ASSIGNMENT

Q1. Explain the following:-

Just in Time Production: Just in time is a pull system of production, so actual orders
provide a signal for when a product should be manufactured. Demand-pull enables a firm to produce only what is required, in the correct quantity and at the correct time. This means that stock levels of raw materials, components, work in progress and finished goods can be kept to a minimum. This requires a carefully planned scheduling and flow of resources through the production process. Modern manufacturing firms use sophisticated production scheduling software to plan production for each period of time, which includes ordering the correct stock. Information is exchanged with suppliers and customers through EDI (Electronic Data Interchange) to help ensure that every detail is correct. Supplies are delivered right to the production line only when they are needed. For example, a car manufacturing plant might receive exactly the right number and type of tyres for one days production, and the supplier would be expected to deliver them to the correct loading bay on the production line within a very narrow time slot.

Advantages of JIT

Lower stock holding means a reduction in storage space which saves rent and insurance costs As stock is only obtained when it is needed, less working capital is tied up in stock There is less likelihood of stock perishing, becoming obsolete or out of date Avoids the build-up of unsold finished product that can occur with sudden changes in demand

Less time is spent on checking and re-working the product of others as the emphasis is on getting the work right first time

Disadvantages of JIT

There is little room for mistakes as minimal stock is kept for re-working faulty product Production is very reliant on suppliers and if stock is not delivered on time, the whole production schedule can be delayed

There is no spare finished product available to meet unexpected orders, because all product is made to meet actual orders however, JIT is a very responsive method of production.

Lean Manufacturing System:

Lean production system is the western term for Toyota

Production System. This production philosophy is now widely used in auto industry around the world. This system has been modified everywhere in the auto industry, adapted to some extent on the local industrial situation or practices, however its core principles remain the same. This system is not only used in auto industry but also in other non-auto industries involved in assembling process. In order to understand lean production system, it is important to understand it in its historical perspective first. If we study the history of automobile industry, it can be separated in three eras, which can be termed as milestones of automobile industry. These milestones are: 1. Invention of Automobile (1880) 2. The Henry Fords Mass Production System (1910) 3. The Toyota or Lean Production System (1933)

There are two major pillars of lean production system. One is Just-in-Time system and other is Kaizen. Just-in-Time System was developed as a result of

adoption and adaptation of Mass Production Techniques. Taiichi Ohno and his associates had been successful to tailor Ford Production system according to the Japanese market and economic constraints of that time.

Just-in-Time System:The definition of JIT is very simple and self-explanatory i.e. Producing only what is needed, in necessary quantity and at necessary time. As discussed earlier, JIT is basically based on the concept of total elimination of inventories or safety stocks during the production of automobile. The same could not be possible without putting certain techniques and related philosophies into action. Here is the list of those elements that make this system run:
1. Levelled Production 2. Pull System 3. Continuous Flow Processing 4. Takt Time 5. Flexible Work Force (Shojinka) 6. 3 Ms (Muda, Mura, Muri) 7. 5Ss (Sifting, Sorting, Sweeping, Spick-n-Span and Sustenance)

Computer Integrated Manufacturing: One of the keys to success in the manufacturing

business is to lessen errors and to enhance productivity. The more one can produce with fewer flaws, the more one can make at the bottom line. Over a period of time factory owners have integrated computer systems in order to streamline the production process. CAD, or computer aided design, has been able to aid the operators in the formulation and blueprints of more sophisticated products and technology.

CAM, or computer aided manufacturing, has offered the means by which to produce the more sophisticated items. CAM also enhances the productivity of the factory's output. Together the CAD and CAM systems reduce cycle times, enhance productivity, and aid in the streamlining of the overall production process.

Since the 1980's CAD and CAM have worked together to move from the idea phase to the application phase. This process has not ceased because of the implication. The factory sector has slowly been phasing in computer integrated manufacturing, or CIM over the years. This integration will allow for the digital information and computer control of the production process to be intertwined throughout and within the factory.

