10.5 Production and Operations Control
3 min read•june 18, 2024
Production and operations control is the backbone of efficient manufacturing. It involves planning, directing, and coordinating resources to meet production targets. From materials through the production process to tasks, this system ensures smooth operations and optimal resource utilization.
Quality management and continuous improvement are crucial aspects of . Techniques like Total Quality Management, , and help businesses maintain high standards, reduce defects, and eliminate waste. These approaches involve all employees and processes to create a culture of ongoing improvement.
Production and Operations Control
Concept of production control
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- Process of planning, directing, and controlling production to achieve desired outputs efficiently
- Coordinates and optimizes resources (materials, labor, equipment) to meet production targets
- Key aspects in operations management:
- Planning determines production goals, resource requirements, and timelines
- Routing establishes sequence of operations and path materials follow through production process
- Scheduling allocates resources and sets start and finish times for each operation
- issues work orders and instructions to initiate production activities
- Follow-up monitors progress, identifies deviations, and takes corrective actions to keep production on track
- ensures sufficient resources are available to meet production demands
Routing and scheduling in production
- Routing contributes to efficient production by:
- Determining most efficient sequence of operations minimizes material handling and transportation
- Identifying optimal path for materials flow reduces bottlenecks and delays ()
- Ensuring proper utilization of equipment and workstations minimizes idle time (CNC machines)
- Scheduling contributes to efficient production by:
- Allocating resources (labor, equipment) to tasks and time slots optimizes utilization (shift scheduling)
- Coordinating timing of operations minimizes waiting times and inventory buildup ()
- Establishing realistic start and finish times considering dependencies and constraints
- Enabling better coordination with suppliers and customers by providing accurate production timelines
- plays a crucial role in optimizing production scheduling and resource allocation
Gantt charts vs CPM vs PERT
- :
- Visual representation of project schedule using horizontal bars for task duration
- Displays sequence and dependencies of activities (product development phases)
- Easy to understand and communicate project timelines
- Limited in showing relationships between tasks and identifying critical paths
- :
- Network-based technique for scheduling project activities
- Identifies longest sequence of dependent activities () determining minimum project duration
- Manages activities with no slack time that can impact project completion date (construction projects)
- Assumes deterministic activity durations, does not account for uncertainty
- ###program_evaluation_and_review_technique_()_0###:
- Network-based technique similar to CPM considering uncertainty in activity durations
- Uses three time estimates (optimistic, most likely, pessimistic) to calculate expected activity durations and variances
- Determines probability of completing project within given timeframe (software development)
- More suitable for projects with high uncertainty and novel activities (research and development)
- Comparison:
- simple and visual, CPM and PERT more analytical and network-based
- CPM focuses on critical path, PERT incorporates uncertainty in activity durations
- PERT suitable for high uncertainty projects, CPM better for well-defined activities and durations
Quality Management and Continuous Improvement
- ensures products meet specified standards and customer requirements
- is a comprehensive approach to quality that involves all employees and processes
- Six Sigma is a data-driven methodology for eliminating defects and reducing variability in processes
- focuses on minimizing waste and maximizing value in production processes
- integrates quality control across the entire supply network to ensure overall product quality
Key Terms to Review (25)
Assembly Line: An assembly line is a manufacturing process in which parts are added to a product in a sequential manner to create an end result. It is a key concept in mass production, allowing for efficient and standardized manufacturing of goods.
Capacity Planning: Capacity planning is the process of determining and managing the production capacity of an organization to meet changing demands effectively. It involves analyzing the available resources, forecasting future needs, and strategically aligning the production capacity to optimize efficiency and customer satisfaction.
Critical path: The critical path is the longest sequence of activities in a project plan which must be completed on time for the project to conclude by its due date. Any delays in the critical path directly impact the project's schedule and overall completion time.
Critical Path Method: The Critical Path Method (CPM) is a project management technique used to determine the longest stretch of dependent activities and measure the time required to complete a project. It helps project managers identify the most critical tasks that directly affect the project's finish date, allowing for effective resource planning and scheduling. By focusing on these essential tasks, CPM ensures efficient allocation of resources, minimizing delays and optimizing overall project performance.
Critical path method (CPM): The Critical Path Method (CPM) is a project management technique used to identify the sequence of crucial tasks that determine the minimum completion time for a project. It involves identifying the longest stretch of dependent activities and measuring the time required to complete them from start to finish.
Dispatching: Dispatching is the process of assigning and releasing work orders or production orders to the appropriate production facilities or resources within a manufacturing or operations management system. It involves the allocation of tasks, materials, and equipment to ensure the efficient and timely execution of production activities.
