2.1 INTRODUCTION TO PRODUCTION ti nt 1 Production: Concept, Factors of production, Supply chain management sdlecing ond plonina process engineering: Functions, Preliminary part print analysis, manufacturing process, Determining manufacturing sequence Line balancing: Heuristic approach of line balancing : Critical Path Method (CPM) and its application related to project completion: pyre kee oe end of this chapter, students will be able to: : / : Apply principles of supply chain management in the given industrial/domestic application. Plan eppropriate manufacturing processes for manufacturing of the given simple job/component. Skeich precedence diagram for the given simple manufacturing task using line balancing concept. ‘Apply CPM for the given project of the specified industry. Prepare the detailed sequence of operations for manufacturing the given component. When seeds are sowed in soil, grains are produced. When matchstick is rubbed on a matchbox, fire is produced. Similarly when various parts are shaped in a manufacturing firm, a finished product is obtained or produced. So when some raw things are processed, we obtain finished 9008s. ‘Conversion of raw material into a finished good with the use of some operations is defined as production’. Production is defined as “the step-by-step conversion of one form of material into another form through some process to create or enhance the utility of the product to the user.” It is ‘an art of producing something like machines, components, or any other useful products’. The word production is equally used for providing services to people like bank, hotels, educational institutions, theatre, travels and tourism etc. It is the process, thr on raw matenat’ ough which goods or services are created by performing a set of operations Thus, production is a valu re Thus, or © addition process, At each stage of processing, there will be value Edwood Buffa defines production as * Production as ‘a process by which goods and services are created’. Ry7 Industrial Engineering & Quality Control 22 Process Engineering =| | 8. __ Diiling hole of 9 20 mm atthe centre | Centre lathe | Drill | 30 E =| | | Clamp on shaper machine and cuta | Shaper | Keywaytoot | - . __, keyway 7 10. | Clamp on miting machine on Mandel = = . | universal viding head | 11. | Cutthe required numberof teeth Form miling cutter | 40 . - | J 2.10.3 Operation Sheet to Machin a Component on Lathe| Prepare operation sheet and sequence of operati i ion for nent shown in Fig. 2.8, ‘Assume suitable cutting parameters. i me compe! ca cety 244 ring & Quality Control et Process Engineering Table 2.6: Operation sheet for given component sional ___| Machine used [ToolFitures used "| Cuting Speed | Feed —]-Depihot at [ @pwaton | Decnon of - Faw nae I ney et } | Giamp the component in chuck | Centre lathe | 3 jaw chuck = : = | with a projecting length of 55 mn, is ——+ ol [2 Facing operon [eavete | ae ale — | 025 | 3. | Tumaiameter from 50 mm to | Centre lathe | HSS, Fighthand 3% 0.03 ae 35 mm in steps with depth of single pointtool | cut as 1 mm in each step and | fora length of 60 mm — —-—}__| | 4 | Use centre dil and mountitin | Cente lathe | Centre dri and dil = Jc > tal stock _ | chuck i 5 Diiling operation to mark star’ | Centre lathe 7 Centre drill and drill 30 Manual - fointforarilofhicher diameter || chuck —{| | 6 Use 6 mm dameter cil, to dil Centre lathe | 6mm diameter drill 30 Manually i athoughtoe | el 7 | Use Orn dameter dito Cone ae | 10 mm danelar aa 3 Manually | ——>— = Srila through hole ee | 8. | Use a counter bore tol to form | Cente athe Counter bore tool Manually a ‘8 counterbore of 25 x 5 mm Kourting operation on @ 50 mm | Centr Todforlenath of 20mm ee 2.11 CONCEPT OF LINE BALANCING Line balancing means balancing the Production line or an assembly line. * Balancing means all the mach act * The basic objective of line bz e lathe) Kauring tal} ——— one or other machine, * Operation times can operations and applyir be adjusted by redesi ing m igning “quipment, changing machines, combining n economy principles, - ne Z remains idle for 66.66% of its time. Thus, the line is unbalanced as idle time unequal. The line can be balanced by having 3 machines of type X: 2 machines of type Y and 1 mbcrine se type z. + Another method of line balancing is te dig. venly to all the machines. * A line balancing problem can be solved ‘ods like heuristic approach, linear rogramming, dynamic programming and consol method (computer method). Heuristic approach is generally used tor ‘are more complex and the flow is Leanne programming is generally used for continuous flo + Linear Ww and production volume is high.Industrial Engineering & Qu y Control _ 2.11.2 Objectives of Line B: ncing To minimize the total amount of unassigned or idle times at the work station To eliminate bottlenecks, ensuring a smoother flow of production. An __ Process Engineering To determine the optimal number of work stations and operations in each station. + To maintain the morale of workers since the work content of the different workers will not be of great difference. To maximize the manpower utilization by minimizing the idle times of the operators. To minimize intermediate stock or work-in-progress (zero inventory or just-in-time concept). To improve the quality and productivity of the assembled products. + To reduce waste of production and delay. The following assumptions are usually made in simple assembly line balancing: (1) the element time of each element is known; (2) a precedence diagram is available; (3) all tasks must be processed; (4) the fixed and variable costs of each station are the same; (5) the splitting of tasks among two or more stations is not permitted; (6) any task can be processed at any work station; (7) station time is always less than the cycle time; (8) the assembly system is designed for a unique model of a single product. 2.12 HEURISTIC METHOD OF LINE BALANCING ae + The heuristic method involves two stages for line balancing: (2) Determination of the priority order of the elements. It involves drawing a precedence diagram in a particular way which indicates the flexibility available for transferring tasks laterally from one column to another to arrive at the most promising balance. (b) Assignments of elements to the stations subject to the constraints mentioned above. + The heuristic approach involves following procedural steps: (1) Identity the work (job). (2) Break down the work into elemental tasks or steps. For example, threading is a step or elemental task. (3) List the various steps as under (An example). Table 2.7 i - . | Steps or elemental | Immediate Duration of the task | \s tasks predecessor | (minute) | 1 bad 3 2 - | 4 | | 3 1 | 2 4 2 5 5 | 3 4 6 5 8 7 4 2 8 6 4 es ae 6 & —_____|___ Total time 38 minutes{industrial Engineering & Quality Control A Process Engineering Stipa Sia 5 Sian 3 “© Stage vi ‘al path method is a step-by-step project management technique to identify activities on the critical path. The critical Path is the path with longest project duration. * The Critical Path Method is “the sequence of scheduled activities that determines the duration of the project”. These scheduled activities must be performed in a specific order”. €.9. in order to build a house, the walls cannot be constructed before digging and making the foundation. * Each activity takes a different amount of time and resources. The total time taken to complete the sequence along this critical path would give an idea of the project’s minimum duration. * Critical Path Analysis is commonly used with all forms of projects, including construction, aerospace and defense, software development, research projects, product development, engineering, and plant maintenance, among others. Any project with interdependent activities can apply this method of mathematical analysis. 2.13.1 Terms Used in CPM (a) Event: It represents the start or end of an activity. It does not consume any resource and does not have any duration. Event is a point in time. It is represented by a small circle called as node. (b) Activity: It is a part of a project which requires time and resources for its execution. An activity is represented by an arrow, the tail of which represent the start and the head represents finish of the activity. €.g. Running a race is an activity. Start and end of race are events. A © Start painting is an event. i) 7 Painting a wall is an activity. Fig. 2.13 (c) Network: It is a representation on various activities and e vent in a logical se : network also demonstrate the interdependence of events in a project. ae (4) Dummy Activity: An activity that does not consume any resource is a dummy activity. Rules for AOA (Activity-on-Arrow) network construction: Following are some of the rules that are followed while Constructing a network. (2) In a network diagram, arrow represent ay Tr 1 activities vent. The | arrow is of no Slaten S and circles the e 1e length of an (b) Each activity is represented by one arrow only. (©) Every activity start and end in a circle called as event, (4) A network should have only one initial event and only one terminal event. (©) Any event cannot occur until all its incoming activities there been completed.