PRODUCTION

MANAGEMENT
(ME 3105)

Course Note

Prepared by: Vinay V. Panicker

Assistant Professor,
Department of Mechanical Engineering
National Institute of Technology Calicut
Calicut 673 601, Kerala, India
 ME3105 Production Management

MODULE 1
1. INTRODUCTION

The systems aspects of manufacturing are more important than ever today. The word manufacturing
was originally derived from two Latin words manus (hand) and factus(make), so that the
combination means make by hand.

In this way manufacturing was accomplished when the word first appeared in English around
1567. Commercial goods of those times were made by hand. The methods were handicraft,
accomplished in small shops and the goods were relatively simple. As many years passed, the
products become more complex along with processes. Thus factories were developed with many
workers at a single site; the work was organized using machines

Modern manufacturing enterprises that manage these production systems must cope with the
economic realities of the modern world. These realities include the following:

Globalization Trend toward the service sector

International outsourcing Quality expectations

Local outsourcing Operational efficiency

Contract manufacturing

1.1. System: It consists of elements or components. The elements or components are interlinked
together to achieve the objective for which it exists. Eg: human body, educational
institutions, business organizations.
Inputs Outputs
Men Transformation Desirable
Material Process Undesirable
Machine
Money
Information Feedback

Figure 1.1 Transformation process

Components of a system: The input, processing, output and control of a system are called
the components of a system.

Control: There are two types of control, namely Proactive Control and Reactive Control.
There are three types of feedback mechanisms such as feed forward control, feedback control
and concurrent control

2. What is Production management?

In any manufacturing system, the job of a Production Manager is to manage the process of converting
inputs into the desired outputs.

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It is concerned with the production of goods and services, and involves the responsibility of
ensuring that business operations are efficient and effective.

It is also the management of resources, the distribution of goods and services to customers.

Therefore, Production Management can be defined as the management of the conversion process,
which converts land, labor, capital, and management inputs into desired outputs of goods and
services. It is also concerned with the design and the operation of systems for manufacture, transport,
supply or service.

3. Difference between Operations and Production

In the transformation process, the inputs change the form into an output, by adding value to the entity.
The output may be a product or service.

If it is a product centric that is known as production,

If it is a service centric then that is known as operation.

4. Production System

A production system is a collection of people, equipment, and procedures organized to perform the
manufacturing operations of a company (or other organization)

4.1. Components of a production system:

There are two components for a production system such as:

1. Facilities the factory and equipment in the facility and the way the facility is organized
(plant layout)

2. Manufacturing support systems the set of procedures used by a company to manage

production and to solve technical and logistics problems in ordering materials, moving work
through the factory, and ensuring that products meet quality standards

Figure 1.2 Diagrammatic representation for a production system

Facilities include the factory, production machines and tooling, material handling equipment,
inspection equipment, and computer systems that control the manufacturing operations. For the
facilities, plant layout is a significant factor for the production system to be efficient. The plant layout
is the way in which the equipment is physically arranged in the factory

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Manufacturing systems include the logical groupings of equipment and workers in the factory. A
combination of a group of workers and machines are termed as Production line. There can be
instances where there is only one worker and a machine. This arrangement is called as Stand-alone
workstation and worker. Based on the human participation in the production processes, the
manufacturing system can be classified as the following three systems:

Manual work systems - a worker performing one or more tasks without the aid of powered
tools, but sometimes using hand tools. For example, filing work carried out in the central
workshop

Figure 1.3a Diagrammatic representation a manual work system

Worker-machine systems - a worker operating powered equipment. For example, turning done
on a work piece using a Lathe.

Figure 1.3b Diagrammatic representation a worker-machine system

Automated systems - a process performed by a machine without direct participation of a

human For example, turning done on a work piece using a CNC machine.

Figure 1.3c Diagrammatic representation an automated system

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Manufacturing support systems: To operate the production facilities efficiently, a company must
organize itself to design the processes and equipment, plan and control the orders and satisfy product
quality requirements. The support systems have no direct contact with the product, but they plan and
control its progress throughout the factory. The manufacturing support system involves a cycle of
information-processing activities that consists of four functions. The four functions are depicted in
Figure 1.4.

