MEP 407

PRODUCTION MANAGEMENT
PRODUCTION—It is the process of converting row material in to used useful product to
satisfy human needs.
Production is the process of manufacturing from the raw material to contribute to the utility
of individual

Management—it is coordination and administration of a task to achieved a desire goal

within the company, factory or organisation. It involved the application of planning,
organisation, directing and controlling in other to achieved a desire goals of the organisation.

Management is a process of planning, decision making, organizing, leading, motivation

and controlling the human resources, financial, physical, and information resources of an
organization to reach its goals efficiently and effectively.

PRODUCTION MANAGEMENT-It deals with the decision making related to

production process, so that the resulting of goods and service are produce in according to
with the quantitative, specifications, and demand schedule within the minimum cost
As a production manager, you'll oversee the production process, coordinating all production
activities and operations. You'll need to: plan and draw up a production schedule. decide on
and order the resources that are required and ensure stock levels remain adequate
Production management involves the planning, organisation, direction and execution of
production activities. The ultimate goal of any production management solution is to convert
a collection of raw materials into a finished product. Some people refer to production
management as the bringing together of the 6 'Ms':

 Men
 Money
 Machines
 Materials
 Methods
 Markets

These constituents come together to provide consumers and businesses with products that
they need or want.

The Function of Production Management

The role of Production Management is quite elaborate. But the sole aim is to ensure the
business produces quality products that can satisfy the needs of customers on a regular basis.
Below are the functions of production management.
 1. Production Control

Here the manager supervises and directs the production process. He or she also

must find out and ensure the right production plan is followed during the production process.
If there are deviations, the production manager has to take the right steps to correct them.

2. Scheduling This function is critical in every organization. It has to do with planning when
the actual production would begin and ends.

3. Cost and Quality Control

Every company knows how essential quality control and price are. Customers are not just
looking for the best products. But they also want to have them at the lowest possible
price. Quality control is an essential duty the production manager has to perform. It entails
multiple checks performed on the product to ensure quality is intact.

4. Maintenance of Machines

Production management also entails making sure that instruments used are in good working
condition. And that means replacing the ones that are underperforming or changing damaged
parts to enable the machine to function optimally.

TYPES OF PRODUCTION

Production methods may be broadly classified as: Job Production, Batch Production and
Flow Production. (MASS PRODUCTION)
 Job Production: Job production involves the procedure of manufacturing a product
according to a specific customer order. ...
Under this method peculiar, special or non-standardized products are produced in accordance
with the orders received from the customers. As each product is non- standardized varying in
size and nature, it requires separate job for production. The machines and equipment’s are
adjusted in such a manner so as to suit the requirements of a particular job.

Job production involves intermittent process as the work is carried as and when the order is
received. It consists of bringing together of material, parts and components in order to
assemble and commission a single piece of equipment or product.
 CHARCTRISTIC OF JOB PRODUCTION

1. A large number of general purpose machines are required.

2. A large number of workers conversant with different jobs will have to be employed.

3. There can be some variations in production

4. Some flexibility in financing is required because of variations in work load.

5. A large inventory of materials, parts and tools will be required.

6. The machines and equipment setting will have to be adjusted and readjusted to the
manufacturing requirements.

7. The movement of materials through the process is intermittent

LIMITATION

1. The economies of large scale production may not be attained because production is done in
short-runs.

2. The demand is irregular for some products.

3. The use of labour and equipment may be an inefficient.

4. The scientific assessment of costs is difficult

 Batch Production: Batch production pertains to repetitive production.

It refers to the production of goods, the quantity of which is known in advance. It is that form
of production where identical products are produced in batches on the basis of demand of
customers’ or of expected demand for products.

This method is generally similar to job production except the quantity of production. Instead
of making one single product as in case of job production, a batch or group of products are
produced at one time. It is a form of production where identical product is produced

CHARACTERISTIC OF JOB PRODUCTION

1. The work is of repetitive nature

2. There is a functional layout of various manufacturing processes.

3. One operation is carried out on whole batch and then is passed on to the next operation and
so on.
 Mass or Flow Production:
This method involves a continuous production of standardized products on a large scale.
Under this method, production remains continuous in anticipation of future demand.
Standardization is the basis of mass production. Standardized products are produced under
this method by using standardized materials and equipment. There is a continuous or
uninterrupted flow of production obtained by arranging the machines in a proper sequence of
operations. Process layout is best suited method for mass production units.

CHARACTERISTIC OF MASS PRODUCTION

The mass or flow production possesses the following characteristics.

