Beruflich Dokumente
Kultur Dokumente
MANAGEMENT
SYSTEM
It consists of elements or components. The elements or components are interlinked together to achieve the
objective for which it exists. Eg: human body, educational institutions, business organizations.
Components of a system:
The input, processing, output and control of a system are called the components of a system.
Figure 1.1 - Components of a system
Control:
There are two types of control, namely Proactive Control and Reactive Control.
Proactive Control:
When an operation is carried out on a product in a workstation, the quality inspector goes to the workstation and
inspects the product. When the samples that he has taken for the inspection are not confirming to the quality, he
stops the machine and identifies the reason for the deviation and corrects the problem, so that the produced
product thereafter conform to the specifications. This type of control prevents any major quality setback after the
production. This is an example for proactive control.
Reactive Control:
In a planning period, usually the quality target is fixed. Suppose, an organization feels to fix 5% defective is safe
in the targeted production quantity and assumes that at the end of the planning period it finds that the defective
output exceeds the targeted defective products. Then, it has to find out the reason for the deviations, namely,
whether the problem is due to the method of doing the work or the resources used in the process.Then the
planner uses this knowledge to prevent any problem in the future. Thus a Reactive Control is a post mortem
case.
Business System:
The business organization is classified into different subsystems based on the functions like marketing,
production/operation, finance and human resource etc.
Figure 1.2 Business System
Operations Management
Operation system is either manufacturing sector or service sector. The input requirements are shown in
figure1.3 The transformation process, in which part of the value addition takes place to get the required quantity
of the product or services with the targeted quality within the specified time period, is carried out in a most
economical way. Operation Management Plan coordinates and controls all the activities in the operation system
to achieve the stated objectives.
Thus (the activities listed in the diagram) the Operations Management activities, ensure the objective of
quantity, quality, delivery time and economical way of doing work. The communication links between the various
activities are shown in the figure1.3. Each activity is dealt in detail in different sections of this material. This
figure (figure1.3) will be very much appreciated after getting a clear understanding of all the activities.
What is operation management (OM)?
Operation Management is a way or means through which the listed objectives of an operating system are
achieved. There is always confusion between the word OM & PM (Production Management). It is accepted
norm that OM includes techniques which are enabling the achievement of operational objectives in an operation
system.
The operation system includes both manufacturing sector as well as service sector, but when you use the word
PM, you should be careful to note that it refers to the manufacturing sector but not the service sector. Suppose,
you are designing a layout for the hospital you should say that you are applying Operations Management
Technique not the Production Management Technique.
When you design a layout for a manufacturing sector you can say that you are applying Production Technique
or Operation Technique or vice versa. From, the above discussion we can come to a conclusion that production
management is a subset of Operations Management.
HISTORY OF OM
Physical
(Manufacturing,
Mixing)
Location Services
(Transportation)
Exchange Services
(Retailing/wholesaling)
Storage Services
(Warehouse)
Other Private
Services
Primary Resources
(Insurance, Finance,
Utilities, Real Estate)
External
Materials and
Government
Market
Supplies
Nature
of Production Systems:
Legal/Political
Services
Competition
Personnel
Social
(Local, State, Federal)
Product
Capital
and
Economic
Information
Conversion
Capital Goods
Inputs
SystemsSystem
Technological
Control
Customer desires
Products and
Services
Outputs
F
e
e
d
b
a
c
k
Job Shop
Batch
Mass
Continuous Production
Auto repairing
Hospital
Machine shop
Characteristics:
Merits/Demerits
Characteristics:
Merits/Demerits
Production planning and control and material handling are also complex.