Figure 1.4 Information processing cycle

i. Business functions - sales and marketing, order entry, cost accounting, customer billing

This function is the principal means of communication with the customer

This represents the beginning and the end of the information-processing cycle

It is at this function, the customer comes in contact with the company and places an order

The production (or customer) order will be (1) order to manufacture an item to customers
specifications (2) customer order to buy one or more of the manufactures product and (3)
an internal company order based on a forecast of future demand.

ii. Product design - research and development, design engineering, prototype shop

The role of the product design team depends on the production order. As mentioned above,
the production order may change.

iii. Manufacturing planning - process planning, production planning, MRP, capacity planning

Process planning is the sequence of individual processing and assembly operations needed
to produce the part.

Production planning considers the logistics issues in the production process

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The authorization to produce the product must be translated into the Master Production
Schedule (MPS)

MPS is a list of products to be made, the dates on which they are to be delivered, and the
quantities of each are included

Based on the MPS, individual components and the sub-assemblies that make up each
product must be planned.

MPS must not list more quantities of products than the factory capacity for a period.

Capacity planning plans the manpower and machine resources of the firm.

iv. Manufacturing control - shop floor control, inventory control, quality control

Managing and controlling physical operations in the factory to implement plans.

Shop floor control monitors the progress of the product as it is being processed, assembled,
moved and inspected in the factory

o Materials being processed in the factory are called as Work-in-process (WIP)

inventory.

o Both shop floor control and inventory control overlap each other.

Inventory control tries to strike a balance between the risk of too little inventory
(stock-out situation) and the carrying cost of too much inventory.

o Right quantity to order and when to re-order a given item

Quality control ensures the quality of product and its components meet the standards
specified by the product designer.

o Raw materials and component parts from outside sources are inspected when
they are received and final inspection and testing is done to ensure functional
quality and appearance.

4.2. Aim of production: The aim of a production system is to provide goods and services for
mankind

In right quantities

At the appropriate place

At the desired time

With the required quantity

At a reasonable cost

4.3. Challenges in manufacturing : The challenges in manufacturing includes

Changing market conditions shift from sellers market to buyers market

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Rate of change is faster

Global competition

Need to be pro-active

Increased customer focus the customers are less loyal.

4.4. Characteristics features of production system

1. Production is an organized activity.

2. The system transforms the various inputs into useful outputs.

3. Production system does not operate in isolation from the other organizational
systems.

4. There exists a feedback about the activities which is essential to control and improve
system performance.

4.5. Classification of production system

The production system can be classified on the basis of the following:

Type of production Job shop production, Batch production, Mass production

Size of the plant Large size plant (eg. Oil refinery), Medium size plant, Small size plant
(eg. Printing press)

Type of product- Complex to manufacture (Aircraft) and simple to manufacture

Physical flow of material Automated flow, Semi-automated flow and Manual flow

Nature of order/demand pattern Stable demand, Unstable demand

Variety of jobs More variety (eg. Automobiles/electronic goods), One variety (eg. Oil
refinery)

4.6. Job shop production

Characterised by make-to-order strategy

There are three possible situations for production quantity

o Product is manufactured only once

o Small quantities of product are repeated at irregular time intervals (demand not
certain)

o Small quantities of product are repeated at regular time intervals

In Job shop production, first and second situations are common.

End product is most of the time as per the customer need.

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No standard methods and time standards can be developed as the job is not regularly
produced.

Machines and resources must be of general purpose and flexible.

Highly skilled workforce is needed to work on product variety.

In-process inventory is high.

Machines are grouped as per their functional capabilities.

System is flexible

Planning and control is very difficult.

Job-shops are typically inefficient and have long lead times, large work-in-process
inventory and high costs.

Example: Commercial printer, Boiler manufacture, Tailoring shop

4.7. Batch production

Batch of identical articles are manufactured

The demand rate is lesser than the rate of production and hence batch production method
is traditionally adopted

There is a built-up of inventory in batch production

There are three possible situations

o A batch is manufactured only once (make-to-order)

o Batch is repeated at irregular time intervals (make-to-order)

o Batch is repeated at regular time intervals (make-to-stock)

Final product is usually standard. The basic design is same.

