UNIT I.

Mass Production Technique

I.

MASS PRODUCTION

MASS PRODUCTION is a system

of manufacturing based on principles such
as the use of interchangeable parts, largescale production, and the high-volume
assembly line.
Such manufacturing processes attain high
rates of output at low unit cost, with lower
costs expected as volume rises.

Mass production methods are based on two general principles:

1. The division and specialization of human labor
2. The use of tools, machinery, and other equipment, usually automated,
in the production of standard, interchangeable parts and products.
The use of modern methods of mass production has brought such
improvements in the cost, quality, quantity, and variety of goods available
that the largest global population in history is now sustained at the highest
general standard of living.

II.

FourFactors needed for Mass Production

I.

Effect of Mass Production

Effects of Mass Customization on Manufacturing

Mass customization is a concept whereby the customer has a much

higher involvement in the manufacturing process, being able to specify the
features of the product that they want, for example, selecting the functional
and aesthetic features of cars. Essentially, this trend reflects a change in
manufacturers attitudes. This covers key aspects of mass customization in
regards to manufacturing, from changing attitudes, though to disadvantages
and advantages.

How Attitudes Have Changed

Manufacturing has been predominately about producing as much of a
certain product at the lowest unit cost in order to create value for the
manufacturer, better known as mass production.
As a result, this production-centric approach has told the customer what
they need, leaving very little scope for input from the consumer.
In essence, mass customization is a response to consumers demand for far
greater control over the features of products that they wish to buy.

Adopting a Mass Customization Approach

The most important facets that a business can have are agility and a
better understanding of supply chains in order to meet the customers
specific needs and still manufacture efficiently. In addition to this,
incorporating effective customer-centric design and being more flexible are
key to economically customizing a companys product offerings and
producing them efficiently.

Advantages
Customers are often more pleased with the finished product they receive,
as its to their specification.
Your workforce is more fulfilled as they now partake in numerous tasks as
opposed to one production line responsibility.
Customized products are more attractive to consumers than uniform
products.
Companies can forge strong relationships with their customers. That loyalty
leads to return business time and again.
Disadvantages
Maintaining a high level and variety of stock can incur high warehousing
costs. Large amounts of capital are also tied up in stock.
Typically, as the products are custom made they have a higher cost.
Offering mass customization with mass production efficiency is very
difficult to achieve.
If you are coming from a mass production background it is extremely tough
to change your organizational structure and culture.

UNIT II. Production Organization

I.

Organization and Production Management

Production manager- is the responsible person for

making raw materials which are provided to make

finished product effectively. It supervises the
procedures for making the work more efficient and
the more enjoyable.Has close monitoring during
the production to minimize the wasted of materials
for the sake of the organizational profits.
Organizational Profitsmay lead to benefit for all employees and also for the

organization.

II.

How to StudyProduction Organization

The organization of production is concerned with the achievement ofas

signed goals as rapidly as possible with optimal utilization of production reso
urces.
The most important methods of production organization are the flow, b
atch, and unit methods. The most progressive is theflow method, which provi
des for the assignment of a limited list of jobs and for the arrangement of wo
rk positions andproduction sections according to the path dictatedby the stag
es in a products manufacture.

III. How to Analyze Production Organization and

Plant

Four Main Types of Plant Layout

1. Product or Line Layout:
If all the processing equipment and machines are arranged according
to the sequence of operations of the product, the layout is called product
type of layout. In this type of layout, only one product of one type of
products is produced in an operating area. This product must be
standardized and produced in large quantities in order to justify the product
layout.
The raw material is supplied at one end of the line and goes from one
operation to the next quite rapidly with a minimum work in process, storage
and material handling. Fig. 8.3 shows product layout for two types of
products A and B.

Advantages offered by Product Layout:

Lowers total material handling cost.

There is less work in processes.

Better utilization of men and machines,

Less floor area is occupied by material in transit and for temporary

storages.

Greater simplicity of production control.

Total production time is also minimized.

Limitations of Product Layout:

No flexibility which is generally required is obtained in this layout.

The manufacturing cost increases with a fall in volume of production.

If one or two lines are running light, there is considerable machine

idleness.

Specialized and strict supervision is essential.

2. Process or Functional Layout:

The process layout is particularly useful where low volume of
production is needed. If the products are not standardized, the process
layout is lower desirable, because it has creator process flexibility than other.
In this type of layout, the machines and not arranged according to the
sequence of operations but are arranged according to the nature or type of
the operations. This layout is commonly suitable for non repetitive jobs.
Same type of operation facilities are grouped together such as lathes
will be placed at one place; all the drill machines are at another place and so
on. See Fig. 8.4 for process layout. Therefore, the process carried out in that
area is according to the machine available in that area.

Advantages of Process Layout:

There will be less duplication of machines. Thus, total investment in

equipment purchase will be reduced.

It offers better and more efficient supervision through specialization at

various levels.

There is a greater flexibility in equipment and man power thus load

distribution is easily controlled.

