MANUFACTURING

PROCESSES
PRODUCTION/OPERATION AS A
CONVERSION SYSTEM
• PRODUCTION ( OPERATION) IS A
CONVERSION SYSTEM : IT CONVERTS
INPUTS INTO OUTPUT

TRANSFORMATION OUTPUT
INPUT
PROCESS

FEEDBACK FEEDBACK FEEDBACK

CONTROL SYSTEM
AN OPERATIONS MANAGEMENT
CONSISTS OF FIVE BASIC
ELEMENTS:

1. INPUT
2. TRANSFORMATION PROCESS
3. OUTPUT
4. CONTROL SYSTEM
5. FEED BACK
 1. INPUT
INPUT OF OPERATIONS MANAGEMENT

PHYSICAL NON PHYSICAL

RESOURCES RESOURCES
o LABOUR INFORMATION
o MATERIALS EXPERIENCE
o EQUIPMENT INTELLIGENCE
SKILL
INSTRUCTION
SUPERVISION
2. TRANSFORMATION PROCESS
ARE THE ACTIVE PROCESSES THAT
CHANGE PHYSICAL GOODS OR
RESTRUCTURE HUMAN RESOURCE
ACTIVITIES TO PROCIDE THE DESIRED
GOODS OR SERVICE OUTPUT
ACTIVE PROCESSES INCLUDE
- MECHANICAL AND CHEMICAL
OPERATIONS
- ASSEMBLY & TESTING
CONT….
- CONCEPTS, PROCEDURES, AND NON-
EQUIPEMENT TECHNOLOGIES
- RULES, GUIDELINES AN STEPS USED TO
CONVERT INPUT INTO DESIRED
OUTPUT
TRANSFORMATION(OR CONVERSION)
PROCESS :
• TRANSFROMATION ( OR CONVERSION)
PROCESS INVOLVES OPERATIONS
( PURPOSEFUL ACTIVITIES)
CONT….
- MECHANICAL OR CHEMICAL OPERTIONS –
TO CONVERT !
- CHANGE INPUTS INTO OUTPUT
* IT INCLUDES ACTIVITIES THAT ASSIST
CONVERSION
e.g.
- RECEIPT STORAGE AND ISSUE OF MATERIAL
- MATERIAL HANDLING
- INSPECTION
- ASSEMBLY & TESTING
- STORAGE OF FINISHED GOODS
 3. OUTPUT
OUTPUT REFERS TO THE OUTCOME OF
THE TRANSFORMATION PROCESS
WHICH CAN BE EITHER
- TANGIBLE OBJECT, ( e.g. AUTOMOBILE)
- INTANGIBLE SERVICE ( e.g. DOCTOR’S
DIAGNOSIS)
 4. CONTROL MECHANISM
ARE THE SUB- SYSTEMS INTEGRATED INTO
INPUT, TRANSOFRMATION PROCESS AND
OUTPUT ELEMENTS TO MONITOR AND
CORRECT SYSTEM BEHAVIOUR THAT IS
DEVIATING FROM DESIRED MANAGEMENT
OBJECTIVES.
e.g. a) QUALITY CIONTROL SYSTEMS , TO
ENSURE PRODUCTS HAVE ZERO DEFECT.
b) PPC SYSTEMS TO ENSURE GOOD
UTILISATION OF FACILITIES
 5. FEEDBACK
FEEDBACK IS ANY VERBAL, WRITTEN OR
ELECTRONIC INFORMATION DESCRIBING
THE PHYSICAL STRUCTURE AND
BEHAVIOURAL US OF THE GOODS AND
SERVICES THAT ARE INCOMING,
OUTGOING AND BEING TRANSFORMED IN
THE OPERATIONS MANAGEMENT
SYSTEM.
FEEDBACK IS THE COMMUNICATION LINK
BETWEEN THE INPUT, TRANSFORMATION
PROCESS AND OUTPUT ELEMENTS AND
THE CONTROL SUB- SYSTEMS.
 CHOICE OF PROCESS
 MANUFACTURING PROCESS MAY BE
VIEWED AS TRANSOFORAMTION
PROCESS, THE WAY THE PROCESS
CREATES PRODUCTS OR SERVICES.
 MANUFACTURING PROCESS HAS A
SIGNIFICANT IMPACT ON THE ABILITY
OF THE MANUFACTURING ( OR
OPERATION) TO SATISFY CUSTOMERS
NEEDS
A PROCESS WHICH HAS BEEN LOCATED
IN THE WRONG PLACE, OR WITH
INSUFFICIENT CAPACITY, OR
ARRANGED IN A JUMBLED AND
CONFUSED LAYOUT, OR GIVEN IN
APPROPRIATE TECHNOLOGY, OR
STAFFED WITH UNSKILLED PEOPLE,
CANNOT SATISFY CUSTOMERS
BECAUSE IT CAN NOT PERFORM
EFFICIENTLY OR EFFECTIVELY.
 GOOD PROCESS DESIGN
INFLUENCES PERFORMANCE
OBJECTIVES
SR. PERFORMANCE INFLUENCE OF GOOD
NO OBJECTIVE PROCESS
1 QUALITY CAN PROVIDE APPROPRIATE
RESOURCES WHICH ARE
CAPABLE OF PRODUCING THE
PRODUCT OR SERVICE TO ITS
DESIGN SPEC.
2. SPEED CAN MOVE MATERIALS
INFORMATION OR CUSTOMERS
THROUGH EACH STAGE OF THE
PROCESS WITHOUT DELAYS
SR.NO PERFORMANCE INFLUENCE OF GOOD
OBJECTIVE PROCESS
3. DEPENDABILITY CAN PROVIDE
TECHNOLOGY AND STAFFS
WHO ARE THEMSELVES
DEPENDABLE
4. FLEXIBILITY CAN PROVIDE RESOURCES
WHICH CAN BE CHANGED
QUICKLY SO AS TO CREATE
A RANGE OF PRODUCTS OR
SERVICES
5. COST CAN ENSURE HIGH
UTILISATION OF
RESOURCES WITH LOW
COST PROCESSES
MANUFACTURING PROCESSES
ARE OF FOLLOWING TYPES
1. PROJECT PROCESSES
2. JOBBING PROCESSES
3. BATCH PROCESSES
4. MASS PROCESSES
5. CONTINOUS PROCESSES
 TYPES OF MANUFACTURING PROCESSES

