small scale industry

Subject :Production Management & Materials management Topic : Production Functions Small Scale Industry Visited : Balaji Paper Dish S.Y.BMS - B

Thaught by: Angira madam
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PROJECT MADE BY:
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VINIT SHAH: VIVEK SHAH: RAMSAGAR TIWARI: ANKUSH PANDEY: GIRISH TRIPATHI: PRAJWAL: NADEEM SHAIKH:

123 124 165 92 166 119 127
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PRODUCTION FUNCTION
Production function is backbone of any organization. Production function is made possible only through efficient and economical production. Production function can be succeed if there is advantages in the areas of: • Good quality at economical cost. • Reduced wastage. • Optimum inventory control. • Better customer services. • Shorter manufacturing time. • Safety at work • Adaptability of production unit. Definition: Production function is the maximum set of output(s) that can be produced with a given set of inputs. Use of a production function implies technical efficiency. Synonym for production frontier, the technically efficiency part of a feasible production set, the set of all input- output combinations that are feasible (but not necessarily efficient). Alternatively, a production function can be defined as the specification of the minimum input requirements needed to produce designated quantities
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of output, given available technology. This is just a reformulation of the definition above.

1. MATERIAL PLANNING AND PROCUREMENT:
Material planning (MP) is a production planning and inventory control system used to manage manufacturing processes. Most of the material planning in small scale industry are conduct by hand An MP system is intended to simultaneously meet three objectives:


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Ensure materials and products are available for production and delivery to customers. Maintain the lowest possible level of inventory. Plan manufacturing activities, delivery schedules and purchasing activities.

The material in paper dish industry used is card paper. The material used is of least cost and do the job well. Without this material there can be no output. Material input may account for as much as 80% -85% of cost of output. Raw material as well as standard parts and semi finished products must be available when required so the production can start on time.
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Procurement means Complete process of obtaining goods and services from preparation and processing of a requisition through to receipt and approval of the invoice for payment.

It commonly involves (1) purchase planning, (2) standards determination, (3) specifications development, (4) supplier research and selection, (5) value analysis, (6) financing, (7) price negotiation, (8) making the purchase, (9) supply contract administration, (10) inventory control and stores, and (11) disposals and other related functions. Based on the consumption purposes of the acquired goods and services, procurement activities are often split into two distinct categories. The first category being direct, production-related procurement and the second being indirect, non-production-related procurement. Direct procurement occurs in manufacturing settings only. It encompasses all items that are part of finished products, such as raw material, components and parts. Direct procurement, which is the focus in supply chain management, directly affects the production process of manufacturing firms. In contrast, indirect procurement activities concern “operating resources” that a company purchases to enable its operations. It comprises a wide variety of goods and services, from standardised low value items like office supplies and
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machine lubricants to complex and costly products and services like heavy equipment and consulting services.

2.SELECTION OF PRODUCTION PROCESS:
Deciding the right production process is core function of the production department. This function gets importance to manufacture process the raw material at proper quality, at required speed. The possible methods of manufacture try to define the best method compatible with a given set of circumstances and facilities. The production process in a paper dish industry is carried in such a way,

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RAW MATERIAL CUTTING MOULDING FINISHED GOODS

A method of three dimensionally forming articles from paper web drawn from a reeled supply wherein a single ply of such web is cyclically advanced into registered cut position relative to a

reciprocating cutting die for production of register cut, article blanks, such blanks being advanced into a heated reciprocating die press for three dimensional shaping into said articles, the improvement comprising the steps of: A. Driving said cutting die at a reciprocation cycle rate that is at least twice greater than said die press cycle rate; B. Holding cut article blanks produced within a single cycle interim of said die press in a position clear of said die press; and,

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C. Simultaneously releasing said held article blanks for simultaneous loading and forming by said die press within a single cycle thereof.

3. SELECTION OF MACHINES & EQUIPMENT:
Industrial production is closely related to available production facilities coupled with appropriate machine and equipment. The machinery gets decided on the basis of scale of production. Because once machinery are installed they cannot be changed again & again. This
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is major investment by the company. So it is essential to strike balance for installing production machinery. It is also economically desirable to standardize on the processing equipments when it is decided to add equipments in the plant, there are three possibilities: • Equipments can be purchased fresh or second hand • Equipments can be leased or rented • Equipments can be fabricated within the plant Paper Plate Punching machine is designed by development to follow after the market demand. It is an automatic dish sharper of air motion model that is first found in the whole nation. Our company owns the independent knowledge right. This equipment has fullautomatically pass paper, moulding, produce dishes and constant temperature control, auto-count functions etc. Paper plate punching machine have two working stations, and with two molds in one machine, you can produce two size plates or make the same size plates in one machine.

