Escolar Documentos
Profissional Documentos
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&
Production Methods
Part-I
LESSON PLANS
Note: There are no (Part II) Operation Sheets in Industrial Planning & Production Methods, because
of theoretical subject.
CONTENTS
Industrial Planning 01
Site Selection 05
Plant Layout 09
Types of Plant Layout 11
Criteria for a good Layout 13
Advantages of a good Layout 15
Production Methods 17
Types of production 19
Job Analysis 21
Micro Motion Study 23
Therbligs 25
Time study 29
Time Study Equipments 31
Time Study Procedure 33
Production Planning & Control 35
Quality Assurance 39
Maintenance Activities 41
Maintenance Schedule 43
Cost Determination 45
Factory Overheads 47
LESSON PLAN
1
Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch
With teacher student activities Teaching Aids/Evaluation
10 Various Aspects of Industrial A number of aspects are to be planned before
Min Planning deciding/finalizing the set-up of a new industry. For
example, the product, the site/Area, the cost, the
process etc.
Testing & Follow Up:- (to see if leaner accompanied information or skill)
Define industrial planning__________________________
Enlist various phases of Industrial Planning__________________
2
LESSON PLAN
3
Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch
With teacher student activities Teaching Aids/Evaluation
10 Selection of Material The material required to produce the product is
Min selected/finalized
Testing & Follow Up:- (to see if leaner accompanied information or skill)
When & how the design of the product is prepared_____
__________________________________________________
4
TITLE OF TOPIC (Short, Description) Lesson No: 3
Site Selection Name: Khalid Mahmood
Subject (Course Title): MECH-331 Time: 50 Minute
Ind. Planning and production methods
GENERAL OBJECTIVES:-
To know about the site/ area, which is to
be selected for the proposed industry
SPECIFIC OBJECTIVES:- Expected Entry behaviors
5
Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch
With teacher student activities Teaching Aids/Evaluation
15 Economical Factors involved in Site Many Economical factors are considered while
Min Selection selecting a new site. The Area/Piece of land must be
cheap in cost, easily approachable, must have
transport facilities. The sources of power must be
easily available. In some Areas, Government has
allowed Rebates in Taxes to invite industrials to
establish industries in that Area. For example
Gawadar in Pakistan.
10 Availability of Labour The site selected must be that Area where some type
Min of industry is already established. It will help to
share the technical knowledge, expertise, materials
etc. It will also help the availability of technical
labour required for new industry otherwise special
transport or housing arrangements are to be made if
site selected in far Areas.
Testing & Follow Up:- (to see if leaner accompanied information or skill)
How a site is decided for new industry___________________
Name various factors considered in Site Selection____________
6
LESSON PLAN
10 Transportation & Communication The site selected must have easy approach by
Min Road. Almost all industries use transport facilities
Means
to transport raw material, manpower, finished
product to the market. The site must have
modern communication facilities such as
Telephone, Micro wave, Internet etc. However
this factor has least weightage.
7
Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch
With teacher student activities Teaching Aids/Evaluation
10 Consumption of the product The consumption of the product is calculated in
Min following grounds:
i) Actual Population of that Area
ii) The wealth factor of the people.
iii) The living standard of the people. Generally
an industry must be located in that Area
where it has its consumption otherwise
transportation cost will increase its cost.
Testing & Follow Up:- (to see if leaner accompanied information or skill)
8
LESSON PLAN
9
Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch
With teacher student activities Teaching Aids/Evaluation
10 Objectives of plant layout An optimum layout is one which provides
Min maximum satisfaction to all parties i.e. Employees
management production. The objectives of plant
layout
i. Effective utilization of place
ii. Worker convenience
iii. Less material handling
iv. Maximum labour utilization
v. High turnover production rate
vi. Overall satisfaction
Testing & Follow Up:- (to see if leaner accompanied information or skill)
Define plant Layout____________________________________
Enlist objective of plant layout_______________________
10
LESSON PLAN
11
Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch
With teacher student activities Teaching Aids/Evaluation
15 The process lay-out This lay-out is particularly useful where low volume
Min of production is required. It has greater process
flexibility. This lay-out is commonly suitable for job,
lot or non-repetitive jobs. Same type of operation
facilities one grouped according to function such all
easting work in foundry, mechanic works in machine
shop. Lot of flexibility in equipment and manpower
is obtained.
