ROUTING,PROGRESS REPORTING AND EXPEDITING

PRESENTED BY:

GOPAL KRISHAN DIXIT

ROUTING: Definition and Meaning

Routing involves the:The determination of which machines or work centers will be used to manufacture a particular item. Routing is specified on a route sheet, the route sheet identifies operations to perform, sequence and materials, tolerances, tools and time allowances.

Routing includes the planning of: what work shall be done on the material to produce the product or part, where and by whom the work shall be done. It also includes the determination of path that the work shall follow and the necessary sequence of operations which must be done on the material to make the product.

ROUTING: Definition and Meaning

Routing means determination of the route to be followed by each part/component being transformed from input/raw material into final product. Following questions decide how the job is routed. If a job has a number of operations which can be done in different orders, which ordering should be used? If an operator has choice of many machines with different process time and machine time, which machine should be chosen? Should a job be sent to the flexible manufacturing cell or be done by an expert on a manual all purpose machine?

ROUTING

PROCEDURE

INVOLVES

FOLLOWING

DIFFERENT

ACTIVITIES. (1) Analysis of the article to determine what to make and what to buy. (2) To determine the quantity and type of material (3) Determining the manufacturing operations and their sequence. (4) Determination of lot sizes (5) Determination of scrap factors

(6) Organization of production control forms

(7) Analysis of cost of the article

MAKE AND BUY DECISION

The product is analyzed to determine its components/parts and decision is made whether to manufacture all its parts in the factory or to be purchased from outside. For example a bicycle company may decide to manufacture all its parts/components by itself or buy some of them like chains, tyres, tubes etc from outside. The decision to make or to buy is in view of the following facts:
Cost comparison for making and buying

Whether the available man power can be utilized for the purpose of making with the
plant. Whether the existing machines which are idle can be utilized. Whether the input materials and machines are available in the plant for manufacture or require procurement. Capital funds

QUALITY, QUANTITY AND TYPE OF MATERIAL

-Bill of Materials (BOM) describes all the components/parts (purchased and to be

manufactured) at every level of manufacturing process, that are needed to make a

product of desired quantity. -Bill of Material is a listing of all of the assemblies, intermediates, parts and raw

material that go into a parent assembly showing the quantity of each required to
make that assembly - From BOM the quantity of material required for each part is known and accordingly can be procured. Some firms prepare separate lists for finished components and raw materials. To know how much material is to be purchased or procured, the amount of materials in the stores should be known.

QUALITY, QUANTITY AND TYPE OF MATERIAL

BILL OF MATERIAL
Date: __________ Part No.________
Part No. Name of the Part Drg. No. Finished Components Name Specifications Name Specifications Input Material Raw Material Length Width Thickness No. Of

Ref. Drg. No.____

S. No .

Wt/. Piece

Total

Remarks

DETERMINING THE MANUFACTURING OPERATIONS AND THEIR SEQUENCE

Routing section analyses the product to determine the operations
involved in manufacturing of each of its parts, sub-assemblies and assemblies. These operations are then analyzed to determine their sequence. The routing decision establishes the operations necessary for processing the product and lists them in their sequence on route sheet and operation sheet

DETERMINATION OF LOT SIZE

Routing section also determine the number of units to be produced in one lot. The lot size is generally determined

by the economic order quantity. These quantities are of

course affected by other factors such as availability of production capacity and other resources.

DETERMINATION OF SCRAP FACTOR

-Scrap factor is the percentage factor in the product structure used to increase gross requirements to account for anticipated loss within the manufacturing of a particular product. -The scrap factor is inverse of a yield percentage, whereas the yield percentage indicates the quantity of good material from a process. Following are the formulas used for adjusting the planned quantity Quantity Planned=Quantity Needed + Yield percentage =Quantity Needed + (1-Scrap Factor) -The usual practice should be to establish these factors from past experience, to determine the manpower, the essential machines/equipment and the materials. This scrap factor plays an important role in the determination of man power requirements and loading of various machines

TO PROVIDE NECESSARY INFORMATION AND FORMS In order to carry out routing as planned, various forms
and procedures are required which furnish necessary information for the purpose. Various forms used e.g. production order, job ticket, inspection ticket, move order, tool ticket and equipment ticket are also prepared in this

process.

