This document discusses product planning, product control, and process planning. It provides details on:
1) The product planning process which includes marketing analysis, performance studies, and advanced product planning to determine customer needs and technical feasibility.
2) Process planning which converts product designs into manufacturing plans specifying operations, machines, and process parameters.
3) Methods for determining optimal batch sizes in batch production to minimize total costs including setup and inventory carrying costs.
2. PRODUCT PLANNING
Evaluation of range
Pricing of existing and new products
Pricing based on future market requirements
Pricing to satisfy company objectives
Specify the design and development support
4. NEED FOR PRODUCT
PLANNING
1. Need determined from current deficiencies
1. Wanted occurring in present condition
2. Need determined from anticipated
deficiencies
1. Need through prediction of social, technology etc.
5. PRODUCT PLANNING
PROCESS (8mark)
Everyone wants a new product
And every one make the product successful
STEPS:
1. Marketing and marketing analysis
2. Performance and feasibility studies
3. Advanced product planning
6.
7. 1. Marketing and marketing analysis
Marketing does not require the engineering
involvement
Technical details for promotion
Technical support for answering the customer
queries
Product planned – to satisfy customer needs or not?
Availability of proper technology to satisfy needs
8. 2. Performance and feasibility studies
It is to extend the market analysis
Arriving at the preferred system configuration
Firm will offer the product.
ELEMENTS OF FESIBILITY:
A detailed need analysis
System operation requirments
Maintenance support requirments
Identification of alternate configuration
Screening and evaluating of available resources’
9. 3. Advanced product planning
It is the combined results of Preliminary market
analysis and feasibility study.
IT INCLUDES:
1. Product selection and justification
2. Product specification and plans
3. Product acquisition plan
4. Product evaluation plan
5. Product use and logistic support plan
6. System proposal
10. VALUE ANALYSIS (10 mark)
Systematic identification Elimination of
unnecessary cost
Less expensive material
Less costly methods
VALUE ANALYSIS is always known as
VALUE ENGINEERING, VALUE
ASSURANCE, VALUE MANAGEMENT
11. VALUE ANALYSIS approach ensure that
FUNCTIONS OF MINIMUM COST WITHOUT
COMPARISION OF QUALITY
PURPOSE:
Achieving all functions at lower cost
12.
13. CONCEPT OF VALUE AND FUNCTION
DEFINITION OF VALUE:
value =-----------
Difficult to define because, it changes person to person.
TYPES OF ECONOMIC VALUE:
1. USE VALUE (Properties, qualities, features)
2. ESTEEM VALUE (appearance)
3. COST VALUE (sum of all cost)
4. EXCHANGE VALUE (Properties for exchange)
COST
FUNCTION
14. FUNCTION
Working function of a product
TYPES OF FUNCTION:
PRIMARY FUNCTION (Designed product function,
call function in phone)
SECONDARY FUNCTION ( other than primary
function , mp3 player)
TERITARY FUNCTION ( Esteem nature, torch in
mobile)
15. VALUE ANALYSIS vs VALUE
ENGINEERING
Value analysis is a remedial process
Value engineering is a preventive process
USES OF VALUE ANALYSIS:
Reduce cost
Better fashion
New ideas and concepts
employees with new innovative ideas
Fulfill customer needs
16. REASON FOR UNNECESSARY
COST
1. Poor Design
2. Lack of ideas
3. Lack of standardisation
4. Un avoidable delivery constrains
5. Poor production planning
17. STEPS IN VALUE ANALYSIS (16 mark)
1. BLAST
1. Identify the product (product for study)
2. Collect relevant information(information in
manufacturing, engineering, economics)
3. Define different functions ( Functions setting)
2. CREATE
1. Create different alternatives
2. Critically evaluate alternatives
3. REFINE
1. Develop the best alternative
2. Implement the alternative
18. PHASES OF VALUE ANALYSIS (16 mark)
1. ORIENTATION PHASE (data collection)
2. INFORMATION PHASE(Identify facts)
3. FUNCTIONAL ANALYSIS(basic function)
4. CREATIVE PHASE( rearrange the information)
5. EVALUATION PHASE(create various alternatives)
6. DEVELOPMENT PHASE (alternatives for
technical requirement)
1. RECOMMENDATION PHASE(decision making)
2. IMPLEMENTATION PHASE(approval)
3. FOLLOW UP PHASE(compare with expectation)
19. PROBLEMS IN LACK OF PRODUCT PLANNING
Improper planning may disturb entire cycle chain
It may affect development stages of product like raw material
inspection, shop floor production, in house inspection etc.
The entire product outlook cannot be observed unless there is a
proper selection of process parameters
There is a higher variation in the process planning if the
standard procedures for a particular product with respect to the
customer requirements is not followed.
The product at the end gets delayed , due to which they cannot
reach the customers on time. This may also cause
dissatisfaction to the end customers.
