Operations Final

8/2/2019 Operations Final

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WORLD CLASS MANUFACTURING

TECHNIQUES AND WHERE THEYARE USED IN INDIA

ByAnkit ShashwatKhushboo Mathur

Riddhi ShahRohan BatraSaiyati KamdarTarmeem ShaikhTulsi ShahUjas Sanghvi


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Director of the American Quality andProductivity Institute, has often said:

The people work in a system.

The job of the manager isTo work on the systemTo improve it, continuously,

With their help.


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IMPORTANCEOFWORLD

CLASSTECHNIQUES

Important for quality and process improvement

Help you Go Global

Edge over competitors

Increase in productivity


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STATISTICAL PROCESS

CONTROL

Monitoring production process to detect and preventpoor quality

Developed by WALTER SHEWHART in the early 1920s

expanded upon by Dr. W. Edwards Deming, whointroduced SPC to Japanese industry after WWII.

Contributes to TQM goals.

Primarily, manage charts & other SPC methods are

used to decrease variation & improve manufacturingprocesses


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ILLUSTRATIONS

Ex: hospitals

Staff response to requests,speed of admittance andcheck outs

Airlines

Waiting time at ticket counters,flight delays, accurateinformation

Grocery stores

Frequency of stock out items,customer complaints.


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MAKE TO ORDER

It is a strategy that customizesthe specifications of thecustomers.

It manufactures only the endproduct after the order isplaced.

It creates additional wait time

but at the same time is flexible. In India: Dell, BMW, Bata ,Star

India Company.


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STREAMLINE PROCESS

Effectively organizing and simplifying themanufacturing processes.

Identifying and eliminating (or at leastreducing) non-value-added activity.

In India: Fiat, Visa process, Companies.


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ILLUSTRATION :AUTOMATIONPROCESS


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TOTAL PREVENTIVEMAINTAINANCE

Approach that places the responsibility for routinemaintenance on the workers who operate themachinery.

Used in many Japanese companies, TPM givesemployees "a sense of responsibility andawareness of the equipment they use and [cuts]down on abuse and misuse of the equipment.

Among the main benefits of TPM is thatemployees gain a more complete understanding ofthe functioning of the system.


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ABI Showatech (India) Ltd, Pulivalam

Hindustan Unilever Ltd, Nashik Factory

Hindustan Unilever Ltd, Pune Tea ExportsFactory

Hospet Steels Limited

National Engineering Industries Ltd, NewaiPlant

Titan TimeProducts Limited

TVS Motor Company Mysore Plant


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JUST IN TIME

Just in time (JIT) is a production strategy that strives to

improve a business return on investment by reducing in-process inventory and associated carrying costs.

JIT focuses on continuous improvement , quality, andefficiency.

To meet JIT objectives, the process relies onsignals between different points in the process, whichtell production when to make the next part.

The real challenge before Indian managers is toestablish priorities among potential JIT techniques toachieve best possible advantage of JIT implementation inIndian industries.

TCS, Wipro to apply just-in-time model to hire freshers


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HIGH EMPLOYEE

INVOLVEMENT

Contribute to continuous improvement Retains your best employees

Suggestion systems Helps in quality management Ex: provide quality service to Disneys guests


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QUICK CHANGEOVER

Reducing waste in a manufacturing process reduces production lot sizesProductivity increases

Reduced production timeElimination of setup errors and defects Improved qualityNew attitudes on controllability of work process

amongst staff


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CROSS FUNCTIONAL TEAM

A cross-functional team is a group of people withdifferent functional expertise working toward a commongoal. It may include people from finance, marketing,operations, and human resources departments

Self-directed teams responding to broad and decision isbased on consensus.

Benefits: Less unidirectional

Greater scope of information Greater depth of information

Greater range of users

Less teleological


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VARIABLEREDUCTION

Selecting Production System Control Mechanism- toemphasize that the system should be as self-regulating aspossible thereby reducing the time constant of reaction andconveying information upstream and downstream. Onemethod that is both visual and effective is a kanban system.

Kanban: A Card to Pull Production Toyotas Taichi Ohno introduced kanbanas a tool in the development of

Just In Time manufacturing.


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KANBAN.CONT

Kanban, meaning billboard or sign, is a scheduling system

that pulls production based on actual demand thus reducingcost and variables used like handling, inventory and transport.

Kanbancontrols the timing and quantity, as well as the preciseitem to be produced.

A kanbansystem requires a fair level and well-understooddemand, as well as careful analysis of the capabilities of themanufacturing process. Example: In grocery stores, It is easy to imagine the final assembly point or

final storage area for finished goods as the display shelf. As customer orders

deplete the supply of finished goods, a point is reached that triggers aproduction order. Likewise, when a production order depletes raw material tobelow its trigger point, a purchase order is sent to the external supplier.


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CELLULAR MANUFACTURING

FEATURES: Cell: Group of workstations, machines or equipments

arranged strategically

Dedicated to a process, a sub-component, or an entire

product

Production is through successive operations

Cellular configurations can be in several forms

Suitable for factories as well as offices Ensure higher productivity and short manufacturing

lead times

Used in companies like Coca-Cola, Bisleri, Kingfisher

Beer, Pepsi


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LARGE LOT SIZES

What encourages us to use large lotsizes?

The lot size is the amount produced for

each machine setupA setup uses time on the constraintLarger lots cause fewer setups

To maximize throughput select the lotsize as large as possible

One Remedy: Reduce the setup time


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SMALL LOT SIZE

What encourages us to use small lotsizes?

Small lots reduce cycle timeWIP is proportional to cycle timeReducing cycle time reduces inventory


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BENEFITS OF SMALL LOT

Better quality control

Better delivery performance

Smaller manufacturing investmentSmaller finished goods inventoryFaster response to engineering

changes

Increased visibility of problemsPermits greater flexibility in

scheduling


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THANK YOU!!!

Operations Final

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