1. The units’ flow from one operation point to another throughout the whole process.

2. There will be one type of machine for each process.

3. The products, tools, materials and methods are standardised.

4. Production is done in anticipation of demand.

5. Production volume is usually high.

6. Machine set ups remain unchanged for a considerable long period.

7. Any fault in flow of production is immediately corrected otherwise it will stop the whole
production process.

LAYOUT PLANNING
Layout planning is deciding the best physical arrangement of all resources that consume
space within the facility. These resources may be including a desk a work centre, a cabinet, a
person and entire office or even a department.
Layout planning is also referring the arrangement of all plant facility, such as equipment,
machine, material, manpower etc. and services of the plant within the area of plant site.so that
the greatest possible output at high quality as lowest possible cost can be achieved.
The aim of layout planning is to increased productivity and employee satisfaction by
maximizing production and keep the production cost at minimal level

Advantage of layout planning

1. Reduce the number of accident
2. Reduce the set up time involved
3. Decrease maintenance cost
4. Provide adequate and convenient storage facilities
5. Reduce the cost of supervision
6. Provide changed method and future expansion
7. Reduce the manufacturing circle in each department
8. Etc.
Importance of layout planning
1. Minimize cost of production
2. Ensure efficient control over the various production process
3. Improve quality of production
4. Ensure convenient and safety of workers
5. Ensure optimum utilisation of plant facilities (Men, machineries etc.

NECESSITY FOR LAYOUT PLANNING

1. Setting up a new plant
2. Change in the design of product this may require to change in the manufacturing
operation or sequence of operation
3. Expansion of existing department
4. Relocation of existing department
5. Addition of new department
6. Addition of news product on the existing facilities

TYPES OF LAYOUT PLANNING

1. Product layout---in this type the machine, equipment and centres are arranging on
a straight line or curve line. In the order that in which they have to be used. That is
according to Sequence of operations needed to manufacture a product. This system is
suitable for mass production where standardised and large quantity product can be
achieved

ADVANTAGE OF PRODUCT LAYOUT

1. Reduce tool production line
2. Easy supervision, easy inspection and easy coordination
3. Higher productivity
4. Reduce delay due to flow of work in forward stroke
5. Less flow area needed par unit of production
2. Process layout (functional layout) –is the layout that are group resources base on
the similar functions or operations. This type of layout is seen in a companies with
intermittent processing system. Since different items are produced each with unique
processing requirement, is not possible to dedicate of entire family with each items.
Its more efficient to group recourses base on their functions. The product will move
from one resources to another base on their unique needs. Such layout is suitable for
low volume production (batch or job production)

ADVANTAGE OF PRODUCT LAYOUT

1. Ease of maintenance
2. Changing of product design can be easily accommodate (greater flexibility in
production)
3. Better control complicated or precision equipment especially when much
inspection is needed
4. It offers better more and efficient supervision as similar job is produced on
similar machine.
Disadvantages
1. Higher rate of accidents
2. Longer production circle
3. More floor space is required
4. More labour cost, because the work has to be skilled work or general purpose
machine
 3. CELLULAR LAYOUT
In this layout the machine is group according to the process requirement for a
set of similar items (family parts) that require similar processing. Those group
are called cell. That is similar parts or those that requiring similar operations
are group together in the family. All the equipment needed to manufacture a
family parts are group in to the cell.

ADVANTAGES
1. It provides faster processing time, less material handling in process
inventory, reduce set up time. All of which reduce cost
2. Since workers are responsible for their cell output, more autonomy and
job ownership is presents

4. Group Technology or Cellular Layout

Group technology or Cellular layout is considered a technique through which it is feasible to
identify and group similar or related parts involved in the process of production; for the
purpose of utilizing the inherent economy of methods of the flow production.

In other words, group technology layout or cellular manufacturing layout is the type of layout
in which different machines can be grouped as per the process requirements for a similar set
of items or families of similar parts that require a similar kind of processing. Groups that are
formed in such a way are termed as cells.

In this type of layout, cells are formed by grouping different processes. This process includes
the identification of parts having similar characteristics in terms of their design i.e. size,
function, and shape. And also, characteristics of a similar process i.e. required processing
type, type of machinery to perform such process, and the sequence of processing.

In group technology or cellular layout, workers are given cross-training in order to enhance
their skills to operate different equipment in a particular cell and be responsible for the output
of that cell. In a few cases, the formation of a cell is based on using particular equipment for
producing the parts of a family in which the actual movement of equipment into a physical
cell is not required. These cells are termed nominal or virtual cells. By doing so, an
organization can avoid the headache of rearrangement of its current layout.

The cellular layout also has an automated version i.e. flexible manufacturing system (FMS).
Through this technology, a system or computer takes care of the controlling of transferring
parts to the different processes. This enables manufacturers to gain a few advantages of
product layouts and at a similar time, they can maintain the flexibility of the production-
related to a small batch.

For example, there is a manufacturing unit that produces 10,000 parts. It may group these
parts into the group of 50/60 families of parts. Each family includes a similar type of design
and characteristics of manufacturing.