Such production of standardized items on a continuous basis is called repetitive

production.

Customer may be external or internal. For example, in an automobile plant, the engine
assembly plant will be an internal customer for gear assembly plant)

Machines and resources must be of general purpose or semi-automated.

Skilled workforce is needed to work on product variety.

Less supervision is need in comparison with job-shop

Less flexible than job-shop

Machines are grouped as per their functional capabilities.

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4.8. Mass production

The demand rate is more than the rate of production.

Similar product is manufactured and hence, standard method and time standard is to be
analysed.

Most of the machines used in mass production are special purpose. The equipment is
dedicated to the manufacture of a single product type such as light bulbs, medicines etc.

The system is capital intensive and a long term planning needed before the investment.

Semi-skilled labour is only needed as the product design is similar mostly.

This system is a rigid production system.

Figure 1.5 Process flexibility Vs. Product variety

5. Product design

Product design is the process of deciding on the unique characteristics and features of the
companys product. Process selection is the development of the process necessary to produce the
designed product. Product design and process selection are typically made together. Product
design must support product manufacturability (the ease with which a product can be made).
Product design defines a products characteristics of;

appearance,

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materials,

dimensions,

tolerances, and

performance standards

Service design is unique in that the service and entire service concept are being designed. When a
service is designed, the designer must define both the service and service concept.

Service design defines a services characteristics such as: Physical elements, aesthetic &
psychological benefits. For example, promptness in service, friendliness during the service,
ambiance of the service premises. In addition, product and service design must match the needs
and preferences of the targeted customer group

5.1. Phases of product development

The phases of product development are encapsulated in Table 1.1. The activities carried out
in the product development phase with regard to the different departments in the organization
is explained.

Phase 0: Planning

Planning phase is referred as phase zero; precedes the project approval and launch of actual
product development process. The output of this phase is the project mission statement which
specifies the target market for the product, business goals, key assumptions and constraints.

Phase 1: Concept Development

In Concept development, needs of the target market is identified, alternative product concepts
are generated and evaluated, and one or more concepts are selected for further development
and testing.

Phase 2: System-Level design

System level design includes product architecture and decomposition of products into sub-
systems and components.

- Final assembly of the product is decided

- Geometric layout of the product

- Functional specification of each of the layout sub-system

- Preliminary process flow diagram for final assembly process

Phase 3: Design Detail

Complete specification of the geometry, materials, and tolerances of all the unique parts in the
product.

- Identification of standard parts

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- Tooling is designed

Phase 4: Testing and Refinement

Construction and evaluation of multiple pre-production versions of the product

- Will product work?

- Whether product satisfies customer needs

Phase 5: Production Ramp-up

- Train the work force

- Work out remaining problems

- Products supplied to preferred customers and evaluated.

5.2. Economic analysis of product development

Economic analysis can only capture those factors that are measurable and have both positive
and negative implications that are difficult to quantify. Economic analysis is useful in atleast
two different circumstances using the following measurable factors to help determine:

o Operational design and development decisions should we outsource to save

time? Should we launch the product in four months at a unit cost of 10000
INR or wait for six months, when we can reduce to 8500 INR?

o Go/no-go milestones should we try to develop a product to address market

opportunity? Should we proceed? Should we launch?

Product/ service ideas

Economic and technical

feasibility studies

Product/ service design Production/process design

Product and market new product

Figure 1.6 Product development process

If initial feasibility studies are favourable, engineers prepare an initial prototype design. This
prototype design should exhibit the basic form, fit and function of the final product, but it
will not necessarily be identical to the production model.

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Table 1.1 Product development phase in different departments of an organization

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Performance testing and re-design of the prototype continues until this design-test-redesign
process produces a satisfactorily performing prototype. Market sensing and evaluation is
accomplished by demonstrations to potential customers, market tests or market surveys. If
the response to the prototype is favourable, economic evaluation of the prototype design is
performed to estimate production volume, costs and profits for the product.