Better utilization of equipment available is possible.

Break down of equipment can be easily handled by transferring work to

another machine/work station.

There will be better control of complicated or precision processes,

especially where much inspection is required.

Limitations of Process Layout:

There are long material flow lines and hence the expensive handling is
required.

Total production cycle time is more owing to long distances and waiting
at various points.

Since more work is in queue and waiting for further operation hence
bottle necks occur.

Generally, more floor area is required.

Since work does not flow through definite lines, counting and
scheduling is more tedious.

3. Fixed Position Layout:

This type of layout is the least important
for todays manufacturing industries. In
this type of layout the major component
remain in a fixed location, other materials,
parts, tools, machinery, man power and
other supporting equipments are brought
to this location.
The major component or body of the product remain in a fixed position
because it is too heavy or too big and as such it is economical and
convenient to bring the necessary tools and equipments to work place along
with the man power. This type of layout is used in the manufacture of boilers,
hydraulic and steam turbines and ships etc.
Advantages Offered by Fixed Position Layout:

Material movement is reduced

Capital investment is minimized.

The task is usually done by gang of operators, hence continuity of

operations is ensured

Production centers are independent of each other. Hence, effective

planning and loading can be made. Thus total production cost will be
reduced.

Limitations of Fixed Position Layout:

Highly skilled man power is required.

Movement of machines equipments to production centre may be time

consuming.

Complicated fixtures may be required for positioning of jobs and tools.

This may increase the cost of production.

4. Combination Type of Layout:

Flexibility is a very important factory, so layout should be such which
can be molded according to the requirements of industry, without much
investment. If the good features of all types of layouts are connected, a
compromise solution can be obtained which will be more economical and
flexible.

UNIT III.Production System and Procedure

I.

Production System and

Procedure

Production methods
Different scales of textiles production call for
different production
methods.

1. One-off production
In one-off production a single product is
designed and made to a client's
specification. Labor and material costs are
high and a high level of design and
manufacturing skills are needed. An example of one-off production would be
a made-to-measure wedding dress.
2. Batch production
In batch production set quantities of a
product are manufactured to order. Batch
production requires a high level of design,
pattern making and sampling skills. Materials
are cost-effective and manufacturing costs are
lower than one-off production. Garments are
designed to fit a range of standard sizes and
shapes. The quantity varies from a set of four cushions made by a
designer/maker to 20,000 jumpers made for a department store.
3. Mass production
Mass production is the industrial-scale manufacture of large
quantities of products, usually on a production line. Standardized
production methods mean it is suitable for products that rarely need to be

redesigned. Mass production is used for products that are needed in very
large numbers, e.g. socks or jeans. Often, products are made overseas where
labor costs are lower.
4. Just-in-time
Just-in-time manufacturing is when
materials are ordered so they arrive just as
they are needed.

II.

Production Planning and Control

Production planning and control address a fundamental problem of low

productivity, inventory management and resource utilization.
Production planning is required for scheduling, dispatch, inspection,
quality management, inventory management, supply management and
equipment management.

Production control ensures that production team can achieve required

production target, optimum utilization of resources, quality management and
cost savings.
Planning and control is an essential ingredient for success of an
operation unit. The benefits of production planning and control are
as follows:

It ensures that optimum utilization of production capacity is achieved,

by proper scheduling of the machine items which reduces the idle time
as well as over use.

It ensures that inventory levels are maintained at optimum levels at all

time, i.e. there is no over-stocking or under-stocking.

It also ensures that production time is kept at optimum level and

thereby increasing the turnover time.

Since it overlooks all aspects of production, quality of final product is

always maintained.

Production Planning
Production planning is one part of production planning and control
dealing with basic concepts of what to produce, when to produce, how much
to produce, etc. It involves taking a long-term view at overall production
planning. Therefore, objectives of production planning are as follows:

To ensure right quantity and quality of raw material, equipment, etc.

are available during times of production.

To ensure capacity utilization is in tune with forecast demand at all the

time.

A well thought production planning ensures that overall production

process is streamlined providing following benefits:

Organization can deliver a product in a timely and regular manner.

Suppliers are informed will in advance for the requirement of raw

materials.

It reduces investment in inventory.

It reduces overall production cost by driving in efficiency.

Production planning takes care of two basic strategies product

planning and process planning. Production planning is done at three different
time dependent levels i.e. long-range planning dealing with facility planning,
capital investment, location planning, etc.; medium-range planning deals
with demand forecast and capacity planning and lastly short term planning
dealing with day to day operations.
Production Control
Production control looks to utilize different type of control techniques to
achieve optimum performance out of the production system as to achieve
overall production planning targets. Therefore, objectives of production
control are as follows:

Regulate inventory management

Organize the production schedules
Optimum utilization of resources and production process

The advantages of robust production control are as follows:

Ensure a smooth flow of all production processes

Ensure production cost savings thereby improving the bottom line
Control wastage of resources
It maintains standard of quality through the production life cycle.

