presentation about production management

1. INTRODUCTION TO
PRODUCTION MANAGEMENT
BRANCH - E.T.
BATCH C-9

2. MEANING AND CHARACTERISTICS
Production and Operations Management (POM) is about the
transformation of production inputs into outputs that, when
distributed, meet the needs of customer.
It is the Conversion Process.
Characteristics of Production Management are: -

3. Product
Performance, Aesthetics, Quality, Reliability, Quantity, Production Cost, Delivery dates
Plant
Future Demand, Design and layout out of factory & equipment & offices, productivity
and reliability of equipment, need for maintenance, Health and safety, Environmental
issues
Processes
Available capacity, Available skills, Type of production, Safety, Production cost,
Maintenance requirement
Programmers
Purchasing Patterns, Cash Flow, Need for/availability of storages, Transportation
People
Wages and salaries, Safety and training, Work conditions, Leadership and motivation,
Unionization, Communication

4. PLANT LOCATION
• Plant location is an important decision which decides the fate of
the business.
• In past, decision of the location of the plant.
• Governmental steps in the selection of the location of the plant.
• Location of the small scale industry.
• Location of the large scale industry.

5. IMPORTANCE OF PLANT LOCATION
• 1) A good location may reduce the cost of production and distribution.
• 2 ) Government sometimes plays an important role in the choice of the
location keeping in view the national benefits.
• 3) Location fixes some of the physical factors of the overall plants
design.
-heating -ventilation -storage -water , fuel -transportation . . . .
. . . .
4) Plant consist of large investment if the site selection is wrong the
company can face great loss.
5)”Probably no location is so perfect as to guarantee success. But bad
location can be so bad as to bankrupt a company”.

6. FACTORS AFFECTING SELECTION OF
FACTORY
1. Selection of region:
Generally the geographical area is divided on the basis of
natural regions or political boundaries, e.g.: GUJARAT,
MAHARASHTRA. The suitability of various regions is considered
on the basis of comparative cost, advantages available.
2. Selection of locality,
After selection of region, the specific locality within the region is
considered such as: URBAN, RURAL AND SUBURBAN AREA.

7. SELECTING LOCATION OF FACTORY
• Availability of raw materials
• Proximity to markets
• Availability of labour
• Transport and communication facilities
• Availability of power and fuel

8. • Climatic condition
• Availability of water
• Ancillary industries
• Financial and other aids
• Business and Commercial facilities

9. STATE REGULATIONS ON LOCATION
• There is unbalanced distribution of
industries in India.
• The concentration of industries in few
selected regions or cities due to favorable
locational factors has created uneven
distribution of population and wealth.
• The concentration of industries in there
areas has also created problems of pollution.
• Like Mumbai, Calcutta

10. DISADVANTAGES
• Problems of pollution : air, water and food
pollution.
• Unbalanced industrial growth and problems
of poverty and unemployment in industrially
backward area.
• Increasing fixed, operating and living cost
due to concentration of industries.
• Congestion, bad sanitation, traffic jam etc.
• Inequitable distribution of wealth and

11. BACKWARD AREAS AND INDUSTRIAL
POLICY
• Incentives for industries units in backward areas
• Measures taken to minimize regional imbalance

12. GOVT. POLICIES FOR DECENTRALIZATION
• Measures to achieve
decentralization
• Objectives of Govt.
intervention and control
• Balance regional
development
• Strategic defence policy
• Concentration of
industries
• Narrow gap of ineuqality

13. INDUSTRIAL ESTATE
INDUSTRIAL ESTATES
• Industrial estates is a piece of vast land sub-divided into different industrial plots
systematically developed, wherein factory shades are constructed. Govt. Of India has
planned a national policy for the development of industrial estates to State Government. In
each state Development Corporations are established. Industrial estates have commerce.
Industrial estates provides all amenities and facilities as well as public utility services to a
number of small business units.
• The plots of land in industrial estates are sold to the prospective promoters. Thus
industrial estates has group of small factories, workshop or business units with suitable
sites and facilities to run the business smoothly. The number of units can enjoy common
amenities and benefits of site, sheds, water supply, power supply , roads , transport ,
drainage, etc. at reasonable charges.
Advantages of Industrial Estates
• Industrial development helps in promotion of small and medium sized industries in the
under developed areas.
• The entrepreneur is not required to carry out survey for finding suitable location for his

14. PLANT LAYOUT
A plant layout is an arrangement of facilities and services in the plant,
it outlines the relationship between production centres and
departments.
It is the optimum arrangement of industrial facilities including
personnel, equipment , storage space, material handling equipment
and all other supporting services.
It involves tactically locating machines processes and plant services
within the factory to get the greatest possible output and lowest
production cost.
Plant layout has an important bearing on utilization of facilities or
manufacturing methods.

