Manufacturing Planning and Scheduling Techniques - Assignment Example

Manufacturing Planning and Scheduling Techniques Task 1) Question 1) Light alloy wheels have become the first choice of all the big brands of cars as they provide many high-quality features like strength, durability, style and dependability. In this paper, the case study I have chosen is BMW light alloy wheels, whose maintaining and scheduling techniques will be discussed later in the paper. The manufacturing process of light alloy wheels includes a number of complex techniques that need to be thoroughly understood prior to designing a part. BMW light alloy wheels are the symbol of quality all over the world. The class they offer is simply unmatched. Authentic BMW Light alloy wheels are the consequence of a complicated innovation and style practice – concentrated around the private BMW versions along with the numerous problems. The outcome is a sizable collection of light alloy wheels that satisfy the finest quality criteria and are flawlessly incorporated into the all-round depiction of the BMW they were meant for. Forging Forging is a basic process included in the production process of light alloy wheels. A paired thermo-mechanical form of the analysis of plastic-type deformation and ambiance substitute is personalized in the binding component configuration. With the intention to take into consideration the strain-rate impact on element traits in conjunction with the flow and pressure dependence on high temperature, the inflexible visco-plasticity is commonly employed in the display. An assortment of process scenarios was applied to the display such as punch pace, side perimeter, along with the deepness of the die cavity. Evaluation for a more straightforward and compact style is conducted and matched against the appearance in regards to forging load to verify the genuineness of the structure customized. Following that, various methods with full-scale item for a 6061 aluminium-alloy wheel are simulated. Material flow, pressure distributions exerted on the die fortification, heat distributions and then forging weight are summarized similarly to basic data for process structure and selection of an appropriate press equipment. High Pressure Die Casting With this particular method of High Pressure Die Casting, the alloy in the liquid form is injected at extremely swift speed and significant stress into a steel cast. This equipment consists of two upright platens upon which enhancers are placed which cause the die to be maintained as halves. One platen is installed, whereas, the other may move very well, guaranteeing that the die is going to be exposed and closed. An evaluated level of metal is put into the strike sleeve and after that released into the cast cavity employing a piston that is able to be driven hydraulically. The moment the metal has solidified, the die is released and the casting removed. Throughout this practice, certain preventive measures must be accustomed to abstain from a number of gas inclusions which lead to blistering during the course of follow heat-treatment or welding of the casting object. Since these tools and its dies are incredibly costly, that is why pressure die casting is suitable only for mass production. Low Pressure Die Casting Within the Low Pressure Die Casting process, pressures of as high as 0.7 bar are standard. Low-pressure die casting is especially ideal for the production of components that are symmetric with regard to an axis of flipping. Usually, the Light automobile rims are created by this process. It is a known fact that that low pressure die casting is the normal technique approved for light-weight aluminium rims traded in the automobile market, nevertheless, it offers an outstanding worth for the previously owned additionally. Low pressure die casting works by using a relatively low pressure (around 2 bar) to achieve a rapid mold packing to be able to produce a dense microstructure resulting in a finished item that has improved mechanized characteristics as compared to a gravity cast wheel. On the other hand, it leads to moreover, in sparingly improved production cost rather than gravity casting. While utilizing suitable approach methods, LPDC wheels will provide improvements in ductility over HPDC magnesium rims and any kind of cast aluminium wheels, they continue to be considerably less ductile compared with cast magnesium. Gravity Casting Gravity Casting is regarded as the most fundamental and most affordable phase of wheel generation. The process involves doing away with molten alloy directly into the wheel forged, implementing simply the stress of gravity to pressure the alloy into the cast. This yields the little thick steel. Naturally, the Gravity Cast alloy are believed to be weightier and more tangible, when compared with metal found in other manufacturing strategies, in order to have the ability to carry just as much as required resilience to be employed safely for wheels. Gravity Casting constitutes of a conventional cast for gravity die casting. Cores which are found inside the molds, are generally produced from bonded sand. Gravity die casting is acceptable for bulk production and for entirely mechanized casting. Gravity casting offers smart development cost and is a first-rate approach for casting layouts that are more visually concentrated or when the reduction of the wheel mass is not an important concern. Because of the reason the process is dependent just on gravity to stock up the cast, the cast structure, usually shows much more imperfection compared to that produced by several other casting processes. As a consequence, gravity cast wheels are generally likely to carry a rather greater mass to achieve the required resilience (Davis, 213-214) Quality Control At the time of the quality control process, every single wheel is vigilantly scrutinized making sure that the surface finish is near to more than required if much easier to the genuine assembly plant surface texture. The goal of quality control process is to make it possible for any wheels to place the unit until it is definite that it is 100% up to the criteria and prepared to be brought back to the client. Tires are there after reinstalled to