Testing & Follow Up:- (to see if leaner accompanied information or skill)
Enlist the type of lay-out___________________________
Which one Lay-out is the most recommended task___________
12
LESSON PLAN
13
Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch
With teacher student activities Teaching Aids/Evaluation
05 4. Maximum accessibility All points of machines and equipments (operating /
Min serving) must be readily accessible. It will help the
operator to operate the machine or equipment In an
easy way and also for the maintenance of the
department
05 5. Minimum Handling The handling work adds cost to the product which
Min does not increases its value. It should be reduced to
a minimum level by the use of conveyers, lifts,
knuckles, industrial vehicles etc.
05 6. Minimum discomfort Proper light, Temperature help the worker to work
Min more diligently. The suitable environment should be
ensure In the lay-out. The worker must be provided
comfort during his work
05 7. Maximum safety All lay-outs must be safe. No person should be
Min exposed to danger. Moving parts of machines must
be covered properly. Dangerous areas must be
restricted
05 Fire, theft moisture deteriorates the Plant.
8. Maximum security
Min Safeguards against these must be provided in the
original lay-out. Barriers and the cages are the good
examples
Testing & Follow Up:- (to see if leaner accompanied information or skill)
Enlist different criteria for a good lay-out___________________
__________________________________________________
14
LESSON PLAN
15
Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch
With teacher student activities Teaching Aids/Evaluation
20 Procedure of preparing a Lay-out Following are the key-points for preparing a Lay-out:
Min 1) Prepare model
2) Study the operation sequence
3) Choose “Key” operations
4) Locate ”Key” operations on plan
5) Locate main gauge ways
6) Locate remaking work areas
7) Locate major gauge ways
8) Plan individual areas in detail (Different section/
Departments)
9) Locate subsidiary equipment
10) The conyrleted Lay-out against the principles of
a good Lay-out
11) Verify the Lay-out on floor
12) Check against company’s policy
Testing & Follow Up:- (to see if leaner accompanied information or skill)
What are the advantages of a good lay-out_________________
Write down the procedure in sheet for preparing a Layout_____
16
LESSON PLAN
17
Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch
With teacher student activities Teaching Aids/Evaluation
15 2. Batch Production As quantity of the product increase work is carried
Min out under batch production. The work content on
any product is divided into parts or operations. Each
operation is completed throughout the whole batch
before the next operation is undertaken. The
production of Automobiles parts, electrical
instruments, transformers is the typical examples of
this type of production
Testing & Follow Up:- (to see if leaner accompanied information or skill)
Define production______________________________________
Enlist the different types of Production_____________________
18
LESSON PLAN
19
Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch
With teacher student activities Teaching Aids/Evaluation
20 Requirements for the Flow Followings are the requirements of Flow
Min Production production:
1. Continuity in demand
2. Standardized product
3. Material to specification
4. All production stages balanced
5. Operations must be defined
6. Work must be of quality
7. Specialized plant/equipment
8. Maintenance of equipment (Preventive)
9. Inspection “In Line” with production
Testing & Follow Up:- (to see if leaner accompanied information or skill)
Define Flow production______________________________
Give examples of Mass production_________________________
Special Assignment:- (Usually home work)
Prepare an assignment of requirements of Flow Production____
_______________________________________________
20
LESSON PLAN
21
Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch
With teacher student activities Teaching Aids/Evaluation
30 History of Gilbreth In 1885 Gilbreth as a young man entered the employ
Min of a building contractor. In these days brick
construction was the most popular method, so
Gilbreth learnt bricklayer trade. From the very
beginning of the century, he noticed that each
worker used his own method in doing his work. He
also observed this that worker did not use the same
set of motions. These observations led Gilbreth to
begin investigations to fluid” The best way” of doing
the given task. He readily learnt improvements in
methods. He continued to make program in bringing
about increased output among his workers. Gilbreth
invented a scaffold which could quickly be raised at
any height to the convenient level at all times.
Testing & Follow Up:- (to see if leaner accompanied information or skill)
Define Motion Study_______________________________
What are the purposes of Motion Study____________________
22
LESSON PLAN
23
Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch
With teacher student activities Teaching Aids/Evaluation
15 Cycle graph Gilbreth developed the technique of cycle graph for
Min the study of this motion path of an operator. It is
possible to record the path of motions of an operator
by attaching an electric bulb to the finger hand or
arm of the operator. The photographs are taken with
a moving camera; the path of the light as it moves
through space is recorded. Such a record is called
Cycle graph.