5.3. Break-even analysis

Break-even analysis is a technique widely used in production management. It is based on

categorising production costs between those which are "variable" (costs that change when the
production output changes) and those that are "fixed" (costs not directly related to the volume
of production). The variable and fixed costs are compared with sales revenue in order to
determine the level of sales volume, sales value or production at which the business makes
neither a profit nor a loss (the "break-even point").

The Break-Even Chart: The break-even chart is a graphical representation which

represents the relationship between the various costs of production with the volume of
production.

Figure 1.7a Break-even chart

The point at which neither profit nor loss is made is known as the "break-even point
(BEP)" and is represented on the break-even chart by the intersection of the lines
representing total cost and total revenue.

As output increases, variable costs incurred increases, meaning that total costs (fixed +
variable) also increase. At low levels of output, costs are greater than revenue or
income. At the point of intersection, BEP, total costs are exactly equal to total revenue
or income, and hence neither profit nor loss is made.

Fixed Costs: Fixed costs are those business costs that are not directly related to the level of
production or output. In other words, even if the business has a zero output or high output, the
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level of fixed costs will remain broadly the same. In the long term fixed costs can alter - perhaps
as a result of investment in production capacity (e.g. adding a new factory unit) or through the
growth in overheads required to support a larger, more complex business.

Examples of fixed costs:

- Rent and rates

- Depreciation

- Research and development

- Marketing costs (non- revenue related)

- Administration costs

Variable Costs: Variable costs are those costs which vary directly with the level of output. They
represent payment output-related inputs such as raw materials, direct labour, fuel and revenue-
related costs such as commission.

A distinction is often made between "Direct" variable costs and "Indirect" variable costs.

Direct variable costs are those which can be directly attributable to the production of a particular
product or service and allocated to a particular cost centre. Raw materials and the wages those
working on the production line are good examples.

Indirect variable costs cannot be directly attributable to production but they do vary with output.
These include depreciation (where it is calculated related to output - e.g. machine hours),
maintenance and certain labour costs.

5.3.1 Computation of Break-even point:

BEP is the quantity of goods, the company needs to sell to cover its costs.

F
Q BE
( SP VC )

where, QBE Break even quantity

F Fixed costs

SP selling price/unit

VC Variable cost

Break-even analysis also includes calculating

Total cost = sum of fixed cost and variable cost

Total cost (TC) = F + (VC)*Q

Revenue amount of money brought in from sales

Revenue (TR) = (SP) x Q

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Q = number of units sold

As a production manager, the focus will be to shift the BEP towards left, by moving the total cost
curve down. This is possible only by reducing the variable cost. Here lies the importance of value
analysis/value engineering concepts. The concept of value analysis is dealt in

Figure 1.7 b Change of Break-even chart as variable cost changes

_____________________________________________________________________________

Example Problem 1: A Company manufacturer ball-point pens that it is able to sell at INR 15 per
piece. The variable cost of the pen is INR 10 per unit. If the company has a total investment in fixed
costs to the tune of INR 30,000. What is the break-even sale for the pen?

____________________________________________________________________________

5.4. Designing for the customer

A formal method is needed for making sure that everyone working on a design project
knows the design objectives and is aware of the interrelationships of the various parts of
the design. Similar communications are needed to translate the voice of the customer to
technical design requirements. Such a process is called quality function deployment
(QFD).

Designing products for aesthetics and for the user is generally termed as Industrial design.

One approach to getting the voice of the customer into the design specification of a
product is quality function deployment (QFD).

This approach credited by Toyota Motor Corporation for reducing costs on its car by
more than 60% by significantly shortening design times.

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QFD uses a series of matrix diagrams that resemble connected houses. The first matrix,
dubbed the house of quality, converts customer requirements into product-design
characteristics.

As shown in Figure 1.8, the house of quality has six sections: a customer requirements
section, a competitive assessment section, a design characteristics section, a relationship
matrix, a trade-off matrix, and a target values section.

Quality Function Deployment begins with

1. Studying and listening to customers market research consumers product needs

and preferences are defined and broken down into categories called customer
requirements.

