The
Seminar Report
on
MANUFACTURING
PLANNING
Presented by:
Musab Faisal Qazi
Roll No: 42
Sem VII M
2
!
Manu"a#turin$ in%ol%es the trans"ormation o" ra& materials into use"ul "inished $oods' This
trans"ormation is a##omplished throu$h the utilization o" #ompany resour#es: labor( materials(
"a#ilities( and e)uipment' To assure that manu"a#turin$ is a##omplished in an e""i#ient manner(
manu"a#turin$ plans must be established' These plans $i%e detailed in"ormation on ho& the
produ#t &ill be made' It in#ludes identi"i#ation o" pur#hased materials( e)uipment to be used(
operations to be per"ormed( "lo& o" materials throu$h the plant( labor re)uirements( et#'
Manu"a#turin$ plannin$ be$ins &ell in ad%an#e o" any a#tual produ#tion' In "a#t( a #ontra#tor
should #reate preliminary plans as an input to their #ost estimatin$ "or the bid pro#ess' The plans
are #ontinuously updated throu$hout produ#tion as e""orts are underta*en to impro%e the pro#ess'
The #reation o" a manu"a#turin$ plan re)uires a systemati# pro#ess "or ans&erin$ )uestions su#h
as the "ollo&in$:
+ ,hat is the produ#t to be produ#ed-
+ ,hat assemblies.parts.#omponents #ompose the "inal produ#t-
+ ,ho &ill manu"a#ture the #omponents-
+ ,hat e)uipment.operations are re)uired-
+ ,here &ill the #omponents be made-
+ ,hat type o" labor is in%ol%ed-
+ /o& lon$ does it ta*e to produ#e the #omponents.assemblies-
+ ,hat ra& materials are re)uired-
+ /o& mu#h o" ea#h #omponent.assembly must be produ#ed-
+ /o& should the produ#t "lo& throu$hthe plant-
+ ,hat should the lot sizes be-
The "irst step in #reatin$ a manu"a#turin$ plan is to $ain a thorou$h understandin$ o" the item to
be produ#ed' This is a##omplished by re%ie&in$ dra&in$ and detailed desi$n spe#i"i#ations' 0ne
o" the most use"ul dra&in$s is the e1ploded assembly dra&in$' Not only does this dra&in$ $i%e
the planner a "eel "or the types o" #omponents and #omple1ity o" the produ#t( but also allo&s the
planner to %isualize ho& the #omponents must be assembled' I" e1ploded assembly dra&in$s are
not a%ailable( the planner may rely on a prototype &hi#h #an be disassembled'
2 supplement to the e1ploded assembly dra&in$ is the bill3o"3materials' This $i%es the planner a
stru#tured list o" all assemblies.parts.#omponents that ma*e up the "inal produ#t
2"ter re%ie&in$ the o%erall produ#t throu$h assembly dra&in$s( prototypes( and bill3o"3materials(
the planner must obtain detailed dra&in$s "or ea#h #omponent and.or subassembly in the produ#t'
These &ill be re)uired to determine detailed routin$s and operations needed to manu"a#ture ea#h
#omponent'
0n#e the planner has a thorou$h understandin$ o" the produ#t( de#isions must be made on &hi#h
parts &ill be made in3house %ersus those that &ill be #ontra#ted to other or$anizations' These
de#isions are mana$ement de#isions &hi#h re)uire input "rom other or$anizations( su#h as:
mar*etin$( pur#hasin$( "inan#e( industrial en$ineerin$( pro#ess en$ineerin$( et#' This step
re)uires ans&erin$ )uestions su#h as:
+ 4o &e ha%e the #apability to ma*e this part-
+ 4o &e ha%e the #apa#ity to ma*e this part-
+ ,hat e)uipment is re)uired-
+ ,hat labor s*ills are re)uired-
+ Is there an out3o"3house sour#e "or this part-
+ ,hat is the e#onomi#al impa#t-
Typi#ally( i" in3house #apability e1ists( then the part should be made in3house' I" in3house
#apability does not e1ist( then the part should be pur#hased' Many parts &ill #arry a ma*e or
pur#hase desi$nation be#ause both #ontra#t and in3house #apability e1ists' In these #ases( the
most e#onomi#al alternati%e should be #hosen' /o&e%er( there are e1#eptions to these rules'
Most e1#eptions deal &ith the ability o" a %endor to meet re)uired deli%ery dates' I" a %endor
#annot deli%er in time to meet "inal produ#t deli%ery( then the part may ha%e to be made in3house
e%en thou$h this is not the most e#onomi#al alternati%e'
Subse)uent to the ma*e.buy de#isions( all parts and ra& materials must be identi"ied alon$ &ith