alloy wheels with top of the line valves before acquiring safely equipped to the client’s vehicle. There are lots of different color coatings available. All through the alloy wheel refurbishment process every single wheel is diligently scrutinized to make sure the finish is often as near as is achievable to the real factory feel. BMW light alloy wheels are made sure to pass through vigilent quality control processe that’s the reason why they are so reliable and strong. Question 2) PERT / CPM Program Evaluation and Review Technique, known as PERT, is an enlightening method for preparing the timely accomplishment of projects that was originally manufactured by the Navy in 1958 to cope with the Polaris missile project. CPM (Critical Path Method) is an exceptionally identical strategy that was put together by the RAND Network in 1957 (and potentially 'acquired' by the Navy). There surely is not any type of main practical difference between PERT and CPM, and a wide range of individuals currently look at them to be the similar strategy. Nonetheless, particular academics consider them as two various methods since they actually possess a couple of insignificant specialized categories. PERT just happens to be realistically similar to other particular organizing techniques, like Gantt Charts and Material Requirements Planning (MRP) additionally; the link that is most basic to observe is that, in an exceedingly genuine way, all three techniques count in back from the favored finish time to plan task start times. Essentially, PERT/CPM assessment is employed for three purposes: First, Sketching a diagram that shows the progression through which the numerous responsibilities will probably be finished. Secondly, discovering the minimum of venture end time, and finally finding out the essential way, the compilation of tasks which can render the entire project deferred in the event that one of the responsibilities a longer time than estimated. It is a fact that MRP was actually established in One of a Kind Process eventually in tandem with the PERT-CPM. When finished, an extremely typical approach is accomplishing the preliminary order BOM approximation influenced by the critical path nodes of the PERT, together with the second order BOM is paired implementing due date tolerances around the preliminary order identified ones. It is primarily a tuned as well as relatively revolutionary approach, asking for a means (from PERT to MRP) software application integration. However, the bothersome aspects are the following ones: The PERT is squandered as a substantial way of link along the association because of the cracking from "phases" into "bills of materials". The phases arranging is widely seen as the genuine strategy of connection at the shop floor stage and with the planning-engineering section. Plant capability arranging and rescheduling are not feed backed to the different PERT-GANTT likely manually simply because this amounts to a good amount of work. Unquestionably, they prove to be rapidly obsolete and uneven for preparation preferences. A brand new forthcoming procreation of production arranging and control options for OKP (and additionally all in all) is regarded to deal with four puzzling particulars: useful (and little) stock, high effectiveness of direct and indirect manual labor, wonderful customer care and structure and production continuously minimizing adjustments. Because of the fact that these modifications are widening in consistency and effect, some sort of link is important between the SFC (shop floor control) size and the PERT-GANTT elevation, otherwise emanating a great deal of links, inadequate inventory management, mixed up traceability of elements and a large amount of nonessential coverture in both the protection shares and protection lead-times. Definitely, this link is going to be a sterilized reaction, not allowing for aggravating changes at the PERT-GANTT stage to include unwanted "nervousness" inside the plan (Davis 250) Question 3) Total capacity management: Capacity is not anything that can be produced by way of a variety of carefully structured and executed schedules that perform an evident and extensive regime or approach with specific timeframes and strict economic restrictions (Azzam 117). It is a genuine procedure for development and enhancement relating to trials and comprehending like it goes on. That is why, many individuals currently focus on capacity expansion as opposed to capacity building, to emphasize that it must be a technique rather than a magic formula. This established three typical volumes of capacity and the ICID/FAO course examined way of applying these to irrigation and water discharge. Level I, the enabling set up, represents the broad national and global track record within which irrigated agriculture can develop. Level II is the organizational phase, which explains the massive amount of institutions related to alloy production for wheels. The capability of a business is entered in the ability of its people to work together within established rules and principles and to correspond with other businesses. Level III, the individual level, is regarded as the structured and familiar portion of capacity growth and includes training and guidance of the various stakeholders, from farmers to local experts. Question 4) Scheduling Approaches: Alloy wheel Generation processes furthermore, make use of operations scheduling approaches: Makespan: The overall time essential to achieve various sorts of assignments is called makespan. Minimizing makespan can help the contending plainly-visible components of price (reduced inventory) and time (submission rate). Total Commodities: This effectiveness gauge is used to evaluate the performance of routines for manufacturing processes. The volume of planned records and on-hand inventories is the total stock. Allocation: The amount to which equipment, place, or the personnel is in fact being employed, determined as the ratio of the standard production rate to ideal prospective. Taking advantage of the consumption of a technique allows the competing objective of price (slack prospective). Precedence sequencing rules may be used to approach several procedures. Every single