Beruflich Dokumente
Kultur Dokumente
Presented by:
Dr. Subhash Singh,
Assistant Professor
Manufacturing Engineering Department
National Institute of Technology Jamshedpur
Jamshedpur, Jharkhand, INDIA-831014
E-Mail:subh802004@gmail.com, subhash.prod@nitjsr.ac.in
Quantity Production Method
Syllabus
UNIT-I
Classification of production, Industrial and economical aspects of
production in large quantity, various methods of quantity production,
production of common engineering objects like rods, bars, rails, tubes,
threaded objects, gears, bearings, cams, cutting tools etc.
UNIT-II
Purpose, design and use of jigs and fixtures. Role of automation in
quantity production scheduling, tool layout and cam layout for semi-
automatic and automatic machine tools. Large quantity production by
special purpose and transfer machines.
UNIT-III
Quantity production of small items like washers, seals laminates, cups,
strong and soft tubes, coins etc. by shearing forming and embossing in
press tools, Industrial methods of manufacturing of pins, needles,
wires, rims and similar products.
UNIT-IV
Large scale production of various objects made of polymers, ceramics
and composites. Quantity production by processes like spinning,
bulging, hydroforming, magneto-forming and explosive forming.
UNIT-V
Group Technology, selection of processes, tools and systems and
process planning for feasible and economic production. Flexible
automation and computer control in manufacturing. Assessment and
control of productivity, quality and economy in quantity production.
Quantity Production Method
UNIT-I
Classification of production, Industrial and economical aspects of
production in large quantity, various methods of quantity production,
production of common engineering objects like rods, bars, rails, tubes,
threaded objects, gears, bearings, cams, cutting tools etc.
Production Syste m
What is Production
Edwood Buffa defines production as ‘a process by which
goods and services are created’. Some examples of
production are: manufacturing custom-made products
like, boilers with a specific capacity, constructing flats,
some structural fabrication works for selected customers,
etc., and manufacturing standardized products like, car,
bus, motor cycle, radio, television, etc.
The production system is ‘that part of an organisation, which
produces products of an organisation. It is that activity whereby
resources, flowing within a defined system, are combined and
transformed in a controlled manner to add value in accordance
with the policies communicated by management’. A simplified
production system is shown below:
The production system has the following characteristics:
1. Production is an organized activity, so every production system
has an objective.
2. The system transforms the various inputs to useful outputs.
3. It does not operate in isolation from the other organisation
system.
4. There exists a feedback about the activities, which is essential to
control and improve system performance.
Classification of Production
Classification of Production
Job-Shop Production
Limitations
Following are the limitations of Job-shop Production:
1. Higher cost due to frequent set up changes.
2. Higher level of inventory at all levels and hence higher inventory cost.
3. Production planning is complicated.
4. Larger space requirements.
Royce Royal Car Air Force One
Batch Production
American Production and Inventory Control Society (APICS) defines Batch
Production as a form of manufacturing in which the job pass through the functional
departments in lots or batches and each lot may have a different routing. It is
characterized by the manufacture of limited number of products produced at regular
intervals and stocked awaiting sales.
Limitations
Following are the limitations of Batch Production:
1. Material handling is complex because of irregular and longer flows.
2. Production planning and control is complex.
3. Work in process inventory is higher compared to continuous production.
4. Higher set up costs due to frequent changes in set up.
Mass Production
Limitations
Limitations
It is long-term commitment
It facilitates the production process, minimizes material handling,
time and cost, and allows flexibility of operations
It facilitates easy production flow, makes economic use of the
building, promotes effective utilization of manpower, and provides
for employee’s convenience, safety, comfort at work, maximum
exposure to natural light and ventilation.
It affects the flow of material and processes, labour efficiency,
supervision and control, use of space and expansion possibilities .
Types of layout
1. Low cost of material handling, due to straight and short route and absence
of backtracking.
2. Smooth and uninterrupted operations
3. Continuous flow of work
4. Lesser investment in inventory and work in progress
5. Optimum use of floor space
6. Shorter processing time or quicker output
7. Less congestion of work in the process
8. Simple and effective inspection of work and simplified production control
9. Lower cost of manufacturing per unit
Disadvantages of Product or Line Layout
1. It saves time and cost involved on the movement of work from one
workstation to another.
2. The layout is flexible as change in job design and operation
sequence can be easily incorporated.
3. It is more economical when several orders in different stages of
progress are being executed simultaneously.
4. Adjustments can be made to meet shortage of materials or
absence of workers by changing the sequence of operations.
Disadvantages of Fixed Position Layout
Machining Stamping
Casting Coining
o Sand Casting Cold Drawing
o Metal Mould Casting Rolling
o Die Casting Extrusion
o Investment Casting Powder metallurgy
o Shell mould Casting Plastic Moulding
o Centrifugal Casting Wire EDM
General Applications Of Gears
Gears of various type, size and material are widely used in several
machines and systems requiring positive and stepped drive. The major
applications are
1. Speed gear box, feed gear box and some other kinematic units of machine
tools.
2.Speed drives in textile, jute and similar machineries
3.Gear boxes of automobiles.
4.Speed and / or feed drives of several metal forming machines
5.Machineries for mining, tea processing etc.
6.Large and heavy duty gear boxes used in cement industries, sugar
industries, cranes, conveyors etc.
7.Precision equipment, clocks and watches.
8.Industrial robots and toys.
Bearing