Mod-4

Types and examples of production

There are several types of production, each with its own advantages and disadvantages. The most
common types of production are:

Mass production: This type of production is used to produce large quantities of identical products. It is
characterized by a high degree of automation and a standardized production process. Examples of mass
production include the production of cars, appliances, and consumer goods.
Batch production: This type of production is used to produce smaller quantities of products, often to
meet specific customer orders. It is characterized by a more flexible production process than mass
production. Examples of batch production include the production of custom furniture, clothing, and food
products.
Job production: This type of production is used to produce one-of-a-kind products, such as custom-built
homes, ships, and aircraft. It is characterized by a high degree of customization and a unique production
process for each product.
Service production: This type of production is used to produce intangible products, such as financial
services, healthcare, and education. It is characterized by a high degree of interaction between the
producer and the consumer. Examples of service production include banking, insurance, and healthcare.
Customized production: This type of production is a hybrid of mass production and batch production. It
is used to produce large quantities of products with a high degree of customization. Examples of
customized production include the production of cars and clothing with customizable options.

Here are some examples of production in different industries:

Manufacturing: The manufacturing industry produces physical goods, such as cars, electronics, and
clothing. Mass production is the most common type of production used in the manufacturing industry.
Agriculture: The agriculture industry produces food and other agricultural products. Batch production is
the most common type of production used in the agriculture industry.
Construction: The construction industry builds and maintains buildings and infrastructure. Job
production is the most common type of production used in the construction industry.
Services: The services industry produces intangible products, such as financial services, healthcare, and
education. Service production is the most common type of production used in the services industry.
The type of production that a company uses depends on a number of factors, including the type of product
it produces, the volume of production, and the needs of its customers.
PPC
PPC (Production Planning and Control) is the process of planning and controlling the production of
goods and services. It is a critical function for any manufacturing or service organization, as it helps to
ensure that products are produced on time, within budget, and to the required quality standards.

Need and Importance of PPC

PPC is important for a number of reasons:
● It helps to ensure that the organization has the right products, in the right quantities, at the right
time, and at the right cost.
● It helps to improve efficiency and productivity by reducing waste and minimizing bottlenecks.
● It helps to improve quality by ensuring that products are produced to the required standards.
● It helps to reduce costs by optimizing the use of resources and reducing inventory levels.

Functions of PPC
The main functions of PPC include:

● Demand forecasting: Forecasting the demand for products and services.

● Production planning: Planning the production of goods and services to meet the forecasted
demand.
● Scheduling: Scheduling the production of goods and services to ensure that they are completed
on time.
● Dispatching: Releasing production orders to the shop floor.
● Monitoring: Monitoring the progress of production and making necessary adjustments to ensure
that products are completed on time and within budget.
● Controlling: Controlling the production process to ensure that products meet the required quality
standards.

Forms used and their importance

A variety of forms are used in PPC, including:
● Master production schedule: This form shows the planned production of all products for a
given period of time.
● Bill of materials: This form shows the list of materials required to produce a given product.
● Production order: This form authorizes the production of a given quantity of a product.
● Job card: This form tracks the progress of a job through the production process.
● Time ticket: This form records the time spent by workers on a given job.
These forms are important because they help to ensure that the production process is well-organized and
efficient.
General approach for each type of production
The general approach to PPC varies depending on the type of production. However, there are some
common principles:
● Mass production: The focus is on efficiency and productivity. The production process is highly
standardized and automated.
● Batch production: The focus is on flexibility and meeting customer orders. The production
process is more flexible than mass production, but it is still efficient.
● Job production: The focus is on customization and meeting the unique needs of each customer.
The production process is highly flexible and customized.
● Service production: The focus is on meeting the needs of the customer and providing a high
level of service. The production process is highly interactive between the producer and the
consumer.
● Customized production: The focus is on meeting the unique needs of each customer, while also
producing large quantities of products. The production process is flexible and efficient.

Conclusion
PPC is a critical function for any manufacturing or service organization. It helps to ensure that products
are produced on time, within budget, and to the required quality standards. The specific approach to PPC
will vary depending on the type of production, but there are some common principles.

Scheduling- meaning and need for productivity and

utilisation
Scheduling is the process of planning and organizing tasks over time. It is a critical function for any
organization, as it helps to ensure that tasks are completed on time, within budget, and to the required
quality standards.

Scheduling is important for productivity and utilization for a number of reasons:

● It helps to focus attention on the most important tasks.

