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Maintenance Planning
Planning of maintenance jobs basically deals
with answering two questions, what and Howof the job; what activities are to be done? and
how those jobs and activities are to be done?
PRODUCTION MANAGEMENT
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Steps of Job Planning
1. Knowledge base: It includes knowledge about equipment, job,
available techniques, materials and facilities.
2. Job investigation at site: It gives a clear perception of the total
jobs.3. Identify and document the work: Knowing the earlier two
steps and knowing the needs of preventive, predictive and
other maintenance jobs.
4. Development of repair plan: Preparation of step by stepprocedures which would accomplish the work with the most
economical use of time, manpower and material.
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5. Preparation tools and facilities list indicating the needs ofspecial tools, tackles and facilities needed.
6. Estimation of time required to do the job with work
measurement technique and critical path analysis.
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REASONS FOR GENERATION
AND ACCUMULATION OFOBSOLETE, SURPLUS AND
SCRAP ITEMS.
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1. Changes in product design
2. Cannibalization
3. Faulty planning and forecasting4. Faulty purchase practices
5. Other causes
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IDENTIFICATION AND CONTROL OF WASTE
PRODUCTION MANAGEMENT
The combining process of combining the stock
records and movement analysis has been found
very effective in locating such stocks in the
total inventory.Sl. No. Part description A
B
C
Date of issue Stock on
hand
Value
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Whenever changes in production programme,design and product lines are contemplated, a
senior executive from materials management
must definitely be kept in the picture. This helpsin several ways. He is in a position to inform topmanagement of the amount of stock of materialson hand that are likely to be rendered obsolete if
and when the changes are introduced.
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Disposal of scrap when handled in an imaginativemanner can result in handsome returns to the
organization. An effective disposal requires acompact disposal organization reporting to thematerials manager, continuous market survey onthe prices of various categories of scrap generatedin the plant and constant touch with the industrieswhich generate similar scrap and with the end-users.
PRODUCTION MANAGEMENT
DISPOSAL OF SCRAP
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AUTOMATION
Automation is a technology concerned with theapplication of mechanical, electronic, and
computer based systems to operate and control
production.
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TYPES OF AUTOMATION
1. Fixed automation,
2. Programmable automation, and
3. Flexible automation.
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PRODUCTION MANAGEMENT
1. FIXED AUTOMATION The typical features of fixed automation are:
(a) High initial investment for customEngineeredequipment.
(b) High production rates.
(c) Relatively inflexible in accommodating product changes.
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2. PROGRAMMABLE AUTOMATION
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(a) High investment in general-purpose equipment.
(b) Low production rates relative to fixed automation.
(c) Flexibility to deal with changes in product configuration.(d) Most suitable for batch production.
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PRODUCTION MANAGEMENT
3. FLEXIBLE AUTOMATION
(a) High investment for a custom-engineered system.
(b) Continuous production of variable mixtures of
products.
(c) Medium production rates.
(d) Flexibility to deal with product design variations.
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PRODUCTION MANAGEMENT
REASONS FOR AUTOMATION
1. Increased productivity
2. High cost of labour
3. Labour shortages
4. Trend of labour toward the service sector
5. Safety6. High cost of raw materials
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7. Improved product quality
8. Reduced manufacturing lead time
9. Reduction of in-process inventory
10. High cost of not automating
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AUTOMATION STRATEGIES
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1. Specialization of operations.
2. Combined operations.
3. Simultaneous operations.4. Increased flexibility.
5. Improved material handling and storage
systems.
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7. On-line inspection.8. Process control and optimization.
9. Plant operations control.
10. Computer integrated manufacturing(CIM).
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COMPUTER INTEGRATED
MANUFACTURING
PRODUCTION MANAGEMENT
The computers had done a dramatic impact on the
development of production automation technologies.
Nearly all modern production systems are implemented
today using computer systems. The term computerintegrated manufacturing (CIM) has been coined to
denote the pervasive use of computers to design the
products, plan the production, control the operations, and
perform the various business related functions needed ina manufacturing firm. Computer Aided Design and
Computer Aided Manufacturing (CAD/CAM) in another
term that is used synonymously with CIM.
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AUTOMATED FLOW LINES
PRODUCTION MANAGEMENT
An automated flow line consists of several
machines or workstations which are linked
together by work handling devices that
transfer parts between the stations.
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PRODUCTION MANAGEMENT
Production
Auto 1
Production
Auto 2
Production
Auto 4
Production
Auto 3
Production
Auto 5
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PRODUCTION MANAGEMENT
The objectives of the use of flow lineautomation are:
1. To reduce labor costs.
2. To increase production rates.3. To reduce work-in-process.
4. To minimize distances moved between operations.
5. To achieve specialization of operations.
6. To achieve integration of operations.
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In-line Type Rotary Type
There are two general forms that theworkflow can take.
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AUTOMATED GUIDED VEHICLESSYSTEMS
An automated or automatic guided vehicle
system (AGVS) is a materials handlingsystem that uses independently operated,
self-propelled vehicles that are guided along
defined pathways in the floor.
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PRODUCTION MANAGEMENT
Types of AGVS
1. Driverless trains: The type consists of a towing
vehicle (which is the AGV) that pulls one or
more trailers to form a train.
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2. AGVS pallet trucks: Automated guided pallet trucks are used to
move palletized loads along predetermined routes. In thetypical application the vehicle is backed into the loaded pallet
by a human worker who steers the truck and uses its forks to
elevate the load slightly.
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PRODUCTION MANAGEMENT
3. AGVS unit load carriers: This type of AGVSis used to move unit loads from one station to
another station. They are often equipped for
automatic loading and unloading by means ofpowered rollers, moving belts, mechanized lift
platforms, or other devices.
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PRODUCTION MANAGEMENT
END