School of Industrial and Information Engineering

Design and Management of Production Systems

Presentation

Prof. Alessandro Brun

Department of Management, Economics and Industrial Engineering
 Instructors’ Information

Alessandro Brun
Dept. Management, Economics and Industrial Engineering
Tel.: 02 2399 2799
E-mail: [email protected]
Office: 1.39

Violetta Giada Cannas

Dept. Management, Economics and Industrial Engineering
Tel.: 02 2399 3995
E-mail: [email protected]
Office: 1.56

Office Hours:
• Please e-mail to make an appointment indicating [DMPS] in the subject
• Do not e-mail technical questions:
• lengthy or potentially difficult questions should be handled face to face

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 Learning objectives (1)

The course of «Design and Management of Production Systems»

intends to deliver basic knowledge about:
§ Technical organisation of production systems
§ Design methods
§ Management methods

Looking at “Operations” (all the activities carried out in a production

system), main focus is on “Production”.
§ Production, i.e., the processes and methods used to transform
tangible inputs (raw materials, semi-finished goods,
subassemblies) and intangible inputs (ideas, information,
knowledge) into goods or services. Resources are used in this
process to create an output that is suitable for use or has
exchange value.

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 Industrial Organisation Chart (typical)

Operations

….

Facilities design and construction; maintenance; production planning; inventory control;

scheduling; materials control; quality assurance and control; supply-chain management;
purchasing management; manufacturing; tooling; fabrication; assembly; product design and
development; detailed product specifications; industrial engineering; efficient use of machines,
space and personnel; process analysis; development and installation of production tools and
equipment, distribution, logistics, safety, …

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 Knowledge areas

Supply Chain

Production System

design
New product
development

plan

source make deliver

Knowlegde area of
Knowlegde area of
Production System
Production System Design
Management
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Product Life Cycle affects decisions

Introduction Growth Maturity Decline

Best period to Practical to change Poor time to Cost control
increase market price or quality change image, critical
Company Strategy/Issues

share image price, or quality

R&D engineering is Strengthen niche Competitive costs

critical become critical
Defend market
position

Sales

(Heizer & Render)

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Product Life Cycle affects decisions

(Heizer & Render)

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Product Life Cycle affects decisions

Introduction Growth Maturity Decline

Product design Forecasting Standardization Little product
and critical Fewer product differentiation
development Product and changes, more Cost
critical process minor changes minimization
Frequent reliability Optimum Overcapacity
product and Competitive capacity in the
process design product industry
changes Increasing
OM Strategy/Issues

improvements stability of Prune line to

Short production and options process eliminate
runs Increase capacity Long production items not
High production Shift toward runs returning
costs product focus good margin
Product
Limited models Enhance improvement Reduce
Attention to distribution and cost cutting capacity
quality

(Heizer & Render)

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Product Life Cycle affects decisions

Cost of development and production

Sales, cost, and cash flow

Sales revenue
Net revenue (profit)

Cash
flow

Negative
cash flow Loss

Introduction Growth Maturity Decline

(Heizer & Render)

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Learning objectives (2)

§ Be able to understand the main problems related to the design

and management of production systems

§ Learn the reference methods and techniques to solve those

problems within a system(at)ic approach

§ Acquire the basic knowledge to effectively interact with all the

company experts and professionals

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Course Outline

Introduction to production systems

Performance of the production systems

Design of fabrication systems

Design of assembly systems

Production management (planning)

Demand analysis and forecasting

Aggregate production planning

Materials planning

Operative planning of production

Japanese production techniques (hints - as time permits)

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Prerequisites

— 086448 MANAGEMENT AND INDUSTRIAL ENGINEERING or

086468 MECHANICAL PLANTS or
equivalent (as knowledge and skills) is needed

§ We will recall some topics, but …

§ Still it’s critical knowledge; in case, to be recovered

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Course Information

Course homepage:

§ https://beep.metid.polimi.it
• Course information (ref. presentation)
• Lecture material
• Readings & Handouts
• Syllabus

§ Check the page for further course information and

announcements

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 Required Textbooks

§ Lecture material (slides) with some readings and handouts (not in the
textbooks), available on the course website (https://beep.metid.polimi.it)

§ Textbooks :

§ Garetti M., Design of Production Systems, Franco Angeli, Milano, 2015

ISBN: 9788891710307 (mainly used in the first part of the course)

§ VV.AA., Management of Production Systems, McGraw-Hill, 2015

(selection of chapters from McGraw-Hill books)

ISBN: 9781308406824 (mainly used in the second part of the course)

§ Practicebook:
§ Cagno, Micheli, Trianni, Mangiaracina, Neri, “Design and Management of
Production Systems - Exercises”), CUSL, 2017.

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 Other References (Italian)

Textbooks:
§ Portioli, Pozzetti, “Progettazione dei sistemi produttivi”, HOEPLI

§ Brandolese, Pozzetti, Sianesi, “Gestione della produzione industriale”, HOEPLI

§ Chase, Jacobs, Aquilano, Grando, Sianesi, “Operations Management nella

produzione e nei servizi”, McGraw-Hill

§ Sianesi, “La gestione del sistema di produzione”, Rizzoli Etas

Textbooks (tutorials):
§ Cagno, Micheli, Trianni, Mangiaracina, “Progettazione e Gestione degli Impianti di
Produzione - Esercizi”, CUSL

§ Amici di Francesco Turco, “Esercizi di gestione della produzione industriale”, CUSL

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 Lecture Format

Classes (schedule)