2. Requirements are weighted based on their relative importance.

3. Customer is asked to compare and rate the companys products with the products
of competitors

To evaluate its product in relation to others

Better understanding and focus on product characteristics that require

improvement

4. A set of technical characteristics of the product is developed

Evaluate the strengths and weaknesses of the product in terms of

technical characteristics.

Figure 1.8 Outline of QFD

5.5. Value analysis

The purpose of value analysis/value engineering is to simplify products and processes.

Value analysis (VA) (also known as value engineering) was developed by General Electric in
1947 to eliminate unnecessary features and functions in product designs.

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VA is a set of activities undertaken to investigate the design components in a product

development process strictly from a cost-value perspective and alert the product development
team to alternatives that could bring down the cost of improve value in terms of functionality
and performance without increasing the cost.

o Tata Nano project Rane group which makes rack-and pinion steering system
focussed on reducing weight of the materials used, the steel rod of the steering with
steel tube which could reduce cost.

o GKN Driveline India designed shaft of small diameter which made it lighter and
saved material costs.

It has re-emerged as a technique for use by multifunctional design teams.

Usually several questions are raised which include the following:

1. Can we eliminate certain features from the design? Does the item have any design
features that are not necessary?

2. Are there instances of overdesign in certain components, increasing the cost? Can two
or more parts be combined into one?

3. Are there certain features of design that cost more than they are worth?

4. Is it possible to replace the proposed method of manufacture with less costly one?

5. Is it possible for someone else to produce certain components cheaper, faster and
better? (make or buy decision)

6. How can we cut down the weight?

7. Are there nonstandard parts that can be eliminated?

The objective of VA is to achieve equivalent or better performance at a lower cost while

maintaining all functional requirements defined by the customer.

The design team defines the essential functions of a component, assembly, or product using a
verb and a noun. For example, the function of a container might be described as holds fluid.

Then the team assigns a value to each function and determines the cost of providing the
function. With that information, a ratio of value to cost can be calculated for each item.

The team attempts to improve the ratio by either reducing the cost of the item or increasing its
worth.

VA/VE does this by identifying and eliminating unnecessary cost/features.

Updated versions of value analysis also assess the environmental impact of materials, parts,
and operations. This leads us to the next section on design for environment.

5.6. Process and capacity analysis

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One of the important decision points in the design and operational control of an operations
system concerns the capacity to be deployed in the system.

Often hear of excessive delays and waiting time in service systems. Similarly, we hear that
some factories work with near 100% utilization of their resources.

Improper choice in the amount of capacity deployed and poor planning of the existing
capacity will lead to loss of productivity and overall profitability of the operating system.

The basic building block of capacity analysis is process analysis.

A process is the basic building block of operations. Process consists of a set of activities that
need to be performed by consuming some resources and time.

Process design determine aspects such as the time taken to serve the customer, the cost
involved, the productivity of people, and utilization of resources.

An operations manager may need to understand the following issues in the process design:

Do I have adequate resources to meet the demand? If I need to add some extra
resources, where should I add them?

What is the extent to the utilization of my resources?

To increase the capacity of my system, how should I modify the process? Should I
add more resources? What will happen to the cost of my operations?

Process analysis tools include the following:

Process flow analysis: In process analysis, we use some analytical mechanisms to understand the
impact of the process design on output, cost, or any other performance metric.

Process flowchart: is the use of a diagram to present the major elements of a process using the
symbols as shown in Figure 1.9. The basic elements can include tasks or operations, flows of
materials or customers, decision points, and storage areas or queues. It is an ideal methodology by
which to begin analysing a process.

Figure 1.9 Symbols used for process flow

charting

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5.7. Common terms used in process analysis

A buffer refers to a storage area between stages where the output of a stage is placed prior to
being used in a downstream stage.

Blocking occurs when the activities in a stage must stop because there is no place to deposit
the item just completed. If there is no space for an employee to place a unit of work down,
the employee will hold on to it and not able to continue working on the next unit.

