Communication Cable Manufacturer in Organisation - Term Paper Example

Prof: TASK Communication Cable manufacturer and distributer Wires and cables require high precision during the manufacturing process to ensure quality. Top Cable, a communication cable manufacture and distributor, offers value-added augmentation, unmatched access to the products, and professional after sale services. Additionally, as the region’s biggest manufacturer and distributor of incorporated supply services, Top Cable offers more than communication cables. The company offers cost-efficient solutions that meet the communication and electrical needs of the consumers. Providing a full range of communication cable products as well as services is the company’s primary purpose. The company also offers value creation solutions by improving productivity and reducing costs of operation through service solutions such as cutting, custom making, and kitting (Top Cable 1). Conductor The initial process of manufacturing a conductor is the process of wire-drawing. This process involves the reduction of the diameter of the copper wire slowly to its final diameter. Wire-drawing process increases conductivity and ductility of the communication cables and wires. The copper wires usually arrive at Top Cable from the foundry in huge coils each measuring 5 tonnes. This copper is known as “wire rod” in technical terms and measures 8 mm. The wire drawing method performed in these wires takes place in two methods: drawing and further reduction or annealing. Top Cable thereafter takes the wires through wiring stage where the engineers make conductors with differing cross-sections. Insulation Top Cable takes the copper wires to the next process of insulation. Insulation involves covering of the conductors to ensure that current leakages do not occur. Top Cable uses different insulation materials depending on the features of the communication cable it needs. The company considers heat resistance and insulation capacity to determine the insulation quality, and the quality of the resultant insulated cables. In some communication cables, Top Cable uses high heat resistant insulation materials to allow the wires from the previous stage to transmit a lot of power as compared to other wires that have low heat resistance. Top Cable adds the insulating material by an extrusion process that involves high temperature. This method ensures that no leakages of current occur. Various materials used in insulation include EPR, PVC, and XLPE. Once the insulation process ends, the manufacturing process subjects the insulated cables to voltage tests to make sure that the layers of insulation do not have any fault. Phase Wiring Phase wiring is the putting together of myriad insulated conductors to come up with a multicore cable. Top Cable normally identifies the various cables through color coding or numbering system. After the completion of this stage, the various cables go through electrical integrity control were a voltage tester measures the amount of voltage transmitted throughout a cable that has undergone phase wiring. Additional coverings Additional coverings are not always required, except in cases where the cables need extra protections. Additional coverings improve operation and operation of the cables. Top cable uses coverings, also known as screens, to insulate the extra signals that are distributed throughout the cable. This insulation prevents any probable external interference. Additional coverings also protect communication cables from possible interference from signal circuits located adjacently. In the manufacturing of communication cables, armour, which are mechanical coverings protect the communication cable from outside damage that may result from rodents, knocks, and any other probable cause of damage. The armour is made of aluminum or steel and can come in the form of braids, metal strips, or wires. Outer Sheath Cables normally have an outer covering that constitutes of a polymer to ensure extra protection. The sheath or outer sheath offers protection to the conductors and the insulators from outside elements that may change the properties of the communication cables, such as humidity. The outer sheath includes thermosetting plastic. The application of the outer sheath occurs in a process similar to the process involved in applying the insulation – extrusion at extremely high temperature. Various materials can make the sheath depending on the protection, flexibility, and target environment required during the process of manufacturing. The outer sheath includes important information regarding the cables such as the cable name, trade name, manufacturer, cross-section, CE marking, construction standards and regulation, and product’s certification (Top Cable 1). Process planning techniques Critical Path Method (CPM) Top Cable applies Critical Path Method (CPM) in determining the activities that are required to complete a project or task. Communication cable manufacturing requires several tasks and activities that have a close relationship. In developing a CPM for cable manufacturing and distribution, Top Cable forms an activity network. The activity network consists of the following activities: conductor, insulation, phase wiring, additional coverings, outer sheath, quality control, shipping, and sustainability. The table below shows the various activities and the duration needed. Using this technique in cable manufacturing is essential as it aids in quantifying the time each activity will take leading to a reduction in delays (Gitman and McDaniel 272). Activity Predecessor Duration Conductor Wire drawing Wiring - 2 hours Insulation Electrical Integrity Control A 1 hour Phase wiring Electrical Integrity Control B 1 hour Additional coverings AC 1 hour Outer Sheath ABCD 1 hour Quality Control A Shipping ABCDE 1 week Sustainability Table 1: Critical Path Method’s activities for production of a communication cable unit Program Evaluation Review Techniques (PERT) The PERT scheduling method assists Top Cable to schedule the various activities in the cable manufacturing and distribution process. The scheduling process emphasizes the association between the cost each activity consumes and the time each of the activity takes and this leads to a good projection of the anticipated cost and time that the entire cable manufacturing project requires. This technique leads to various advantages as it enhances management of the cable manufacturing process. The PERT technique, as used in cable manufacturing, in Top Cable, involves representation of the various orders of activities comprising cable manufacturing by means of a network subsuming of circles and arrows. The arrows stand for activities or tasks that are distinct sections of the production process. The PERT diagrammatic