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Production Capacity 62584
Production Capacity 62584
1.1 INTRODUCTION
Production/operations are the process, which combines and transforms various resources used in
the production/operations subsystem of the organization into value added product/services in a
controlled manner as per the policies of the organization. Therefore, it is that part of an
organization, which is concerned with the transformation of a range of inputs into the required
(products/services) having the requisite quality level.
1.2CONCEPT OF PRODUCTION
Production function is that part of an organization, which is concerned with the transformation of
a range of inputs into the required outputs (products) having the requisite quality level.
Production is defined as “the step-by-step conversion of one form of material into another form
through chemical or mechanical process to create or enhance the utility of the product to the
user.” Thus production is a value addition process. At each stage of processing, there will be
value addition. Edwood Buffa defines production as „a process by which goods and services are
created‟. Some examples of production are: manufacturing custom-made products like, boilers
with a specific capacity, constructing flats, some structural fabrication works for selected
customers, etc., and manufacturing standardized products like, car, bus, motor cycle, radio,
television, etc.
Fig. 1.1 Schematic production system
The production system has the following characteristics: 1. Production is an organized activity,
so every production system has an objective. 2. The system transforms the various inputs to
useful outputs.3. It does not operate in isolation from the other organization system. 4. There
exists a feedback about the activities, which is essential to control and improve system
performance.
Production systems can be classified as Job Shop, Batch, Mass and Continuous Production
systems.
JOB SHOP PRODUCTION: Job shop production is characterized by manufacturing of one or
few quantity of products designed and produced as per the specification of customers within
prefixed time and cost. The distinguishing feature of this is low volume and high variety of
products. A job shop comprises of general purpose machines arranged into different departments.
Each job demands unique technological requirements, demands processing on machines in a
certain sequence. Characteristics
3. Highly skilled operators who can take up each job as a challenge because of uniqueness.
5. Detailed planning is essential for sequencing the requirements of each product, capacities for
each work centre and order priorities.
Advantages Following are the advantages of job shop production: 1. Because of general purpose
machines and facilities variety of products can be produced. 2. Operators will become more
skilled and competent, as each job gives them learning opportunities. 3. Full potential of
operators can be utilized. 4. Opportunity exists for creative methods and innovative ideas.
Limitations Following are the limitations of job shop production: 1. higher cost due to frequent
set up changes. 2. Higher level of inventory at all levels and hence higher inventory cost. 3.
Production planning is complicated. 4. Larger space requirements.
Advantages Following are the advantages of batch production: 1. Better utilization of plant and
machinery. 2. Promotes functional specialization. 3. Cost per unit is lower as compared to job
order production. 4. Lower investment in plant and machinery. 5. Flexibility to accommodate
and process number of products. 6. Job satisfaction exists for operators. Limitations Following
are the limitations of batch production: 1. Material handling is complex because of irregular and
longer flows. 2. Production planning and control is complex.
3. Work in process inventory is higher compared to continuous production. 4. Higher set up costs
due to frequent changes in set up.
Production facilities are arranged as per the sequence of production operations from the first
operations to the finished product. The items are made to flow through the sequence of
operations through material handling devices such as conveyors, transfer devices, etc.
Characteristics Continuous production is used under the following circumstances: 1. Dedicated
plant and equipment with zero flexibility
SCOPE OF PRODUCTION
PRODUCT DESIGN
Product design deals with conversion of ideas into reality. Every business organization has to
design, develop and introduce new products as a survival and growth strategy. Developing the
new products and launching them in the market is the biggest challenge faced by the
organizations. The entire process of need identification to physical manufactures of product
involves three functions: marketing, product development, and manufacturing.
Product development translates the needs of customers given by marketing into technical
specifications and designing the various features into the product to these specifications.
Manufacturing has the responsibility of selecting the processes by which the product can be
manufactured. Product design and development provides link between marketing, customer
needs and expectations and the activities required to manufacture the product.
Production planning and control can be defined as the process of planning the production in
advance, setting the exact route of each item, fixing the starting and finishing dates for each item,
to give production orders to shops and to follow up the progress of products according to orders.
The principle of production planning and control lies in the statement „First Plan Your Work and
then Work on Your Plan‟. Main functions of production planning and control includes planning,
routing, scheduling, dispatching and follow-up. Planning is deciding in advance what to do, how
to do it, when to do it and who is to do it. Planning bridges the gap from where we are, to where
we want to go. It makes it possible for things to occur which would not otherwise happen.
Routing may be defined as the selection of path which each part of the product will follow,
which being transformed from raw material to finished products. Routing determines the most
advantageous path to be followed from department to department and machine to machine till
raw material gets its final shape. Scheduling determines the programmer for the operations.