In the CIM system some processes will be different. Data entry will now be stored in hard drives. This will allow for the manipulation and the retrieval of the data with a simple keystroke. The means by which the processing of data into the production of products will also be streamlined within hardware and software. This will allow operators to alter and enhance programs in order to improve products. The CIM system will also provide the necessary algorithms to bring all the data together. The data will then be able to intermingle with the sensor and modification components of the system.

While the CIM system is the optimal choice to aid in the manufacturing process, it does come with a unique set of challenges. The greatest challenge is to get all the different machines within the factory to work on the same system. In the typical factory, there are a variety of machines that perform different tasks, that are made by a variety of suppliers. The issue is to get every one of these machines to accept the programming, and tasks from one mainframe computer. The second challenge of the CIM system is encapsulated within the data itself. While many operators may be lost on the actual production floor, there will be a need for operators to maintain the integrity of the data that is transmitted to the machines. The challenge is in acquiring competent individuals who can assure that all the data within the system is at its optimum operating integrity.

The third, and final challenge that has been encountered in the use of the CIM system is process control. This entails assuring that the whole process runs smoothly. This particular challenge ties the data entry people, the programmers, and the production operators together. The factory will need to assure that the individuals working with the system throughout the factory are competent and knowledgeable. These individuals will need to be well trained, and probably need to update

their

training

periodically.

The goal of the CIM system is to eliminate the waste within the manufacturing process. This is done by taking the design, analysis, planning, purchasing, cost accounting, inventory control and distribution departments and interlink them with the factory floor, material handling, and management departments. The CIM system will have an impact on every system within the factory. The CIM system, which is sometimes referred to as the integrated computer aided manufacturing system, operates on both hard and software. Simply put, the software is what runs the factory, or the brains. The hardware is what makes the machines run, or the muscles. The CIM system runs on an efficient output process. This means that the whole factory works together, not as separate parts. As a unified unit, it operates for the peak benefit of the whole factory. Simply put, the CIM system does not backload or store up work. It does not warehouse products. The CIM system keeps work flowing through computer integration in order to keep all the parts of the system constantly functioning. It registers all the raw material received by the factory. It then walks the material through the factory and the production process.

The CIM system fractions every individual "center" of the factory into work cells. As work cells, they are then divided into individual stations. The stations are then broke down to the individual processes, and the processes are what metamorphosizes the raw materials into actual products. This may seem complicated, but it streamlines the whole manufacturing process. With each division of the factory broken down in such a manner, it allows operators to make any necessary changes to the system without shutting down the whole system.

Cim is a very interactive, hands on system. If it is applied correctly, it will enhance the productivity of the whole factory. It will link several departments and functions together. It is simple to install. It usually is installed through a LAN, or local area network, connection.

Q2. Explain the following:(a) Name the steps involved in the Product Design :
Developing a product can seem like a daunting task but if you know the basic steps and phases required things will be much easier. Product design can be broken into 7 steps that I will explain in this article.

Problem Assessment: It is a good idea to write down what the problem is first. Don't write down the solution to the problem at this point, even if you know how to do so. You simply need to state what the problem is and nothing more. I have seen the development of new products become complicated and time consuming simply because the problem was never written down. A proper statement of the problem helps keep everyone on the same page and works to eliminate project creep.

Design Specification: This is the step in which a solution to the previously defined problem begins to form. At this point a list of requirements of everything you can think of should be written down. You are not coming up with a solution just yet only setting the requirements necessary to create the product. Some examples of what should be on your list include, a retail price (how much are people whiling to pay for this), size of the object (does it need to fit into someone's hand or through a door or in a garage), how fast should it go, does it need to be water proof, what should it be made of, does it use batteries or plug into the wall. This list can go on and on but the important thing is that you list what is important to you. This list will help you and your designer in the next step.