● It helps to avoid procrastination and distractions.
● It helps to ensure that tasks are completed in the most efficient order.
● It helps to identify and eliminate bottlenecks.
● It helps to make better use of resources.
● It helps to reduce stress and improve morale.
When tasks are well-scheduled, workers are more likely to be productive and efficient. They are also
more likely to be satisfied with their jobs, as they know what they need to do and when they need to do it.

Here are some specific examples of how scheduling can improve productivity and utilization:
 ● A manufacturing company can use scheduling to ensure that its production lines are running at
full capacity.
● A service company can use scheduling to ensure that its employees are assigned to the right tasks
at the right time.
● A project manager can use scheduling to ensure that a project is completed on time and within
budget.
● A sales team can use scheduling to ensure that they are following up with leads and customers on
a regular basis.
Overall, scheduling is an essential tool for improving productivity and utilization in any organization.

Here are some tips for effective scheduling:

● Set clear goals and priorities. What do you need to accomplish? What is most important?
● Break down large tasks into smaller, more manageable ones.
● Estimate how long each task will take.
● Create a schedule that is realistic and achievable.
● Be flexible and adaptable. Things don't always go according to plan, so be prepared to adjust
your schedule as needed.
● Use a scheduling tool to help you stay organized and on track.
By following these tips, you can create a schedule that will help you to be more productive and efficient.

3) Gantt chart- Format and method to prepare

A Gantt chart is a type of bar chart that illustrates a project schedule. It shows the start and end dates of
each task in the project, as well as the dependencies between tasks. Gantt charts are a popular tool for
project managers, as they provide a clear and concise overview of the project schedule.

Format of a Gantt chart

A Gantt chart typically consists of two axes:

● Horizontal axis: This axis shows the time span of the project. It can be divided into days, weeks,
months, or years, depending on the length of the project.
● Vertical axis: This axis lists the tasks in the project.
Each task is represented by a horizontal bar on the Gantt chart. The length of the bar represents the
duration of the task. The start and end dates of the task are indicated by the left and right ends of the bar,
respectively.

Dependencies between tasks can be shown using arrows or lines on the Gantt chart. For example, if Task
B cannot start until Task A is completed, an arrow would be drawn from Task A to Task B.

Method to prepare a Gantt chart

To prepare a Gantt chart, you will need to:

 1. Identify all of the tasks in the project.
2. Estimate the duration of each task.
3. Identify the dependencies between tasks.
4. Create a table that lists the tasks, their durations, and their dependencies.
5. Draw a Gantt chart, using the table as a guide.

Here are some tips for preparing an effective Gantt chart:

● Be specific when identifying tasks. The more specific the tasks are, the easier it will be to
estimate their duration and dependencies.
● Be realistic when estimating the duration of tasks. It is better to overestimate the duration than to
underestimate it.
● Be clear when identifying dependencies between tasks. This will help to ensure that the project
schedule is realistic and achievable.
● Use a Gantt chart software tool to help you create and manage your Gantt chart. This will make it
easier to update the chart as needed.

Gantt charts can be a valuable tool for project managers, as they provide a clear and concise overview of
the project schedule. By following the tips above, you can create a Gantt chart that will help you to
manage your project effectively.

Critical ratio scheduling-method and numeric

examples
Critical ratio scheduling is a priority scheduling rule that prioritizes jobs based on their critical ratio. The
critical ratio is calculated as follows:

Critical ratio = (Due date - Today's date) / Remaining processing time

Jobs with a higher critical ratio are prioritized over jobs with a lower critical ratio. This ensures that jobs
that are at risk of falling behind schedule are completed first.

Method

To use critical ratio scheduling, follow these steps:

Calculate the critical ratio for each job.

Sort the jobs in ascending order of critical ratio.
Schedule the jobs in the order that they are sorted.
Numeric examples

Here is an example of how to use critical ratio scheduling:

 Job Processing time (days Due Date (days) Critical Ratio

A 10 20 1.0

B 15 30 1.5

C 20 40 2.0

The critical ratios are calculated as follows:

Job Critical ratio

A (20-11)/10=1.0

B (30-11)/15=1.5

C (40-11)/20=1.5

The jobs are then sorted in ascending order of critical ratio:

Job Critical ratio

A 1.0

B 1.5

C 1.5

Therefore, the jobs would be scheduled in the following order:

1. Job A
2. Job B
3. Job C
This ensures that Job A, which has the lowest critical ratio, is completed first. This is because Job A is
most at risk of falling behind schedule.