Scheduling may be defined as „the fixation of time and date for each operation‟ as well as it
determines the sequence of operations to be followed.
Capacity Strategies
Within supply chain optimization and manufacturing and production management, there are
three basic capacity strategies used by different organizations when they consider increased
demand:
As the name suggests, the lead capacity strategy adds capacity before the demand actually
occurs. Companies often use this capacity strategy, as it allows a company to ramp up production
at a time when the demands on the manufacturing plant are not so great.
If any issues occur during the ramp-up process, these can be dealt with so that when the demand
occurs, the manufacturing plant will be ready.
However, the lead capacity strategy does carry some risks. If the demand does not materialize,
the company could quickly find itself with unwanted inventory as well as the expenditure of
ramping up capacity unnecessarily.
This is the opposite of the lead capacity strategy. With the lag capacity strategy, the company
will ramp up capacity only after the demand has occurred.
Although many companies follow this strategy, success is not always guaranteed. However,
there are some advantages to this method.
Initially, it reduces a company‟s risks. By not investing at a time of lesser demand and delaying
any significant capital expenditure, the company will enjoy a more stable relationship with its
bank and investors.
Secondly, the company will continue to be more profitable than companies who have made the
investment in increased capacity.
Of course, the downside is that the company would have a period where the product is
unavailable until the capacity is finally increased.
The match capacity strategy is one in which a company tries to increase capacity in smaller
increments to coincide with the increases in volume.
Although this method tries to minimize the overcapacity and under-capacity of the other two
methods, companies also get the worst of the two, as they can find themselves over capacity and
under capacity at different periods.
To optimize your supply chain, you need to be able to supply your customers with what they
want, when they want it—and accomplish that by spending as little money as possible. By
understanding and taking advantage of your facility's actual manufacturing and
production capacity, you can accomplish this all-important supply chain optimization goal.
That being said, many of the most popular and innovative of today‟s order fulfillment
technologies have embraced the concept of modularity, giving operations increased flexibility as
to how they choose to deploy and invest their capital. Instead of requiring a complete warehouse
redesign or system overhaul, many operations can now add technologies like goods-to-
person, AGVs, AMRs, and other technologies piece by piece, preventing the need of putting in
too great of an investment.
Efficiency of plant.
Volume, capacity, and uniformity of production
Technical factors, Technical factors are the most important ones. These include
proper location, layout and size of the plant and machinery, correct design of machines
and equipment, research and development, automation and computerization, etc. If the
organization uses the latest technology, then its productiveness will be high.
These are factors that provide the physically immersive qualities of an experience. They generally are
the parameters which lead us to label an experience belonging to a particular medium, and within that
medium, the degree of sensorial details. Of course, for some media, the values of some factors will be
at the zero end of the spectrum—i.e., not all media are interactive, or physically immersive.
Location factors : Production also depends on location factors such as Law and order
situation, infrastructure facilities, nearness to market, nearness to sources of raw-
materials, skilled workforce, etc
Product capacity measurements
Defining Capacity
Capacity is defined under 3 categories; design capacity, effective capacity and actual capacity.
The operations utilization of resources and the efficiency of its processes can then be calculated
using these.
Design Capacity
This is a theoretical number and not one that is applied to the daily production of an operation.
Design capacity is the output that an operation can produce continuously, at maximum rate
without stopping for any shift changeovers, maintenance or any other delays. What the process is
capable of producing under perfect conditions. In some cases this might be interpreted as
maximum capacity.
Effective Capacity
This considers how the operation will run on a long term basis, how it will be staffed and how it
will be maintained. All planned stoppages under the normal working time frame are taken into
consideration. This can also be known as available capacity. These stoppages may include shift
changeovers, lunch breaks, set up times and many other operational factors.
Actual capacity
This is the same as effective capacity but contains unplanned losses as well as planned ones.
These could include poor work rate, absenteeism or new staff training for example.
