Planning and Control For Mass and Batch Production

Flow Shop: repetitive operations in sequence Job Shop: variety of jobs done in small batches Project: unique

Mass Production


 

Breaking-up of work into simple elements Assembly line concept Standardized products having less variety Determining factor is demand

Characteristics


Merits
   

 

Smooth flow of materials Small WIP inventories Production time/unit short Closely spaced WS reduce material handling PPC simple Skill labour not required. Training costs less

Demerits
  

 

Failure of one machine stops the production Assembly lines not flexible Production speed determined by slowest machine. Line balancing difficult General supervision not specific one Capital intensive

Assembly Line
   

Grouping of Tasks for WS CT-Cycle Time ST Station Time Line Efficiency (LE) = Total Station Time /(CT * No. of WS) * 100 Balance Delay (BD) = Total idle time of All Stations/(Total Available working time of all stations) *100 Smoothness Index (SI) = (max. Station time Station times of Station i )2 Maximum Work Element Time: Tmax <= C<= Ti

Batch Production
 

Variety of products but in low volume Rate of production exceeds the rate of demand Scheduling based on batch sizes and their sequence

Merits
   

Fewer machines and better utilization Specialized supervision Low investment in machinery Flexibility in equipment and personnel

Demerits
    

Material Handling costlier PPC elaborate Longer Production time WIP inventory high Higher order Skills required

Batch production
   

Economic Lot Size Set Up Cost Carrying Cost Production Lot Size Nu = 2US/(RC(1-d/p))
      

Nu = Optimum production run size U=Annual Sales in Units S=Setup Cost per batch R= factory cost per unit C=Carrying costs as a per cent of finished goods D= Sales rate/Demand in units per day P=production rate in units daily

Aggregate production Planning



Strategy 1: Work force constant: Production output rate constant .



When cumulative demand less than production high inventory carrying cost when greater high shortage cost

Strategy 2: Production adjusted according to demand

  

Minimize inventory carrying cost Overtime Pay during peak demand MPS according to units and the corresponding workforce

Material Requirement Planning MRP



Parts Explosion Requirements : Process of determining components and sub-assemblies from the master schedule of end products

 

Line of Balance (LoB) Batch Scheduling



Three Batching Methods

  

Individual batch size fixed for each parts Aggregation of parts which are treated as one batch Fixed batch quantity for a product rather than of parts