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Planning and Control For Mass Production: Presented By: Amrita Kadam

This document discusses planning and control for mass production. It begins by describing different types of production processes and domains of production systems. The key ideas of mass production are then outlined, including logical breakdown of work, division of labor, interchangeable parts, and assembly lines. The document notes that mass production is best suited for production quantities of 20,000 units or more. It then details how to design assembly lines, including precedence diagrams, grouping tasks into work stations using different methods like positional weight ranking, and measures to evaluate line performance. Challenges and future prospects of mass production are also briefly mentioned.

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79 views17 pages

Planning and Control For Mass Production: Presented By: Amrita Kadam

This document discusses planning and control for mass production. It begins by describing different types of production processes and domains of production systems. The key ideas of mass production are then outlined, including logical breakdown of work, division of labor, interchangeable parts, and assembly lines. The document notes that mass production is best suited for production quantities of 20,000 units or more. It then details how to design assembly lines, including precedence diagrams, grouping tasks into work stations using different methods like positional weight ranking, and measures to evaluate line performance. Challenges and future prospects of mass production are also briefly mentioned.

Uploaded by

amrita3585
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Planning and Control for Mass Production

Presented by : Amrita Kadam

Types of production processes:


Type of production

Intermittent production

Continuous Production

Job Production

Batch Production

Project Production

Mass Production

Flow Production

Domain of production systems


Job Shop Production

Product Variety

Batch Production Mass Production


Continuous Flow Production

Production Volume

Underlying Ideas of Mass Production


Logical Break down of work Division of Work into Work Stations
Adam Smith Henry Ford

Ideas

Interchangeable and Replaceable parts


E. Whiteny

When to go for mass production

Cost

20,000 10,000 2,000 4,000 Production Quantity

Assembly Line and Fabrication line


Assembly Line
Builds components Use series of machines Repetitive process Machined pace Balanced by physical design

Fabrication line
Assembles fabricated parts Use work stations Repetitive process Paced by tasks Balanced by moving tasks

Designing of Assembly Line


Objective
Minimize the total idle time or the no. of workstations for a given assembly line speed.

Division of work into pats


The precedence Diagram

Grouping of tasks into Work Stations


The feasible range of cycle time Line balancing methods
Helgeson & Birnie (Rank position Weight method) Kilbridge & Wester (No of predecessors) Arcus (COMSOAL) (Generation of alternative by simulation )

Choice of the best design

Measures of performance
Line Efficiency
N

LE = STi
i=1

Balanced Delay BD = (1- LE)


Smoothness Index
N i=1

K CT

100 %

Si = (S Tmax STi )

Precedence Diagram
3 4 2 6

2
5

3
5

7
1

1
3 6

6
4
10

9
4
11

7
12

Duration

Element No

No of elements = 12 Cycle Time


k

Tmax Cycle Time Ti


i=1

7 Cycle Time 50 Desirable Cycle Time = 10

No. of predecessors Method


3 4 2 6

2
5

3
5

7 6
1 4
10

1
3 6

9
4
11

7
12

4
WS - 1 8

5
WS - 2 9

WS - 3 9

WS - 6 8

WS - 4 6

WS - 5 10

Desirable Cycle Time = 10


Work Stations WS - 1 WS - 2 WS - 3 WS - 4 WS - 5 WS - 6
Elements (1,4)

(2,5) (3,6) (7,10) (8,11) (9,12) Total Time

Total time 8 9 9 6 10 8 50

Idle Time 2

1 1 4 0 2

Line Efficiency = 83.3% Balanced Delay = 16.7% Smoothness Index = 50.9

Ranked Positional Weight


2
5 3 31 4

3 28
5

2 15

13

1
50

6
3 6
24

1 8

7
12

4
10

4
11

4
33

5
30

15

11

Desirable Cycle Time = 10


Work Stations WS - 1 WS - 2 WS - 3 WS - 4 WS - 5 WS - 6 Elements (1,4) (2,5) (3,6) (7,10,9) (8,11) (12) Total time 8 9 9 7 10 7 Idle Time 2 1 1 3 0 3

Line Efficiency = 83.3% Balanced Delay = 16.7% Smoothness Index = 4.9

Total Time

50

Problems of Mass Production


Variable Work Element Time Break down at Work Station Multi Product Line

Prospects of Mass Production


Modular Production and Group Technology Automation and Robotics

Thank You

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