Critical ratio scheduling is a simple but effective way to prioritize jobs. It is especially useful for projects
with a tight deadline.
Scheduling using Gantt Chart
Example 1:

Components:
● Component 1: 10 units
● Component 2: 5 units
● Component 3: 3 units
Machining Operations:
● Operation 1: Setting time: 30 minutes, Operation time: 10 minutes per unit
● Operation 2: Setting time: 15 minutes, Operation time: 5 minutes per unit
● Operation 3: Setting time: 10 minutes, Operation time: 3 minutes per unit
Resources Available:
● Machine A
● Machine B
Gantt Chart:

Time | Machine A | Machine B

------- | -------- | --------
00:00 | |
00:30 | Comp. 1 Op. 1 | Comp. 2 Op. 1
01:40 | Comp. 1 Op. 2 | Comp. 2 Op. 2
02:55 | Comp. 1 Op. 3 |
03:05 | | Comp. 3 Op. 1
03:20 | | Comp. 3 Op. 2
03:30 | | Comp. 3 Op. 3

Example 2:

Components:
● Component 1: 15 units
● Component 2: 10 units
● Component 3: 5 units
Machining Operations:
● Operation 1: Setting time: 30 minutes, Operation time: 15 minutes per unit
● Operation 2: Setting time: 15 minutes, Operation time: 10 minutes per unit
● Operation 3: Setting time: 10 minutes, Operation time: 5 minutes per unit
Resources Available:
● Machine A
● Machine B
● Machine C
Gantt Chart:
Time | Machine A | Machine B | Machine C
------- | -------- | -------- | --------
00:00 | | |
00:30 | Comp. 1 Op. 1 | Comp. 2 Op. 1 |
01:45 | Comp. 1 Op. 2 | Comp. 2 Op. 2 | Comp. 3 Op. 1
03:15 | Comp. 1 Op. 3 | Comp. 2 Op. 3 | Comp. 3 Op. 2
04:30 | | Comp. 3 Op. 3 |
These are just two examples to demonstrate how to use a Gantt chart to schedule machining
operations for multiple components. The specific schedule will vary depending on the specific
components, operations, and resources available.

To create a Gantt chart, you can use a spreadsheet or a dedicated Gantt chart software. Once
you have created your chart, you can use it to track the progress of your machining operations
and identify any potential bottlenecks.

Additional Tips:
When creating a Gantt chart, be sure to include all of the necessary information, such as the
component name, operation name, setting time, operation time, resource required, and quantity.
You can also include additional information on your Gantt chart, such as the due date for each
operation and the status of each operation (e.g., in progress, completed, etc.).
Be sure to update your Gantt chart regularly as your machining operations progress. This will
help you to identify any changes to the schedule and make adjustments as needed.

Bottlenecking
Meaning:
A bottleneck is any point in a process or system that limits the overall throughput. It is often the
slowest step in the process, and it can have a significant impact on the overall efficiency and
productivity.

Effect:
Bottlenecks can have a number of negative effects, including:
● Reduced productivity and efficiency
● Increased costs
● Delayed deliveries
● Decreased customer satisfaction

Ways to Reduce Bottlenecks:

There are a number of ways to reduce bottlenecks, such as:
● Identify the bottleneck. The first step is to identify the bottleneck in the process or
system. Once you know where the bottleneck is, you can start to develop a plan to
address it.
 ● Increase the capacity of the bottleneck. One way to reduce a bottleneck is to increase
the capacity of the slowest step in the process. This may involve adding more resources,
such as people or machines, or improving the efficiency of the process.
● Reduce the workload on the bottleneck. Another way to reduce a bottleneck is to
reduce the workload on the slowest step in the process. This may involve outsourcing
some of the work, or changing the way the work is done.
● Improve the overall process. In some cases, the best way to reduce a bottleneck is to
improve the overall process. This may involve eliminating unnecessary steps, or
streamlining the way the work is done.

Here are some specific examples of how to reduce bottlenecks in different industries:

● Manufacturing: In a manufacturing setting, a bottleneck could be a particular machine

or process that is slower than the others. To reduce this bottleneck, the manufacturer
could increase the capacity of the machine, such as by adding another one, or they
could improve the efficiency of the process, such as by streamlining the workflow.
● Customer service: In a customer service setting, a bottleneck could be a particular
department or process that is overwhelmed with requests. To reduce this bottleneck, the
customer service team could hire more staff, or they could implement a new system for
prioritizing and handling requests.
● Software development: In a software development setting, a bottleneck could be a
particular task or phase of the development process that is taking longer than the others.
To reduce this bottleneck, the development team could break down the task into smaller
pieces, or they could use a different development methodology.

By identifying and reducing bottlenecks, businesses can improve their productivity, efficiency,
and profitability.