Starving occurs when the activities in a stage must stop because there is no work. If an
employee is waiting at a work station and no work (job) is coming to the employee to
process, the employee will remain idle until the next unit of work comes.

Bottleneck occurs when the limited capacity of a process causes work to pile up or become
unevenly distributed in the flow of a process. If an employee works slowly in a multi-stage
process, work will begin to pile up in front of that employee. In this case, the employee
represents the limited capacity causing the bottleneck.

Pacing refers to the fixed timing of the movement of items through the process. This can be
observed in assembly line operations.

___________________________________________________________________________

Example problem 1: Consider a shirt-manufacturing process. There are five steps of manufacturing
and three storage points. The store stocks raw material and other materials such as buttons and thread.
The cloth is moved to the first stage of processing where it is systematically spread out and the
relevant markings are made. After this, it is sent for cutting. Once the cutting operation is complete,
various individual pieces that make up one shirt when put together are segregated into two bundles.
One bundle goes to the first stitching operation while the other bundle goes to the second stitching
operation. After stitching is complete, they are temporarily stored. The assembly process consists of
matching the pieces and attaching them into a completed shirt. Assembly operation is followed by an
inspection and pressing operation. Finally the shirt is stored. Prepare a process chart for the above
process.

___________________________________________________________________________

5.8. Process performance metrics

Process performance metrics are to be determined to review whether a process is functioning properly
as required. The process performance metrics measures the different process characteristics that tell us
how a process is performing.

The commonly used process performance metrics are as follows:

Efficiency: is a ratio of the actual output of a process relative to some standard.

Throughput time: is the elapsed time from the first stage of the process to the last stage of the
process. It is also known as lead time.

Run time: is the time required to produce a batch of products. (time required to produce each unit x
batch size)

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Set-up time: is the time required to prepare a machine to make a particular item.

Operation time = Run time + Set-up time

Cycle time: is the elapsed time between two successive outputs from a process that is continuously
operating in the given period of time.

Bottle neck: that stage of the process that dictates the output of a process.

Process velocity (or throughput ratio): is the ratio of the total throughput time to the value-added
time.

Throughput rate: is the output rate that the process is expected to produce over a period of time. For
example, Throughput rate of the assembly line is 120 units per hour. Also, Throughput rate is the
mathematical inverse of the cycle time.

____________________________________________________________________________

Example problem 1: A toy manufacturer receives crafted toys from local carpenters and performs
the final operations before stocking it for sale. The process consists of five steps. The first step is to
arrange a set of four toys in a pallet. After this, the pallet moves to the next station where the toys are
pre-treated. This is to increase the toys life. The next step is to send it to the spray painting chamber,
where it is painted as per the specifications. At present there is only one spray painting machine. After
painting it is left in an open area for drying. The painting process and the pre-treatment process are
specialized so the paint dries quickly. Finally the toys are inspected and packed.

Step 1: Preparation of toys 8 minutes

Step 2: Pre-treatment 12 minutes

Step 3: Painting 20 minutes

Step 4: Drying 10 minutes

Step 5: Inspection and packing 5 minutes

Develop a process flow diagram for these steps and answer the following.

(a) What is the throughput time for this manufacturing process

(b) Identify the bottleneck for this process?

(c) What is the cycle time for this process?

(d) What is the productive capacity of the process?

(e) What are the assumptions behind this computation?

_______________________________________________________________________________

5.9. Design strategy: The design considerations include the following strategies.

Make-to-stock strategy: In the make-to-stock environment, goods are produced before

customers place orders. The retail environment is an example of make-to-stock.
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Goods are produced and put into inventory at the retailer. The make-to-stock strategy
typically allows manufacturers to produce goods in long production runs, taking
advantage of production efficiencies. Because the make-to-stock environment
produces goods on a consistent basis, a master production schedule determines the
exact number of units to produce for each production run.