15. OBJECTIVES OF GOOD PLANT LAYOUT
A good layout is one which allows materials rapidly and directly for processing, one which
helps improve industrial productivity.
• Integrate the production centres
• Reduce material handling
• Effective utilization of available space
• Worker convenience and job satisfaction
• Flexibility
• Removal of bottlenecks
• Quick disposal of work
• Avoids industrial accidents
• Eliminates physical efforts
• Maintenance of decency

16. IMPORTANCE OF PLANT LAYOUT
• Determines arrangement of facilities and services-Product canters +
Service department
• Flow in the plant
• Type of handling system
• Specifies location accessibilities, size, space
• Amount of supervision, degree of specialization
• Span of activity, working time, fatigue and efficiency

17. FACTORS INFLUENCING PLANT LAYOUT
• Management policy
Decisions made by the management on many matters-
Nature and Quality of Products, Size of the Plant, Employee
Facility, Plans for Expansion.
• Manufacturing Process
The type of manufacturing Process-Synthetic/Analytical,
continuous/intermittent and repetitive/non repetitive.

18. • Nature of Product: The product to be manufactured one of the major
factor for example light and small objects may be moved easily to machines
while for heavier objects we need to move the moved and requires assembly
bays. Quality and fragility of the product influences the plant layout.
• Volume of Production: The plant layout and equipments in large
scale organisation will be different compared small scale organisation.
• Type Of Equipment: Single and multi-purpose machine affects the
plant layout. Similarly, noisy and vibrating machines require special attention.
• Type of building: The covered area, parking, storage etc will affect
the plant layout.

19. • Availability of floor area: The allocation of space for machines, storage, work
benches etc will be on the basis of area available.
• Arrangement of material handling equipment: The plant layout and
material handling service affect arrangement of production process and needs adequate
space for free movement of various objects.
• Service facilities: The layout of factory must include various facilities for welfare of
workers like canteen, lockers, drinking water, first aid etc.
• Possibility of future expansion: Plant layout is made in the light of future
requirements and installations of additional facilities .

20. TYPES OF PLANT LAYOUT
•Process Layout
•Product Layout
•Mixed Layout
• Static Layout

21. •Process / Functional Layout :
In this layout, all machines performing similar type of
operations are grouped together at one location.
This layout is more suitable for job order industries like
steel fabrication, hosiery, printing etc.

22. Merits :
• Eliminates the duplication of machines.
• Specialized supervision is possible.
• The firm has the ability to handle a variety of processing
requirement.
Demerits :
• Material handling cost increases.
• Inspection & Supervision cost increases.
• Constantly changing schedules and routings
make juggling process requirements more difficult.

23. Product / Line Layout :
In this type of layout, machines and auxiliary are arranged
in line according to the sequence of operations to be
performed on the work.

24. Merits :
• Speedier movements of materials.
• Supervision costs and material handling reduces.
• Maximum utilization of machine.
Demerits :
• Duplication of machines and equipment.
• Specialized supervision is not possible.
• Breakdown in any machine in the line interrupts entire process.

25. Mixed or combined layout
• Combination of product and process layout.
• Production Shops may be arranged by process layout, while the
assembly is
done in line.
Static or fixed position layout
• Adopted when work piece is too heavy to transfer and layout is generally
made fixed in one place.
Advantages of Static Layout
Least movement of workers , maximum flexibility , etc.
Disadvantages of Static Layout
Low utilisation of labours , Highly skilled labours are required , etc.

26. BREAK-EVEN ANALYSIS
• Factors of profit
• Minimize Cost of production
• Increase in output
• Using cheaper material
• Maintaining inventory levels
• Standardization and mass production
• Developing human resources
• Improving efficiency
• Ways of break even analysis

27. ASSUMPTION IN BREAK-EVEN ANALYSIS
• Fixed and variable cost
• Fixed cost ?
• Variable cost
• Selling price
• Only one product
• Perfect synchronization
• Productivity and effeciency

28. PLOTTING THE BREAK-EVEN CHART
• Cost and revenue on vertical axis.
• Quantity on horizontal axis.
• Fixed cost shown as straight line parallel to horizontal axis.
• Variable costs superimposed upon the horizontal line of cost
and top line is total cost line.
• Sales income line passes through the origin.
• Intersection point of total cost line and sales income line is
BREAK EVEN POINT.
• Region on the left of B.E.P. is loss and on the right is the profit.

29. MARGIN OF SAFETY
• Distance between BEP and O/P
• Implications on Profit
• Measures (during unsatisfactory conditions):
Quantitative  Increase SP, O/P OR Decrease FC, VC
Qualitative  Pay more attention to the Profitable goods

30. PROFIT VOLUME
• Measures profitability wrt sales (Use: Compare profitability of
different products)
• Implications of P/V ratio
• P/V ratio = (Contribution/Sales) x 100 = [(S – V)/S] x 100
• Uses:
• BEP determination
• Increasing SP, reducing VC
• Know P for given S volume.