INTERMITTENT CONTINOUS
PRODUCTION PRODUCTION

PROJECT JOBBING BATCH

PRODUCTION PRODUCTION PRODUCTION

MASS FLOW PROCESS

PRODUCTION PRODUCTION
 1. PROJECT PRODUCTION
ARE CHARACTERISED BY COMPLEX SET
OF ACTIVITIES THAT MUST BE
PERFORMED IN A PARTICULAR ORDER
WITHIN THE GIVEN PERIOD AND
WITHIN THE ESTIMATED EXPENDITURE
 CHARACTERISTICS OF
PROJECT PRODUCTION
• DEFINITE BEGINNING & DEFINITE END
• NON- UNIFORM REQUIREMENTS OF
RESOURCES
• INVOLVEMENT OF DIFFERENT AGENCIES
• “FIXED POSITION” LAYOUT
• HIGH COST OVER RUNS
• PERSONNEL PROBLEMS
• SCHEDULING & CONTROL
 TYPICAL EXAMPLES
* INFRASTRUCTURE DEVELOPMENT PROJECT
LIKE
- BRIDGES
- ROADS
- TUNNELS
- DAMS
- FLYOVERS
- WATER AND SEWERAGE SUPPLY SCHEMES
 TYPICAL EXAMPLES
* INDUSTRIAL PLANTS SUCH AS
- SUGAR PLANTS
- CEMENT PLANTS
- PAPER MILLS
- REFINERIES ETC.

* PRODUCTION OF SHIPS, LOCOMOTIVES,

AIRCRAFTS, BOILERS, ETC.