their ma*e.buy desi$nations' Ra& materials &ould be identi"ied "or ma*e parts only' This may be
summarized in a parts list as sho&n in "i$ure 2' In our e1ample( the in3house manu"a#turin$
"a#ility &ill produ#e all ma5or plasti# #omponents( assemble all subassemblies as &ell as the "inal
assembly( and pur#hase e%erythin$ else'
0n#e ma*e.buy de#isions are determined( de#isions must be made on 6ho& to6 manu"a#ture all in3house
#omponents and assemblies' This step re)uires sele#tin$ the spe#i"i# pro#esses( e)uipment(
and labor to be used "or ea#h part' For ea#h part( a route sheet is de%eloped' This do#ument
$i%es details o" all steps re)uired to manu"a#ture the part' This re)uires intimate *no&led$e o"
the pro#ess and e)uipment #apability &ithin a plant' 7e#ause di""erent plants ha%e di""erent
e)uipment and labor s*ills( it is hi$hly unli*ely that the route sheets "or the same produ#t in t&o
di""erent plants &ould be identi#al' In "a#t( be#ause pro#ess planners ha%e di""erent *no&led$e( it
is not un#ommon "or t&o pro#ess planners &ithin the same plant to #reate sli$htly di""erent
pro#ess plans "or the same part'
Sin#e di""eren#es in pro#ess plans is the norm instead o" the e1#eption( it is imperati%e that anyone
responsible "or produ#tion sur%eillan#e ha%e a##ess to the a#tual pro#ess plansin use'
4etermination o" s#hedule slippa$e or part re)uirements based on hypothesized plans &ill al&ays
pro%ide erroneous results'
2 sample route sheet "or one o" the manu"a#tured parts e'$' the lens housin$! in the o%erhead
pro5e#tor is pro%ided in "i$ure 8' 2s a minimum( a route sheet should pro%ide the "ollo&in$:
+ 9omponent name.number + Set3up times
+ 0peration des#ription + :nit produ#tion times
+ Toolin$ re)uirements + Ra& material re)uirements
+ Pro#ess.;)uipment.<abor re)uirements
2lthou$h the route sheet $i%es detailed in"ormation on the manu"a#ture o" ea#h part.#omponent(
it does not #ontain in"ormation on ho& to #ombine the #omponents.subassemblies into the "inal
produ#t' This in"ormation is "ound on an assembly #hart &hi#h is de%eloped by the produ#tion
planner' The assembly #hart is #onstru#ted by e1plodin$ the "inal produ#t into its elemental
#omponents "ound in the bill3o"3materials or parts list' 2n e1ample assembly #hart #an be seen in
"i$ure 4' In this #hart a #ir#le denotes an operation( &hereas a s)uare denotes an inspe#tion'
The assembly #harts and route sheets #an be #ombined to pro%ide an o%erall pi#ture o" the
produ#t "lo& &ithin the plant' This #hart is #alled an operation pro#ess #hart' 2 sample
operation pro#ess #hart is depi#ted in "i$ure =' This #hart is one o" the most %aluable #harts used
to des#ribe the produ#tion pro#ess be#ause it sho&s se)uen#in$ and pre#eden#e o" all operations
re)uired to manu"a#ture the produ#t' Pur#hased parts #an be easily identi"ied by the "a#t that
these parts do not #ontain any operations'
2 %ariation o" the operation pro#ess #hart is the pre#eden#e dia$ram or manu"a#turin$ plan' This
#hart is a net&or* dia$ram similar to a P;RT #hart &hi#h adds s#hedule in"ormation to the
operation pro#ess #hart'
9onstru#tion o" the manu"a#turin$ plan re)uires *no&led$e o" the lot sizes released to
produ#tion' Various te#hni)ues( su#h as e#onomi# order )uantity or e#onomi# produ#tion
)uantity( are used to determine optimal lot sizes' 4es#ribin$ these te#hni)ues is beyond the s#ope
o" this paper> ho&e%er( in"ormation on these te#hni)ues is readily a%ailable in any te1t on
0perations Resear#h( Produ#tion 9ontrol( or In%entory Mana$ement
,ith *no&led$e o" lot sizes and the route sheets( &e #an determine times needed to #omplete a
$i%en operation' In "i$ure 8( &e see that t&o di""erent departments are in%ol%ed in manu"a#turin$
the lens housin$' Moldin$ o" ea#h pie#e ta*es ?'@ minutes' Flash trimmin$ and inspe#tion o" ea#h
pie#e ta*es a total o" ? minute' Sin#e an in5e#tion moldin$ ma#hine is basi#ally automati#( the
operator #an be trimmin$ and inspe#tin$ at the same time the ma#hine is ma*in$ the part'
