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Chap4 Productionplanning
Chap4 Productionplanning
PLANNING
Introduction.
Principles and Factors of efficient Production Planning.
Line Balancing (Hai Bun)
Line Balancing Calculation
Production Planning
The planning for any organization
forms the backbone of production
process.
Manpower
Manpower planning requires accurately
estimating the number of employees required to
do the work. The capacity of the workforce has
to match the capabilities of the equipment to
plan for the highest efficiency.
6 Principles of Production
Planning
Processes
Effective production planning makes sure that the
processes used for the output continue to operate
efficiently and safely.
Controls
A final production planning principle puts in place
controls that detect problems as soon as they
occur. Verification of inventory, use of qualified
suppliers and personnel, standardization where
possible.
When controls are in place, it enables to take
possible corrective actions to minimize the effects
and return production to the required levels.
Line Balancing..
Purpose is to minimize the number
of people and/or machines on an
assembly line that is required to
produce a given number of units
EXAMPLE
Green Grass’s plant manager just received marketing’s latest
forecasts of fertilizer spreader sales for the next year. She
wants its production line to be designed to make 2,400
spreaders per week. The plant will operate 40 hours per week.
D
H
B 40
20
30 E
6
A
F
40 C
25
50
I
18
G
15
t 244
Efficiency = (100) = = 81.3%
nc 5(60)
where
c = cycle time in hours
r = desired output rate
t
TM =
c
where
t =total time required to
assemble each unit
Idle time = nc – t
where
n =number of stations
t
Efficiency (%) = nc (100)
A None
40
B A
80
C D, E, F
30
D B
25
E B
20
F B
15
G A
120
H G
145
Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7 – 18
Solved Problem 2
SOLUTION
a. Substituting in the cycle-time formula, we get
1 8 hours
c= = (3,600 sec/hr) = 150 sec/unit
r 192 units
t 720 sec/unit
TM = = = 4.8 or 5 stations
c 150 sec/unit-station
145 130
B E C
80 20 30
J
A F 115
40 G 15 I
H
120 130
145
S2
S3
S4
S5
B E C
80 20 30
J
A F 115
40 G 15 I
H
120 130
145
t 720 sec/unit
Efficiency (%) = nc (100) =
5(150 sec/unit)
= 96%
43
Total = 5 H
If the desired output rate is 30 units per hour, what are the cycle
time and theoretical minimum?
1 1
c= = (3600) = 120 sec/unit
r 30
t 435
TM = = = 3.6 or 4 stations
c 120
t 435
Efficiency (%) = nc (100) = (100) = 90.6%
480
Work
Elements Idle Time
Station Assigned Cumulative Time (c = 120)
1
2
3
4
5
Work
Elements Idle Time
Station Assigned Cumulative Time (c = 120)
1 H, C, A 120 0
2 B, D, G 98 22
3 E, F 110 10
4 I, J, K 107 13
5 A fifth station is not needed