Higher setup cost
Auto Manufacturing
TV Manufacturing
Cigarettes
Characteristics:
Merits/Demerits
Performance
Aesthetics
Quality
Reliability
Quantity
Production costs
Delivery dates
PLANT
To make PRODUCT, PLANT of some kind is needed. This will comprise the bulk of the fixed
assets of the business. In determining which PLANT to use, management must consider
areas such as:
-
PROCESSES
There are many different ways of producing a product. Management must choose the best
process, or series of processes. They will consider:
-
Available capacity
Available skills
Type of production
Layout of plant and equipment
Safety
Production costs
Maintenance requirements
PROGRAMMES
The production PROGRAMME concerns the dates and times of the products that are to be
produced and supplied to customers. The decisions made about programme will be
influenced by factors such as:
-
PEOPLE
Production depends on PEOPLE, whose skills, experience and motivation vary. Key peoplerelated decisions will consider the following areas:
Goods
Can be resold
Can be inventoried
Some aspects of quality measurable
Selling is distinct from production
Product is transportable
Site of facility important for cost
Often easy to automate
Revenue generated primarily from tangible product
Product is transportable
Site of facility important for cost
Often easy to automate
1. The work of a goldsmith is purely based on the frequency of his customer's orders. The
goldsmith makes goods (ornaments) on a small-scale basis as per his customer's
requirements. Here, ornaments are not done on a continuous basis.
2. Similarly, the work of a tailor is also based on the number of orders he gets from his
customers. The clothes are stitched for every customer independently by the tailor as
per one's measurement and size. Goods (stitched clothes) are made on a limited scale
and is proportional to the number of orders received from customers. Here, stitching is
not done on a continuous basis.
The
characteristics of an intermittent production system are listed as follows:
1.
The requirement of resources is not same (it varies). Generally, the resource
requirement at the beginning is low. Then in mid of production, the requirement
increases. Finally, it slows down when the project is near its completion phase.
Many agencies are involved in the project. Each agency performs specialized jobs.
Here, coordination between agencies is important because all jobs are
interrelated.
Delays take place in completion of projects due to its complexity and massiveness.
As routing and scheduling changes with fresh orders, proper inspection is required
at each stage of production.
The production of items takes place in small lots. Sometimes only one product is
produced at one time.
The items are manufactured strictly as per customer's specifications.
Highly skilled labour is required to perform specialized jobs.
There is disproportionate manufacturing cycle time. For e.g. the time needed to
design the product may be more than the manufacturing time.
3. Batch production flows:
In batch production flows, the production schedule is decided according to specific orders
or is based on the demand forecasts. Here, the production of items takes place in lots or
batches. A product is divided into different jobs. All jobs of one batch of production must
be completed before starting the next batch of production.
Examples of batch production flows include manufacturing of drugs and
pharmaceuticals, medium and heavy machineries, etc.
The products are made and kept in stock until their demand arises in the market.
General purpose machines and handling equipments, which can do many different
jobs quickly are installed. This is because large varieties of items are to be
produced.
There is a possibility of large work-in-progress due to many reasons.
There is a need for detailed production planning and control.
The production system of a food industry is purely based on the demand forecast. Here,
a large-scale production of food takes place. It is also a continuous production.
Similarly, the production and processing system of a fuel industry is also purely based
on, demand forecast. Crude oil and other raw sources are processed continuously on a
large scale to yield usable form of fuel and compensate global energy demand.
The features of a continuous production system are depicted below.
The
characteristics or features of process production flows are as follows
Examples:
The examples of a production system are as follows:
Tangible goods: Consider an example of a manufacturing industry like a Sugar Industry.
Here, sugarcane is first used as an input, and then the juice of sugarcane is processed
through a conversion process, finally to get an output known as a refined sugar (used for
mass consumption).
Intangible goods: Consider an example from a service industry that of a softwaredevelopment firm or company. Here, initially, written program codes are used as an
input. These codes are then integrated in some database and are provided with a userfriendly interface through a conversion process. Finally, an output is made available in
form of an executable application program.
CLASSIFICATION OF MANUFACTURING SYSTEMS:
Facility Layout:
A layout is the physical configuration of departments, workstations, and equipments in the conversion
process. it is arrangement of physical resources used to create the product. Success of operations
depends on the physical layouts of the facilities. Flow of raw material. Productivity and human
relationship are all affected by the arrangements of the conversion facilities.
Plant layout involves: i) planning and arranging facilities in new plant ii) improvements in existing
layout to introduce new methods.
FACILITY LAYOUT
Layout decisions have long term consequences on cost and companies ability to serve the customers.
Major objectives of layout
Types of Layouts:
The layouts are differentiated by the types of workflow they entail and workflow in turn is
dictated by the nature of product. Basic layouts are:
1. Process layout
2. Product layout
3. Grouping technology layout
4. Fixed position layout
5. Hybrid layout
Process layout
These are appropriate for intermittent operations where work flow is not consistent for all output.