Design capacity:
Maximum output rate under ideal conditions
𝒘𝒐𝒓𝒌𝒊𝒏𝒈 𝒉𝒐𝒖𝒓𝒔 𝒑𝒆𝒓 𝒅𝒂𝒚∗𝒘𝒐𝒓𝒌 𝒅𝒂𝒚𝒔 𝒊𝒏 𝒂 𝒘𝒆𝒆𝒌∗𝒂𝒎𝒐𝒖𝒏𝒕 𝒐𝒇 𝒘𝒐𝒓𝒌𝒆𝒓
Design capacity = 𝒘𝒐𝒓𝒌𝒆𝒓 𝒔𝒑𝒆𝒏𝒅 𝒕𝒊𝒎𝒆 𝒑𝒆𝒓 𝒑𝒊𝒄𝒆𝒔 𝒐𝒇 𝒘𝒐𝒓𝒌
Effective capacity:
Maximum output rate under normal (realistic) conditions
Design capacity minus allowances such as personal time (e.g. coffee break), maintenance, and
scrap
𝐰𝐨𝐫𝐤𝐢𝐧𝐠 𝒉𝒐𝒖𝒓𝒔 𝒑𝒆𝒓 𝒅𝒂𝒚 𝒎𝒊𝒏𝒖𝒔 𝒕𝒉𝒆 𝒍𝒐𝒔𝒕 𝒕𝒊𝒎𝒆∗𝒘𝒐𝒓𝒌 𝒅𝒂𝒚𝒔 𝒊𝒏 𝒂 𝒘𝒆𝒆𝒌∗𝒂𝒎𝒐𝒖𝒏𝒕 𝒐𝒇 𝒘𝒐𝒓𝒌𝒆𝒓
Effective capacity= 𝒘𝒐𝒓𝒌𝒆𝒓 𝒔𝒑𝒆𝒏𝒅 𝒕𝒊𝒎𝒆 𝒑𝒆𝒓 𝒖𝒏𝒊𝒕 𝒐𝒇 𝒘𝒐𝒓𝒌
𝐰𝐨𝐫𝐤𝐢𝐧𝐠 𝒉𝒐𝒖𝒓𝒔 𝒑𝒆𝒓 𝒅𝒂𝒚 𝒎𝒊𝒏𝒖𝒔 𝒕𝒉𝒆 𝒂𝒗𝒆𝒓𝒂𝒈𝒆 𝒍𝒐𝒔𝒕 𝒕𝒊𝒎𝒆∗𝒘𝒐𝒓𝒌 𝒅𝒂𝒚𝒔 𝒊𝒏 𝒂 𝒘𝒆𝒆𝒌∗𝒂𝒎𝒐𝒖𝒏𝒕 𝒐𝒇 𝒘𝒐𝒓𝒌𝒆𝒓
Actual output capacity =
𝒘𝒐𝒓𝒌𝒆𝒓 𝒔𝒑𝒆𝒏𝒅 𝒕𝒊𝒎𝒆 𝒑𝒆𝒓 𝒖𝒏𝒊𝒕 𝒐𝒇 𝒘𝒐𝒓𝒌
Example in the agro stone production technology only the output capacity measurement
system is used. The output measures count the finished units from the process such as a
production of 6 boards per day per labor. To measure capacity the agro stone industry use
the formula such as
In the organization 15 workers work in 0ne shift an eight hour per day for six work days in
a week. They take to fifteen minute’s tea breaks and have a half hour lunch break. The
time available for work is seven hours per day per worker. Each worker spends 70 minutes
with each board. How many boards could the workers process during a six day in a week?
Design Capacity
Design capacity is the output that an operation can produce continuously, at maximum rate
without stopping for any shift changeovers, maintenance or any other delays. What the
process is capable of producing under perfect conditions. In some cases this might be
interpreted as maximum capacity.
From the above information design capacity of agro stone production technology is
calculated as
Effective capacity
This considers how the operation will run on a long term basis, how it will be staffed and
how it will be maintained. All planned stoppages under the normal working time frame are
taken into consideration. This can also be known as available capacity. These stoppages
may include shift changeovers, lunch breaks, set up times and many other operational
factors.
From the above information in addition to one hour lost in tea break and lunch the agro
stone production technology panned 30 minutes or 0.5hours lost per day considering this
the effective capacity of the company is calculated as
Effective
o Actual capacity
This is the same as effective capacity but contains unplanned losses as well as planned ones.
These could include poor work rate, absenteeism or new staff training for example.
From the calculation in addition to the existing information the operational manager tell us
that due to poor work rate and absenteeism an average of 20 minutes or 0.33 hours lost per
day by considering this the actual capacity of the agro stone production technology is
calculated as
𝟔.𝟏𝟕𝒉𝒐𝒖𝒓𝒔∗𝟔𝟎𝒎𝒊𝒏𝒖𝒕𝒆𝒔∗𝟔 𝒅𝒂𝒚𝒔∗𝟏𝟓𝒘𝒐𝒓𝒌𝒆𝒓𝒔
Actual capacity=
𝟕𝟎𝒎𝒊𝒏𝒖𝒕𝒆𝒔
540 boards per week and design capacity of the company is 680 so
476 𝑏𝑜𝑎𝑟𝑑𝑠
Utilization= ∗ 100% which is equal to 88.1%
540
Remark
To measure production capacity in our case we choose only capacity utilization formula
(ለእኛ በዋናነት የምንጠቀመው በመጨረሻ ካፓሲቲ ዩቲላይዜሽንን ነው፡፡)