operation is managed independently. When a workstation becomes idle, the precedence guideline is placed on the projects looking ahead to that procedure, together with the job with the highest priority is selected. When that process is finished, the task is directed to the following process in its design, in which it remains until it once more bears the highest priority. Task 2) Inventory management for alloy wheels: Inventory management is just as essential in alloy wheel outlets just like other health and wellness shops. The main responsibility of inventory management is the management of parts and merchandise products throughout the selected obtaining and supply chain from hiring to consumption stage (Piasecki 167) Because of this responsibility, inventory management is liable for the real and financial quantities of stock keeping, the assistance grade provided to consumers, the control factors within the stock system and just about all the prudence associated methods in the whole process. Furthermore inventory management is subject to handling each and every item, through its acknowledged capabilities, on a day to day routine. Ensuring that the beneficial use of personnel connected with the management practice, furnishing information and also feedback on the overall performance of the inventory program. The most of inventory organizing stages stay with the business preparing series based on a 12 months’ time frame. Details of the expected changes in these types of components as seasonality, quantities, supplier lead times, required assistance ranges, products and operational expenses, and particular needs, within the average term period of time need to be designed for inventory management with sufficient lead time to establish and employ any changes to the methods and/or control over the inventory program. In the most of inventory strategies, the factors and tools that find out the key reasons which result in the quantities of stock stored on a line by line routine are not at all instances good at being responsive quickly ample to meet unexpected temporary variations and unbalances. At this time inventory management frequently see fit to be involved. Task 3) Kanban and two-bin inventory management procedures for alloy wheels: Kanban, the Japanese term for a card employed to notify the need for inventory replenishment, has become a term detailing the “pull” technique for keeping production lines optimally accumulated with necessary items and tools - in case they are needed and in the suitable quantity. Given that an item is utilized in the production practice, an agreement for depleted stock is immediately put, perhaps by means of a Kanban card or electronically by way of an self-regulating Kanban program. Because this process of consumption-driven replenishment demonstrates its performance across tiers of syndication and supplier devices, it is increasingly becoming an exceptionally strong replacement for more regular Material Requirements Planning (MRP) or “push” design methods, which rely on forecasts to find out what and the amount to produce. Despite the fact that predictions have confirmed useful in foreseeing all in all requirements, they can be insufficient alarms of exactly which items will probably be needed and when. However, hand-operated Kanban’s benefits are considerably limited in the event that a supplementary supplier arrives into the supply chain. In a programmed Kanban system the card information is translated into a barcode that is scanned as well as electronically delivered at each and every stage of the replenishment series (application, shipping, gathering, and so on). In such a manner, automatic Kanban considerably boosts the efficiency of Kanban during the course of the supply chain (Croxton 16). A Kanban card generally contains information for instance the Part name and quantity, the Supplier process title, the quantity per section, the Delivery location, the Space for storing address and the amount of cards in the system. A Kanban system employing cards differs most significantly from the two-bin system, considering the fact that the card is pulled the instance the first part is leased out. In the 2-bin system, constant bins or storage units perform the purpose of the Kanban card. A clear bin signifies that extra components are required. The choice of clear bins need to follow time-based typical work whenever possible to make sure that one individual can supply the elements sensibly for a unit or field. Task 4) Question 1) Stock Record: Programmed stock records are run on similar principles to hand-operated ones, nevertheless, are usually more adaptable and information is less complicated to recuperate. It is easy to instantly get a stock official recognition or find out how adequately a particular item of stock is in mobility. A programmed stock record technique is a great idea for alloy wheel production businesses managing a number of stock. Other useful traits include: Stock and expenses data growing with accounting and invoicing techniques. Most of the systems reap the benefits of the similar group of information, so it is needed to only have to get into the input once. Sales Order Working and Purchase Order Working can be built-in the program with the intention that stock controls and figures are immediately amended as sales purchases are completed. Automated stock monitoring, launching orders when the re-order amount is achieved. Automated batch control in the event that the products are produced in batches. RFID: Radio Frequency Identification (RFID) offers a company to identify various products and components, and to keep track of them all through the supply chain from production to point-of-sale (Croxton 28). An RFID tag is a tiny microchip, in addition to a little aerial that could contain a range of digital specifics of the particular item. Tags are encapsulated in plastic-type, paper or similar material, and set to the item or its packaging, to a pallet or container, or maybe to a van or delivery truck. The tag is interrogated by an RFID readers which direct and receive radio signals to and from the tag. Readers may differ in proportions from a transportable machine to a "portal" through which several