Productionprocess
The basic term that should be considered and explained is ‘process’. There are numerous definitions of the term ‘process’ presented in literature, as it is applicable in many fields including:
- Business,
- Technology,
- Biology
- Psychology
- Computing,
- Engineering,
- Management
- And others.
Depending on the field of application, definitions of the term may slightly differ on account of specific conditions and constraints typical for the area.
The most general definition is the one introduced by a typical encyclopedia dictionary, and it is as follows:
Process is a series of actions that produce something or that lead to a particular result [Merriam-Webster].
The definition is general, as it does not indicate in any way neither the character of actions mentioned, nor the result expected. It can be presented graphically, in a simple graph presented below (Fig. 1):
Fig. 1. A process
In the graph, the nature of transformation is not indicated. Transformation process is in general presentation a so called “black box” as it may substantially differ from one field to another. In more detailed analysis it can presented as a specific set of operations.
The definitions referring to manufacturing and production can be found in the dictionary of a specific orientation, which is the before mentioned APICS dictionary, and the definitions there are as follows:
(1)Process is a planned series of actions or operations (e.g., mechanical, electrical, chemical, inspection, test) that advances a material or procedure from one stage of completion to another. [Apics]
(2)Process is a planned and controlled treatment that subjects materials or procedures to the influence of one or more types of energy (e.g., human, mechanical, electrical, chemical) for the time required to bring about the desired reactions or results. [Apics]
Resulting in a clearer way of transformation process:
Transformation process – the process of converting inputs into finished goods or services. In a service firm, the input may be a customer. [Apics]
In these definitions reference to production and manufacturing area is quite clear, as they specify the actions to be taken, as well as the result expected, and they can be coined directly into production and manufacturing process definitions:
Production process – the activities involved in converting inputs into finished goods. [Apics]
and:
Manufacturing process – the series of operations performed upon material to convert it from the raw material or a semi-finished state to a state of further completion. Manufacturing process can be arranged in a process layout, product layout, cellular layout, or fixed-position layout. Manufacturing process can be planned to support make to stock, make to order, assemble to order and so forth, based on strategic use and placement of inventories. [Apics]
Note that production process is more general than manufacturing process.
Manufacturing – a series of interrelated activities and operations involving the design, material selection, planning, production, quality assurance, management, and marketing of discrete consumer and durable goods. [Apics]
Taking the above considerations into regard, the graphical presentation of the presentation could be completed with explanation of inputs, outputs and transformation process. Hence, in the graph presented in Figure 1., the inputs would include the following:
- Materials,
- Energy,
- Human labor.
and the outputs:
- Products (finished goods or services),
- Waste (material, energy etc.)
The nature and characteristics of processes are crucial aspects to be analyzed when examining organizations and their performance.
Production system
Manufacturingsubsystemthatincludesallfunctionsrequired to design, produce, distribute, and service a manufacturedproduct.
Production management
Definitions are the following:
- Production management is the Art of Managing the Production. It basically concerns itself with the conversion of inputs into outputs.
- Production management can be also defined as “The job of coordinating and controlling all the activities required in making a product”.This concept is not restricted to only industrial or manufacturing sectors; it is also applicable to service industries.
Operations management isthe conversion of inputs into outputs, using physical resources, so as to provide the desired utility/utilities of form, place, 1
possession or state or a combination thereof to the customer while meeting the other organizational objectives of effectiveness, efficiency and adaptability.
Production management is the planning, scheduling, execution, and control of the process of converting inputs into finished goods [Apics]
The production management’s responsibility sees to the following areas; men (labor), machines, methods, materials and money.
3 aims of performance of the Production and Operations Management Systems:
•Effectiveness – productiveutilization of resources
•Customersatisfaction
•Efficiency
Production management history includes, but is not limited to the following events:
1776 – in his work, Welath of Nations, Adam Smith introduced specialization of labor in manufacturing as the key factor for economic growth.
1801 - Eli Wihtney built ten guns made of the same parts, disassembled them, mixed the parts and assembled them again easily proving that interchangeable parts are crucial for manufacturing efficiency, the idea contributed to mass production development.
1832 - in Economy of Machine, Charles Babbage discussed the commercial advantages coming from division of labor based on skills, first introduced in 1815 by MelchiorreGioia.
1900s- the Gilbreths’ studies on work motion, focusing on increased work efficiency thanks to reduced moves of operators.
1910s- development of a chart by Henry L. Gantt used as a scheduling technique.
1911- Frederick W. Taylor published The Principles of Scientific Management in which he divided planning the work from doing it, focusing on time of work reduction.
1913 – Henry Ford introduced the moving assembly belts in the Ford plant in Highland Park in the U.S. state of Michigan, improving efficiency of processes forcing a specific organization of material flow - the creation of buffer inventory to maintain continuity of production [Pfohl 1995 ],
1915 - Harris introduced his Economic Order Quantity formula.
1975- Material Requirements Planning, published in 1975 by Joseph Orlicky, the publication presents the essence of the MRP, with principles and guidelines of material requirements planning, approach to procurement, which is the essence of many of today's solutions in this field and an integral part of computer support systems.
1990- The Machine That Changed the World by James Womack, Daniel Jones and Daniel Roos, published in 1990 by MIT, presents the essence of lean manufacturing (lean production) , recognized as the biggest revolution since the Ford assembly line, forcing the integration of the environment through cooperation and coordination of the supply chain.
