Lean Manufacturing Concepts -Production Management & Technology

Lean Manufacturing Concepts -Production Management & Technology

Production Management　???

１.  Purpose

The purpose of production management is keeping delivery date and

Utilizing human resources, product equipment, and money efficiently.

And realize effective production activity.

２.  Responsibility

a.    Keeping delivery date

You have to keep delivery date in any case.

If the delivery delayed, you would lose customer’s trust.

b.    Average working volume

As you know, company cannot have extra workers to make profit...

You need to consider averaging work volume

to utilizing human resources effectively and keeping constant number of workers.

c.     Inventory control

As you know, the expense accompanies production activity.

Like material cost, personnel cost, Utility cost, etc.

These are remain debt until you get money from customer after the product delivery. Over Stock make cash flow worse and become heavy burden of company management.

★Key-word…JUST-IN-TIME

３.  Tool

a.    Gantt Chart

Gantt Chart covers all production plan and you can find that when do you planning production and What Product is planned production in the future, at one glance.

And all projects on the chart ordered clearly.

You can make management point clear by describing design process on the chart,

Manufacturing process (assembly etc.), Testing process on the Gantt Chart.

And if you distribute Gantt Chart to the related department,

all the related department recognize your plan and due date.

b.    Scheduling system(Production Planning System)

Scheduling system is one of the most important systems in all the production management system.

This become origin for all. If you input the date that you described on your Gantt Chart, the day registered becomes official date of the factory.

Everybody at the factory can confirm the registered schedule and share the

information of production schedule. And you can calculate weekly, monthly working volume automatically.

c.     Work volume planning system(Production Planning System)

This is the system which can calculate work volume automatically

based on the date of registered in the scheduling system.

By using this system, you can grasp future work volume and

how many workers would be required in the future.

d.    Inventory control system

When the assembly parts are warehoused, if the tag is sticked to the parts,

you can grasp the location of the parts anytime. The date of stocked in the warehouse is described on the tags.

The important thing is to grasping how much time have past from parts arrival.

The old parts cause problem of quality and over stock.

４.  Daily operation

a.    Planning schedule of production

At first, you confirm the overall schedule of each project,

and understand the key point like, Delivery date, Product work volume, etc.　

And you plan the production schedule.

At second, you describe the production schedule on your Gantt Chart (so, you can find over lapping), and you decide the schedule.

Make sure you input it to the Production Planning system.

b.    Progress management

You have to check the progress of production process.

You confirm the progress is good or not every time.

The best way of confirming is progress meeting.

You assemble people of Design Dept., Manufacturing Dept., Quality Assurance Dept., Procurement Dept., and discuss about the progress and problems in the meeting.

c.     Parts management

There are two kind of management, one is parts gathering management,

the other is inventory control.

Gathering management is management approach for how to gather the assembly parts. You have to gather the assembly parts until the beginning day of assembly.

Some of the parts take 4 to 6 months to procure from PO released.

You have to try controlling upper process to ensure the procurement period as much as possible.

Inventory control is the management approach for grasping inventory volume in the factory, and how to control it.

If some parts are kept in warehouse over 1 year, you have to act and solve the problem.

d.    Logistic control

Based on the production schedule, you need to grasp volume of dispatching and the timing of dispatch.

Then, you should contact with Logistic Company to share the dispatch

information and control it with no problem.

５.  conclusion

Production management Dept.is responsible for all the process of production

from design process to delivery. You need to consider production schedule carefully,

and keep the planned production process and delivery date.

On the other hand, you should use factory resources effectively and try to production

with minimum cost.

　　　　　　　　　　　　　　　　　　　　　　　　　

                                                                                   


Satyendra Sinha