PRODUCTION DEPARTMENT

Production Department is the department which directly involves in manufacturing products. Examples are the machining, finishing, and assembling departments. Functions of Production Department Production is the functional area responsible for turning inputs into finished outputs through a series of production processes. The Production Manager is responsible for making sure that raw materials are provided and made into finished goods effectively. He must make sure that work is carried out smoothly, and must supervise procedures for making work more efficient and more enjoyable. Five Production sub-functions In a company the Production function may be split into five sub-functions: The Production and Planning department will set standards and targets for each section of the production process. The quantity and quality of products coming off a production line will be closely monitored. In businesses focusing on lean production, quality will be monitored by all employees at every stage of production, rather than at the end as is the case for businesses using a quality control approach.

The Purchasing department will be responsible for providing the materials, components and equipment required to keep the production process running smoothly. A vital aspect of this role is ensuring stocks arrive on time and to the right quality.

The Stores department will be responsible for stocking all the necessary tools, spares, raw materials and equipment required to service the manufacturing process. Where sourcing is unreliable, buffer stocks will need to be kept and the use of computerized stock control systems helps keep stocks at a minimal.

The Design and Technical support department will be responsible for researching new products or modifications to existing ones, estimating costs for producing in different quantities and by using different methods. It will also be responsible for the design and testing of new product processes and product types, together with the development of prototypes through to the final product. The Technical support department may also be responsible for work study and suggestions as to how working practices can be improved.

The Operations department will be concerned with the manufacture of products. This will include the maintenance of the production line and other necessary repairs. The works department may also have responsibility for quality control and inspection. A key aspect of Modern Production is ensuring quality. The term quality means fitness for purpose i.e. a product; process or service should do exactly what is expected of it. The main role of production is to turn inputs (raw materials)

into outputs (finished goods). Outputs refer to a finished product or service and inputs are the materials that are needed to manufacture certain goods. When a business completes this process they are able to achieve customer satisfaction by producing products that are ready to be used and fit for purpose. The Production department is responsible for ensuring quality is achieved in each item produced. They will need to carry out inspections and implement suitable quality initiatives. This is one of the major duties of this department in Indian Foods (P) Limited because if mistakes are made on products, customer satisfaction will be decreased or if products are ruined during the production process it. Both aspects will lead the company to a loss of profit. Quality assurance will is carried out every day on a number of occasions to ensure that the production process is working efficiently and effectively. Indian Foods (P) Limited will carry out approximately 200 inspections per day to ensure quality is being achieved and also to make sure all equipment is running well. Production Planning Planning is exercise of intelligent anticipation in order to establish how an objective can be achieved, or a need fulfilled, in circumstances which are invariable restrictive. Planning provides the supporting arithmetic for an objective which has already been decided. It does not establish whether the objective is right or wrong, good or bad, worthwhile or worthless except in terms which have also been decided beforehand.

Consequently, only plan is invariably biased in favor of the chosen objective Planning is an act of prediction, the accuracy of which varies enormously depending upon the kind of objective, kind of circumstances, the skill of the planner and his techniques and chance. Planning is necessary because resources are

limited. Production planning activities originate at the aggregate level and consider decisions relevant to a specific planning horizon. A planning horizon can be a period as short as four weeks a month, or a quarter (03weeks) but more commonly refers to periods of from six months to a year or more. The aggregate planning problem is to determine the production rate which satisfies the anticipated output requirements; while minimizing the related costs associated with the fluctuation of work force, inventories, and other relevant decision variables such as overtime hours subcontracting and capacity utilization. Production planning translates sales forecast into master production schedules. Production Scheduling Scheduling is more specific and less oriented to the future. Scheduling accepts current conditions like available machinery, manpower and material etc and provides as detailed spots for utilizing these facilities to achieve immediate product objectives. Scheduling starts with the desired end results and provides BLUE-PRO for accomplishing the task on hand. Schedules may be as specific as time and cost per. They may outline general steps needed to complete a task or they may lay down specific operations like start time, completion time etc. Often the more specific schedule is the better it can be used as a production control device.