Assemble-to-order strategy: Certain fast-food restaurants use an assemble-to-order

strategy. A customer walks in, places an order for a pizza; and the pizza gets
assembled from a stock selection of ingredients. This strategy forces the restaurant to
carry enough ingredients to make every pizza combination a customer might request.
Automobile manufacturers also use the assemble-to-order strategy. A customer can
pick and choose from many features including interior fabrics, exterior paints, and
seat, engine, wheel or tire options. Once the dealer places the customer order, the
manufacturing plant assembles the standard component parts to the customer. Dell
can be another example for assemble to order.

Make-to-order strategy: Companies that use a make-to-order strategy produce goods

after receiving an order from the customer. Most often a company that uses the make-
to-order strategy produces one-of-a-kind goods. Examples include custom-tailored
clothing, custom machinery and few jewellery shops.

The various strategies are depicted in Figure 1.10

Figure 1.10 Different design strategies

6. Productivity

It is a very comprehensive concept, both in its aim and also in its operational content. It is a
matter of common knowledge that higher productivity leads to a reduction in cost of production,
reduces the sales price of an item, expands markets, and enables the goods to compete effectively
in the world market. In fact the strength of a country, prosperity of its economy, standard of
living of the people and the wealth of the nation are very largely determined by the extent and
measure of its production and productivity. By enabling an increase in the output of goods or
services for existing resources, productivity decreases the cost of goods per unit, and makes it
possible to sell them at lower prices, thus benefiting the consumers while at the same time
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leaving a margin for increase in the wages of the workers. Productivity can be defined in many
ways. Some of them are as follows:

Productivity is nothing but the reduction in wastage of resources such as labour,

machines, materials, power, space, time, capital, etc.

Productivity can also be defined as human endeavour (effort) to produce more and more
with less and less inputs of resources so that the products can be purchased by a large
number of people at affordable price.

Productivity implies development of an attitude of mind and a constant urge to find

better, cheaper, easier, quicker, and safer means of doing a job, manufacturing a product
and providing service.

Productivity aims at the maximum utilization of resources for yielding as many goods
and services as possible, of the kinds most wanted by consumers at lowest possible cost.

Productivity processes more efficient works involving less fatigue to workers due to
improvements in the layout of plant and work, better working conditions and
simplification of work. In a wider sense productivity may be taken to constitute the ratio
of all available goods and services to the potential resources of the group.

Productivity is a common measure on how well resources are being used. In the broadest sense, it
can be defined as the following ratio:

Output
Pr oductivity
Input

A firm deals about Total (or composite) productivity when it is interested to know about the overall
productivity of all input factors. This technique will give us the productivity of an entire organization or
even a nation.
Output Goods and services produced
Total Measure Productivity
Input All resources produced

Partial productivity measurement is used when the firm is interested in the productivity of a selected
input factor. It is the ratio of output values to one class of input.

Output Output Output Output

Partial measures of productivity
Labour Capital Materials Energy

This productivity measurement technique is used when the firm is interested to know the productivity of a
group of input factors but not all input factors.
Output
Multifactor measures of productivity
Labour Capital Energy
Output

Labour Capital Materials

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Example Problem 1: You have just determined that your service employees have used a total of
2400 hours of labor this week to process 560 insurance forms. Last week the same crew used only
2000 hours of labor to process 480 forms. Which productivity measure should be used? Is
productivity increasing or decreasing?

Answer: This problem can be classified as a Total Measure or Partial Measure.

Last weeks productivity = 480/2000 = 0.24, and this weeks productivity is = 560/2400 = 0.23.

So, productivity is decreasing slightly.

Problem 2: As operations manager, you are concerned about being able to meet the sales
requirements in the coming months. You have just been given the following production report. Find
the average monthly productivity.

Jan Feb Mar Apr

Units Produced 2300 1800 2800 3000
Hours per machine 325 200 400 320
Number of machines 3 5 4 4

Problem 3: An electronics company makes communication devices for military contracts. The
company just completed two contracts. The navy contract was for 2,300 devices and took 25 workers
two weeks (40 hours per week) to complete. The army contract was for 5,500 devices that were
produced by 35 workers in three weeks. On which contract were the workers more productive?

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7. Learning curves

A learning curve is a line displaying the relationship between unit production time and the
cumulative number of units produced. Learning (or experience) curve theory has a wide range of
application in the business world.