Production control cannot be same across all the organization.

Production control is dependent upon the following factors:

Nature of production(job oriented, service oriented, etc.)

Nature of operation
Size of operation

Production planning and control are essential for customer delight and
overall success of an organization.

UNIT IV.Production Quality and Excellence

I.

In Search of a world-class Manufacturing

World Class Manufacturing

Manufacturing has evolved considerably since the advent of industrial
revolution. In current global and competitive age, it is very important for
organization to have manufacturing practice which is lean, efficient, costeffective and flexible.
World class manufacturing is a collection of concepts, which set
standard for production and manufacturing for another organization to
follow. Japanese manufacturing is credited with pioneer in concept of worldclass manufacturing. World class manufacturing was introduced in the
automobile, electronic and steel industry.
World class manufacturing is a process driven approach where various
techniques and philosophy are used in one combination or other.
Some of the techniques are as follows:

Make to order

Streamlined Flow

Cellular or group
manufacturing

Total preventive maintenance

Quick replacement

Zero Defects

Just in Time

Smaller lot sizes

Collection of parts
Doing it right first time

Increased consistency

Multi-Skilled employees

Higher employee
involvement

Visual Signaling

Statistical process control

Cross Functional Teams

Idea of using above techniques is to focus on operational

efficiency, reducing wastage and creating cost efficient organization.
This leads to creation of high-productivity organization, which used
concurrent production techniques rather than sequential production
method.

World Class Manufacturers

World class manufacturers tend to implement best

practices and also invent new practices as to stay above the
rest in the manufacturing sector. The main parameters which
determine world-class manufacturers are quality, cost effective,
flexibility and innovation.

World class manufacturers implement robust control techniques

but there are five steps, which will make the system efficient. These
five steps are as follows:

Reduction of set up time and in tuning of machinery: It is

important that organizations are able to cut back time in setting up
machinery and also tune machinery before production.

Cellular Manufacturing: It is important that production processes are

divided into according to its nature, with similar nature combined
together.

Reduce WIP material: It is normal tendency of manufacturing

organization to maintain high levels of WIP material. Increased WIP
leads to more cost and decreased WIP induces more focus on
production and fast movement of goods.

Postpone product mutation: For to achieve a higher degree of

customization many changes are made to final product. However, it is
important that mutation conceived for the design stage implement
only after final operation.

Removal the trivial many and focus on vital few: It is important

for organization to focus on production of products which are lined with
forecast demand as to match customer expectation.

II.

Improvement of Production Management

Sustainability is an initiative increasingly

essential to the core business model of many companies. There are

many diverse perspectives on sustainability. Some companies consider

it to be the burden of more government regulations, new compliance
requirements and higher manufacturing costs. However, industry
leading companies recognize that sustainability can actually be a
business driver for next-generation products, more efficient operations
and increased profitability.

The high-level commitment to sustainability is evident, but the

success of these programs will be driven by the implementation
details. A challenge for many manufacturers is determining where to
focus sustainability efforts given global operations with varying
geographical expectations. While there are many variations on
sustainability programs, the core components of an effective
sustainability program include:

Performance management of key sustainability information

Energy usage reduction
Raw material usage reduction
Product innovation and development.
Tools are available today that can help companies successfully
drive implementation of sustainability programs and recognize the
benefits of these efforts. This article examines how new software
solutions can aid a company's efforts.

Product Innovation and Development

As companies begin to develop new products and alter existing
products to reduce usage and waste, the agility of the entire
manufacturing process must be improved. The ability to quickly adapt
existing procedures and equipment to enable manufacturing of new
and improved products is essential to maintaining competitiveness.

A more unique application of production management and

execution solutions as related to product innovation is efficiently
handling the associated changes required in procedures and operating
instructions.

Effective solutions provide a platform from which the changes

required in the standard operating procedures and operating
instructions as a result of changes associated with modified production
can be handled with relative ease.

References:

https://www.britannica.com/technology/mass-production

http://www.encyclopedia.com/topic/Mass_production.aspx
http://www.yourarticlelibrary.com/industries/plant-layout/four-maintypes-of-plant-layout/34604/
http://www.yourarticlelibrary.com/industries/plant-layout/four-maintypes-of-plant-layout/34604/
http://www.businessdictionary.com/definition/factors-of-production.html
http://www.faberinfinite.com/operational-excellence-in-textile-industry/
http://www.managementstudyguide.com/world-classmanufacturing.htm
Kheinman, S. A. Ekonomicheskie problemy organizatsii promyshlennog
o proizvodstva. Moscow, 1961.
Organizatsiia i planirovanie proizvodstva na mashinostroitelnom predp
riiatii. Edited by V. A. Letenko. Moscow, 1972.
http://www.bbc.co.uk/schools/gcsebitesize/design/textiles/texsystemspr
acticesrev3.shtml

Prepared by:
Angel Mae F. Faingason
Noime M. Tuante
BTTE IV-A (GFD)

Instructor:
Helmar C. Ea