4. LOCATION OF PLANT:
The placement of equipment and handling of material is mostly determined by plant layout. Some of the factor to be studied under location of plant are : • Cost of land and building • Nearness to market • Power and energy availability • Tax rate
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Distribution network Competitors location Suppliers location Growth potential

This firm is located in Ina puna wadi, opp. Saraswat Bank, T Junction Road- 3, Mahim East. The location of the plant is nearest to station. Which helps them to supply goods easily to the wholesalers. This firm is located in industrial area. The land of this firm is on rent. The power and energy is available to the firm 24 *7. This product is distributed all over Mumbai & Thane. The competitor named Channel Packaging is located few steps ahead from this firm. In short, “a plant should be located at a place where inhabitants are interested in its success, the product cab be sold profitably and production cost is minimum.”

5. PLANT LAYOUT AND MATERIAL HANDLING:
The plant layout is a very critical part of running an efficient cost. All work areas, production lines, material storage facilities, etc. should be designed to perform to the highest rate and the corresponding shortest cycle time.
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When designing a plant layout it is necessary to take into account all the functions within the business. The design must include not only the needs for the present business levels but should also have provisions for future expansion. This is included to avoid frequent and costly changes to the design as demand increases. An in depth study is made of the workings of the business, looking carefully at each function and the interrelationships between functions. This will provide a clear understanding of the present and future needs of the business and the interaction of each department and will be used to design the facility for the most efficient and productive workflow possible. As part of this study the following areas at a minimum, are reviewed: * Total facilities power requirement * Interaction between functions * Work space requirements by function * Work flow * Material handling requirements * Physical constraints * Special process requirements * Employee needs (legal requirements)

These plans are not necessarily those that can be used for construction purposes but will be the information that will guide an architect’s design for the construction phase of the project, if required. Material handling is a very critical part of the design and the needs of a manufacturing facility. Materials need to be properly stored and transported to and from work
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station/centers with a view towards minimizing the movement and avoiding damage to the product. The cost of this being implemented incorrectly could be devastating to the profitability of the business and also could endanger the employees. In some instances special handling equipment may be necessary to insure that the material is handled properly. The storage also becomes an important step since some material has specific shelve life criteria, corrosive material storage, environmental criteria, etc. The design needs to take into account all of these aspects for the proper storage and handling of material. Doing a proper layout correctly the first time pays significant and continuing dividends long after the task has been completed.

6. CAPACITY PLANNING:
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Every equipment has certain production capacity. On the basis of the demand of the goods the capacity is planned. Capacity have direct influence with resource and output performance. Excess capacity results in low productivity. In this firm capacity is fully depended on the demand of the dish in the market. The machinery can take load of producing dish because its depended on man power also. If workers work in multiple shifts the capacity of machine can be increase. The capacity planning decision are taken in view of contracting or expanding the facilities as per the requirement time to time. Capacity planning has seen an increased emphasis due to the financial benefits of the efficient use of capacity plans within material requirements planning systems and other information systems. Insufficient capacity can quickly lead to deteriorating delivery performance, unnecessarily increase work-in-process, and frustrate sales personnel and those in manufacturing. However, excess capacity can be costly and unnecessary. The inability to properly manage capacity can be a barrier to the achievement of maximum firm performance. In addition, capacity is an important factor in the organization's choice of technology. Capacity planning is the process used to determine how much capacity is needed (and when) in order to manufacture greater product or begin production of a new product.

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7. PRODUCTION PLANNING & CONTROL:
The production process involves the planning and control of how goods will be manufactured. This usually includes the identification of raw materials required, the quantities of components needed to manufacture items, and the human workforce required to produce these products. These functions are the tasks carried out by the Production Planning and Control Department. Production Planning Process The production planning process within the production department involves the planning of what materials are required for the production of supplies and what is required to put these materials together. Issues to consider when conducting the production planning process include:




Future Demand Planning – what is the trend of customers’ orders? Are there any upcoming events that might increase or decrease the number of orders? Lead Times – What are the time frames to manufacture an item? Are all the materials and tools required to manufacture an item available?

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Components Availability – are the components required to manufacture an item in stock? If the components are to be ordered this has to be taken into account and included in the time required to manufacture the item. Workforce Availability – this takes into consideration the skills and availability of the workforces.