In manufacturing, it can be used to estimate the time for product design and production, as
well as costs.

Learning curves are important and are sometimes overlooked as one of the trade-offs in just-
in-time (JIT) systems, where sequencing and short runs achieve lower inventories by
forfeiting some benefits of experience from long product runs.

Learning curves are also an integral part in planning corporate strategy, such as decisions
concerning pricing, capital investment, and operating costs based on experience curves.

Learning curves can be applied to individuals or organizations. Individual learning is

improvement that results when people repeat a process and gain skill or efficiency from their
own experience. That is, practice makes perfect.

Organizational learning results from practice as well, but it also comes from changes in
administration, equipment, and product design. In organizational settings, we expect to see
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both kinds of learning occurring simultaneously and often describe the combined effect with a
single learning curve.

Learning curve theory is based on three assumptions:

The amount of time required to complete a given task or unit of a product will be less
each time the task is undertaken.

The unit time will decrease at a decreasing rate.

The reduction in time will follow a predictable pattern.

In this application, it is observed that, as production doubled, there is a 20 percent reduction in direct
production worker-hours per unit between doubled units. Thus, if it took 100,000 hours for Plane 1, it
will take 80,000 hours for Plane 2, 64,000 hours for Plane 4, and so forth. Because the 20 percent
reduction meant that, say, Unit 4 will take only 80 percent of the production time required for Unit 2,
the line connecting the coordinates of output and time is referred to as an 80 percent learning curve.

Figure 1.10 Learning curves

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Example Problem 1: Captain Nemo, owner of the Suboptimum Underwater Boat Company (SUB),
is puzzled. He has a contract for 11 boats and has completed 4 of them. He has observed that his
production manager, young Mr. Overick, has been reassigning more and more people to torpedo
assembly after the construction of the first four boats. The first boat, for example, required 225
workers, each working a 40-hour week, while 45 fewer workers were required for the second boat.
Overick has told them that this is just the beginning and that he will complete the last boat in the

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current contract with only 100 workers! Overick is banking on the learning curve, but has he gone
overboard? (Chase et al. 2010)

Because the second boat required 180 workers, a simple exponential curve shows that the learning
percentage is 80 percent (180 225). To find out how many workers are required for the 11th boat,
we look up unit 11 for an 80 percent improvement ratio in learning curve table and multiply this value
by the number required for the first sub. By interpolating between Unit 10 and Unit 12 we find the
improvement ratio is equal to 0.4629. This yields 104.15 workers (0.4269 interpolated from
table225). Thus, Overicks estimate missed the boat by four people.

Example Problem 2: A manufacturer of diesel locomotives needs 50,000 hours to produce the first
unit. Based on the past experience with similar products, you know that the rate of learning is 80
percent. Use the logarithmic analysis to estimate the direct labour required for the 40 th diesel
locomotive and the cumulative average number of labour hours per unit for the first 40 units. Also,
plot a learning curve for this situation.

Example Problem 3: The manager of a turbine manufacturer has just received a production schedule
for an order for 30 turbines. Over the next 5 months, the company is to produce 2, 3, 5, 8, 12 turbines
respectively. The first unit took 30000 direct labour hours and experience on past projects indicates
that a 90% learning curve is appropriate. Each employee works an average of 150 hours per month.
Estimate the total number of full-time employees needed each month for the next 5 months.

Month No. of units in the month Cumulative no. of units

1 2 2
2 3 5
3 5 10
4 8 18
5 12 30
Month 1:
First unit = 30000 hours
Second unit = 30000 x 0.9 = 27000 hours
Total hours = 30000+27000 = 57000
57000
Number of employees needed = = 380
150

Month 2
Third unit = 30000 x 0.846 = 25386 hours
Fourth unit = 30000 x 0.810 = 24300 hours
Fifth unit= 30000 x 0.783 = 23490 hours
Total hours = 25386+24300+23490 = 73176
73176
Number of employees needed = = 488
150

Month 3: Number of employees needed = 731

Month 4: Number of employees needed = 1067
Month 5: Number of employees needed = 1480.
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