Mass production (also called flow production or repetitive flow production) is the production of large amounts of standardized products on production lines. It was popularized by Henry Ford in the early 20th Century, notably in his Ford Model T. Mass production is notable because it permits very high rates of production per worker and therefore provides very inexpensive products. Mass production is capital intensive, as it uses a high proportion of machinery in relation to workers. With fewer labor costs and a faster rate of production, capital is increased while expenditure is decreased. However the machinery that is needed to set up a mass production line is so expensive that there must be some assurance that the product is to be successful so the company can get a return on its investment. Machinery for mass production such as robots and machine presses have high installation costs. One of the descriptions Continue reading
Production Management
Concept of Material Handling – Definition and Functions
Material Handling involves the movement of material, manually or mechanically in batches or one item at a time within the plant. The movement may be horizontal, vertical or combination of horizontal or vertical. Material Handling is the movement, storage, control and protection of materials, goods and products throughout the process of manufacturing, distribution, consumption and disposal. The focus is on the methods, mechanical equipment, systems and related controls used to achieve these functions. Briefly, Material Handling is the moving of materials from the raw stage through production to ultimate Customer with the least expenditure of time and effort so as to produce maximum Productive Efficiency at the lowest Material Handling cost. Material Handling is concerned with motion, time, quantity and space. Material Handling Institute describes this as follows: Material Handling is MOTION. Parts, material and finished products must be moved from store to location. Material Handling is concerned with moving Continue reading
Principles of Material Handling
Material Handling is the art of implementing movement of materials-economically and safely. In the classic sense, Material Handling is the act of creating Time and Place utility, as distinct from Manufacturing, which creates form utility. The proper application of Material Handling knowledge will result in the smooth integration of all the process in an enterprise into one efficient Production Machine. The principles presented here represent an accumulation of experience equivalent to untold years of practice. They are adapted from those stated in the literature, with certain changes made for clarification and with several new one added to round out the coverage of the field. In reviewing the principles it will be found that nearly every one applies to several aspects of Material Handling and aids in accomplishing one or more objectives. 1. Principle of Planning: All Handling activities should be planned. Description: If there is one principle on which all Continue reading
Line Balancing in Production Management
A production line is typically associated with continuous or flow production system. Production lines are particularly appropriate for high volume operations. In a production line work is divided into individual tasks and assigned to consecutive workstations on the line. In mass production on progressive assembly line the workload between various machines or workstations should be balanced. The need for balancing the line becomes obvious when it is considered that the output to be received from the line is determined by the maximum time involved in the performance of work at one particular workstation. The imbalances existing in the line would lead to wastage of time at all other work stations when one work station holds up the total output rate. Therefore, it is necessary to level out or balance the cycle times at each workstation. Line balancing refers to the apportionment of sequential work activities into workstations in order to Continue reading
Production planning- Definition, Objectives and Levels
Production planning is concerned with deciding in advance what is to be produced, when to be produced, where to be produced and how to be produced. It involves foreseeing every step in the process of production so as to avoid all difficulties and inefficiency in the operation of the plant. Production planning has been defined as the technique of forecasting or picturing ahead every step in a long series of separate operations, each step to be taken in the right place, of the right degree, and at the right time, and each operation to be done at maximum efficiency. In other words, production planning involves looking ahead, anticipating bottlenecks and identifying the steps necessary to ensure smooth and uninterrupted flow of production. It determines the requirements for materials, machinery and man-power; establishes the exact sequence of operations for each individual item and lays down the time schedule Continue reading
Differences Between Manufacturing and Service Operations
Generally speaking, process efficiency is the most important to manufacturing operations while production and marketing are inseparable to service operations. Manufacturing’s tangible output can be consumed overtime, less labor and more equipment are used in production, since automation has increased capital intensity while as a result reduced customer contact. Consumers rarely take part in the manufacturing process, many manufacturing operations have emphasized efficiency while compromising flexibility, the methods for monitoring and using resources are sophisticated while producing. On the other hand, service operations are different from those of manufacturing operations. Consumption and production of services takes place simultaneously or closely, and there are more labor and more customer participation, which means service businesses, usually are more customer-oriented. while elementary methods are frequently used for monitoring and using resources. To be specific, there are mainly six differences between manufacturing operations and service operations. 1. Basic organize style in operation Basically, manufacturing Continue reading