Tuesday 14:30 (sharp!) – 18:15 room L.09

Thursday 09:30 (sharp!) – 11:15 room L.07
Friday 10:30 (sharp!) – 13:15 room L.09

Since cases discussion will be made and solution shared during the
classes, attendance is expected to previously read the text and come
well-prepared

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 Syllabus

Date Day Hours Topic Teacher

27/02/2018 Tuesday 4 Course introduction + Production systems Brun
01/03/2018 Thursday 2 Performance measurement Brun
02/03/2018 Friday 0 Holiday/Suspension
06/03/2018 Tuesday 0 Holiday/Suspension
08/03/2018 Thursday 2 Performance measurement Brun
09/03/2018 Friday 3 Job shop Brun
13/03/2018 Tuesday 4 Manufacturing Cell + Group technology Brun
15/03/2018 Thursday 2 Manufacturing Cell + Group technology Brun
16/03/2018 Friday 3 Performance measurement - Practice 1 Cannas
20/03/2018 Tuesday 4 Production line Brun
22/03/2018 Thursday 2 Performance measurement - Practice 2 Cannas
23/03/2018 Friday 3 Performance measurement - Practice 3 Cannas
27/03/2018 Tuesday 4 Production line - Assembly line Brun
29/03/2018
30/03/2018
Thursday
Friday
0
0
Holiday/Suspension
Holiday/Suspension During the semester the syllabus
03/04/2018
05/04/2018
Tuesday
Thursday
0
2
Holiday/Suspension
Job shop - Practice 1 Cannas could be updated.
06/04/2018 Friday 3 Job shop - Practice 2 Cannas
10/04/2018 Tuesday 4 Assembly line Brun
12/04/2018 Thursday 0 Holiday/Suspension
13/04/2018
17/04/2018
Friday
Tuesday
3
4
Job shop and Cellular manufacturing - Practice 1
Production planning
Cannas
Brun
In case of modifications the up-to-
19/04/2018
20/04/2018
Thursday
Friday
0
3
Holiday/Suspension
Demand Forecasting Brun
date version will be uploaded on
24/04/2018
26/04/2018
Tuesday
Thursday
0
0
Holiday/Suspension
Holiday/Suspension beep.
27/04/2018 Friday 0 Holiday/Suspension
01/05/2018 Tuesday 0 Holiday/Suspension
03/05/2018 Thursday 2 Job shop and Cellular manufacturing - Practice 2 Cannas
04/05/2018 Friday 3 Aggregate planning Brun
08/05/2018 Tuesday 4 Inventory management Brun
10/05/2018 Thursday 2 Inventory Management Brun
11/05/2018 Friday 3 Production line - Practice Cannas
15/05/2018 Tuesday 4 Assembly line - Practice Cannas
17/05/2018 Thursday 0 Holiday/Suspension
18/05/2018 Friday 3 Production planning - Practice Cannas
22/05/2018 Tuesday 4 Inventory Management Brun
24/05/2018 Thursday 2 On-Demand Management Brun
25/05/2018 Friday 3 Aggregate planning - Practice Cannas
29/05/2018 Tuesday 4 On-Demand Management Brun
31/05/2018 Thursday 2 Scheduling Brun
01/06/2018 Friday 3 Inventory management - Practice Cannas
05/06/2018 Tuesday 4 On-Demand Management - Practice Cannas
07/06/2018 Thursday 2 Scheduling - Practice Cannas
08/06/2018 Friday 3 Exam simulation Brun

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 Exams

Based on lecture material, text books, readings and handouts

The exam, to be taken in the scheduled dates (2 calls in June-July, 2

calls in September; 1 call in January), is a combination of:
§ Written test
§ Oral test:
o optional (admission only upon passing of the written test)
o mandatory when written exam result >= 27/30

The written test consists of a set of:

§ Theoretical (open) questions – Closed-book exam
§ Numerical exercises – Open-book and open-notes exam
The evaluation of the numerical exercises will take place only when the
theoretical questions result >= 5/30 (i.e. 5 out of 9 on theoretical
questions)

If the written test result is <= 10/30, students will not be admitted to
next scheduled call within the same exam session (but if they withdraw,
the rule doesn’t apply)
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 Exams

Theoretical questions + Numerical exercises

(Closed-book) (Open-book)

We correct theoretical questions first:

• if your grade is <5/30 we don’t correct your exercises and you fail the exam
• if your grade is >= 5/30 we correct your exercises and give you a final grade for the written test

Written test Final grade written test

(sum of the theoretical questions grade and numerical exercise grade)

F.G. <= 10/30 10/30 < F.G. < 18/30 18/30 <= F.G. < 27/30 F.G. >= 27/30
You fail the exam and you will not be You fail the exam You pass the exam, but you have You pass the exam, and you are
admitted to the next call in the same the possibility of attending obliged to attend
session oral test (optional) oral test (mandatory)
Remember that you can withdraw!

WHAT DO YOU MEAN? Oral Test

Call Failed? Admitted?
1st call of July Yes, T<10/30 The oral test must be attended in the same
Example 1
2nd call of July NO session of the written test.
2nd call of July Yes, T<10/30 Not in the Remember that oral test may have a
Example 2
1st call of September Yes same session! negative response

The final grade of the exam is an overall

evaluation of your written test and your
oral test, not just the sum!

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 Exams

Oral exam must be sustained in the same call of the written exam.

Oral examination could give also a “negative” (-) response.

No laptop, tablet, smartphone and other ICT devices permitted.

Only calculator is admitted (e.g., no smartphone).

You must be registered (on line system): No registration = No exam.

You must take an ID Card (e.g., passport) with photo.

You must write in pen (no pencil).

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