Production facilities

Production (manufacturing, repair and research) facilities

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2. CONTENTS Production facilities Facilities Planning Facility Location Facility Design Production & Manufacturing systems Facility Layout Material Handling in Facility Inspection Testing & Coordination in Facilities Conclusion

3. PRODUCTION FACILITIES Key aspect of production management Allows s mooth transformation of inputs into the outputs i.e. manufacturing process with all the required machinery, tools, contrivances and manpower etc Ensures proper methods, arrangements, procedure is adopted to produce different types of goods or services Planed on the basis of requirement and availability of the resources to the organization

4. Determines how can activity’s tangible fixed assets best support achieving the activity’s objectives. Example In Manufacturing, the objective is to support production In an airport, the objective is to support the passenger airplane interface. In a hospital, the objective is to provide medical care to patient FACILITIES PLANNING

5. FACILITIES PLANNING HIERACHY

6. FACILITIES PLANNING HIERACHY Location- Placement of a facility w.r.t customers, suppliers and other facilities with which it interface Structure- Consists of building and services e.g. gas, water, power, heat, light, air and sewages etc P&M Systems- Includes type of product, product quantity, product variety, competitors, market and demand etc Layout & Handling- Consists of equipments, machinery, furnishing and the mechanism by which all interaction requirement e.g. information, personnel and material

7. Objectives of business (manufacturing or ser vices) is to maximize the profits and to minimize the cost Facility location selection should be such that it enables the business to achieve its objectives efficiently FACTORS Nearest to raw material Land and labor cost Transportation Close to related and ancillary industries FACILITY LOCATION

8. FACILITY DESIGN Structural Design Sequential Approach Integrated Approach Impressive results in cost, quality, productivity, sales, customer satisfaction, delivery time, inventory levels, space and handling requirements etc

9. Facilities organized in the most efficient way to serve the particular mission of the plant and depends on: Production systems Product quantity Product variety Manufacturing systems Manufacturing industries FACILITY DESIGN Production & Manufacturing Systems

10. Number of different product or part design or types ‘Hard’ product variety – products differ greatly Few common components in an assembly ‘Soft’ product variety – small difference between products Many common components in an assembly FACILITY DESIGN Production & Manufacturing Systems Product variety

11. Number of units of a given part or product produced monthly / quarterly or annually by the plant Depends on type of product Three quantity ranges: Low production – 1 to 100 units Medium production – 100 to 10,000 units High production – 10,000 to millions of units FACILITY DESIGN Production & Manufacturing Systems Product quantity

12. Job shop – makes low quantities of specialized and customized products Products are typically complex (e.g., specialized machinery, prototypes) Equipment is general purpose Plant layouts: Fixed position Process layout Low Production Quantity

13. Batch production – A batch of a given product is produced, and then the facility is changed over to produce another product Changeover takes time – setup time Typical layout – process layout Hard product variety Cellular manufacturing – A mixture of products is made without significant changeover time between products Typical layout – cellular layout Soft product variety Medium Production Quantity

14. Quantity production – Equipment is dedicated to the manufacture of one product Standard machines tooled for high production (e.g., stamping presses, molding machines) Typical layout – process layout Flow line production – Multiple workstations arranged in sequence Product requires multiple processing or assembly steps Product layout is most common High Production Quantity

15. Product variety and quantity relationship FACILITY DESIGN

16. Primary industries – cultivate and exploit natural resources e.g. agriculture, mining etc Secondary industries – convert output of primary industries into products e.g. manufacturing, construction, power generation etc Service industries – service sector e.g. Banking, education, transportation, legal services etc Process industries – e.g. chemicals, petroleum, basic metals, foods and beverages etc Discrete product industries – e.g. cars, aircraft, appliances, machinery, and their component parts FACILITY DESIGN Manufacturing Industries

17. FACILITY DESIGN Manufacturing Industries

18. Planning for location of all machines, utilities, employees, workstations, customer service areas, material storage areas, canteens, offices etc Planning for flow of patterns of materials and people around, into and within buildings Factors: Products variety and quantity Production & Manufacturing system Purchase and inventor y Safety and personnel policies FACILITY DESIGN Facility layout

19. FACILITY DESIGN Facility layout Layout decision tends to be: Infrequent Expensive to implement Studied and evaluated extensively Long term commitment Proper layout enables: Higher utilization of space, equipment and people Improved flow of information, material Improved flexibility and customer interaction Improved working conditions

20. Layout Strategies Fixed Position Layout – Building large bulky projects e.g. ships, buildings etc Process oriented layout – Low quantity, high variety production i.e. job shop Product oriented layout – Best personnel and machine use in continuous production Office layout – Office workers, their equipment and space to provide movement of information Service layout – Lot of shelf space and able to respond customer behavior Warehouse layout – Trade off between space and material handling

21. Area of Concerns in Layout Strategies

22. An understanding of capacity and space requirements Selection of appropriate material handling equipment Decisions regarding environment Identification and understanding of the requirements for information flow Identification of the cost of moving between the various work areas Requirement of Good layout

23. Layout Levels

24. Material transport Vehicles, e.g., forklift trucks, AGVs, monorails Conveyors Cranes Storage systems Unitizing equipment Automatic identification and data capture Bar codes RFID Other AIDC Material Handling FACILITY DESIGN

25. Time spent in Material Handling

26. Inspection – conformance to design specifications Inspection for variables – measuring Inspection of attributes – gauging Testing – observing the product (or part, material, subassembly) during operation Inspection and Testing

27. Solid inter and intra level coordination between allied sections or groups Production control Quality control and its allied sections Service sections e.g. Finance, sales and marketing Purchase and inventory Warehouse coordination Out sourced industries Coordination and Control

28. Conclusion PRODUCTION FACILITIES To carry out any production process, planning of required facilities is necessary Before Starting of any production process, the organization has to decide about facilities to produce the same Facilities has to be installed on the basis of requirement and availability of resources to the organization

29. Q & A