Planning and Control for Mass Production

Presented by : Amrita Kadam

Types of production processes: Type of production Intermittent production Continuous Production Job Production Batch Production Project Production Mass Production Flow Production .

Domain of production systems Job Shop Production Product Variety Batch Production Mass Production Continuous Flow Production Production Volume .

Whiteny .Underlying Ideas of Mass Production • Logical Break down of work • Division of Work into Work Stations • Adam Smith • Henry Ford Ideas • Interchangeable and Replaceable parts • E.

000 2.000 10.000 4.When to go for mass production Cost 20.000 Production Quantity .

Assembly Line and Fabrication line Assembly Line • Builds components • Use series of machines • Repetitive process • Machined pace • Balanced by physical design Fabrication line • Assembles fabricated parts • Use work stations • Repetitive process • Paced by tasks • Balanced by moving tasks .

Designing of Assembly Line • Objective Minimize the total idle time or the no. of workstations for a given assembly line speed. • Division of work into pats The precedence Diagram .

Grouping of tasks into Work Stations • The feasible range of cycle time • Line balancing methods  Helgeson & Birnie (Rank position Weight method)  Kilbridge & Wester (No of predecessors)  Arcus (COMSOAL) (Generation of alternative by simulation ) • Choice of the best design .

LE) Smoothness Index N i=1 K × CT × 100 % Si = ∑ (S Tmax – STi ) 2 .Measures of performance Line Efficiency N LE = ∑ STi i=1 Balanced Delay BD = (1.

Precedence Diagram 3 4 2 6 2 5 3 5 7 1 8 1 3 6 6 4 10 9 4 11 7 12 4 5 j Duration Element No i .

No of elements = 12 Cycle Time k Tmax ≤ Cycle Time ≥ ∑ Ti i=1 7 ≤ Cycle Time ≥ 50 Desirable Cycle Time = 10 .

3 9 WS .1 8 5 WS .5 10 .No.6 8 WS .2 9 WS .4 6 WS . of predecessors Method 3 4 2 6 2 5 3 5 7 6 1 4 10 8 1 3 6 9 4 11 7 12 4 WS .

11) (9.3 WS .10) (8.6) (7.12) Total Time Total time 8 9 9 6 10 8 50 Idle Time 2 1 1 4 0 2 Line Efficiency = 83.3% Balanced Delay = 16.5) (3.6 Elements (1.4 WS .9 .5 WS .Desirable Cycle Time = 10 Work Stations WS .1 WS .7% Smoothness Index = 50.4) (2.2 WS .

Ranked Positional Weight 2 5 3 31 4 3 28 5 7 2 15 6 8 13 1 50 6 3 6 24 1 8 9 7 12 4 10 4 11 7 4 33 5 30 15 11 .

3% Balanced Delay = 16.9 Total Time 50 .Desirable Cycle Time = 10 Work Stations WS .11) (12) Total time 8 9 9 7 10 7 Idle Time 2 1 1 3 0 3 Line Efficiency = 83.1 WS .9) (8.4 WS .4) (2.6 Elements (1.10.6) (7.7% Smoothness Index = 4.5) (3.2 WS .5 WS .3 WS .

Problems of Mass Production • Variable Work Element Time • Break down at Work Station • Multi Product Line Prospects of Mass Production • Modular Production and Group Technology • Automation and Robotics .

Thank You .

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