appc manufacturing process

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APPC Manufacturing systems. NIFT, Navi Mumbai, Presentation by Ranjan Kumar Saha, Associate Professor for classroom discussion

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Page 1: APPC manufacturing process

APPCManufacturing systems.

NIFT, Navi Mumbai,

Presentation by Ranjan Kumar Saha, Associate Professor for classroom discussion

Page 2: APPC manufacturing process

Productive system types

• Process-Focused systems– The nature of the demand on the productive system results in intermittent demand for the system’s facilities, and each component flows from one process to the next intermittently. Thus, the process-focused system with intermittent demand on process types must be flexible as required by the custom product, and each generic department and it’s facilities are used intermittently as needed by the custom orders.

Page 3: APPC manufacturing process

Productive system types

• Process-Focused systems– for e.g. in a machine shop we might expect to find milling machine departments, lathe departments, drill departments and so on. The flow of the items being processed in such productive system is dictated by individual product requirements, so the routes through the system are variable.

Page 4: APPC manufacturing process

Productive system types

• Product-Focused systems: The nature of the demand on the productive system that produces high volume, standardized products results in continuous use of the facilities. Processing is adapted completely to the product. Individual processes are physically arranged in the sequence required, and the entire system is integrated for a single purpose. Thus continuous system have a product focus.

Page 5: APPC manufacturing process

Types of Production Systems

1) Intermittent Production system-

(For custom order manufacturing)

a) Project Production

b) Jobbing Production

c) Batch Production(can be production for stock)

2) Continuous system- (Production for stock)-

a)Mass Production.

b) Process production.

Page 6: APPC manufacturing process

Intermittent System

• These are those where the prod’n facilities are flexible enough to handle a wide variety of products and sizes.

1. Most products are produced in small qty’s.

2. Machines and equipments are laid out by process.

3. Workloads are generally unbalanced.

4. Highly skilled operators are reqd. for efficient use of machines and equipments.

5. In-process inventory is large.

6. Flexible to suit prod’n varieties.

Page 7: APPC manufacturing process

Features of Intermittent system

1. Demand can be discontinuous .

2. All operational stages may not be balanced.

3. Elaborate sequencing and scheduling is required.

4. Needs high inventory.

5. Storage is necessary at each stage of production process.

6. Can adjust to new situation and specification.

7. Items are manufactured according to order.

Page 8: APPC manufacturing process

Types of Intermittent Systems

• A) Project production: Project production is characterized by complex sets of activities that must be performed in a particular order within the given period and within the estimated expenditure. Where output of a project is a product, such products are generally characterized by immobility during transformation. Operations of such products are carried out in fixed position assembly type of layout. e.g. production of ships, locomotive and aircraft, construction of roads, buildings.

Page 9: APPC manufacturing process

Project production system

• Characteristics of project production:

• A)Definite beginning and definite end.

• B)Non-uniform requirement or resources.

• C) Involvement of different agencies.

• D)Fixed position Layout.

• E)High cost overruns.

Page 10: APPC manufacturing process

Job production

• Job production/Jobbing production : - Job or

‘make complete’ is the Production charactersed by the manufacturing of one or few numbers of a single product designed and manufactured strictly to customer’s specifications, within the given period and within the price fixed prior to the contract.e.g. general repair shops, special purpose machine tool manufacturers, tailoring shops manufacturing made-to-measure suite of clothes.

Page 11: APPC manufacturing process

• Characteristics of job/jobbing production:

• A) In this system the goods are produced to definite customer’s orders. There is no assurance of continuous demand for specific items.

• B)small production runs.

• C) Discontinuous flow of materials

• E) Disproportionate manufacturing cycle time.

• F)General purpose machines and process layout.

• G)high skilled labour.

Page 12: APPC manufacturing process

Batch production

• Batch production is characterised by the manufacture of a limited mumber of a product( but many such quantities of different products) produced at regular intervals and stocked in warehouses as finished goods(or finished parts) awaiting sales (or withdrawal for assembly).

• E.g. Process industry such as pharmaceuticals, paints, chemicals, manufactures of readymade garments, etc.

Page 13: APPC manufacturing process

Batch production

• Characteristics of Batch production:• a) short production runs.

• B) skilled labour in specific trade.

• C) General purpose machines and process type of layout.

• D) large work in progress.

• F) Flexibility of production schedules.

• G) Need to have production planning and control.

• H) Limited function of production planning and control.

Page 14: APPC manufacturing process

Continuous system

• In this the items are produced for the stocks and not for specific orders. Before planning mfg to stock, sales forecast is made to estimate likely demand of product and master schedule is prepared to adjust the sales forecast according to past orders and level of inventory. After setting master production schedule, detailed planning is carried on.

Page 15: APPC manufacturing process

• In continuous manufacturing systems each production run manufactures in large lot sizes and the production process is carried on in a definite sequence of operations in a pre-determined order. FIFO priority rules are followed in the system. In short, here input-output characteristics are standardized allowing for standardization of operations and their sequence.

Page 16: APPC manufacturing process

Features of continuous system

1. There must be continuity of demand.

2. The product must be standardized .

3. Material should be per specifications and delivered on time.

4. All operation stages in the process must be balanced.

5. Work must conform to quality standard.

6. Inspection must be in line with production.

Page 17: APPC manufacturing process

Types of continuous system

• Mass production (Mass & flow Prod.)

• Process production

Page 18: APPC manufacturing process

Mass & Flow production

• Mass as well as flow production are characterized by the manufacturer of a several number of a standard product produced and stocked in the warehouses as finished goods awaiting for sales.

