UNIT 2

PRODUCTION DESIGN AND PLANNING

 Production design and planning are crucial components of the
manufacturing process. They involve the creation of a blueprint or a plan
for the production process, which includes the design of the product, the
selection of raw materials, and the implementation of the production
process itself

 Production design refers to the process of creating a plan for the

manufacturing process. It involves identifying the requirements of the
product, designing the production line, selecting the raw materials,
and determining the manufacturing process. The production design
phase also involves the creation of blueprints or models for the product,
as well as the development of prototypes and testing of the product to
ensure it meets the required standards

 Production planning, on the other hand, involves the actual

implementation of the production design. It includes the scheduling of
the production process, the management of resources, the
coordination of workers, and the monitoring of the production process.
The production planning phase also includes the creation of a production
schedule, which outlines the sequence of activities required to produce
the product
IMPORTANCE OF PRODUCTION DESIGN AND PLANNING
1. Improved efficiency: Effective production design and planning can help
streamline the manufacturing process, reducing waste, improving
productivity, and ultimately reducing costs. By optimizing the use of
resources and minimizing downtime, manufacturers can increase their
efficiency and competitiveness.
2. Consistent quality: Production design and planning enable
manufacturers to establish and maintain consistent quality standards for
their products. By identifying the best raw materials, selecting the right
production processes, and ensuring that every step of the process is
properly executed, manufacturers can produce products that meet or
exceed customer expectations.
3. Faster time-to-market: Effective production design and planning can
help manufacturers bring their products to market faster. By ensuring
that every aspect of the production process is optimized, manufacturers
can reduce their time-to-market and gain a competitive advantage over
their rivals.
4. Reduced costs: Production design and planning can help manufacturers
minimize costs by identifying the most efficient production processes,
selecting the best raw materials, and optimizing the use of resources. By
reducing waste and minimizing downtime, manufacturers can lower
their production costs and improve their bottom line.
5. Flexibility: Production design and planning enable manufacturers to
respond quickly to changing market conditions and customer demand.
By having a well-designed and well-planned production process,
manufacturers can quickly adjust their production schedules, switch
between products, and respond to unexpected events.
PRINCIPLES OF LAYOUT

PRINCIPLE OF LAYOUT

FLOW

SPACE UTILISATION

FLEXIBILITY

SAFETY

ERGONOMICS

The layout of a manufacturing facility plays a crucial role in its efficiency,

productivity, and safety. There are several principles of layout that
manufacturers should consider when designing their facilities:

1. Flow:
The flow of materials, people, and equipment should be carefully
planned to ensure that everything moves smoothly and efficiently.
Materials should be moved from one process to another in a logical
sequence, and people and equipment should be positioned in a way that
minimizes travel time and maximizes productivity.

2. Space utilization:
The space within a manufacturing facility should be used efficiently, with
minimal waste. This means that the layout should be designed to
minimize the amount of unused space while still providing adequate
space for people, equipment, and materials to move around safely
3. Flexibility:
The layout of a manufacturing facility should be flexible enough to allow
for changes in production processes, product lines, and market
demands. This means that equipment should be easily movable and
adaptable, and the layout should be designed to allow for easy
reconfiguration as needed

4. Safety:
The layout of a manufacturing facility should prioritize the safety of
workers and equipment. This means that aisles and walkways should be
wide enough to allow for safe movement, and equipment should be
positioned to minimize the risk of accidents and injuries

5. Ergonomics:
The layout of a manufacturing facility should be designed to minimize
physical strain on workers, reducing the risk of repetitive motion injuries
and other health issues. This means that workstations and equipment
should be positioned at the appropriate height and angle to minimize
strain and fatigue.
TYPES OF LAYOUTS [VERY IMPORTANT]
1. FIXED POSITION LAYOUT
2. PROCESS OR FUNCTIONAL LAYOUT
3. PRODUCT OR LINE LAYOUT
4. CELLULAR OR COMBINATION LAYOUT
5. HYBRID LAYOUT

