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Unit 1

Unit 1. The Nature and Role of Analysis and Management in Green Manufacturing Systems. Effectively using constrained resources is the task of operations planning personnel in a manufacturing organization. Areas for Analysis. Product Equipment and tools Personnel Facility Material

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Unit 1

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  1. Unit 1 The Nature and Role of Analysis and Management in Green Manufacturing Systems

  2. Effectively using constrained resources is the task of operations planning personnel in a manufacturing organization

  3. Areas for Analysis • Product • Equipment and tools • Personnel • Facility • Material • Material handling • Processes • Instruments

  4. Analysis Leads To: • Improvement options • Implementation of options • Measurements • Management

  5. Is concerned with overseeing, designing, and redesigning business operations in the production of goods and/or services. Involves the responsibility of ensuring that business operations are efficient in terms of using as little resources as needed, and effective in terms of meeting customer requirements. Concerned with managing the process that converts inputs (in the forms of materials, labor, and energy) into outputs (in the form of goods and/or services). Operations management programs typically include instruction in principles of general management, manufacturing and production systems, plant management, equipment maintenance management, production control, industrial labor relations and skilled trades supervision, strategic manufacturing policy, systems analysis, productivity analysis and cost control, and materials planning. Operations Management

  6. Operations Management Programs Include: • Instruction in principles of general management, manufacturing and production systems, • Plant management, • Equipment maintenance management, • Production control, • Industrial labor relations and skilled trades supervision, • Strategic manufacturing policy, • Systems analysis, • Productivity analysis and cost control, and • Materials planning.

  7. Jacobs et al Chapter 5: Sales and Operations Planning • Sales and operations planning fundamentals should consider the following: • Balance between demand and supply • Volume of products to be produced • Mix of products to be produced

  8. Sales and Operations Planning and Management

  9. The Sales and Operations Planning Process

  10. Sales and Operations Planning Displays

  11. Defining Green Manufacturing Green Manufacturing means manufacturing that employs less energy, uses eco-efficient materials, and better use of resources which will result in lower costs and increased revenues for businesses

  12. Sustainability Means development that meets the needs of the present without compromising the ability of future generations to meet their own need The goal of sustainable design is to produce products that reduce use of non-renewable resources, minimize environmental impact, and relate people with the natural environment

  13. Green and Sustainability

  14. Facilities Equipment Tools Workers Parts & Materials Products & Scheduling Operations & Processes Energy Green Manufacturing Touches:

  15. Analysis Is: The process of breaking a complex topic, device, product, system, group or substance into smaller units or parts to gain a better understanding of it.

  16. Analysis of: Facilities Equipment Tools Workers Parts & Materials Products & Scheduling Operations & Processes Energy Green Manufacturing Analysis Involves:

  17. Sample Tool Locator Tool Crib No. Total Adjustable Die Stocks 2, 6 6 Allen Wrenches 2, 5 6 Angle Plate 4 7 Arbors 16 2 Arbor Supports 16 29 Awls 2 3 Band Saw Blades 8 16 Benders 3 0 Bevel Protractors 1 1 Bolts 16 111 Boring Bar Tools 2 3 Brissel Pads 3 1 Brooms 20 3

  18. Product Analysis Areas 1. Parts2. Prices3. Materials4. Processes5. Suppliers6. Supply chain7. Design8. Function9. Durability10. Weight11. Volume12. Others

  19. 1. Parts2. Cost3. Materials4. Processes5. Suppliers6. Speed7. Weight8. Tooling9. Automation10. Weight11. Volume12. Location13. Energy usage14. Condition15. Function16. Others Equipment Analysis Areas

  20. Workers Analysis Areas 1. Number2. Training3. Skills4. Diversity5. Rank6. Schedule7. Sex8. Tasks or responsibilities9. Age10. Education11. Location or office

  21. Facility Analysis Areas 1. Space2. Contents3. Energy usage4. Processes5. Workstations6. Schedule7. Cribs and storage8. Layout9. Ergonomics10. Location11. Output or takt time12. Others

  22. Materials Analysis Areas 1. Types2. Quantity3. Sources4. Cost5. Suppliers6. Supply chain7. Inventory8. Storage9. Shapes10. Forms11. Green12. Manufacturing properties13. Others

  23. Material Handling Analysis Areas 1. Types2. Quantity3. Automation4. Energy usage5. Suppliers6. Cost7. Design8. Others

  24. Processes Analysis Areas 1. Machines2. Automation3. Cost4. Layout5. Efficiency6. Cycle time7. Types8. Green9. Compatibility with personnel10. Compatibility with materials11. Others

  25. Instruments Analysis Areas 1. Types2. Quantity3. Locations4. Inventory5. Cost6. Dealers7. Parts8. Status9. Condition10. Others

  26. Hardware Analysis Areas 1. Types2. Quantity3. Locations4. Inventory5. Cost6. Dealers7. Parts8. Status9. Condition10. Others

  27. Management Means: • Checking current performance of a system against pre-determined or set standards • Ensuring that tasks are being carried out according to a set plan. • Measurement and correction of performance in order to make sure that enterprise objectives and the plans devised to attain them are accomplished.