representation and process integrate with the CPM (Gitman and McDaniel 272). Manufacturing Resource Planning (MRP II) Top Cable utilizes Manufacturing Resource Planning (MRP II), which is a modification of the Materials Requirement Planning (MRP) to integrate data such as financial and employee needs with availability of materials. With a computer based MRP II system, Top Cable can coordinate the arrival of various component materials with the availability of labor and machine in realtime. This technique is particularly important during the arrival of copper to Top Cable’s manufacturing plants from the foundry. The characteristics of the company’s MRP II technique include the financial and operation system that are similar, a simulation of capabilities that allow for efficient prediction, and all aspects of business starting from planning to execution. The company’s MRP II system offers a systematic process for procuring and planning materials to give production the necessary support. It includes simple ideas that a computer assists in implementing (Toomey 2–3). Capacity assessment technique A complete metrics assessment technique at the initial stage of the communicable cable manufacturing is essential. This assessment measures the capabilities of the manufacturer to complete the project successfully. The assessment technique uses a Likert scale that ranges from one through five measuring the attainment of the manufacturing process. In order to make sure that the project delivers significant and reputable quality, various forms of assessment can aid. The result of the assessment shows the capability of the manufacturer when compared to the minimum expectations. Scheduling Scheduling involves making decisions regarding manufacturing processes or stages. The function of scheduling involves the determination of the sequences in orders, time-sequences, and operations. It also involves the allocation of the proper resources to complete the required tasks in the right order and within the time. Since the production environment for communication cable manufacture is a dynamic one that involves unforeseen events, scheduling ensures the maximization of capability. Scheduling the wire drawing and wire grouping processes in the manufacturing process requires sequencing, routing, timing, reconfiguration, forecasting, labeling, grouping, aggregation, and disintegration. Two scheduling techniques can be done during the wire drawing phase of the manufacturing process. The first technique, simulated annealing, involves a computational approach that emanates from statistical mechanics. This approach can work in assisting to schedule batch wire drawing where there will be zero wait hindrances requiring adaptation of nearby structures. Other than that, tabu-search, another scheduling approach, involves the avoidance of moves that have long sequences (Gitman and McDaniel 273). TASK 2 Application of the principle of inventory management Effective inventory management is based on the tenet that the operator of the warehouse must be able to meet all demands for materials for manufacturing while maintaining an inventory that is as low as possible. To meet this objective, systems of inventory control need qualities that allow companies to store materials in a secure manner and identify roles that will lead to demand satisfaction. If the information cable manufacturing company maintains proper tracking of materials and predicts their demand, their inventory system can satisfy the main tenet. To meet the inventory objective of inventory management, Top Cable practices the following principles: Accuracy Top Cable ensures that its inventory control system is accurate giving the correct number of component units in stock. At times, manual counting of the component units occurs to ensure high accuracy (Narayan and Subramanian 70). Security The major function of a system of inventory is to have materials stored in a secure manner. The inventory system ought to control access of personnel to the warehouse keeping the materials and products safe from damage and exploitation (Narayan and Subramanian 196). Location Top Cable’s inventory system tells the precise location of products and material so that one can know the actual number in the company’s inventory (Narayan and Subramanian 117). Demand Top Cable estimates current and future demand before it ventures into the process of manufacturing and placing the items in the inventory. This ensures that manufacturing does not lead to excess or fewer production units (Narayan and Subramanian 162). TASK 3 Stock control Systems Although systems today are highly computerized and automated, sometimes they fail, take too long to implement, and lead to myriad bottlenecks. The two bin system of stock control, though, is a simple traditional method of controlling stock that can effectively remind an organization when to replenish the inventory. The two bin stock control system works well for stocking the communication cable company. This system makes use of a two-bin system that requires twin storage containers. Each of the containers holds a prearranged quantity of the same units of production. Quite simply, Top Cable uses the system to track demand by emptying one bin and then the other. The first bin to be emptied gets replenished, and the reorder card placed back to its rightful place (Waters 377). Where it is hard to predict demand and supply time are lengthy, the ideal action for a company is to react aptly to observed demand. Kanban stock control technique works as a demand signal that proliferates through the supply chain system. Top Cable can use this system in its inventory management to ensure better management of intermediate stocks in the supply chain. With Kanban stock management system, Top Cable will maintain the lest inventory. The process involves much more than tuning production supplier and control systems, where a company minimizes inventory by supplying production units only when they are required, and work in progress is closely examined. The essence of the system is to offer production units to warehouse only when they are called for so that storage does not occur in the production zone (Waters 352). TASK 4 Documenting systems Bin cards Bin cards are essential documents are of use in production processes such as those of Top Cable company. Bin cards record and manage the amount of material in store. The principal storekeeper gets and issues the material. Production plants store or keeps bin cards in every tray or cabinet of material. With the use of bin cards, companies are able to control material. Material control subsumes planning, controlling, and organizing the procurement, usage, as well as storage of material for achieving the economy and efficiency objectives. Material