1991- The 21st Century Manufacturing Enterprise Strategy , developed by Roger Nagel and Rick Dove (Iacocca Institute) in 1991, a report on trends in the modern production and management , primarily customer orientation and flexibility in meeting its expectations and requirements , and customer integration into the flow of materials.
1993- ECR - Efficient Consumer Response - Effective Customer Service, solution introduced since 1993 (USA) / 1994 (Europe) by ECR Europe, aimed primarily aimed at streamlining and reducing the cost of customer service in the consumer sector by integrating the entire supply chain.
1997- Leagility: interfacing the lean and agile manufacturing paradigm in the total supply chain, in 1997, in which the term leagility appears first, coined by J.B. Naylor , M. M. Naim and D. Berry and interpreted as a combination of agile and lean strategies.
and many others, however these prove that production management is a scientific discipline and can be defined as:
.. a field of study that focuses on the effective planning, scheduling, use, and control of a manufacturing organization through the study of concepts from design engineering, industrial engineering, management information systems, quality management, inventory management, accounting and other functions as they affect the transformation process. [Apics]
Considering the above presented definition, production management functions are distinguished as follows:
1)Selection of product and design.
2)Selection of production process.
3)Selection of right production capacity.
4)Production planning.
5)Production control.
6)Quality and cost control.
7)Inventory control.
8)Maintenance and replacement of machines.
Productionprocessorganization
Manufacturing process definition is directly based on a process definition.
Manufacturing process encompasses various types of operations performed with dedicated machinery. [Apics]
As mentioned in the definition, manufacturing process is a set of operations. Operation can be defined as follows:
Operation is a job or task, consisting of one or more work elements, usually done essentially in one location. [Apics]
Operation is the performance of any planned work or method associated with an individual, machine, process, department or inspection. [Apics]
Operation is one or more elements that involve one of the following: the intentional changing of an object in any of its physical or chemical characteristics; the assembly or disassembly of parts or objects; the preparation of an object for another operation, transportation, or storage; planning, calculating or giving or receiving information. [Apics]
All the definitions presented introduce various aspects of operations, referring to its character, resources it uses, and result it generates. The set of operations, which is a manufacturing process, may be organized in many ways. There are types of production systems:
(a) Continuous production - It is also known as mass flow production or assembly line production. The system is suitable in plants involving large volume and small variety of output e.g. oil refineries reform cement manufacturing etc.
(b) Job or unit production - The system requires comparatively smaller investment in machines and equipment. It is flexible and can be adapted to changes in product design and order size without much inconvenience. This system is most suitable where heterogeneous products are produced against specific orders.
(c) Intermittent production (batch production) - Under this system the goods are produced partly for inventory and partly for customer's orders. E.g. components are made for inventory but they are combined differently for different customers: Automobile plants, printing presses, electrical goods plant are examples of this type of manufacturing.
Continuous manufacturing is also defined as follows.
Continuous manufacturing – a type of manufacturing process that is dedicated to the production of a very narrow range of standard products. The rate of production change and new product information is very low. Significant investment in highly specialized equipment allows for a high volume of production at the lowest manufacturing cost. Thus unit sales volumes are very large, and price is almost always a key order-winning criterion. Examples of items produced by a continuous process include gasoline, steel, fertilizer, glass, and paper. [Apics]
Continuous production is a production system in which the productive equipment is organized and sequenced according to the steps involved to produce the product. This term denotes that material flow is continuous during the production process. The routing of the jobs is fixed and setups are seldom changed. [Apics]
Continuity of production is based on the narrow assortment and some specific characteristics of the process. Another way of process organization is repetitive production.
Repetitive production – the repeated production of the same discrete products or families of products. Repetitive methodology minimizes setups, inventory, and manufacturing lead times by using production lines, assembly lines, or cells. Work orders are no longer necessary; production scheduling and control are based on production rates. Products may be standard or assembled from modules. Repetitive is not a function of speed or volume. [Apics]
Manufacturing process can be performed with human involvement and without it.
Automation – the substitution of machine work for human physical and mental work, or the use of machines for work not otherwise able to be accomplished, entailing a less continuous interaction with humans than previous equipment used for similar tasks. [Apics]
Manufacturing process is performed in a production system and may be organized in various forms, including production cells and lines, and with various approaches, including mass production, customized production, lean and agile production.
Flexible Manufacturing systems
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QuickResponsemanufacturing
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CIM
Manufacturing management is a broad area, encompassing numerous issues, of high variety. It makes the decisions within the area difficult. Since manufacturing management influences company’s performance, it should be executed at the highest level possible. To achieve this, computer support is employed.
CAD computer aided design – the use of computers to in interactive engineering drawing and storage of designs. Programs complete the layout, geometric transformations, projections, rotations, magnifications and interval (cross-section) views of a part and its relationships with other parts. [Apics]
CAM – computer aided manufacturing – the use of computers to program, direct, and control production equipment in the fabrication of manufacturing items. [Apics]
CIM computer integrated manufacturing – the integration of the total manufacturing organization through the use of computer systems and managerial philosophies that improve the organization’s effectiveness; the application of a computer to bridge various computerized systems and connect them into a coherent, integrated whole. For example, budgets, CAD/CAM, process controls, group technology systems, MRPII, and financial reporting systems are linked and interfaced. [Apics]
CNC computer numerical control – a technique in which a machine tool controller uses a computer or microprocessor to store and execute numerical instructions. [Apics]
Mass Customization
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ean Management
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