Idea Generation: Now you are getting somewhere, the problem has been defined and requirements have been set. At this point you should brainstorm and sketch out your ideas. Don't worry if the drawings are not pretty, you are only trying to see if the concepts could work or if there is an obvious flaw. If you are not mechanically inclined, you may want to find someone who specializes in product or industrial design to help. Many design companies have no problem meeting with you to discuss and sketch a few ideas before you will be under

any obligation to sign a contract or pay anything. You will want to come up with one or two good ideas before moving to the next step. Concept Design: Once at least one good idea for the new product has been sketched you will want to have the design worked out in a little more detail. The designer will come up with a basic 3d design on a computer that is detailed enough to be sure the idea will work but not so detailed that it takes more than just a few hours to complete. This is the last step where an idea is either given the green light or trashed. Detailed Design: Now that a solid concept design has been created its time to get down to the details. In this phase the designer will create full detail 3d virtual models of all parts, work out design problems, create assembly and part drawings for every part, find suppliers for all purchased components and create 3d physical prototypes if necessary. This phase is complete when all problems have been solved and a full set of drawings have been delivered. Testing: Testing is a very important part of product design and should not be overlooked. This step can be as simple as having a few people use the product for feed back or as complicated as sending it to a testing laboratory such as UL for a thorough testing by professionals. The level of testing will most likely be determined by requirements of any retail stores that will be selling the product. It is important that you have someone test the product that has not been involved in the design process even if it's a friend. Someone who has not been part of the design will give a less biased opinion plus you can watch for any difficulty they may have using the product. Manufacturing: The final step in the design process is manufacturing, in this step you or your designer will find suitable manufacturing facilities to create the product. You will need to come up with an agreement with the manufacturer on the terms of what they will be providing, the cost and when it will be delivered.
(b) Value analysis:

All organizations strive to create value for their customers. This value creates mind space for product and services. Value analysis, therefore, is a scientific method to increase this value.

Value is a perception hence every customer will have their own perceptions on how they define value. However, overall at the highest level, value is quality, performance, style, design relative to product cost. Increasing value necessarily does not mean decrease in all-inclusive cost of production but providing something extra for which a premium can be charged. The objective and benefits of value analysis can be summarized as below:

Value analysis aims to simplify products and process. There by increasing efficiency in managing projects, resolve problems, encourage innovation and improve communication across organization.

Value analysis enables people to contribute in the value addition process by continuous focus on product design and services.

Value analysis provides a structure through cost saving initiatives, risk reduction and continuous improvement.Activities for Value Analysis Activities for value analysis are separated into following activities: Product/Service - The 1st step is to identify the product or service which is based on usage/demand, complexity in development and future potential. Cost Analysis: The next step understands in detail cost structure in developing and manufacturing the product. Define product and function: The next step is to define all the primary function of the product and service through satisfying the basic need and then taking next step in delighting the customer. For this better understanding of product components and characteristics is required. Evaluation of alternatives: Through brainstorming possible alternatives can short listed which can provide value to the primary function of the product. Cost evaluation at high level needs to be done for all the alternatives, and the cheapest alternative is short listed. Secondary Function evaluation: Secondary functions of the product and services are studied and evaluated.

Recommendation: Value Analysis done has to communicate to the various level of the management team as to get acceptance. Value Analysis Team The process of value analysis is carried out by value analysis team. So it becomes paramount that team selection for value analysis also follows a structured process. Value analysis team consists of trained and qualified team members who have background and knowledge about the project. Team leader is selected by the project manager. Team size for value analysis is 5 to 8. Value Analysis Process Value analysis process can be divided into three phases of mainly pre-analysis, analysis and post analysis. Pre-analysis contains activities of project selection and team selection. Analysis phase as the name suggests consists of activities like investigation, speculation, evaluation, development and presentation of the report. Post analysis consists of activities implementation of the report and regular audit. Functional Analysis part of Value Analysis Function analysis is required to transform the project elements from design of product towards function of product. The main categories are Basic, Secondary, Required Secondary Aesthetic, Unwanted, Higher Order and Assumed.