1. FIXED POSTION LAYOUT

 In this type of layout the major part of an assembly or material remains at
a fixed position
 All its accessories, auxiliary material, machinery, equipment needed, tools
required and the labour are brought to the fixed site to work.
 Thus, the product by virtue of its bulk or weight remains at one location.
Therefore the location of the major assembly, semi assembly component
and materials are not disturbed till the product is ready for dispatch
 This layout is suitable when one or a few pieces of an item are to be
manufactured and material forming or treating operation requires only
tools or simple machines.
 This layout is highly preferable when the cost of moving the major piece of
material is high and the responsibility of product quality by one skilled
workman or group of skilled workers is expected.
 This type of layout is mainly adopted for extremely large items
manufactured in very small quantity such as ships, aero planes, boilers,
reactors etc.
 Fixed Production Layout
MERITS: -
1. Minimum movement of men, material, and tooling during manufacturing
process
2. This layout is high flexible as the type of product and the related processes
can be easily changed without any change in the layout

DEMERITS: -
1. The cost of equipment handling is very high
2. Labours and equipment are difficult to utilize fully
3. It is limited to large items only

APPLICATIONS
This type of layout is mostly adopted for extremely large items manufactured in
very small quantity such as ships, aero planes, aircraft, locomotive, ship
assembly shops, shipyards, boilers, reactors etc.

2. PROCESS OR FUNCTIONAL LAYOUT

 In this type of layout arrangements of similar machines, production
facilities and manufacturing operations are grouped together according to
their functions.
 Machine tools of one kind are positioned together so that all the similar
operations are performed always at the same place
 For e.g. all the lathes may be grouped together for all kinds of turning and
threading operations, all drilling machines in one area for carrying out
drilling work, all tapping machines in one area for carrying out tapping
work, all milling machines in one area for carrying out milling work all
buffing and polishing machines at one place for carrying out surface
finishing work, and so on
 This type of layout is normally preferred for the industries involved in job
order type of production and manufacturing and/or maintenance activities
of non- repetitive type. This layout needs not to have to be changed every
time of the product or component changes. Also the breakdown of any
machine does not affect the production.

MERITS

1. There exists a wide flexibility regarding allotment of work to equipment and

workers
2. Comparatively less numbers of machines are needed in this layout and
hence thus reducing capital investment
3. There is an improved product quality, because the supervisors and workers
attend to one type of machines and operations
4. Varieties of jobs coming as different job orders thus make the work more
interesting for the workers
5. Workers in one section are not affected by the nature of the operations
carried out in another section. For example, a lathe operator is not affected
by the rays of the welding as the two sections are quite separate
6. This type of layout is highly suitable for batch production

DEMERITS

1. Work in progress inventory is high needing greater storage space

2. More frequent inspection is needed which results in costly supervision

FOR MORE:- https://accountlearning.com/process-or-functional-layout-

suitability-advantages-disadvantages/

3. PRODUCT OR LINE LAYOUT

  This layout implies that various operations on raw material are
performed in a sequence and the machines are placed along the
product flow line, i.e., machines are arranged in the sequence in which
the raw material will be operated upon.
 In this type of layout all the machines are placed in a line according to
the sequence of operations, machines are placed in such a way that the
output of one machine becomes the input of the next machine

MERITS:-
1. Since the production process is continuous and uninterrupted, work-in-
progress is less
2. It helps in reducing inventory
3. Production time is reduced in this layout
4. This layout involves automatic material handling which leads to
minimum possible cost of manufacturing

DEMERITS:-
1. It is very difficult to increase production beyond the capacities of the
production lines
2. This layout is very less flexible for product change
3. The rate or pace rate of working depends upon the output rate of the
slowest machine and hence leading to excessive idle time for other
machines if the production line is not adequately balanced
4. Machines being put up along the line, more machines of each type have
to be installed for keeping a few as stand by, because if on machine in
the line fails, it may lead to shut down of the complete production line.
That is why the line or product layout involves heavy capital investments
APPLICATIONS
1. Typically used in automobile industries etc
2. Also used for electric appliances manufacturing where mass production
is adopted
FOR MORE:- https://accountlearning.com/product-layout-suitability-
advantages-disadvantages/

4. CELLULAR LAYOUT

 A cellular layout is a manufacturing layout where machines and

workstations are arranged in a group, or "cell", to produce a specific
group of products.