It is important to note that the division between planning, scheduling a control is artificial. Much of the value of production plans and scheduled are lost if procedures do not exist to provide information feedback, how well are plans functioning planning efforts. The inventory control is the related aspect under production control; through inventors control is a complex attain involving both cost and the use of certain important concept and techniques. The amount inventory on hand will affect production plans as well as customers delivery and the form of inventory like raw or finished material, and the goods at various stages of processing. It is readily apparent the need for adequate production planning, especially in situation where long lead time are required to change production

capabilities. Requirement of rare work force skills of imported equipment or raw materials of expanded plants of facilities can often severally reduce a companys ability to meet changing market condition.

WAREHOUSE DEPARTMENT

A warehouse is a hub in a logistics network where goods are temporarily stored or rerouted to a different network. A basic distinction can be made among supply, handling and distribution warehouses. 1. Supply warehouse

Supply warehouses are usually part of the production operation and are used to store raw materials, auxiliary supplies and other resources needed for production as well as semi-finished products and finished goods used during particular seasons.

2. Trans-shipment warehouse

Trans-shipment warehouses house goods for short periods between their transfers from one means of transportation to another. They are frequently operated by logistics providers and retail companies.

With so-called Cross docking, manufacturers send goods that have been prepicked for particular retail outlets to the retailers warehouse. Here, shipments from various manufacturers for the respective retail outlet are batched and then delivered together. This dispenses with the need to pick goods bound for separate retail outlets in the retailers central warehouse. All or most of the inventory is eliminated as well.

3. Distribution warehouse

The composition of the flow of goods is changed in the distribution warehouse. Distribution warehouses are classified into central, regional and local distribution warehouses depending on the area they serve. Central distribution warehouses are generally referred to as central warehouses, while decentralized regional or local distribution warehouses are called supply or delivery warehouses. In supply warehouses, goods from various suppliers are collected and distributed to one or more production or retail operations. In delivery warehouses, goods from production are stored before being delivered to customers. Duties of the Warehouse: Receiving procured materials and items, ensuring they match the purchase order specifications, and applying receipt and storing procedures. Storing materials and items as per applied storing rules, and maintaining them from fire or damage. Delivering the materials and items, after completing the applied regulations, and filling and packing them for shipping. Monitoring stock level, and reporting the items that have reached the replenish level. Organizing and maintaining cards and forms, recording materials, items and activities, and entering the information into the system.

 Preparing monthly statements of materials, items and activities. Defining store requirements for manpower, equipment, materials, and providing them. Preparing periodical reports on store activities, achievements, and work development, and presenting them to the General Manager for Administrative & Financial Affairs. Storage functions are usually an extension of receiving department duties. The basic functions of storage are the movement of products from the dock area to a holding location, the recording of the location and quantity, and the updating of storage records so that the product can be found easily when it is needed. Retrieval of products from holding locations may also be assigned to storage operations and/or may be a function of picking operations. There are two basic methodologies for setting up a storage system in Indian Foods (P) Limited Company:

They simply use the floor, lining pallets up in rows and stacking pallets of like product on top of each other. This method is usually referred to as bulk storage. This can be a valid option for a warehouse with a very low ceiling. It can also be a good option for storing many pallets of the same product like Cookies, Biscuits.

They install pallet rack and/or shelving in rows. This widely accepted method, usually referred to as rack storage, usually makes good use of available space and is cost effective so long as the ceiling height allows at least three levels of full pallet storage. The higher the ceiling, the more cost effective rack storage usually becomes.

Warehousing Objectives In designing warehousing systems it is desirable to maximize: 1. Space utilization 2. Equipment utilization 3. Labor utilization 4. Accessibility of all materials 5. Protection of all materials. Storing goods in adequate space with the proper equipment, well trained personnel in a properly planned layout results in maximum protection of items is the goal of the Warehousing Department in Indian Foods (P) Limited.