tagged devices can be shifted simultaneously, e.g. on a pallet. The information that the reader gathers is released and equipped making use of particular computer programs. Readers can be placed at different places within a manufacturing facility or safe-keeping place to show when items are transported, supplying continuous stock control. Question 2) Routine discharge of Work Orders: Most of the structured work mandates are immediately organized by MRP in relation to their release and timetabled dates (Azzam 21). Back Scheduling Approach: MRP immediately computes the structured order release date from the order planned date. To find out the discharge date, MFG/PRO eB utilizes the generation lead time to neutralize the variety of shop days needed before the anticipated date. The shop journal is used to figure out the work week and understands both the shop and non-work instances. That is a back scheduling approach. From a planning perspective, it is crucial to make certain that the lead times are accurate and that the planning horizon is sufficient in period to manage the greatest lead time item. Work order processes are back organized from the MRP order anticipated day. Back scheduling employs the standard process installation, run, and move times along with work middle queue as well as wait situations. Process start and finish times can be manually altered by the scheduler; however, these will restore if CRP is recalculated. Task 5) Question 1) Grouping into families: The basis for group infrastructure is analogous to these kinds of situations. A firm can make a lot of different parts in an environment that is turning into more and more complex as good deal of dimensions get smaller in size and the variety of parts increases. If they are examined thoroughly, nevertheless, plenty of parts are identical somehow or other. A design specialist challenged with the strategy of arranging a part needs to be knowledgeable about the identical or the exact same part had been produced before. Similarly, a manufacturing engineer challenged with the procedure of determining the approach to generate a part wishes to figure out in case an identical process technique earlier is out there. Afterward there could be economies to be recognized from grouping components into families with identical functionality. The subsequent data base would certainly be less complicated to manage; as a result, the Manufacturing Company ought to be less complicated to manage (Croxton 22). Group technology is begun by starting to band parts into families based on their traits. Normally, these features are based on geometric and/or generation method capabilities. Geometric classification of families is normally based on size and type, while manufacturing process category will depend on the sort, sequence, and selection of methods. The type of operation depends upon particular things like the technique for working, the technique for maintaining the part, the tooling, together with the issues of working. Question 2) Coding strategy: With group technology the work bits and machining methods must be classified. This simply means that a suitable technique for coding has to be discovered which may conveniently be utilized for hand-operated technique or computer-aided group techniques. With the manually operated technique the description of elements and ready are identified. When a work item is estimated for production, a record search is designed to find out a suitable growth process and collection. When the computer is commonly employed, the specifics of the part and the structure method is saved in a storage area device equipment and the manufacturing data are retrieved immediately. Among the main issues for coding is to select which variables are important for recognition. No challenging guideline may be introduced as the factors may differ, depending on the part variety. An extremely typical exercise is to separate rotational from non-rotational parts. Device improvements and set up times usually contribute considerably to working cost. Similarly, the number of machining sequences must be minimal. The entire machining procedure must be controllable by one operator; or perhaps, problems may be suffered during the course of rescheduling of production runs. Task 6) Work Breakdown Structure and Gantt Chart Resource, Material and Tools Sheet Resource Allocation Critical Path Management (CPM) Cost Determination Project Plan Description The Microsoft Project (a project management tool) is utilized for development of plan for the project of developing hundred (100) units of the Alloy Wheels. In the planning phase of the project, it is planned that the commencement date of the project is 26th May 2014, however, the project would be completed on 23rd June 2014 i-e the project duration is twenty one (21) days. Similarly, the estimated cost of producing the hundred (100) units of producing the alloy wheels in twenty one (21) days is $23,332. The estimated cost of the project can be divided into three (3) major components include: the HR cost, Material Cost and Tools / Machinery Cost. Moreover, the cost of the project is dependent on the activities, as twelve (12) major have been identified to complete the project. These activities have to be performed by the human resources (team cost), by using some machinery (if any) and / or material. Some of the identified activities are critical (shown above in the Gantt chart and the CPM diagram in red color), whereas, the others are non-critical (blue color). The screenshots of the project plan developed in the MS Project including the Work Breakdown Structure (WBS), Gantt chart, Critical Path Management (CPM), Resource Allocation and Cost estimation are given above in the document. Work Cited Davis, Joseph. Aluminium and Aluminium Alloys, ASM International, 213-324, 1993 Croxton, K., S. Garcia-Dastugue, and D. Lambert, “The Supply Chain Management Processes,” The International Journal of Logistics Management, V. 12, No. 2, 2001, pp. 13–36. Amy M. Azzam, “Flow Through warehousing equals inventory on the move”, APICS Magazine, Volume 11 No. 8, June 2001 Piasecki, Dave, “Guide to Inventory Accuracy” Inventory Operations Consulting LLC, 2001. Read More