.
Enlarge all jobs wherever possible.
Use sub contractors.
Separate big and small jobs.
Close liaison with marketing.
PROBLEMS AND ISSUES IN SCHEDULING
Centralized scheduling Vs Decentralized scheduling.
Availability of realistic time estimates for various jobs/operations.
What is the time span/period for which a rigid schedule is to be made?.
Feedback on the schedules and rescheduling of jobs/activities.
Change of priorities and extraneous causes that affect schedules.
Assessment of delivery schedules given by vendors/suppliers (outside source) and synchronization of internal and external schedules.
Optimization in scheduling – the role of quantitative techniques.
Compares in production scheduling and control.
Integrating production scheduling with maintenance schedules.
SCHEDULING TECHNIQUES
Run Out List for Selecting Items.
The time when inventory on hand plus production of the items already schedules will be used.
Objective is to assign available production capacity in such a way that runs out time for all items are the same.
Inventory of each item expected on hand at the end of the period being scheduled.
Inventory on hand or scheduled in production on the scheduling date scheduled production of the item.
Expected usage of the item during the period.
Inventory expected on hand (end of scheduled period).
RUN OUT TIME WITH ECONOMIC RUN LENGTHS
A run out list can be used for scheduling an operation which makes a number of stock items which are to made in economical, fixed or minimum batches or lots and where the operating length has been set.
Divide the inventory on hand (or in production) for such item by estimated usage rate. This gives the run out time if no extra production is scheduled.
Then standard lots are scheduled beginning with item with the shortest run out time until the total time scheduled equals the planned production time.
LOADING SCHEDULES WILL HELP IN…
To make maximum possible use of plant and personnel.
To establish and meet target dates.
To determine the necessities of new plant.
To improve operator’s morale.
LOAD GENERALLY EXPRESSED IN HOURS OF WORK/MONEY/WEIGHT/LENGTH/QUANTITY
Load Delivery date Schedule Load.
It is faulty to set a delivery date without due regard for the load yet this is done frequently that it can be the general practice.
IN PREPARE SCHEDULES ATTENTION MUST BE PAID TO:
Variations to schedule.
Capacities of various sections/departments.
Efficiencies of various sections/departments.
Maintenance schedules.
Holidays.
Anticipated sickness/Absenteeism.
Existing commitments.
Availability of materials.
Basic Objective of Scheduling to obtain a Smooth, Timely Flow of Product through Manufacturing Steps.
GANNT charts, network techniques, line of balance etc. Modern software technology, Help in scheduling.
LINE OF BALANCE
Just as critical path analysis cab used to schedule and controls a single project; LOB can be used to schedule and control a single batch.
LOB – PRE – REQUISITES
There must be identifiable stages in production at which managerial control can be exercised.
Manufacturing times between these stages must be known.
A delivery schedule must be available.
Resources can be varied as required.
In controlling a number of batches the computational difficulties become great.
STEPS IN LOB
Construct a CPA diagram to show the logic and timing of production.
Carry out a reverse forward pass from time ‘0’ at the final event.
Rank the activities in the descending order of ‘equivalent week Number’. (this is also reported as stages).
Prepare a calendar and accumulated delivery quantity.
From the tables schedule the quantity of each actively which should be completed by a particularly date.
Record the actual progress on LOB chart or life table.
MANUFACTURING PROCESS AND MACHINES
Metal cutting process forms the basis of the engineering industry and is involved either directly or indirectly in the manufacture of nearly every product.
Manufacturing requires tools and machines that can produce economically as well as accurately. Economy depends to large extent on the proper selection of the machine or process that will give satisfactory finished products.
In small lot or jobbing type manufacturing, general purpose machines such as the lathe, drill press and planer may prove to be the best type, since they are adaptable, have lower initial cost, require less maintenance and process the flexibility to meet changing conditions in shop.
A special purpose machine should be considered for large quantities of a standardized product. A machine built for one type of work or operation will do the job well, quickly and at low cost with the service of a semi skilled operator.
In manufacturing any product, there are usually a number of machining operations, which are as follows:
Turning
Grinding
Broaching
Drilling
Milling
Reaming
Shaping etc
The type of different tools and machines most commonly used in the manufacturing sector:
Turning. Machines: Turning machines are more commonly known as lathes.
Centre lathes or Engine lathes.
Gap bed lathes.
Tool room lathes.
Bench lathes.
Hollow spindle lathes.
Special purpose engine lathes.
Turret lathes & Drum turret lathes.
Capstan lathes.
Vertical turret lathes.
Automatic lathes.
Copying lathes.
Numerically controlled lathes.
Chucking lathes.
Grinding and abrasive machines.
Abrasive
Machines Abrasive machining is a primary stock removal process which competes favorably with other stock removal methods. It is not a finishing operation like conventional grinding or lapping. Not limited to bonded wheel operations, it includes coated and free abrasive processes as well.
Grinding Machines-
Classification of grinding and abrasive machines:
Cylindrical grinder.
Internal grinder.
Surface grinder.
Universal grinder.
Tool grinder.
Special grinding machines.
Surface preparing.
Abrasive grinding.
Broaching-Broaching is a machining process in which a cutting tool, having multiple transverse cutting edges, is pushed or pulled through a hole or a surface to remove metal by axial force.
Broaching Machine:
Drilling.
Drilling machines.
Drilling machine size.
TYPES
Hand feed drilling machine, Radial drilling machine,
Milling-
Milling is a machining process in which metal is removed by a rotating multiple tool cutter.
Milling machines-
Milling machines are employed for machining flat surfaces, contoured surfaces, surfaces of revolution, external and internal threads and helical surfaces of various cross sections.
TYPES
Column and knee-type machines, Horizontal milling machines, vertical milling machines.
TYPES of milling cutters- There are 3 general designs of cutters Arbor cutters.
Shank cutters.
Face cutters.
The cutters most generally used are classified principally according to their general shape or the type of work they do.
Plain milling cutter, Slide milling cutter, Metal slitting saw cutter, Angle milling cutter, Form milling cutter, End milling cutters, T-slot cutters and Inserted tooth cutter.
A number of different types of machines are available for different type of operations. (Now a day’s improved version of new software technology are being used to build additional strength for the above to have more accuracy and prompt fine finished work)
The above information is a brief idea about production planning and control. It may differ slightly from an industry to industry due to improved versions of technology.
This information is an instance about the sector I have been involved with. The reader is advised to use the information according to his needs on the basis of his/her manufacturing segment.
0 comments: