Download (a) Continuous production

Production process
The basic term that should be considered and explained is ‘process’. There are numerous
definitions of the term ‘process’ presented in literature, as it is applicable in many fields including:
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Business,
Technology,
Biology
Psychology
Computing,
Engineering,
Management
And others.
Depending on the field of application, definitions of the term may slightly differ on account of
specific conditions and constraints typical for the area.
The most general definition is the one introduced by a typical encyclopedia dictionary, and it is as
follows:
Process is a series of actions that produce something or that lead to a particular result [MerriamWebster].
The definition is general, as it does not indicate in any way neither the character of actions
mentioned, nor the result expected. It can be presented graphically, in a simple graph presented below
(Fig. 1):
INPUTS
TRANSFORMATION
OUTPUTS
Fig. 1. A process
In the graph, the nature of transformation is not indicated. Transformation process is in general
presentation a so called “black box” as it may substantially differ from one field to another. In more
detailed analysis it can presented as a specific set of operations.
The definitions referring to manufacturing and production can be found in the dictionary of a
specific orientation, which is the before mentioned APICS dictionary, and the definitions there are as
follows:
(1) Process is a planned series of actions or operations (e.g., mechanical, electrical, chemical,
inspection, test) that advances a material or procedure from one stage of completion to another.
[Apics]
(2) Process is a planned and controlled treatment that subjects materials or procedures to the
influence of one or more types of energy (e.g., human, mechanical, electrical, chemical) for the time
required to bring about the desired reactions or results. [Apics]
Resulting in a clearer way of transformation process:
Transformation process – the process of converting inputs into finished goods or services. In a
service firm, the input may be a customer. [Apics]
In these definitions reference to production and manufacturing area is quite clear, as they specify
the actions to be taken, as well as the result expected, and they can be coined directly into production
and manufacturing process definitions:
Production process – the activities involved in converting inputs into finished goods. [Apics]
and:
Manufacturing process – the series of operations performed upon material to convert it from the
raw material or a semi-finished state to a state of further completion. Manufacturing process can be
arranged in a process layout, product layout, cellular layout, or fixed-position layout. Manufacturing
process can be planned to support make to stock, make to order, assemble to order and so forth, based
on strategic use and placement of inventories. [Apics]
Note that production process is more general than manufacturing process.
Manufacturing – a series of interrelated activities and operations involving the design, material
selection, planning, production, quality assurance, management, and marketing of discrete consumer
and durable goods. [Apics]
Taking the above considerations into regard, the graphical presentation of the presentation could be
completed with explanation of inputs, outputs and transformation process. Hence, in the graph
presented in Figure 1., the inputs would include the following:
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Materials,
Energy,
Human labor.
and the outputs:
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Products (finished goods or services),
Waste (material, energy etc.)
The nature and characteristics of processes are crucial aspects to be analyzed when examining
organizations and their performance.
Production system
Manufacturing subsystem that includes all functions required to design, produce, distribute, and
service a manufactured product.
Production management
Definitions are the following:
1. Production management is the Art of Managing the Production. It basically concerns itself
with the conversion of inputs into outputs.
2. Production management can be also defined as “The job of coordinating and controlling all
the activities required in making a product”.This concept is not restricted to only industrial or
manufacturing sectors; it is also applicable to service industries.
Operations management is the conversion of inputs into outputs, using physical resources, so as to
provide the desired utility/utilities of form, place, 2
possession or state or a combination thereof to the customer while meeting the other organizational
objectives of effectiveness, efficiency and adaptability.
Production management is the planning, scheduling, execution, and control of the process of
converting inputs into finished goods [Apics]
The production management’s responsibility sees to the following areas; men (labor), machines,
methods, materials and money.
3 aims of performance of the Production and Operations Management Systems:
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Effectiveness – productive utilization of resources
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Customer satisfaction
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Efficiency
Production management history includes, but is not limited to the following events:
1776 – in his work, Welath of Nations, Adam Smith introduced specialization of labor in
manufacturing as the key factor for economic growth.
1801
- Eli Wihtney built ten guns made of the same parts, disassembled them, mixed the
parts and assembled them again easily proving that interchangeable parts are crucial for manufacturing
efficiency, the idea contributed to mass production development.
1832
- in Economy of Machine, Charles Babbage discussed the commercial advantages
coming from division of labor based on skills, first introduced in 1815 by Melchiorre Gioia.
1900s
- the Gilbreths’ studies on work motion, focusing on increased work efficiency thanks
to reduced moves of operators.
1910s
- development of a chart by Henry L. Gantt used as a scheduling technique.
1911
- Frederick W. Taylor published The Principles of Scientific Management in which he
divided planning the work from doing it, focusing on time of work reduction.
1913 – Henry Ford introduced the moving assembly belts in the Ford plant in Highland Park in the
U.S. state of Michigan, improving efficiency of processes forcing a specific organization of material
flow - the creation of buffer inventory to maintain continuity of production [Pfohl 1995 ],
1915
- Harris introduced his Economic Order Quantity formula.
1975
- Material Requirements Planning, published in 1975 by Joseph Orlicky, the
publication presents the essence of the MRP, with principles and guidelines of material requirements
planning, approach to procurement, which is the essence of many of today's solutions in this field and
an integral part of computer support systems.
1990
- The Machine That Changed the World by James Womack, Daniel Jones and Daniel
Roos, published in 1990 by MIT, presents the essence of lean manufacturing (lean production) ,
recognized as the biggest revolution since the Ford assembly line, forcing the integration of the
environment through cooperation and coordination of the supply chain.