At every stage/phase of product development due to improper
plans the process may not start in time. Thus, affecting the
overall product chain.
20. PROCESS PLANNING (16 mark)
Convert the product design in to manufacturing
plan
Manufacture the products and parts
Raw material in to finished state
It is otherwise called as operations planning
PROCESS PLANNING vs PRODUCTION
PLANNING:
How to make the product (Process Planning)
To order raw materials obtaining resources to
require to make insufficient and demand to it
(production planning)
21. DETAILS OF PROCESS PLAN (8MARK)
It contains:
Route sheet
Process
Process parameters
Machine and tools
1. Assembly and component drawings and bill of
materials
2. Machine and equipment details
3. Set up time for job
4. Availability of machine and equipment
22.
23. Factors affecting process
planning
1. Volume of production
2. Skill and man power
3. Delivery dates for parts
4. Material specification
5. Accuracy requirements for parts
27. ANALYISE FINISHED PART REQUIRMENTS:
Analyise the finished part in design softwares.
Either in engineering drawing or cad model format
SELECT MACHINES:
Economic consideration
Durability and dependability
Longer life
MATERIAL SELECTION PARAMETERS:
1. Function
2. Appearance
3. Reliability
4. Service life
5. Environment
6. Compatibility
7. Producibility
8. cost
28. PRE-REQUISITE INFORMATION
NEEDED FOR PROCESS PLANNING
“Process planning, in the manufacturing
context, is the determination of processes and
resources needed for completing any of the
manufacturing processes required for
converting raw materials into a final product to
satisfy the design requirements and intent and
respect the geometric and technological
constraints.”
29. APPROACHES TO PROCESS
PLANNING
Two general approaches:
1. Manual process plan
2. Computer Aided Process plan
1. Retrieval CAPP
2. Generative CAPP
30. MANUAL PROCESS PLANNING
Task involves engineering drawings, making
decisions on machine process selection,
Equipments selection, operations sequence.
ADVANTAGES:
Small scale companies
Highly flexible method
Low investment
DISADVANTAGES:
Very complex and time consuming
Human error takes place, because of planner
Increases paper work
31. COMPUTER AIDED PROCESS PLANNING
To overcome the manual process planning.
CADD provides interface between CAD & CAM
BENEFITS OF CAPP:
1. Process standardisation
2. Productivity improvement
3. Product cost reduction
4. Elimination of human error
5. Reduce in time
6. Reduce paper work
7. Improved legibility ( computer based route sheets prepared)
8. Faster response to engineering changes
9. Incorporate of other application programs
32.
33. QUANTITY DETERMINATION IN BATCH
PRODUCTION
Batch production required when variety of
products needed.
Products made by volume of products needed.
PLANNING FOR BATCH PRODUCTION:
Determination of batch size ( production lot)
Determination of batch scheduling.
34. MERITS AND DEMERITS OF BATCH PRODUCTION
MERITS
1. Easy availability of process layout
2. Similar machines are grouped in a department
3. Better utilization of machines
4. Comparatively low investment
5. Job satisfaction
DE-MERITS
1. Irregular flow of lines, material handling is expensive
2. Production planning and control is elaborate
3. Large amount of work process
4. Higher skills are required
35. STOCK CONTOL
STOCK CONTROL WITHOUT BUFFER STOCK:
Stock control model of batch production which
varies the level of stock
36. STOCK CONTROL WITH BUFFER STOCK:
There is no consumption of stock during
production .
Buffer stock is also known as safety stock.
37. DETERMINATION OF BATCH SIZE
1. SETUP COST:
1. Batch production involves set up cost
2. Rough cost at the time of order
3. SETUP COST INCLUDES:
1. Store requirements
2. Tool requirements.
3. Machine set up
2. INVENTORY COST:
1. Finished product to finally sold condition cost
41. MACHINE CAPACITY
Batch size calculations, for batch production.
Focus on machine loading and unloading.
MACHINE LOADING:
1. It is process of assigning a specific job for
machines
2. Smooth workflow can be ensured
3. Machine loading should ensure maximum
utilization
42. INFORMATION REQUIRED FOR
MACHINE LOADING
1. Number and identification of work order
2. Symbol or identification of part
3. Number of parts
4. List of operations to be performed
5. Necessary tooling's
43. METHODS TO REDUCE
CYCLE TIME
1. Methods-i- To reduce cycle time
2. Methods-ii- Reduce the independent activity
time (workmen don’t wait for
another workmen for interval)
3. Methods-iii- Reduce the concurrent activity
time (Working by several
parteners)
44. BALANCING(Machine
balancing)
Procedure for adjusting the times in working
PROBLEMS OF MACHINE BALANCING:
1. Balanced process
2. Unbalanced process
1min 1min 1min 1min 1min final product
1min 2min 1min 0.5min final product