Gantt charts: A Gantt chart is a visual project management tool that displays the start and finish dates of the various components and tasks required to complete a project. It allows for easy tracking of progress and scheduling, facilitating effective operations management.
Gantt Charts: Gantt charts are a type of bar chart used to visually represent the schedule and progress of a project. They provide a clear and concise way to plan, schedule, and monitor the various tasks and activities that make up a project, helping project managers and teams effectively coordinate and manage project timelines.
Inventory management: Inventory management is the process of ordering, storing, using, and selling a company's inventory. It includes the management of raw materials, components, and finished products, as well as warehousing and processing such items.
Inventory Management: Inventory management is the process of overseeing and controlling the ordering, storage, and use of components that an organization will use to produce a finished product or offer a service. It is a critical function in production and operations management, as well as in wholesale and retail settings, ensuring that the right amount of inventory is available at the right time to meet customer demand efficiently and cost-effectively.
Just-in-Time Production: Just-in-time (JIT) production is a manufacturing strategy that aims to improve a business's return on investment by reducing in-process inventory and associated carrying costs. It involves producing only what is needed, when it is needed, and in the exact amount needed, thereby reducing waste and improving efficiency.
Lean manufacturing: Lean Manufacturing is a systematic method for waste minimization within a manufacturing system without sacrificing productivity. It focuses on enhancing value for the customer by optimizing processes, reducing unnecessary steps, and cutting excess costs.
Lean Manufacturing: Lean manufacturing is a production methodology focused on minimizing waste and maximizing efficiency throughout the entire manufacturing process. It aims to create more value for customers with fewer resources by identifying and eliminating non-value-adding activities.
PERT: PERT, or Program Evaluation and Review Technique, is a project management tool used to plan, schedule, and control complex projects. It is a statistical approach that helps project managers estimate the time and resources required to complete a project by analyzing the tasks involved and their dependencies.
Production Control: Production control is the management of the production process to ensure efficient and effective operations. It involves planning, scheduling, and monitoring the various stages of production to optimize resource utilization and meet customer demand.
Program Evaluation and Review Technique: Program Evaluation and Review Technique (PERT) is a project management tool used to schedule, organize, and coordinate tasks within a project. It is a statistical tool that employs network analysis to quantify the time, resources, and risks associated with project completion.
Program evaluation and review technique (PERT): Program Evaluation and Review Technique, or PERT, is a project management tool used to plan, schedule, and control complex tasks. It involves identifying the specific tasks necessary to complete a project and estimating the minimum time needed to complete each task.
Quality control: Quality control is the process of ensuring that products and services meet specified requirements and standards. It involves monitoring and evaluating various aspects of production to prevent defects, reduce waste, and maintain consistency in quality, which are crucial for effective production and operations management.
Rader Awning & Upholstery: Rader Awning & Upholstery represents a business specializing in the design, production, and repair of awnings and upholstery products. This company epitomizes how operations management strategies can be applied to maintain quality control and efficient production processes in a niche market.
Routing: Routing in the context of Achieving World-Class Operations Management is the process of determining the most efficient path or method for resources to be allocated and tasks to be completed within production and operations control. It outlines the sequence of operations, equipment needs, and workflow to optimize efficiency and productivity.
Scheduling: Scheduling is the process of allocating and coordinating the use of resources, such as personnel, equipment, and facilities, to optimize the efficiency and productivity of an organization's operations. It is a critical component of production and operations control, ensuring that tasks and activities are executed in a timely and coordinated manner to meet production goals and customer demands.
Six Sigma: Six Sigma is a data-driven, systematic approach to improving business processes and reducing defects or variations in products and services. It aims to enhance quality, efficiency, and customer satisfaction by identifying and eliminating the root causes of problems.
Supply Chain Management: Supply chain management is the coordination and management of all activities involved in sourcing, procurement, conversion, and logistics management. It connects suppliers, manufacturers, warehouses, and retailers to ensure that products are delivered efficiently to consumers while minimizing costs and maximizing customer satisfaction.
Total Quality Management (TQM): Total Quality Management (TQM) is a comprehensive and strategic approach to organizational management that focuses on continuously improving the quality of products, services, and processes to meet or exceed customer expectations. It involves the participation and collaboration of all members of an organization to achieve long-term success through customer satisfaction.
Value-stream mapping: Value-stream mapping is a lean-management method used for analyzing the current state and designing a future state for the series of events that take a product or service from its beginning through to the customer. It helps identify waste and streamline production processes.