* SPECIFIC ONE TIME HUGE ASSIGNMENTS SUCH AS

- IMPLEMENTATION OF ISO 9001/ISO 14001
- TQM
- TPM
- SIX SIGMA
2. JOBBING PRODUCTION
IS CHARACTERISED BY THE
MANUFACTURE OF ONE OR FEW
NUMBERS OF A SINGLE PRODUCT
DESIGNED AND MANUFACTURED
STRICTLY TO CUSTOMERS
SPECIFICATIONS, WITHIN THE GIVEN
PERIOD AND WITHIN THE PRICE FIXED
PRIOR TO THE CONTACT
 TYPICAL EXAMPLES
- GENERAL REPAIR SHOP
- SPM MANUFACTURES
- WORKSHOPS TO MANUFACTURE JIGS &
FIXTURES
- TAILORING SHOPS MANUFACTURE MADE-
TO-MEASURE SUITE OF CLOTHES
- MANUFACTURERS OF CRANES, FURNACES,
TURBO- GENERATORS, PRESSURE VESSELS
- MANUFACTURING ARTICLES TO CUSTOMERS
ORDERS
 CHARACTERICS FOR JOBBING
PRODUCTION
- SMALL PRODUCTION RUNS
- DISCONTINOUS FLOW OF MATERIALS
- DISPROPORTINATE MANUFACTURING CYCLE
TIME
- GENERAL PURPOSE MCHINES AND PROCESS
LAYOUT
- HIGHLY SKILLED LABOUR
- HIGHLY COMPETENT KNOWLEDGEABLE
SUPERVISION
- LARGE WORK IN PROCESS
- LIMITED FUNCTIONS OF PPC
 3. BATCH PRODUCTION
IS CHARACTERISED BY THE
MANUFACTURE OF A LIMITED
NUMBER OF A PRODUCT PRODUCED AT
REGULAR INTERVALS AND STOCKED
IN WAREHOUSES AS FINISHED GOODS
(OR FINISHED PARTS) AWAITING SALES
( OR WITHDRAWAL FOR ASSEMBLY)
 TYPICAL EXAMPLES
- PROCESS INDUSTRIES SUCH AS
PHARAMCEUTICALS, PAINTS, CHEMICALS
- MEDIUM AND HEAVY ENGG. INDUSTRIES e.g.
Electric motors, Heavy motor vehicles,
- INTERNAL COMBUSTION ENGINES
- MANUFACTURERS OF READYMADE
GARMENTS
- SUB- CONTRACTORS WHICH TAKE ON
MACHINING OF BATCHES OF COMPONENTS
TO THE DRAWINGS OF A LARGE
MANUFACTURER.
 CHARACTERISTIC OF BATCH
PRODUCTION
- SHORT RUNS
- SKILLED LABOUR IN SPECIFIC TRADE
- SUPERVISOR TO PROCESS KNOWLEDGE OF A
SPECIFIC TRADE
- LIMITED SPAN OF CONTROL
- GENERAL PURPOSE MACHINES ARRANGED IN
PROCESS TYPE OF LAYOUT
- MANUAL MATERIAL HANDLING
- MANUFACTURING CYCLE TIME AFFECTED DUE
TO QUEUES
- LARGE WORK IN PROCESS
- GREATER FLEXIBILITY
- NEED TO HAVE STRONG PPC DEPARTMENT
 4. MASS AND FLOW
PRODUCTION
ARE CHARACTERISED BY THE
MANUFACTURE OF A SEVERAL
NUMBER OF A STANDARD PRODUCT
PRODUCED AND STOCKED IN THE
WAREHOUSES AS FINISHED GOODS
 TYPICAL EXAMPLES
- CONTINOUS MANUFACTURING
INDUSTRIES SUCH AS PLASTIC GOODS,
SINTERED PRODUCTS, HARDWARE
- MANUFACTURING AND ASSEMBLY
SHOPS OF AUTOMOBILES,
REFRIGERATORS, TV SETS, ELECTRIC
FANS, DOMESTIC APPLIANCES
 CHARACTERISTICS OF MASS
AND FLOW PRODCUTION
- CONTINOUS FLOW OF MATERIAL
- SPECIAL PURPOSE MACHINES AND PRODUCT
TYPE OF LAYOUT
- MECHANISED MATERIAL HANDLING
- LOW SKILLED LABOUR
- SHORT MANUFACTURING CYCLE TIME
- EASY SUPERVISION
- LIMITED WORK IN PROCESS
- LESSER FLEXIBILITY IN PRODUCTION
SCHEDULES
5. PROCESS PRODUCTION
IS CHARACTERISED BY THE
MANUFACTURE OF A SINGLE PRODUCT
AND STOCKED IN THE WAREHOUSE
AWAITING SALES.
 TYPICAL EXAMPLES
- SUGAR MILLS
- STEEL
- CEMENT
- PAPER
- COKE
- REFINERIES
 CHARACTERISTICS OF
PROCESS PRODUCTION
- SPECIAL PURPOSE MACHINES WITH INBUILT
CONTROLS
- HIGHLY MECHANISED MATERIAL HANDLING
- VIRTUALLY ZERO MANUFACTURING CYCLE
TIME
- LOW SKILLED LABOUR
- SUPERVISOR TO BE PROCESS SPECIALIST
- NEGLIGIBLE WORK IN PROCESS
- LIMITED PPC FUNCTIONS
 QUALITY

