Method Study is a technique which analyses each operation of a given piece of work very closely in order to eliminate unnecessary operations and to approach the quickest and easiest method of performing each necessary operation; it includes the standardization of equipment, method and working conditions; and training of the operator to follow the standard method. The philosophy of method study is that ‘there is always a better way of doing a job’ and the tools of method study are designed to systematically arrive at this better way of doing a job. Method study is essentially used for finding better ways of doing work. It is a technique for cost reduction. Method Study may also be defined as the systematic investigation of the existing method of doing a job in order to develop and install an easy, rapid, efficient and effective and less fatiguing procedure for doing the same Continue reading
Production Management
Important Aspects of Total Quality Management (TQM)
Total Quality Management (TQM) is a management philosophy that supports the process of continuous improvement within an organization and where total emphasis is placed on the customer. In the socioeconomic viewpoint, TQM defines the customer as all members of society and facets of environment that interact with the activities of the company. TQM is also defined as a set of management practices throughout the organization, geared to ensure the organization consistently meets or exceeds customer requirements. The goal of TQM philosophy is – “Do the right things right the first time, every time.” One of the principal aims of TQM is to limit errors to 1 per 1 million units produced. Total Quality Management (TQM) is a significant advance over traditional Quality Control (QC) programs. Traditional QC concerns itself with the number of final items found defective, replacing them with good items, or else negotiating the predicted failures into a supply Continue reading
Criteria for a Good Layout
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 flow of customers or materials through the manufacturing or service system. The layout design is very important and should be taken very seriously as it can have a significant impact on the cost and efficiency of an operation and can involve substantial investment in time and money. The decisions taken with regards to the facility layout will have a direct influence on how efficiently workers will be able to carry out their jobs, how much and how fast goods can be produced, how difficult it is to automate a system, and how the system in place would be able to respond to any changes with regards to product or service design, product mix, or demand volume. In many operations the installation Continue reading
Method Study Procedure
Method study is the systematic recording and critical examination of existing and proposed ways of doing work, as a means of developing and applying easier and more effective methods and reducing costs. So it is the process of analyzing the methods involved in work flow to increase productivity. It deals with doing the work in a better way, with less time and effort. That is why it is also termed as work simplification. Method study procedure is an organized approach and its investigation rests on the following six basic steps: Select the work to be analyzed. Record all facts relating to the existing method. Examine the recorded facts critically but impartially. Develop the most economical method commensurate with plant requirements Install the new method as standard practice. Maintain the new method. The above basic method study procedure was first developed and articulated by Russell Currie at Imperial Chemical Industries (ICI). Continue reading
Intermittent Manufacturing Systems
In Intermittent manufacturing systems, the goods are manufactured specially to fulfill orders made by customers rather than for stock. Here the flow of material is intermittent. Intermittent production systems are those where the production facilities are flexible enough to handle a wide variety of products and sizes. These can be used to manufacture those products where the basic nature of inputs changes with the change in the design of the product and the production process requires continuous adjustments. Considerable storage between operation is required, so that individual operations can be carried out independently for further utilization of men and machines. Examples of intermittent systems are: machine shops, hospitals, general office etc. Characteristics of intermittent manufacturing systems are: Most products are produced in small quantities. Machines and equipment are laid out by process. Workloads are generally unbalanced. Highly skilled operators are required for efficient use of machines and equipment. In-process inventory Continue reading
Production Control- Definition, Objectives, Levels and Factors
Definition of Production Control All organizations irrespective of size, use production control to some degree. In small organizations, the production control may be performed by one person; but in large complex industries the production control department is normally well-organised and highly specialized. Production control presupposes the existence of production plans, and it involves the use of various control techniques to ensure production performance as per plans. Co-ordinating men and materials and machines is the task of production control. Production control may be defined as “the process of planning production in advance of operations; establishing the exact route of each individual item, part of assembly; setting and finishing dates for each important item, assembly and the finished products, and releasing the necessary orders as well as initiating the required follow-up to effectivate the smooth functioning of the enterprises.” According to Henry Fayol, production control is the art and Continue reading