Cause and Effect diagram are a graphical method for finding the most likely causes for an undesired effect. The Cause and Effect diagram also known as the fishbone diagram or Ishikawa diagram after its creator Kaoru Ishikawa is used to systematically list all the different causes that can be attributed to a specific problem (or effect). A cause and effect diagram can help identify the reasons why a process goes out of control. The Ishikawa diagram is one of the seven basic tools of quality control, which include the histogram, Pareto chart, check sheet, control chart, cause-and-effect diagram, flowchart, and scatter diagram. The purpose of this diagram is to arrive at a few key sources that contribute most significantly to the problem being examined. These sources are then targeted for improvement. The diagram also illustrates the relationships among the wide variety of possible contributors to the effect. The basic concept Continue reading
Operations Management
Routing in Production Management
Meaning of Routing Routing lays down the flow of work in the plant. It determines what work is to be done and where and how it will be done. Taking from raw material to the finished product, routing decides the path and sequence of operations to be performed on the job from one machine to another. The purpose of Routing is to establish the optimum sequence of operations. Routing in production management is related to considerations of layout, temporary storage of in-process inventory and material handling. Routing in continuous industries does not present any problem because of the product type of layout, where the equipment is laid as per the sequence of operations required to be performed on the components (from raw material to the finished products). In open job shops, since, every time the job is new, though operation sheets (sometimes) may serve the purpose, but the route sheets Continue reading
Total Quality Management And Continuous Quality Improvement
Meaning of Total Quality Management (TQM) Total quality management (TQM) is defined as “managing the entire organization so that it excels in all dimensions of products and services that are important to the customer.” As the definition states, this philosophy concentrates on quality as a primary component of the organization’s drive for competitive advantage. Marketing decision-making is directly effected by such a system because quality is a component of product/service design and can be an important decision-making criterion employed by potential buyers. The TQM model goes beyond product and service quality, however, and suggests that a highly structured system of management that emphasizes mechanisms like control and punitive action which stifles people and ultimately hinders an organization’s attempt to produce quality products and services. Rather, the organization that views all its employees as critical, creative resources will be much better able to pursue quality in every activity and through every Continue reading
Continuous Manufacturing Systems
In continuous manufacturing systems the items are produced for the stocks and not for specific orders. Before planning manufacturing to stock, a sales forecast is made to estimate likely demand of the product and a master schedule is prepared to adjust the sales forecast according to past orders and level of inventory. Here the inputs are standardized and a standard set of processes and sequence of processes can be adopted. Due to this routing and scheduling for the whole process can be standardized. After setting of master production schedule, a detailed planning is carried on. Basic manufacturing information and bills of material are recorded. Information for machine load charts, equipment, personnel and material needs is tabulated. In continuous manufacturing systems each production run manufactures in large lot sizes and the production process is carried on in a definite sequence of operations in a pre-determined order. In process storage is not Continue reading
Just-in-Time (JIT) as a Management Control System
Just-in-Time (JIT) – Introduction Just-in-Time (JIT) is a Japanese management philosophy which has been applied in practice since the early 1970s in many Japanese manufacturing organisations. It was first developed and perfected within the Toyota manufacturing plants by Taiichi Ohno as a means of meeting consumer demands with minimum delays. Taiichi Ohno is frequently referred to as the father of JIT. Toyota was able to meet the increasing challenges for survival through an approach that focused on people, plants and systems. Toyota realized that JIT would only be successful if every individual within the organisation was involved and committed to it, if the plant and processes were arranged for maximum output and efficiency, and if quality and production programs were scheduled to meet demands exactly. Just-in-Time(JIT) technique tries to ensure that there are no zero inventories, and goods are produced or ordered only when they are needed. Hence the name, Continue reading
Plant Layouts – Definition and Objectives
Plant layout means the disposition of the various facilities (equipment’s, material, manpower etc.) within the areas of the site selected. Plant layout begins with the design of the factory building and goes up to the location and movement of work. All the facilities like equipment, raw material, machinery, tools, fixtures, workers etc. are given a proper place. Some definitions of Plant Layout are; In the words of James Lundy, “It identically involves the allocation of space and the arrangement of equipment in such a manner that overall cost are minimized”. According to MoNaughton Waynel, “A good layout results in comforts, convenience, appearance, safety and profit. A poor layout results in congestion, waste, frustration and inefficiency”. According to Andrew Greasly (2007), the layout of a plant or facility is concerned with the physical placement of resources such as equipment and storage facilities, which should be designed to facilitate the efficient Continue reading