control makes sure that purchasing, receiving, inspecting, and issuing of material occurs in the required manner. In addition to that, material control through bin cards ensures good maintenance of inventory and stock control records. Bin cards are essential in communication cable manufacturing processes as they ensure that materials are not misappropriated. Bin cards also ensure that a manufacturing plant does not run into an understanding or an overstocking situation (Trenerry 377). Job tickets More frequently referred to as work order, job tickets are documents that are used to record the details of a request for communication cables from a consumer. In Top cables, the job ticket is developed using data mined from sales orders created by the salesperson serving a particular client. There are also instances where Top Cables treats job tickets and sales orders as the same thing, with the specific terms used to define the current status of the satisfaction of the request of the consumer. The job ticket in Top Cables is usually prepared from information that emanates from sales orders prepared by the sales department. Here, the sales order normally includes details about the cables being ordered for, their size, color, units, and other relevant information. The job ticket includes specifics regarding the agreed date of delivery between the consumer and the sales department. If the consumer has voiced a certain preference concerning the method of shipping for the cables, that information will also be contained on the job ticket (Jiambalvo 47). One of the ways used to stock in companies and manufacturing plants such as Top Cables is through work orders. Work orders involve pick plans where one generates a pick plan report. Consequently, pick plans generate the locations of materials in storage and default of the materials source. Work order plans, therefore, guide the company’s inventory and records processing. Data collection and feedback, on the other hand, can guide a company to making the correct decisions regarding stocking. Top Cable collects relevant data and keeps communication channels open to inform decisions on inventory replenishment (Jiambalvo 47). TASK 5 Classification and coding Various systems group as well as organize services and products throughout the economy in a certain fashion. The classes are provisional and aid in the collection of data about products in surveys that offer the foundation for commodity dimension. Development of standards also aids in the comparison of information regarding a product among the nations that share the same classification and coding system. Top Cables conforms to the classification and coding system that contains more than 2200 different forms of cabling. However, all these types fall into three main groups: twisted pair, coaxial cable, and fiber optic cable. The coaxial cable is one of the most common communication cables used in networking. The coaxial cable is famous because of various reasons, which include lightness, cheap cost, and high flexibility. The coaxial cable, in its simplest form, consists of a copper core that is surrounded by insulation. The coaxial cable may have shielding or woven metal meshwork that surrounds the major cables. Shielding protects the data undergoing transmission from absorbing interferences from the environment called noise or stray signals. Twisted pair classification refers to the cables that twist round each other. Twisting is essential in the production of communication cables as it cancels out interference or electrical noise from sources around. Manufacturers combine and twist cables and then cover them with a protective sheath to form one huge cable. Fiber optics usually transmits communication through modulated light pulses. There is also insulation and reinforcement done to fiber optics to ensure proper protection (Top Cable 1). The center of the communication cables carries the relevant electric wires. The wire core can be stranded, or it can be solid. In a situation where the core is made of solid, it is normal copper. Surrounding the central part is the dielectric layer of insulation that segregates the core from the wire mesh. The plaited wire mesh stands as a ground and ensures protection from crosstalk and electrical noise to the core. The wire mesh and the conducting core have to be separate from one another all the time. If they encounter one another, the cable undergoes a short, and stray signals and noise flow right through the copper wire. An electric shock can also occur, but only when the ground and conducting wire meet each other. This contact leads to the direct flow of data or current in an accidental path. Sometimes, shorts may cause blowing or sparkling of fuse material. These events lead to destruction of data and failure of devices. An outer shield that is non-conducting is usually made of plastic, Teflon, or rubber material (Top Cable 1). TASK 6 The production of 100 communication cable units would go through a rigorous process as shown in diagram 1 below. The normal production time of single communication cable units (see table 1) has to increase because of the increase in the output number. All process, though; have to be included, except for additional covering, which might be considered if the communication cables will be used in harsh environmental conditions. In between each stage, the manufacturing company has to make various decisions considering production. Time wastage can also occur in between the stages in a phenomenon referred to as time slack. Diagram 1: production process of 100 communication cable units Conclusion Communication cable manufacturing and distribution processes require several steps and consideration. The process begins by identifying the different components required and the processes of manufacturing needed. Communication cables need to go through conductor, insulation, phase wiring, and outer sheath processes. In the production and distribution process, companies also ought to consider processing techniques. Inventory management is also an essential part of the whole process that ensures manufacturers do not over or under stock a certain product. Works Cited Gitman, Lawrence, and Carl McDaniel. The Future of Business: The Essentials. Cengage Learning, 2008. Print. Jiambalvo, James. Managerial Accounting. John Wiley & Sons, 2009. Print. Narayan, P., and Jaya Subramanian. Inventory Management-Principles and Practices. Excel Books India, 2009. Print. Toomey, John W. MRP II: Planning for Manufacturing Excellence. Springer, 1996. Print. Top Cable. “Electric Cable Manufacturer.” N. p., 2014. Web. 20 May 2014. Trenerry, Alan. Principles of Internal Control. UNSW Press, 1999. Print. Waters, Donald. Inventory Control and Management. John Wiley & Sons, 2007. Print. Read More