Unit 48.1 Production Planning and Workflow
High-Performance Manufacturing
Production Technician
PRODUCTION PLANNING
• Purpose of Planning
• Organize and structure work for effective performance and
goal attainment. Set and balance priorities, anticipate
obstacles, and formulate plans consistent with available
human, financial, and physical resources.
• Production planning
 The process of analyzing and scheduling resources to best meet the
needs of the customer and ensure profitability
• Meeting Customer Demand
• Identifying the customer’s needs. Forecast, a projection of
future demand for a product
PRODUCTION PLANNING
• Scheduling Resources
 Material Availability
 Tool and Equipment Availability
 Scheduling Labor
• Ensuring Safety
 Production plan includes operator training and safety
training
• Key Elements
 Production Environments
 Materials
 Input
 Process
 Output
 Feedback
PRODUCTION PLANNING
• Concurrent Engineering
• A process that brings together people from different departments
to develop the design and the process at the same time. It directly
affects the production worker’s job:
 Determine whether or not a job can be done
 Equipment needs are identified, reducing set-up times
 Identify potential problems
 Reduces the times needed to introduce a new product
 Encourages teamwork and communication
PRODUCTION PLANNING
• Product Life Cycle
 The change in demand for a particular product over time
• Planning Tools
 Flow Charts
• Visual representation of a process in a step-by-step format
 Gantt Charts
 Used to schedule and organize resources within a time frame
• Computerized Planning System
 Applying model systems to company’s specific resources.
Performs calculations designed to organize material,
equipment, and personnel resources
Lean Manufacturing
Four Principles Lean Management
https://www.youtube.com/watch?v=wfsRAZUnonI
WORK FLOW
• Moving Material
• Work flow is the movement of materials through the production
process
• Plant Capacity
• Capacity of a process is the maximum rate at which inputs can be
transformed to create outputs
• Design Capacity
• The target rate at which the facility is designed to operate
• Effective Capacity
• The rate of output under normal working conditions
• Actual Output
• The amount of production in a given period
• Bottlenecks
• Point at which the production rate restricts the flow of materials
WORK FLOW
• Arranging Facilities
• Facility Layout
• Arrangement of work areas, equipment, and
departments
• Production Layout
• Moves large volumes of material in a sequence to
produce standardized goods
• Process Layout
• Groups similar functions into work stations
• Fixed-Position Layout
• Used to produce very large, low-volume products
WORK FLOW
• Cellular Manufacturing
• A combination of process and product layouts. More flexible because
machines can be moved into and out of cell. Team is responsible for
all aspects of the product. They lend themselves to customization of
standard products to meet specific customer needs
• Line Balancing
• Process of deciding how to assign groups of tasks to workstations
• Cycle Time
• Maximum time allowed for each workstation to complete its task
Cycle Time Video
https://www.youtube.com/watch?v=WmAwcMNxGqM
WORK FLOW
• Production Scheduling
• The advantages:
 Shorter lead times for production
 Shorter production cycles
 Efficient use of equipment and labor
 Substantial cost savings
 Less lost time
 Reduced inventory costs
LEGO Exercise
Round 1 - Assemble 3 Vehicles
•Total Quiet (No talking!)
•No Team Involvement
•Only Bin of Parts
•Assemble and measure time
LEGO Exercise
Round 1 - Assemble 3 Vehicles
•Total Quiet (No talking!)
•No Team Involvement
•Only Bin of Parts
•Assemble and measure time
Round 2 - Assemble 3 Vehicles
•Continuous Improvement Process (CIP)
•Job Rotation (optional)
•Team Involvement (anyone can build, subassembly OK)
•Visual and Standardized Work
•Set Goal on Time
•Assemble and measure time, compare to goal!
LEGO Exercise
Round 3 - Assemble 3 Vehicles
•
Continuous Improvement Process (CIP)
•
Job Rotation (optional)
• Team Discussion, draw Layout including Part Introduction
• Create Job Instructions for each person
• Team Involvement (anyone can build, subassembly OK)
•
Visual and Standardized Work
•
Set Goal on Time
•
Assemble and measure time, compare to goal!
• Category: Manufacturing Process and Production
• Production Planning and Workflow
• Individual Work:
• Time: 1:00
• Task:
• Logon and complete the assigned LAB
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