BUS COMPANY
 THE BUSES ARE CLAN AND TIDY
 THE BUSES ARE QUIET AND FUME – FREE
 THE TIMETABLE IS ACCURATE AND USER-
FRIENDLY
 STAFF ARE COURTEOUS, FRIENDLY AND
HELPFUL
 QUALITY

AUTOMOBILE PLANT
 ALL PARTS ARE MADE TO SPECIFICATION
 ALL ASSEMBLY IS TO SPECIFICATION
 THE PRODUCT IS RELIABLE
 THE PRODUCT IS ATTRACTIVE AND BLEMISH
- FREE
 QUALITY

HOSPITAL
 PATEINTS RECEIVE THE MOST APPROPRIATE
TREATMENT
 TREATMENT IS CARRIED OUT IN THE CORRECT
MANNER
 PATIENTS ARE CONSULTED AND KEPT
INFORMED
 STAFF ARE COURTEOUS, FRIENDLY AND
HELPFUL
 SPEED

BUS COMPANY

 THE TIME BETWEEN A CUSTOMER SETTING

OUT ON THE JOURNEY AND REACHING HIS
OR HER DESTINATION KEPT TO A MINIMUM
 SPEED

AUTOMOBILE PLANT
 THE TIME BETWEEN DEALERS REQUESTING
A VEHICLE OF A PARTICULAR
SPECIFICATION AND RECEIVING IT KEPT TO
A MINIMUM
 THE TIME TO DELIVER SPARES TO SERVICE
CENTRES KEPT TO A MINIMUM
 SPEED

HOSPITAL
 THE TIME BETWEEN REQUIRING TREATMENT
AND RECEIVING TREATMENT KEPT TO A
MINIMUM
 THE TIME FOR TEST RESULTS, X-RAYS, ETC. TO
BE RETURNED KEPT TO A MINIMUM
 DEPENDABILITY

BUS COMPANY

 KEEPING TO THE PUBLISHED TIMETABLE AT

ALL POINTS ON THE ROUTE
 CONSTANT AVAILABILITY OF SEATS FOR
PASSENGERS
 DEPENDABILITY

AUTOMOBILE PLANT
 ON-TIME DELIVERY OF VEHICLES TO
DEALERS
 ON-TIME DELIVERY OF SPARES TO SERVICE
CENTRES
 DEPENDABILITY

HOSPITAL
 PROPORTION OF APPOINTEMENTS WHICH ARE
CANCELLED KEPT TO A MINIMUM
 KEEPING TO APPOINTMENT TIMES
 TEST RESULTS, X-RAYS, ETC, RETURNED AS
PROMISED
 FLEXIBILITY

BUS COMPANY
 PRODUCT/SERVICE FLEXIBILITY- THE
INTRODUCTION OF NEW ROUTES OR
EXCURSIONS
 MIX FLEXIBILITY- A LARGE NUMBER OF
LOCATIONS SERVED
 VOLUME FLEXIBILITY- THE ABILITY TO ADJUST
THE FREQUENCY OF SERVICES
 DELIVERY FLEXIBILITY- THE ABILITY TO
RESCHEDULE TRIPS
 FLEXIBILITY

AUTOMOBILE PLANT

 PRODUCT/SERVICE FLEXIBILITY- THE

INTRODUCTION OF NEW MODELS
 MIX FLEXIBILITY- A WIDE RANGE OF OPTIONS
 VOLUME FLEXIBILITY- THE ABILITY TO ADJUST
THE NO. OF VEHICLES MANUFACTURED
 DELIVERY FLEXIBILITY- THE ABILITY TO
RESCHEDULE MANUFACTURING PRIORITIES
 FLEXIBILITY

HOSPITAL
 PRODUCT/SERVICE FLEXIBILITY- THE
INTRODUCTION OF NEW TYPES OF TREATMENT
 MIX FLEXIBILITY- A LARGE NUMBER OF
AVAILABLE TEATMENTS
 VOLUME FLEXIBILITY- THE ABILITY TO ADJUST
THE NO. OF PATIENTS TREATED
 DELIVERY FLEXIBILITY- THE ABILITY TO
RESCHEDULE APPOINTEMENTS