 In this layout, the cell is designed to be self-contained and flexible,

allowing it to produce a range of products with minimal setup time and
reconfiguration

 Each cell typically has its own dedicated set of machines and workers
who are responsible for the production of the specific group of products.

 The goal of a cellular layout is to reduce the distance that materials and
products have to travel between workstations, which can reduce lead
times and improve efficiency
 Cellular layouts are often used in high-volume manufacturing operations
that require a high degree of flexibility and customization, such as in the
automotive industry

MERITS: -
1. Cellular layout reduces the distance materials and products have to
travel between workstations, which can increase efficiency and reduce
lead times
2. Cellular layout allows for a high degree of flexibility and customization,
making it well-suited for high-volume manufacturing operations
3. Dedicated cells with specialized equipment can reduce setup time,
making it easier to switch between products or processes
DEMERITS: -
1. Implementing a cellular layout can require a significant investment in
specialized equipment and dedicated workstations, which can be costly
2. In some cases, specialized equipment or workstations may be
underutilized if demand for the associated products is low
 3. Workers in a cellular layout may require specialized training to operate
the specialized equipment and perform the specific tasks required for
their cell

APPLICATIONS: -
1. Cellular layout is commonly used in the assembly of automobiles, where
specific groups of workers and machines are dedicated to producing
specific parts of the car
2. Cellular layout can be used in the production of large aircraft parts,
where specialized cells are designed for the assembly of specific
components

5. HYBRID LAYOUTS
 A hybrid layout is a manufacturing layout that combines elements of two
or more of the other layout types to create a customized solution that
meets the specific needs of the manufacturing operation
 For example, a hybrid layout could combine a product layout with a
process layout. This could be useful in a manufacturing operation that
produces a range of products that require different processes, but
where the volume of production for each product is not high enough to
justify a dedicated production line.
 By combining the two layouts, the manufacturing operation could
achieve a balance between efficiency and flexibility, allowing it to quickly
switch between products and processes as needed

FACTORS INFLUENCING CHANGES IN LAYOUT

There are several factors that can influence changes in manufacturing layout.
Some of the most common factors include:

1. Changes in product design:

A change in product design may require changes in the manufacturing process
and layout. For example, a new product may require different machines,
equipment, or workstations than an existing product

2. Changes in production volume:

Changes in production volume can impact the layout of a manufacturing

operation. As production volume increases, it may be necessary to add more
machines, equipment, or workstations to increase efficiency

3. Changes in technology or process:

Advances in technology can lead to changes in the manufacturing process and

layout. For example, the adoption of automation technology may require
changes in the layout to accommodate new equipment and processes

4. Changes in customer demand:

If customer demand for a specific product increases, it may be necessary to

reconfigure the layout to increase production efficiency

5. Changes in workforce:

If a company changes its workforce, such as hiring new employees or

restructuring job roles, it may need to reconfigure its layout to optimize
production efficiency and reduce costs

6. Changes in space availability:

If a company expands or relocates its production facility, it may need to
reconfigure its layout to optimize production efficiency and accommodate the
new space
 7. Changes in regulations:
Changes in regulations can impact the layout of a manufacturing operation. For
example, new safety regulations may require changes in the layout to ensure
compliance

PRODUCTION PLANNING AND CONTROL [IMPORTANT]

Production planning and control (PPC) is the process of planning, coordinating,
and controlling the production process in a manufacturing organization to
ensure that products are produced efficiently, on time, and to the required
quality standards.
The main objectives of PPC are to
-optimize the use of resources
-reduce waste
-minimize lead times
-improve overall efficiency and productivity.