1991
- The 21st Century Manufacturing Enterprise Strategy , developed by Roger Nagel
and Rick Dove (Iacocca Institute) in 1991, a report on trends in the modern production and
management , primarily customer orientation and flexibility in meeting its expectations and
requirements , and customer integration into the flow of materials.
1993
- ECR - Efficient Consumer Response - Effective Customer Service, solution
introduced since 1993 (USA) / 1994 (Europe) by ECR Europe, aimed primarily aimed at streamlining
and reducing the cost of customer service in the consumer sector by integrating the entire supply
chain.
1997
- Leagility: interfacing the lean and agile manufacturing paradigm in the total supply
chain, in 1997, in which the term leagility appears first, coined by J.B. Naylor , M. M. Naim and D.
Berry and interpreted as a combination of agile and lean strategies.
and many others, however these prove that production management is a scientific discipline and
can be defined as:
.. a field of study that focuses on the effective planning, scheduling, use, and control of a
manufacturing organization through the study of concepts from design engineering, industrial
engineering, management information systems, quality management, inventory management,
accounting and other functions as they affect the transformation process. [Apics]
Considering the above presented definition, production management functions are distinguished as
follows:
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Selection of product and design.
Selection of production process.
Selection of right production capacity.
Production planning.
Production control.
Quality and cost control.
Inventory control.
Maintenance and replacement of machines.
Production process organization
Manufacturing process definition is directly based on a process definition.
Manufacturing process encompasses various types of operations performed with dedicated machinery.
[Apics]
As mentioned in the definition, manufacturing process is a set of operations. Operation can be defined
as follows:
Operation is a job or task, consisting of one or more work elements, usually done essentially in one
location. [Apics]
Operation is the performance of any planned work or method associated with an individual, machine,
process, department or inspection. [Apics]
Operation is one or more elements that involve one of the following: the intentional changing of an
object in any of its physical or chemical characteristics; the assembly or disassembly of parts or
objects; the preparation of an object for another operation, transportation, or storage; planning,
calculating or giving or receiving information. [Apics]
All the definitions presented introduce various aspects of operations, referring to its character,
resources it uses, and result it generates. The set of operations, which is a manufacturing process, may
be organized in many ways. There are types of production systems:
(a) Continuous production - It is also known as mass flow production or assembly line production.
The system is suitable in plants involving large volume and small variety of output e.g. oil refineries
reform cement manufacturing etc.
(b) Job or unit production - The system requires comparatively smaller investment in machines and
equipment. It is flexible and can be adapted to changes in product design and order size without much
inconvenience. This system is most suitable where heterogeneous products are produced against
specific orders.
(c) Intermittent production (batch production) - Under this system the goods are produced partly
for inventory and partly for customer's orders. E.g. components are made for inventory but they are
combined differently for different customers: Automobile plants, printing presses, electrical goods
plant are examples of this type of manufacturing.
Continuous manufacturing is also defined as follows.
Continuous manufacturing – a type of manufacturing process that is dedicated to the production of a
very narrow range of standard products. The rate of production change and new product information
is very low. Significant investment in highly specialized equipment allows for a high volume of
production at the lowest manufacturing cost. Thus unit sales volumes are very large, and price is
almost always a key order-winning criterion. Examples of items produced by a continuous process
include gasoline, steel, fertilizer, glass, and paper. [Apics]
Continuous production is a production system in which the productive equipment is organized and
sequenced according to the steps involved to produce the product. This term denotes that material
flow is continuous during the production process. The routing of the jobs is fixed and setups are
seldom changed. [Apics]
Continuity of production is based on the narrow assortment and some specific characteristics of the
process. Another way of process organization is repetitive production.
Repetitive production – the repeated production of the same discrete products or families of products.
Repetitive methodology minimizes setups, inventory, and manufacturing lead times by using
production lines, assembly lines, or cells. Work orders are no longer necessary; production
scheduling and control are based on production rates. Products may be standard or assembled from
modules. Repetitive is not a function of speed or volume. [Apics]
Manufacturing process can be performed with human involvement and without it.
Automation – the substitution of machine work for human physical and mental work, or the use of
machines for work not otherwise able to be accomplished, entailing a less continuous interaction with
humans than previous equipment used for similar tasks. [Apics]
Manufacturing process is performed in a production system and may be organized in various forms,
including production cells and lines, and with various approaches, including mass production,
customized production, lean and agile production.
Flexible Manufacturing systems
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Quick Response manufacturing
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CIM
Manufacturing management is a broad area, encompassing numerous issues, of high variety. It
makes the decisions within the area difficult. Since manufacturing management influences
company’s performance, it should be executed at the highest level possible. To achieve this,
computer support is employed.
CAD computer aided design – the use of computers to in interactive engineering drawing and
storage of designs. Programs complete the layout, geometric transformations, projections,
rotations, magnifications and interval (cross-section) views of a part and its relationships with
other parts. [Apics]
CAM – computer aided manufacturing – the use of computers to program, direct, and control
production equipment in the fabrication of manufacturing items. [Apics]
CIM computer integrated manufacturing – the integration of the total manufacturing organization
through the use of computer systems and managerial philosophies that improve the organization’s
effectiveness; the application of a computer to bridge various computerized systems and connect
them into a coherent, integrated whole. For example, budgets, CAD/CAM, process controls,
group technology systems, MRPII, and financial reporting systems are linked and interfaced.
[Apics]
CNC computer numerical control – a technique in which a machine tool controller uses a
computer or microprocessor to store and execute numerical instructions. [Apics]
Mass Customization
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ean Management
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