Variable workflow occurs when variety of products or variation of single product are produced. This is
also called as functional layout or job-shop layout. In this layout similar equipments are grouped and
located at one place like lathe, drilling machines etc.Workers should be highly skilled. Intensive job
instructions should be given to them and technical supervision is required. These layouts
are quick to change and adapt to the unique batches of the products.
Advantages
1.
2.
3.
4.
5.
Greater Flexibility
Better and more efficient supervision possible through specialization
Breakdowns can be taken care by shifting the job to another machine
Capacity of different product line can be expanded easily.
Better utilization of men and machine
Disadvantages
1. More work in progress
2. More floor space
3. More distances traveled by the product
Examples :
1. Car servicing
2. Hospital-Patient requiring various tests
3. Volume low & variety is more
4. Garment factory producing half sleeve shirts, full sleeve shirts, pants and suits.
5. Office buildings, schools, universities, hospitals, aerodrome, library, book store or amusement
centers are planned on this basis.
Assembly
& Test
Milling
Drilling
Grinding
Plating
Product layout
It is appropriate for producing one standardized product, usually in large
volume. It is also called as flow shop layout or straight line layouts. The
machines are arranged according to the progressive steps by which the
product is made. Examples: Chemical, paper, rubber, refineries, cement
industry.
Advantages:
1. Mechanization of materials is possible and material handling cost
can be reduced.
2. It requires less floor area.
3. It facilitates better production control
4. Production bottlenecks are avoided.
Disadvantages
1. Expansion of production line is difficulty
2. There is difficulty in supervising
3. Breakdown of equipment disrupts the production.
Example:
Delivery
Counter
Due to the nature of the product, the user has little choice in the use of a fixed-position
layout. Disadvantages include:
Space. For many fixed-position layouts, the work area may be crowded so that little
storage space is available. This also can cause material handling problems.
Administration. Oftentimes, the administrative burden is higher for fixed-position
layouts. The span of control can be narrow, and coordination difficult.
COMBINATION LAYOUTS
Many situations call for a mixture of the three main layout types. These mixtures are
commonly called combination or hybrid layouts. For example, one firm may utilize a
process layout for the majority of its process along with an assembly in one area.
Alternatively, a firm may utilize a fixed-position layout for the assembly of its final
product, but use assembly lines to produce the components and subassemblies that
make up the final product (e.g., aircraft).
Cellular Layout:
Cellular manufacturing is a type of layout where machines are grouped according to the
process requirements for a set of similar items (part families) that require similar
processing. These groups are called cells. Therefore, a cellular layout is an equipment
layout configured to support cellular manufacturing.
Processes are grouped into cells using a technique known as group technology (GT).
Group technology involves identifying parts with similar design characteristics (size,
shape, and function) and similar process characteristics (type of processing required,
available machinery that performs this type of process, and processing sequence).
Workers in cellular layouts are cross-trained so that they can operate all the equipment
within the cell and take responsibility for its output. Sometimes the cells feed into an
assembly line that produces the final product. In some cases a cell is formed by
dedicating certain equipment to the production of a family of parts without actually
moving the equipment into a physical cell (these are called virtual or nominal cells). In
this way, the firm avoids the burden of rearranging its current layout. However, physical
cells are more common.
An automated version of cellular manufacturing is the flexible manufacturing system
(FMS). With an FMS, a computer controls the transfer of parts to the various processes,
enabling manufacturers to achieve some of the benefits of product layouts while
maintaining the flexibility of small batch production.
Some of the advantages of cellular manufacturing include:
Cost. Cellular manufacturing provides for faster processing time, less material handling,
less work-in-process inventory, and reduced setup time, all of which reduce costs.
Flexibility. Cellular manufacturing allows for the production of small batches, which
provides some degree of increased flexibility. This aspect is greatly enhanced with FMSs.
Motivation. Since workers are cross-trained to run every machine in the cell, boredom is
less of a factor. Also, since workers are responsible for their cells' output, more autonomy
and job ownership is present.
Cellular layout:
Advantages:
Disadvantages:
When volume of production changes, number of workers are adjusted and workers
are reassigned to various cells. To cope with this type of reassignments, workers
must be multi-skilled and cross-trained.