The process involves several key steps, including:

1. Forecasting demand:

The first step in PPC is to forecast the demand for the product. This involves
analysing historical sales data, market trends, and other factors to estimate
how many units of the product will be needed over a given time period.

2. Developing a production plan:

Once the demand has been forecasted, a production plan is developed to

ensure that enough units of the product are produced to meet the forecasted
demand. The plan considers factors such as available resources, production
capacity, and lead times.

3. Scheduling production:

Once the production plan has been developed, the next step is to schedule
production. This involves determining the sequence of operations required to
produce the product, and the amount of time each operation will take.
4. Controlling production:

Once production is underway, PPC involves controlling the production process

to ensure that it is proceeding according to plan. This involves monitoring
progress, identifying and addressing issues that arise, and adjusting the plan as
needed

5. Quality control:

PPC also includes quality control measures to ensure that the products
produced meet the required quality standards. This involves testing and
inspecting products at various stages of the production process, and adjusting
the process as needed to ensure that quality standards are met

IMPORTANCE OF PRODUCTION PLANNING AND CONTROL:

1. Improved Efficiency: PPC helps to streamline the production process,

reduce waste, and optimize resources to improve overall efficiency. This
helps to reduce production costs and increase profitability.

2. Better Quality: PPC ensures that quality control measures are

implemented at every stage of the production process. This helps to
improve the quality of the finished product, reduce defects, and increase
customer satisfaction.

3. Timely Delivery: PPC helps to schedule production activities and ensure

that the production process runs smoothly. This helps to ensure that
products are delivered on time and that deadlines are met.

4. Effective Resource Management: PPC helps to optimize the use of

resources such as labour, machines, and materials. This helps to reduce
waste, increase efficiency, and minimize costs.

5. Increased Flexibility: PPC helps to make the production process more

flexible and adaptable to changes in demand, customer preferences, and
other factors.

BENEFITS OF PRODUCTION PLANNING AND CONTROL:

1. Reduced Costs: PPC helps to reduce costs by optimizing resources,

improving efficiency, and reducing waste.
 2. Increased Productivity: PPC helps to increase productivity by ensuring
that the production process runs smoothly and efficiently.

3. Improved Quality: PPC helps to improve the quality of the finished

product by implementing quality control measures at every stage of the
production process.

4. Better Customer Service: PPC helps to ensure that products are

delivered on time and that customer needs are met, which helps to
improve customer satisfaction.

5. Improved Communication: PPC helps to improve communication

between different departments and teams involved in the production
process, which helps to reduce errors and improve efficiency.

DIFFERENCE BETWEEN CAPACITY PLANNING AND AGGREGATE

PLANNING
Aggregate planning and capacity planning are both important aspects of
production planning, but they focus on different time horizons and levels of
detail

AGGREGATE PLANNING CAPACITY PLANNING

Aggregate planning refers to the Capacity planning, on the other hand,

process of developing a general plan is a more detailed and short-term
for the overall production of goods or process that involves determining
services over a period of time, usually the resources needed to produce a
6-18 months specific product or service

The purpose of aggregate planning is The goal of capacity planning is to

to determine the optimal quantity ensure that the necessary resources
and timing of production for the are available at the right time and in
various products or services that a the right quantities to meet the
company offers, in order to meet production schedule, without
anticipated demand while minimizing overloading the system or incurring
costs unnecessary costs.

Aggregate planning considers factors Capacity planning considers the

such as sales forecasts, inventory available equipment, labour, and
levels, and production capacity, but materials, as well as the expected
does not focus on specific production production volume and time frame.
processes or individual products

Aggregate planning is a higher-level, Capacity planning is a more detailed,

longer-term process that focuses on shorter-term process that focuses on
overall production planning the specific resources needed to
produce a given product or service