Testing & Follow Up:- (to see if leaner accompanied information or skill)
Define a Procer chart_____________________________
Enlist process chart symbol____________________________
24
LESSON PLAN
25
TOPICS,NOTES (Brief) Key points/Reminders/Sketch
With teacher student activities Teaching Aids/Evaluation
40 Therbligs Chart Explanation of Therbligs:
Min 1. Search: The part of the cycle
during which the eyes or hands are
hunting an object and hands when
the object has been found
2. SELECT: The choice of one object
from among several. (Locating a
particular pencil from among
pencil box)
3. Grasp: Taking hold of an object.
(closing fingers around the pen)
4. Transport Empty: Moving the
empty hand in searching for an
object. (Moving Empty hand to
pen on disk)
5. Transport Loaded: Moving an
object from one place to another.
The object may be carried in hands
or fingers by sliding, pushing it
along.
6. HOLD: Relation of an object after it
has been grasped and no
movement of the object taking
place.
7. Release Load: Letting go of the
object is completely separated
from the hands to fingers
Testing & Follow Up:- (to see if leaner accompanied information or skill)
Define Therblig____________________________________
Enlist Therblig developed by Mr. Gilbreth _____________
26
LESSON PLAN
27
Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch
With teacher student activities Teaching Aids/Evaluation
13. Avoidable Delay: Any delay of the
operator for which he is responsible
and he has control over it. It refers
to delays which the operator may
avoid if he wished
14. Plan: A mental reaction which
proceeds the physical movement.
Deciding upon how to proceed with
the job
15. REST: A fatigue factor or allowance
provided to permit the worker to
stop his work. The worker to stop
his work. It is to overcome from thr
fatigue incurred by his work.
Testing & Follow Up:- (to see if leaner accompanied information or skill)
Define Therblig___________________________________
Enlist Therbligs developed by Mr. Gilbreth______________
28
LESSON PLAN
1. _________________ __________________________
2. _________________ __________________________
3. _________________ __________________________
15 Application of Time Study Although time study has greatest use for
Min determining “Standard Time”. It is also being
used for a number of other purposes. It may be
used for
i. Standard for the payment of wages
ii. Determines schedule planning the work
iii. Determining standard cost of Labour
iv. Estimating the cost of the product prior to
manufacturing it
v. Determining the selling price on the basis
of total cost
vi. Determining machine effectiveness, the
Number of machines, Number of men
needed in a gang
29
Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch
With teacher student activities Teaching Aids/Evaluation
25 Time Study Procedure The exact procedure in making Time Study may vary
Min depending upon the type of operation being studied.
The following steps are usually required:
1. Secure & record the information about the
operation and the person being studied
2. Divide the process into elements and record
description of method
3. Record the time taken by the operator
4. Determine the no. of cycles (Times) to be
repeated
5. Rate the operator’s performance
6. Make it secure that sufficient number of
Cycles (Turns) have been timed
7. Determine the time allowances
8. Finally determines the standard time for the
process
Testing & Follow Up:- (to see if leaner accompanied information or skill)
Define Time study_____________________________________
Give the uses of Time study______________________________
30
LESSON PLAN
10 Decimal stop watch The decimal stop watch is the most widely used
Min timing device for time study. The watch has the
dial divided into 100 equal parts, each represents
0.01 minute. The hand making one complete
revolution by the slide. It is possible to stop the
watch at any interval and start it again from their
position. It is also possible to return the time
reading to Zero.
31
Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch
With teacher student activities Teaching Aids/Evaluation
15 Motion picture camera The time for elements of an operation can also be
Min obtained from the motion pictures made by motion
picture camera. The camera speed is 1000 frames
per minute. A motion picture of an operation
becomes a permanent record of the method used as
well as the time taken for each element.
15 Time recording Machine: For some years, machines have been used for
Min recording time on paper tape moving through the
on/c at uniform velocity. The time recording machine
consists of a small box through which a paper tape is
down at a uniform velocity of 10mm/min. The tape
has a printed scale in tenths of a mm. One division
denotes 0.01 minute. It may be used instead of stop
watch, enables the analyst to record shorter
elements.
Testing & Follow Up:- (to see if leaner accompanied information or skill)
Enlist instruments used in Motion and Time Study___________
__________________________________________________
32
LESSON PLAN
33
TOPICS,NOTES (Brief) Key points/Reminders/Sketch
With teacher student activities Teaching Aids/Evaluation
8) Estimate the numbers of cycle to
be timed
9) Record the time of the day when
the study is begun
10) State the stop watch at the
beginning of the first element.