  28. Sample Tool Locator: From Analysis to Management Tool Tool Crib No. Total Busy Adjustable Die Stocks 2, 6 6 5 Allen Wrenches 2, 5 6 4 Angle Plate 4 7 1 Arbors 16 2 0 Arbor Supports 16 29 2 Awls 2 3 3 Band Saw Blades 8 16 5 Benders 3 0 0 Bevel Protractors 1 1 1 Bolts 16 111 25 Boring Bar Tools 2 3 1 Brissel Pads 3 1 1 Brooms 20 3 1

  29. Management Comprises: • Planning • Organizing • Staffing • Leading Or Directing • Controlling

  30. Management of: Facilities Equipment Tools Workers Parts & Materials Products & Scheduling Operations & Processes Energy Green Manufacturing Management Means:

  31. And keep it green and sustainable?

  32. Machine Analysis Involves: • Parts or components of machine tools • Cost or prices of equipment and parts • Green content of equipment and parts • Weights of equipment and parts • Ease of design of equipment and parts • Appraisal of equipment and parts

  33. Structure of Machine Analysis

  34. Use of BOM for material costing Use of process charts in labor costing & planning Use of the Internet for equipment & part pricing Using forecasting models in calculating needed quantities Use of scheduling formulas Use of green factors in calculating green content Analytical Calculations Include:

  35. Analytical Calculations Include: • Use of facility analysis spreadsheet • Use of equipment analysis spreadsheet • Use of product analysis spreadsheet • Use of personnel analysis spreadsheet • Use of process analysis spreadsheet • Use of green and sustainability analysis spreadsheet

  36. Forecasting: Basic forecasting techniques Basic forecasting models Scheduling: Basic MRP record Daily production schedule Generic scheduling JIT MRP Gantt charts PERT Others Purchasing, leading to: Inventory management Material management Hiring and Training, leading to: Personnel management Operations management Financial management Facility management Production management Product management Quality management Others Management Tasks Include:

  37. Jacobs et al Chapter 15: Management of Supply Chain Logistics Supply chain management is the management of a network of interconnected businesses involved in the ultimate provision of product and service packages required by end customers. Supply chain management spans all movement and storage of raw materials, work-in-process inventory, and finished goods from point of origin to point of consumption.

  38. The Breath of Supply Chain Logistics Supply chain management (SCM) encompasses all material flow decisions, from raw materials to final consumption.

  39. Structure of Supply Chain Management

  40. Supply Chain Example: Tin Mining and Supply

  41. Supply Chain Logistical Elements • Transportation • Water, Rail, Hand delivery, Highway, Pipeline, Air etc • Vehicle scheduling analysis • Warehouses • Replenishing systems: ROP/EOQ, Base stock, Distribution requirement planning • Location analysis: Simulation, heuristic, and programming procedures • Inventory

  42. And keep it green and sustainable?

  43. Obi, Chapter 1 Introduction to Industrial Ethics

  44. Industrial Ethics and Values: Some Definitions Principles of right and wrong values in relation to the industrial worker whose initiatives affect productivity and quality of products and services.

  45. Some Ethical Principles • Honesty • Integrity • Mutual assistance • Personal responsibility • Tolerance of diversity • Self-restraint • Self-respect • Care • Fairness • Respect for others

  46. Why We Study Industrial Ethics • A study of 81,000 people on integrity, work attitude and drug use found that: • 24.9% of them admitted to stealing from previous employers • 28.5% admitted to some drug use • 24.0% admitted they had problems with absences in previous jobs • while 30.0% admitted tardiness in previous jobs.

  47. Some Benefits of Ethics to Industry • Better people/workers/society/environment • Better understanding of society's moral values • Knowledge of ethical basis for decision making • Better ethical representation of the profession • Better manager-subordinate-customer relationship • Improved success/quality/productivity • Improved responsibility/accountability • Stronger commitment from industry to society • Learn to treat others fairly • Learn to show good examples

  48. Some Ethical Roles of the Industrial Worker • Relative to the Employer • Relative to the Profession • Relative to the Society • Relative to Colleagues

  49. What Should Be Taught and Learned? • Civic responsibility A person’s duty, charge or obligation as a citizen • Fairness Straight forward justice • Honesty Upright conduct or disposition • Integrity State of being upright, entire or whole • Mutual assistance Reciprocally helping, aiding, supporting • Personal responsibility A person’s duty, charge or obligation as a person • Respect for others Proper regard for other individuals, their characters, or reputations • Self-respect A proper regard for one’s own person, character, or reputation • Self-restraint/control Control over oneself, temper, emotions, and desires • Tolerance of diversity To put up with or support different kinds of individuals

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