TO PROVIDE NECESSARY INFORMATION AND FORMS

MANUFACTURING ORDER
These orders for parts are both instructions and authorization to perform operations. As parts are different, each lot of parts has its own manufacturing order. So, there may be many manufacturing orders to support one assembly order. Manufacturing orders include the order no., the identification no. and description of part to be made, the quantity to make, the wanted date, material to be used and department which has to carry each operation

TO PROVIDE NECESSARY INFORMATION AND FORMS

JOB ORDER/TICKET If the copies of the manufacturing orders are not used to direct and authorize production, this can be done by the means of individual job orders. Job orders are individual operation assignments. A manufacturing order may list dozen or more operations to be performed, but job order covers only one operation. Job orders are generally small, lightweight cardboard forms.

TO PROVIDE NECESSARY INFORMATION AND FORMS

TOOLTICKET/ORDER

Ordinary tools in general use are usually issued to person in exchange for tool ticket. Worker decides or finds from the manufacturing order what tool he needs, then he goes to the tool room and ask for it

TO PROVIDE NECESSARY INFORMATION AND FORMS

INSPECTION REPORT This is a quality check documented used by the quality and inspection department. It is filled by the inspector for each lot on the basis of the inspection results of the lot sample

TO PROVIDE NECESSARY INFORMATION AND FORMS

Move Order
Generally in plants, various orders follows different paths. Therefore the material is moved by hand truck or power truck. This means the trucker should know what material to move and where to take it, move orders are used for this purpose. Move orders tells what the material is , where it is now and where it is to go. It is also used to tell production control that material has been moved and its location

STANDARD ROUTING DOCUMENTS:

The two important documents of routing are:

Route Sheet or Route Card

Operation Sheet

STANDARD ROUTING DOCUMENTS:

ROUTE SHEET
A Route Sheet or Route Card lists manufacturing operations in proper

sequence and associated machine tools for each part.

It also indicates the department in which a particular operation is to be

done on a part/ parts, and to which department the parts must go to for the
next operation. It also include the set-up time and operation time for the machines. A route sheet travels with the parts which move in batches between the processes from one point in the plant to another.

STANDARD ROUTING DOCUMENTS:

ROUTE SHEET
Name of part_______ Product___________ Material___________ Order No.__________ Part No.________ Product No._____ Economic lot size____ Due Date________ Drawing No.________ Quantity____________

Operation No.

Description of Operation

Machines or Equipments

Department

Tooling

Set-up Time

Operation Time

STANDARD ROUTING DOCUMENTS:

ROUTE SHEET

STANDARD ROUTING DOCUMENTS:

OPERATION SHEET
The operation sheet lists the various operations in sequence, required for producing a part.

Operation sheets vary greatly as to details. A simpler operation sheet

specifies only the operation and the machines to be used. Cutting speeds, feeds, and depths of cut are left to the discretion of the operator, particularly if he is skilled and small quantities of parts are involved. However, in more common operation sheets complete details are given regarding cutting speeds, feeds, depth of cut and tools, Often, the time

analysis for each operation is also included in the sheet.

STANDARD ROUTING DOCUMENTS:

OPERATION SHEET
Name of part__________________ Material______________________ Part No.___________________ Quantity___________________

Operation No.

Description of Operation

Machines Tools

Cutting Tools

Cutting Speed

Feed mm/rev

Depth Of cut, mm

Time Analysis

ROUTING IN JOB ORDER PRODUCTION BATCH/INTERMITTENT PRODUCTION CONTINUOUS PRODUCTION

ROUTING IN JOB ORDER PRODUCTION:

In job order production, the machines are arranged according to the process type of layout.

In this type of production since every time there is new job, the operations
change from job to job according to varying specification. Thus the number of operations and their sequence vary considerably. The route sheet is prepared for implementation of each order and hence requires a greater amount of work

experience. The product passes through a larger shop floor involving back
tracking. The routing is also subjected to production bottlenecks, waiting and rushing according to the work back logs and the machine loads available for them. Thus in job order production, the routing procedure is most difficult and complex.

ROUTING IN BATCH ORDER PRODUCTION:

In Batch order/ intermittent production also generally the equipment is arranged in process type layout. The operations and their sequence differ from batch to batch. The route sheets would require revision whenever the production of the batch changes. Thus is relatively simpler as compared to job order production.

