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SRM UNIVERSITY

AGILE MANUFACTURING
Indiaby K.CHANDRA MOHAN

DATE: 23/09/2012

INTRODUCTION
What is Manufacturing  Recent trends in Manufacturing  Manufacturing support system  Lean production  Agile Manufacturing  Market forces & agility  Reorganizing the production system for agility  Managing relationship for agility  Agility vs Mass Production

MANUFACTURING

The Process of Converting Raw Materials Into Products”

RECENT TRENDS IN MANUFACTURING SYSTEM        GROUP TECHNOLOGY FLEXIBLE MANUFACTURING SYSTEM CELLULAR MANUFACTURING DESIGN FOR MANUFACTURING & ASSEMBLY AUTOMATED ASSEMBLY SYSTEMS ARTIFICIAL INTELLIGENCE ?????? .

MANUFACTURING SUPPORT SYSTEMS    PRODUCT DESIGN & CAD CAM (QFD. MRP II) o LEAN PRODUCTION & AGILE MANUFACTURING . AMP) PRODUCTION PLANNING & CONTROL SYSTEMS (JIT. MRP. CP. PRODUCT DESIGN) PROCESS PLANNING & CONCURRENT ENGINEERING (CAPP.

It also can be defined as an adaptation of mass production in which workers and work cell are made flexible and efficient by adopting methods to reduce waste.   . less time and less space while coming closer and closer to providing customers with exactly what they want.LEAN PRODUCTION  The term “ lean production” was coined by reaserchers at MIT to describe the activities and programs that seemed to explain Toyotas success: the efficiency with which they produced cars and the quality of cars they produced.less equipment. Our first definition is a pharaphrase in the book “ THE MACHINE THAT CHANGED THE WORLD” womans and jones define lean as doing” more and more with less and lessless human effort .

CONTINUOUS IMPROVEMENT .4 Principles of Lean Production 1. MINIMIZE WASTE 2. FLEXIBLE PRODUCTION LINE 4. PERFECT FIRST TIME QUALITY 3.

THE FROG! Rebbit! Rebbit! Uh oh! 10OoC 5OoC OoC “Poikilothermic” (= don’t try this at home) .

AGILE MANUFACTURING The term Agile manufacturing was coined to describe a new manufacturing paradigm that was recognized as emerging to replace mass production. The American standard of living is at risk unless US industry can led the transition to agile manufacturing . Agile companies that can rapidly response to demand for customized products Agility requires integration of (1)Flexible production technology. (2)Knowledgable work force. A new competitive environment is emerging that is forcing changes in manufacturing systems and organization. key findings of the study included the following. (3)Management structures.

GENERAL MOTORS. IBM. AT & T.( making profit . TEXAS INSTRUMENTS. CHRYSLER. FMC. MOTOROLLA. survive in the future) Companies successfully implemented agile manufacturing AIR PRODUCTS AND CHEMICALS.DEFINTION Agile production can be defined as (1) an enterprise level manufacturing strategy of introducing new product into rapidly changing markets and (2) an organizational ability to thrive in a competitive environment characterized by continuous and some times unforeseen change. . Agility is strategy for profiting from rapidly changing and continuously fragmenting global market for customized product and services. KINGS BURRY CORP. BOEING.

4 Dimensions of agility Organize to master change Leverage the impact of people Agile manufacturing Cooperate to enhance competition Enrich the customers .

shrinking windows of markt opp  COOPERATIVE BUSINESS RELATIONSHIP: . improved labour mangment relationship  .  FRAGMENTATION OF MASS MARKET: -emergence of niche markets.increasing inter relationship cooperation.MARKET FORCES AND AGILITY IDENTIFYIN COMPETITION: -1) global comp 2) decreasing cost of info 3) pressure to reduce time to market 4)short product life. high rate of model changes. increased out sourcing.

MARKET FORCES AND AGILITY  CHANGING CUSTOMER EXPECTATIONS -market demands changing . increased information content than quality .customers are more sophisticated and indidualistic.

SUV MARKET MAHINDRA SCORPIO  TOYOTA FORTUNE5R  TATA SAFARI  TATA SUMO GOLD  SKODA YETI  BMW X SERIES  AUDI Q SERIES  LANDROVER RAGEROVER  .

WHEN MAHINDRA XUV 500 ENTERS .

HILL HOLD CONTROL  . TILT STEERING  GPS NAVIGATION .MAHINDRA XUV SPECIALITIES 2200CC ENGINE  5TH GENERATION TURBOCHARGER  6 INCH MONOCHROME TOUCH INFO DISPLAY  MICROHYBRID SYSTEM  INTELLIGENT PARKING  RAIN SENSING WIPER  HEADLAMP IMMOBILIZER  ABS.

5 lakhs TOYOTA FORTUNER.Rs 30 lakhs BMW X SERIES ---RS 30.4 lakhs .COMPARISON    MAHINDRA XUV 500 – Rs 13.

CHANGING CUSTOMER EXPECTAION .

jan 2013  . 6 lks .5 lks. july 2012 Mahindra Quonto1500cc.7. sep 2012  Fiord ecosports1000cc . 5 lks .FREQUENT NEW PRODUCT INTRODUCTION  Renault Duster – 1600cc.

AGILITY IN RENAULT  RELEASED 5 NEW MODELS WITH IN 18 MONTHS RENAULT PULSE  RENAULT FLUENCE  RENAULT SCALA  RENAULT KOLEOS  RENAULT DUSTER  .

  PRODUCTION OPERATIONS . MARKETING .REORGANISING THE PRODUCTION SYSTEM FOR AGILITY  PRODUCT DESIGN: .Product design determine app 70% of the mfg cost of a product.The best effort of a design may be lost if the marketing plan is flawed.A sustainable impact of agility can be achieved by reorganizing factory operations .

PRODUCT DESIGN CUSTOMIZABLE  UPGRADABLE  RECONFIGURABLE  DESIGN MODULARITY  FREQUENT MODEL CHANGES  PLATFORM OF INFORMATION AND SERVICES  .

CELLPHONES AND LAPTOPS .

MARKETING AGGRESSIVE AND PROACTIVE PRODUCT MARKETING  CANNABALIZE SUCCESFUL PRODUCTS  FREQUENT NEW PRODUCT INTRODUCTION  LIFE CYCLE PRODUCT SUPPORT  PRICING BY CUSTOMER VALUE  EFFECTIVE NICHE MARKET COMPETITOR  .

CELLPHONES .

MRPII)  .PRODUCT OPERATIONS BE A COST EFFECTIVE. LOW VOLUME PRODUCER  BE ABLE TO PRODUCE TO CUSTOMER ORDER  MASTER MASS CUSTOMIZATION  USE CONFIGURABLE AND REUSABLE PROCESS –(modular fixtures)  BRING CUSTOMER CLOSER TO THE PRODUCTION PROCESS-(pc config)  INTEGRATE BUSINESS PROCEDURES WITH PRODUCTION(MRP.

MANAGING RELATIONSHIPS FOR AGILITY( COOPERATION SHOULD BE THE BUSINESS STRATEGY) .

MASS PRODUCTION VS AGILE MANUFACTURING MASS PRODUCTION AGILE MANUFACTURING Standardized products  Long market life expected  Produce to forecast  Low information content  Single time sales  Pricing by production cost  Customized products  Short market life expected  Produce to order  High information content  Continuing relationship  Pricing by customer value  .

CONCLUSION Single time sales is not enough  Customer retention  Customers are willing and able to pay more if it is customized for them  Increased information content  .

QUERIES .

THANK YOU .