The above considerations will be taken into account by the production team during the planning activity as a reference to organize the work involved according to the skills and machinery available.

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8. LOADING & SCHEDULING:
Scheduling means assigning an appropriate number of workers to the jobs during each day of work. Determining when an activity should start or end, depending on its (1) duration (2) predecessor activity (or activities) (4) resource availability and (5) target completion date of the project. Features of a Scheduling: * A list of people who are accountable for the various activities. * A project breakdown into many manageable packages. This should be based on the deliverables / outputs. * A baseline against which progress can be measured. Concepts such as "early" or "late" have no meaning in planning. * The project interdependencies shown in a clear way. * It should have a pictorial representation of project progress. * The time constraints, key dates and milestones should be clearly visible.
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Both loading & scheduling activities helps in production planning. Each workers here has to prepare
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100 packets from 10am -1.30noon and per day they are instructed to prepare 350 packets . Loading depends on scheduled time of the workers.

9. MAINTENANCE:
Maintenance involves fixing any sort of mechanical or electrical device should it become out of order or broken (known as repair, unscheduled or casualty maintenance). It also includes performing routine actions which keep the device in working order (known as scheduled maintenance) or prevent trouble from arising (preventive maintenance). Maintenance may be defined as, "All actions which have the objective of retaining or restoring an item in or to a state in which it can perform its required function. The actions include the combination of all technical and corresponding administrative, managerial, and supervision actions." The former of these represents a closed loop supply chain and usually has the scope of maintenance, repair or overhaul of the product. The latter of the categorisations is an open loop supply chain and is typified by refurbishment and remanufacture. The main characteristic of the closed loop system is that the demand for a product is matched with the supply of a used product. Neglecting asset writeoffs and exceptional activities the total population of the
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product between the customer and the service provider remains constant Maintenance types Generally speaking, there are two types of maintenance in use:





Preventive maintenance, where equipment is maintained before break down occurs. This type of maintenance has many different variations and is subject of various researches to determine best and most efficient way to maintain equipment. Recent studies have shown that Preventive maintenance is effective in preventing age related failures of the equipment. For random failure patterns which amount to 80% of the failure patterns, condition monitoring proves to be effective. Corrective maintenance, where equipment is maintained after break down. This maintenance is often most expensive because worn equipment can damage other parts and cause multiple damage.

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10. QUALITY CONTROL & INSPECTION:
Quality control and inspection is one of the important function in production. Every firm should have one individual who look after the quality of the goods and also inspect that every thing is working in proper way. A good quality item is one which conforms to some standard specification such as shape, size, colour etc. Inspection helps to maintain good quality control. The manager at firm look after the size in which paper is cut into the shape which would be used to prepare dish and also look after the packaging of the dish in proper packets. Quality control is a process by which entities review the quality of all factors involved
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in production. This approach places an emphasis on three aspects: 1.Elements such as controls, job management, defined and well managed processes performance and integrity criteria, and identification of records 2.Competence, such as knowledge, skills, experience, and qualifications 3. Soft elements, such as personnel integrity, confidence, organizational culture, motivation, team spirit, and quality relationships. The quality of the outputs is at risk if any of these three aspects is deficient in any way.

11. PRODUCTION FORECASTING:
Production Forecasting means process of judging how much production is required to meet estimated sales in a particular forecasting period. Considerations include previous sales, the general state of the economy, consumer preferences, and competitive products. Production forecasting decisions affect budgetary and scheduling decisions. Production forecasting is basic point of the production function. Production forecasting is to study past, present and future needs of the firm.
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It means that in past what was the performance of the company, what where the mistakes done by the company so that the firm can make the necessary changes and improve the production in present and also in future. Production forecasting also helps the firm to improve the quality of the firm. Its also helps to increase the demand of goods in the market. Forecast becomes the basis for the plans and schedule for buying, manufacturing, product selling and other activities of the firm.

12. PRODUCT DESIGN & DEVELOPMENT:
Product design and development is based on market demand. The consumer decides that what kind of dish and what size of dish they want. If product is not designed as per the market demand than it will just waste the manpower, material and equipments. So there should be improvement in the product features to capture the market.
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Product development is the process of creating a new product to be sold by a business or enterprise to its customers. In the document title, Design refers to those activities involved in creating the styling, look and feel of the product, deciding on the product's mechanical architecture, selecting materials and engineering the various components necessary to make the product Development refers collectively to the entire process of identifying a market opportunity, creating a product to appeal to the identified market, and finally, testing, modifying and refining the product until it is ready for production.

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