Production planning and control in mass production
Henry Ford is considered the father of modern mass production. His Ford Motor company was the first to start assembly line production of vehicles. Mass production, as the name suggests follows the concept of assembly line. The task or the production process is broken down or divided into simplest possible components. These components are the grouped to follow production procedures. Assembly line consists of work stations or arrangement of labor and equipment in a sequence. At each work station, a pre decided task is completed. This facilitates the production in large quantities. On an assembly line, the materials move continuously at a uniform average rate. At different work stations, a portion of work is done. Industries such as toys, automobiles, televisions, and computers are all assembly line productions. Assembly line productions can be manual or through conveyor belts carrying materials at a pre decided rate so that there is sufficient time at each work station to perform the allotted task. The conveyor belts are of belt type, chain type, overhead type or screw type.
Mass production
Only one type of product or maximum 2 or 3 type of products are manufactured in large quantities and much emphasis is not given to retail consumer orders. Standardization of products, processes, materials, machines, uninterrupted flow of materials is the main characteristics of this system. Example: - petrochemical industry, cement industry, steel industry, sugar industry, cigarette industry etc.
Appropriateness of Mass production
Mass production pertains to a large quantity of production with standardized products having more or less the same features. This single standard product is manufactured on a continuous basis over a period of time. The determining factor is the demand on the basis of which continuous or batch type production is chosen.
Features of mass production system
- It includes manufacturing of high-volume standardized products.
- There is a smooth flow material from one work station to another workstation.
- Production time of production unit as a whole is short (i.e. because of specialization principle).
- Closely spaced work station reduces material handling.
- Production planning and control is simple.
- Work in progress inventory is less.
Production planning and control is possible under mass production only with the help of line balancing.
Production planning and control in mass production
It is usually far simpler than in a job or batch production. Extensive effort is required for detailed planning before production starts, but both scheduling and control need not be elaborate usually. The output is either limited by available capacity or regulated within given limits to conform to production targets, based on periodic sales forecasts.
Planning problems in mass production
Setting the rate of production from line and arranging the various production centers on the line accordingly Line balancing helpful in equalizing output rates from various work points in mass production line and in reducing idle time of labour.
Process Production planning and control in mass production (with example)
- Define the tasks e.g. a, b, c, d, g, h.
- Identify precedence relationships/ requirements or draw precedence diagram for these task.
- Calculate minimum number of work station required: Minimum no of work station = maximum allowable cycle time per unit / time allowed at a work station per unit = say 380 seconds/ unit 90 seconds / unit = 4.22 stations = 5 station
- Assign task to different stations on some basis or principle or rule. One such rule is longest operation time (LOT) rule – giving top priority to task that has longest operation time.
- Steps: -
- LOT (1) first assigns the task that takes most time to the first station while maintaining precedence requirement.
- LOT (2) after assigning a task determines how much time the station has left to contribute.
- LOT (3) if station can contribute more time, assign it a task requiring as much time as possible while maintaining precedence otherwise return to LOT (1) and continue same steps until all task have been assign to different station.
- Evaluate effectiveness and efficiency (Effectiveness – if desired capacity is achieved) (Efficiency- labour utilization) Calculation of labour utilization efficiency for proposed 90 second lines.
- Seek further improvement by changing time.
Advantages of Mass Production
- There is a smooth flow of material from one work station to the next.
- There are in built inventories at each work station because output of one work station becomes the input of the next.
- Production time is shorter in assembly line productions.
- The material is more efficiently handled since work stations are spaced closely together.
- There is no special expertise required for the staff. Training cost is lesser.
- Production planning and control is simpler.
Disadvantages of Mass Production
- Since the proper functioning of all the machines is required in an assembly line production, maintenance is a challenge.
- Assembly lines are rigid inflexible set ups. Any change in the design layout proves difficult.
- The production speed is determined by the slowest machine.
- Assembly line set ups are capital intensive since they require installation of specific types of machines
Design of an Assembly Line
The assembly line balancing aims to minimize the idle time of machines. It means the reduction in the number of operators to perform a task. The entire assembly is divided into parts. An assembly line may follow any of the following models:
- Modular Production: Such a model is followed to introduce variety in the mass production system. In such a system, a minimum number of parts or processes are developed and produced. These are called modules. They can be combined in a different way to offer variety.
- Group Technology: In a group technology plant layout, parts required in a particular operation are put under different groups. Machines are arranged in such a way that each machine is assigned to the production of one group.
- Automation: Machines, material and control are integrated in such a system. Example of Mass production systems: Production of biscuits in a factory can be taken as an example of mass production. At every stage a particular operation is performed using a specific machine. As is shown below, packs of identical biscuits are produced in an industrial unit
- Stage: 1: MIXING: Flour + fat + sugar + bicarbonate + additives
- Stage: 2: MOULDING: Dough is laminated in a laminator
- Stage: 3: GAUZE ROLLS: Laminated dough is cut as per size and shape
- Stage: 4: BAKING: Biscuits cut into shapes are baked in the oven
- Stage: 5: COOLING: Biscuits are cooled in conveyors once they are baked
- Stage: 6: PACKAGING: The final product is then packed into pouches and cartons.
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