• Mass production E.g. plastic goods.

• Flow production e.g. assembly shops of automobiles, refrigerators, radios, television sets, electric fans,etc.

Page 19: APPC manufacturing process

Mass & Flow production

• Characteristics of Mass & Flow production.

• A)continuous flow of material

• B)special purpose machines and product type layout.

• C)low skilled labour.

• D)Easy supervision

• E)limited work in progress

• F)Less flexibility in production schedule.

Page 20: APPC manufacturing process

Process production

• Process production is characterised by the manufacture of a single product produced and stocked in the warehouses awaiting sales. The flexibility of such product is almost zero as only one type of product can be produced in such plants.

• Typical E.g. of such plants are sugar,steel,cement,coke,refineries,etc.

Page 21: APPC manufacturing process

Process production

• Characteristics of process production:

• A)Special purpose machines with built-in controls.

• B)Highly mechanized material handling.

• C)low skilled labour.

• D) negligible work in progress

• E) limited production planning and control function.

Page 22: APPC manufacturing process

Classification of Production System

• Production systems can be classified as Job Shop, Batch, Mass and Continuous Production systems.

Page 23: APPC manufacturing process

Manufacturing systems in Apparel Industry

• Make through system• Conventional bundle system• Clump system• Progressive bundle system• Flexible flow system• Straight lien system• Synchro flow system• UPS• Modular

Page 24: APPC manufacturing process
Page 25: APPC manufacturing process

Conventional bundle system

• Sewing MC arranged in lines

• Central storage / dispatch area

• Worker 1 collects bundle from distributor, sew, back to distributor

• Distributor passes the bundle to worker 2

Page 26: APPC manufacturing process

Conventional bundle system

Page 27: APPC manufacturing process

The Clump system

• Variation of conventional bundle system

• Operators collects a clump rather than bundle

Page 28: APPC manufacturing process

Conventional bundle adv. & Dis adv.

• Flexible. Copes with frequent style changes

• Less impact of absenteeism as distributors can control the amount of work received & dispatched

• Easy to operate & easy to supervise

• Uniform level of quality. Controller checks quality

• Excessive material handling

• Difficult to control inventory

• WIP cannot be monitored

• Work place engineering is difficult

• High WIP

• Large storage required

Page 29: APPC manufacturing process

Progressive bundle system

• Sewing operations laid out in sequence

• Each operator receives bundle, untie, work, tie and pass to operator no 2

• Need storage as rack/bin/table for storing WIP

Page 30: APPC manufacturing process

Progressive bundle system

Page 31: APPC manufacturing process

Progressive bundle system adv & disadv

• High productivity• High level of labor utilization• A Uniformly high standard of

work can be achieved• Training time and costs can be

reduced• Semi skilled labor can be used• Individual performance can be

monitored and incentives offered

• M/C investment cost is high• Not adaptable for short run

production & frequent style changes, as it require arrangement of workstations.

• High handling costs for bundle handling & transportation

• High WIP , so it involves high capital commitment and can block the cash flow of the factory

• High management skill require to arrange the work flow and decide the no. of operator for each operation

Page 32: APPC manufacturing process

Flexible Flow system

• Similar to progressive

• Workers work at engineered work place

• Work supplied thru rack @ side

• Flow is flexible

Page 33: APPC manufacturing process

Flexible Flow system

Page 34: APPC manufacturing process

Straight line system

• Manufacturing process broken down into several operations which take the same time to complete

• Groups of operators

• Handle only individual garments

• Work passed by tray

• Conveyor belt for distribution can be used and its speed will be set to suit the cycle time

Page 35: APPC manufacturing process

Straight line system

Page 36: APPC manufacturing process

Straight line system

Page 37: APPC manufacturing process

Synchro flow system• Similar to straight line

• Garment parts of same size & color are processed separately

• I.e. they flow in synchronize manner

Page 38: APPC manufacturing process

Synchro flow system adv & dis adv

• Fast throughput time• Low work in progress• Less material handling

time• Does not require a great

deal of technical supervision

• Absenteeism can causes problems, as the system is based on workers working within a time limit.

• MC break down & worker absenteeism may disrupt work flow

• High std of work measurement necessary and high pre production skills needed.

Page 39: APPC manufacturing process

UPS

• Unit production system

• Computer controlled prod line

• Overhead conveyor system to move individual units

• All parts of a single garment are carried by means of hanging carrier

• No need to remove parts from carrier

• Automated material handling

• Electronic data collected

• Payroll & inventory data

• Immediate tracking of styles

Page 40: APPC manufacturing process

UPS

Page 41: APPC manufacturing process

UPS

Page 42: APPC manufacturing process

UPS

Advantage

• Very flexible and complied with work measurement

• Little WIP

• Fast throughput time can be achieved because of the lower WIP in the system.

• Low WIP and over head transport system leads to better space utilization.

• Less handling time

• High quality of garments.

Dis Advantage

• Investment cost of this system is high.

• A central place needed for quality control

• Suitable for large orders for a particular style, as high preparation works are needed for plant layout and line balancing

Page 43: APPC manufacturing process

Modular Manufacturing

• Groups operators into teams / modules

• Team works on one / few garment at a time instead of bundles

• Operators sit/stand

• Rotate workstations

• Self inspect

Page 44: APPC manufacturing process

Modular Manufacturing

Page 45: APPC manufacturing process

Modular Manufacturing