ROUTING IN CONTINUOUS/ MASS MANUFACTURING:

In mass/ continuous manufacturing does not present any problem due to product type of layout, where the machines are arranged according to the sequence of operations which are to be performed on the components. The routing becomes a routine and mechanized function. Production requires special attention to route sheets in following cases
Interruption to production flow due to certain factors like machine
breakdown or power cuts and shortages of materials. As records of job conditions and methods As reference when it is necessary to train new personnel in the standard procedures of the job

PROGRESS REPORTING
- Shortage of parts and failure of production foremen to meet production schedules are common. There are numerous reasons for these occurrences, for example, errors in routing, scheduling and dispatching, lack of material, labor difficulties, breakdown of equipments, lack of proper tools, jigs and fixtures and excessive rejections etc. - Progress reporting is essential to the prevention of above delays. For this it is necessary to check the progress of the order undertaken as it is being produced from the first operation until the order is converted into final product. - Progress reporting is checking the manufacturing activities systematically so that production may be carried out according to the plan, analysis of performance for shortcomings (if any) and following up the management in order to apply corrective action to prevent excessive short fall. Thus Progress Reporting is a function by which one can give early warning when the actual production divert from planned

production.

TYPES OF PROGRESS REPORTS:

The progress reporting can be done by following

When the manufacturing within a department is completed, an

inspection is made to check quality and conformity of the product with the specifications. The inspection ticket is prepared by the inspector and sent back to the production control department. From the information on

the ticket, the progress of the order can be recorded. In this way
production department can follow every job. Dispatch office get job information in several ways like through returned job tickets, move orders, inspection reports etc. Dispatch office send in to the central office all the written reports that they get which serve as reporting of progress of jobs.

TYPES OF PROGRESS REPORTS:

Besides from written reports, foremen tell verbally if anything unusual turns up. If anything goes wrong like unusual amount of scrap, foremen tell it right way to the production control department. Some Companies uses a dial system for reporting work done. Dials similar to telephone dials are spaced around the plant. When a man gets an order he dials in to the production control, giving the order no. and operation no. When he finishes the order he dials out. This method keeps progress reports in central production control department. Tele control is relatively newcomer among devices to control shop operations with minimum of paper work.

EXPEDITING
Expediting is determining the current status of a part which is on order or a production order which is in process and initiating the efforts to speed up operations when failure to meet schedules appears likely. Follow up is the most important part of production control. This step is to ascertain from time to time that the production operations are going on according to the plan. The expeditor or chaser is meant for observing that anything overlooked or not properly executed is set right. This ensures

proper coordination of production activities and plans in order to take

corrective action if necessary. Follow up functioning checks and measure the effectiveness of previous production control functions like: routing, scheduling and dispatching.

EXPEDITING
It regulates the progress of material and parts through the production process. The cause of delays or shortages may also be investigated and an attempt made to prevent their recurrence.
This includes the physical tracing of the work in the plant and the contacting of the vendors who provide outsource parts

Part II

Expeditor or stock chaser is a person who locates lost jobs and push late jobs through to completion. He attempts to foresee and eliminate further delays.

Part I
Expediting is a special form of follow up or progress reporting. Expeditors are used To help to eliminate particular difficulties which are throwing production off the schedule?

To speed up the processing of certain orders.

EXPEDITING
Expediting is divided into two categories: Production operations inside the plant The supply of the parts and materials from outside the plant

Inside expeditor must see that the material and tools are delivered to their scheduled destination in time. He must be familiar with the plant operations and use this knowledge to ensure a free flow of tools and materials to the production line. For the parts and assemblies under this control, he must be familiar with the status of the required materials, production tooling, cutting tools and in-process equipments.
The outside expeditor is usually a sales department representative operating in the plants of vendors. His job is to see that the material and parts flow into the plant as required

REFERENCES
Operations Management by Monks A Text Book of Production Engineering by P.C. Sharma Industrial Engineering & Operations Management by S.K.Sharma , Savita Sharma http://www.du.ac.in/course/material/ug/ba/esb/Lesson_8.pdf Web: www.macro.o.za Modern Production Management by Buffa Elwood. Production Control by Franklin G. Moore Industrial Engineering & Management System by Dalela, Aggarwal Production and inventory control handbook By James Harnsberger Greene, American

1. 2. 3. 4. 5. 6. 7. 8. 9.

Production and Inventory Control Society. Handbook Editorial Board

10. Organization and ManagementBy R.D. Agarwal, Agarwal R D Staff

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