Lecture 1 and 2
What is production
Production is a process of transforming raw materials to finished goods using other resources namely human, machines and equipments, space, time, money, technology and information.
Production is a process of adding value to materials adding utility to their materials
Production is a flow of goods and services provided by flow of information.
Standard of Living
Is an extent to which man can provide himself and his family with basic necessities and some luxuries to sustain and enjoy life.
Basic necessity are food, clothing, shelter, education, hygiene and security.
Food is required to restore energy spent in working and living
Clothing and shelter are required to protect from climatic conditions and body cleanliness.
Education is required to develop hidden potential, enrich skill, to have an opportunity to get employment.
Hygiene is required for protection from diseases and good health.
Security is of 2 types
Economic - is security against loss of opportunity to get an employment in spite of having necessary qualification.
Social – is security against dangers to life, robbery and theft.
First3 things one must earn oneself. Next 3 things, government has to provide, but we have to enable government to provide this things by paying taxes. Therefore one must have sufficient income. Higher the income, higher is the standard of living. Ones standard of living depends upon ones income. National standard of living depends upon per capita income. PCI = Gross National Income / Total population. To increase the PCI, we must increase the numerator and control the denominator. To increase GNI, we must increase production of salable goods and services. There are the 2 ways to do things
Increase employment
Increase productivity
Productivity = output in terms of salable quality of goods and services/ input in terms of
resources
Sumanth David – 5 Pronged / Categories of productivity techniques
Technology Based – CAD, CAM
Employee based – Training, motivation, learning curve
Material based – ABC, XYZ, VED, FSN,GOLF, SDE, MRP2, KANBAN, JIT, EOQ
Product Based – standardization, value analysis, specialization, simplification, R&D
Task Based – Work Study, Method Study
Method Study - is the systematic recording and critical examination of the present and the proposed way of doing work as a means of developing better economical, easier and efficient way of doing work and implementing it.
Work Measurement – is a application of technique designed to establish and time required by qualified worker to carry out specified tasks at defined level of performance. In short, measurement of time to do work
Why Work Measurement / Usage of application of Work measurement (Short Note)
To find out the possibility whether there is scope for improvement
To find out the standard time or time to be allowed to the workmen per unit of production
To estimate standard cost to be used for variance analysis, fixing price, prepareion of tenders, quotations etc.
Use of production, planning and control
Use for developing suitable incentive scheme
Use to compare labour efficiencies, alternative method of doing same work.
To study possibility of one operator more than 1 machine in given time using man machine Chart
Use of line Balancing.
Work Study Procedure/8 steps basic procedure of Work study?
Select
Record
Examine critically
Develop
Measure
Define
Install or implement
Maintain
Select – Select the subject so that there is scope for improvement. The subject can be a product, department, a method of doing work, a manufacturing process, working condition or in general any problem such as higher cost of production, higher frequency of accidents, higher rate of rejection, bad quality of product, excessive overtime, lack of standardization. While selecting the subject, the 3 important considerations are.
Human, Economical and Technological.
Record - Gather and Record all the information about the subject selected using most suitable recording techniques. There are 10 techniques broadly classified under three categories :
1. Recording Technique based upon sequence of activities
a. Flow Process Charts
1. Man type that records activities of man
2. Materials type that records activities carried out on material
3. Equipment type that records activities of equipment
The symbols
Symbol
Activity
Representation
Description of the Activity
O
Operation
Activities changing physical and or chemical characteristics
Assembling Activities
Dismantling Activities
Arranging things in order
Processing of data
Signing of documents
0
Inspection
activities verifying quality and Quantity
"
Transportation
Activities of Displacement
D
Delay or Temporary Storage
If any activity cannot be carried out according to planning due to some reasons, delay is said to take place.
6
Storage
When the material is kept purposely in Storage till it is required
b. Outline Process Charts
c. Two handed process chart
a, b are macro techniques whereas c is micro techniques
2. Recording Techniques based upon movement of man, materials, equipment etc
a. Flow Diagram
b. String Diagram
c. Travel chart
d. cycle Graph
e. Chrono Cycle Graph
a – c macro, d-e micro
3. Recording Techniques using Timescale
a. Man Machine Chart / Multiple Activity chart
b. Simo chart (Simultaneous Motion Cycle chart)
c. MOST – Maynord’s operations Sequence Technique
c. Examine Critically
Critical examination is carried out using Questionnaire technique. A large number of factors are considered for setting questions. Important out of them are
Person doing work
Place of doing work
Sequence of doing work
Means of doing work
Purpose of doing work
Person –
Who does the work
Why he
Who else could do the work
Who should do the work
Place
Where is the work done
Why there
Where else could it be done
Where should it be done
Sequence
When is the work done
Why that time
When else could it be done
When should it be done
Means
How is the work done
Why that way
How else could it be done
How should it be done
Purpose
What is done
Why is it done
What else could be done
What should be done
A,B are primary Questions/ problem stating Questions
C, D are secondary Questions / problem solving Questions.
D. Develop
Develop a new method or seek a solution to the problem as a result of critical Examination.
E. Measure
Measure the time required to carry out the work according to the new method or in a new situation using most appropriate work measurement technique.
Stop watch Time study
Activity Sampling or Work Sampling
PMTS (Pre determined Time and Motions study)
Synthesis
Use of Standard Data
a.b are macro , c,d e are micro
F. Define
Define the new method with the time it takes for future reference and identification.
G. Install
Install the new method as the standard written practice with operators instruction sheets. Working demonstration must be conducted for the acceptance of the method by the workers.
H. Maintain
Maintain a new method using suitable control mechanism till all the concerned employees are fully acquainted with the new method.