So, there will be similar processing of all members of a particular family. This supports
generating efficiencies in the manufacturing process.
 SYSTEMATIC LAYOUT
The systematic layout planning (SLP) - also referred to as site layout planning - is
a tool used to arrange a workplace in a plant by locating areas with high frequency and
logical relationships close to each other the process permits the quickest material flow in
processing the product at the lowest cost and least amount of handling. It is used in
construction projects to optimize the location of temporary facilities (such as engineers'
caravans, material storage, generators, etc.) during construction to minimize transportation,
minimize cost, minimize travel time, and enhance safety.
ADVANTAGES
 Department footprint reduced.
 Unit production and output per shift increased.
 Maintenance of quality, reducing costs and maintaining the integrity of the product.

FIXED POSITION LAYOUT

A fixed-position layout lets the product stay in one place while workers and machinery move
to it as needed. Products that are impossible to move—ships, airplanes, and construction
projects—are typically produced using a fixed-position layout.
Movement of products - The main advantage of the fixed position layout is that the
movement of the products is reduced and so there is a reduction in the capital investment
involved in the movement of products. Continuity of operations - The other advantage of the
fixed position layout is the continuity of operation
Disadvantages include: Space. For many fixed-position layouts, the work area may be crowded so
that little storage space is available. This also can cause material handling problems.
LEAN MANUFACTURING
It is a production process base of the approach of maximizing productivity while
simultaneously minimizing waste within the manufacturing operations.
The aim of lead manufacturing is to cut waste on all kind of labour, equipment, machinery,
management, passonnel.it reduce lead time, operating cost and improve product quality and it
making product available to the customer from the supplier within a short time, so it faster
than the mass production.
7 Companies Using Lean Manufacturing Today
Lean manufacturing is the practice of maximizing productivity without incurring waste. The
concept was actually created by Toyota, but it applies to (and is used in) many industries
around the world today, including C Tek Lean Solutions. From shoes to cars, these seven
companies incorporate the tools, principles, and philosophy of lean manufacturing into their
practices. 
Toyota
Toyota is the company that started lean manufacturing. Toyota introduced the concept 90
years ago in 1930. Since then, it has used lean manufacturing to rise to the top of the auto
production market. Its principle is now replicated around the world. 
Nike
Nike is a global producer of shoes and athletic clothing. Recently, Nike has partnered with
other manufacturers and non-governmental organizations (NGOs) to address sustainability
issues. Nike launched a Sustainable Apparel Coalition as a result. 
Caterpillar Inc.
Caterpillar has modelled its lean manufacturing process after Toyota. Specifically, Caterpillar
incorporated lean principles to expedite production and reduce waste. 
Kimberley-Clark Corporation
Kimberley-Clark adopted the principles of lean manufacturing to increase staff development
and engagement. As a result, absenteeism declined and worker productivity increased. 
Intel
Intel, one of the world’s largest producers of computer chips, uses lean manufacturing
principles to guide product delivery. Today, the company states that it takes 10 days to bring
a computer chip to market, compared to 14 weeks just five years ago. 
Parker Hannifin
Parker Hannifin is one of the world’s largest producers of motion control technology. Nearly
20 years ago, the company began using electronic strategies to incorporate lean
manufacturing into its production cycle. Ultimately, it increased quality and productivity
while simultaneously reducing cost. 
 John Deere
John Deere made a significant investment in lean technology in 2003. Its investment paid off
in the form of reducing waste while improving production time and quality. The company
applied its lean manufacturing principles to its main facility in Iowa. 
7 Examples of Lean Manufacturing in Action
 Cable Manufacturing. A cable manufacturing company wanted to reduce set-up times and
shorten lead time to market. ...
 Truck Manufacturing. ...
 Printing Industry. ...
 Automotive Parts Manufacturing. ...
Advantage of lean manufacturing
 Quality performance, fewer defects and rework (in house and at customer).
 Fewer Machine and Process Breakdowns.
 Lower levels of Inventory.
 Greater levels of Stock Turnover.
 Less Space Required.
 Higher efficiencies, more output per man hour.
 Improved delivery performance.
 Faster Development.
DISADVANTAGES
disadvantage can hinder customer relationships, push customers towards your
competitors, and cost you revenue.
 Warehouse Management. ...
 Customer Service. ...
 Heating and Air-Conditioning Manufacturing.
AGILE MANUFACTURING
It is a manufacturing system which involves putting more emphasis by responding a rapid
response to changing customer demand. In other to maintain competitive advantage within
the market. Manufacturing organisation must find a way to satisfy customer demand within a
short time frame. Agile manufacturing can certainly use lean techniques, but the strategy is
focused on process that are flexible to adopt changes quickly. While lean manufacturing put
strong focus on eliminating waste to reduce cost and shorten the lead time of and items
ADVANTAGES
1. Since the company is constantly changing according to customer need, therefore
customer may be more satisfy
2. New designs are based on the customer need, this mean that a customer will have a
wider variety of chosen
3. The company must be retaining mass production properties while remaining flexible.
because company must response quickly to change

DISADVANTAGES
1. maintenance cost is expensive
2. Due to short time circle the machinery and workers need to be update because of
new technology
3. If the demand suddenly drops during a high production rate, the product could not
be sold