Read & record the time for each
elements of the cycle
11) When the study is completed,
calculations are made
12) Rate the operator’s performance
and record on the observation
sheet
13) Sign with date the study sheet
14) Check that certain numbers of
cycles have been timed
15) Add time allowances to calculate
standard time for the process
Testing & Follow Up:- (to see if leaner accompanied information or skill)
What is an observation sheet____________________________
Write any five steps in observation_______________________
34
LESSON PLAN
35
Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch
With teacher student activities Teaching Aids/Evaluation
20 Objective of PPC Directing: All the efforts can be directed to those
Min production areas which will contribute towards the
accomplishment of a given task. All the plans /
programs can be closely graved according to the
need of organization
Co-ordination: All the productive systems should be
so co-ordinated that the management can quickly
provide information to the customer. All the
activities of the system should be so arranged so as
to result into optimum use of facilities.
Controlling: A controlling mechanism is to be
involved to provide information where corrective
action is necessary. Then the management can
measure both the progress and effectiveness.
Testing & Follow Up:- (to see if leaner accompanied information or skill)
What is PPC_______________________________________
Write the objective of PPC_____________________________
36
LESSON PLAN
37
Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch
With teacher student activities Teaching Aids/Evaluation
15 Scheduling When a customer orders for a certain quantity of
Min goods, he is anxious to know, when the goods will be
delivered to him. If the product is not belonging to a
particular customer, the company will deliver these
to the market at certain schedule. The very
important phase of production control is to make a
program so that estimated delivery date can be
given. The preparation of this program is called
scheduling.
Testing & Follow Up:- (to see if leaner accompanied information or skill)
Define Scheduling___________________________________
Give types of Scheduling system_______________________
38
LESSON PLAN
39
Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch
With teacher student activities Teaching Aids/Evaluation
30 Quality Control Quality is the most important factor for capturing the
Min market because quality of the product influences the
purchaser. The quality of the product plays an
important role in customer’s decision. Once a
particular, then this quality level must be maintained
as a policy matter. Quality control is defined as a
mechanism by which the products are made to the
specifications determined from customer demand.
For carrying out quality control a complete control
procedure is to be designed. Following points are
important;
1. Setting the standards
2. Appraising (conformance)
3. Acting when necessary
4. Planning for improvement
Testing & Follow Up:- (to see if leaner accompanied information or skill)
What is inspection_______________________________
What are the types of inspection______________________
40
LESSON PLAN
41
Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch
With teacher student activities Teaching Aids/Evaluation
30 Types of Maintenance Basically there are two types;
Min 1. Preventive Maintenance Preventive: The maintenance of machines which is
carried / conducted periodically. Regular inspections
are made to locate faulty conditions and to take
corrective action. There are always certain weak
areas in the machines if they are neglected, can
cause serious breakdowns. These breakdowns can be
avoided by regular inspections. Critical parts of
machines, equipment’s are replaced after a definite
period before they fail.
2. Breakdown Maintenance
These steps / measures taken correct or repair the
faults after they have occurred. It is also called
corrective maintenance. In this type machines is
suspended and the repair work is carried out. The
production schedules are referred in this type. So
often industries adopt complete shut down for some
days to overhaul the work plant.
Testing & Follow Up:- (to see if leaner accompanied information or skill)
Define Maintenance________________________________
What are the responsibilities of Maintenance Department_
42
LESSON PLAN
43
Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch
With teacher student activities Teaching Aids/Evaluation
15 Replacement of parts in machines Replacement of parts in machines & equipment’s are
Min & equipment’s necessary due to following reasons;
1) Physical impairment: The particular part / unit
have completed its working Hours / time.
2) Inadequacy: The part / unit have become
inadequate, so it may be replaced.
3) Obsolescence: The unit / part have become
obsolete, so it may be replaced
4) Rapid technological changes.
Testing & Follow Up:- (to see if leaner accompanied information or skill)
Explain maintenance schedule____________________________
What is replacement policy___________________________
44
LESSON PLAN
45
Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch
With teacher student activities Teaching Aids/Evaluation
25 Elements of Cost The industrial expenditures can be put under
Min following heads:
Testing & Follow Up:- (to see if leaner accompanied information or skill)
Define total cost of the product______________________
Describe elements of cost_____________________________
46
LESSON PLAN
47
Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch
With teacher student activities Teaching Aids/Evaluation
vi. Insurance: The services rendered by the
factory for its assets and employees from
some insurance companies are charged
under factory overheads. The monthly or
annual contribution made to insurance
company is included in factory overheads.
vii. Service department: all the expenses made
by service department are part under this
category.
Testing & Follow Up:- (to see if leaner accompanied information or skill)
What is Factory Overhead____________________________
Enlist different factory overhead_________________________
48