Production is a process of transforming raw materials to finished goods using other resources namely human, machines and equipments, space, time, money, technology and information.
Production is a process of adding value to materials adding utility to their materials
Production is a flow of goods and services provided by flow of information.
Standard of Living
Is an extent to which man can provide himself and his family with basic necessities and some luxuries to sustain and enjoy life.
Basic necessity are food, clothing, shelter, education, hygiene and security.
Food is required to restore energy spent in working and living
Clothing and shelter are required to protect from climatic conditions and body cleanliness.
Education is required to develop hidden potential, enrich skill, to have an opportunity to get employment.
Hygiene is required for protection from diseases and good health.
Security is of 2 types
Economic - is security against loss of opportunity to get an employment in spite of having necessary qualification.
Social – is security against dangers to life, robbery and theft.
First3 things one must earn oneself. Next 3 things, government has to provide, but we have to enable government to provide this things by paying taxes. Therefore one must have sufficient income. Higher the income, higher is the standard of living. Ones standard of living depends upon ones income. National standard of living depends upon per capita income. PCI = Gross National Income / Total population. To increase the PCI, we must increase the numerator and control the denominator. To increase GNI, we must increase production of salable goods and services. There are the 2 ways to do things
Increase employment
Increase productivity
Productivity = output in terms of salable quality of goods and services/ input in terms of
resources
Sumanth David – 5 Pronged / Categories of productivity techniques
Technology Based – CAD, CAM
Employee based – Training, motivation, learning curve
Material based – ABC, XYZ, VED, FSN,GOLF, SDE, MRP2, KANBAN, JIT, EOQ
Product Based – standardization, value analysis, specialization, simplification, R&D
Task Based – Work Study, Method Study
Method Study - is the systematic recording and critical examination of the present and the proposed way of doing work as a means of developing better economical, easier and efficient way of doing work and implementing it.
Work Measurement – is a application of technique designed to establish and time required by qualified worker to carry out specified tasks at defined level of performance. In short, measurement of time to do work
Why Work Measurement / Usage of application of Work measurement (Short Note)
To find out the possibility whether there is scope for improvement
To find out the standard time or time to be allowed to the workmen per unit of production
To estimate standard cost to be used for variance analysis, fixing price, prepareion of tenders, quotations etc.
Use of production, planning and control
Use for developing suitable incentive scheme
Use to compare labour efficiencies, alternative method of doing same work.
To study possibility of one operator more than 1 machine in given time using man machine Chart
Use of line Balancing.
Work Study Procedure/8 steps basic procedure of Work study?
Select
Record
Examine critically
Develop
Measure
Define
Install or implement
Maintain
Select – Select the subject so that there is scope for improvement. The subject can be a product, department, a method of doing work, a manufacturing process, working condition or in general any problem such as higher cost of production, higher frequency of accidents, higher rate of rejection, bad quality of product, excessive overtime, lack of standardization. While selecting the subject, the 3 important considerations are.
Human, Economical and Technological.
Record - Gather and Record all the information about the subject selected using most suitable recording techniques. There are 10 techniques broadly classified under three categories :
1. Recording Technique based upon sequence of activities
a. Flow Process Charts
1. Man type that records activities of man
2. Materials type that records activities carried out on material
3. Equipment type that records activities of equipment
The symbols
Symbol
Activity
Representation
Description of the Activity
O
Operation
Activities changing physical and or chemical characteristics
Assembling Activities
Dismantling Activities
Arranging things in order
Processing of data
Signing of documents
0
Inspection
activities verifying quality and Quantity
"
Transportation
Activities of Displacement
D
Delay or Temporary Storage
If any activity cannot be carried out according to planning due to some reasons, delay is said to take place.
6
Storage
When the material is kept purposely in Storage till it is required
b. Outline Process Charts
c. Two handed process chart
a, b are macro techniques whereas c is micro techniques
2. Recording Techniques based upon movement of man, materials, equipment etc
a. Flow Diagram
b. String Diagram
c. Travel chart
d. cycle Graph
e. Chrono Cycle Graph
a – c macro, d-e micro
3. Recording Techniques using Timescale
a. Man Machine Chart / Multiple Activity chart
b. Simo chart (Simultaneous Motion Cycle chart)
c. MOST – Maynord’s operations Sequence Technique
c. Examine Critically
Critical examination is carried out using Questionnaire technique. A large number of factors are considered for setting questions. Important out of them are
Person doing work
Place of doing work
Sequence of doing work
Means of doing work
Purpose of doing work
Person –
Who does the work
Why he
Who else could do the work
Who should do the work
Place
Where is the work done
Why there
Where else could it be done
Where should it be done
Sequence
When is the work done
Why that time
When else could it be done
When should it be done
Means
How is the work done
Why that way
How else could it be done
How should it be done
Purpose
What is done
Why is it done
What else could be done
What should be done
A,B are primary Questions/ problem stating Questions
C, D are secondary Questions / problem solving Questions.
D. Develop
Develop a new method or seek a solution to the problem as a result of critical Examination.
E. Measure
Measure the time required to carry out the work according to the new method or in a new situation using most appropriate work measurement technique.
Stop watch Time study
Activity Sampling or Work Sampling
PMTS (Pre determined Time and Motions study)
Synthesis
Use of Standard Data
a.b are macro , c,d e are micro
F. Define
Define the new method with the time it takes for future reference and identification.
G. Install
Install the new method as the standard written practice with operators instruction sheets. Working demonstration must be conducted for the acceptance of the method by the workers.
H. Maintain
Maintain a new method using suitable control mechanism till all the concerned employees are fully acquainted with the new method.
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