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Chapter Page no.
Chapter 8 – Scheduling 1
Planning
• Determining what products are to be produced and the quantities to be produced
in defined time periods.
• Dividing the complete product in to its component assemblies and individual
parts. This process is called the planning breakdown.
• Evolving the optimum methods for economic and timely production of the
assemblies and their individual parts.
• Assigning the task to be performed to identified groups such as divisions of
company, department of a division, work centers of a department.
• Scheduling the sequence, priorities and time periods for each task for each group.
• Arranging to provide the resources in time for execution of the tasks.
• Setting targets and standards of performance for each task in terms of
time/cost/quality.
• Authorizing the execution of work.
Execution
• Carrying out the tasks in each group as authorised by planning.
Control
• Constantly monitoring the progress of execution of the tasks in each group against
the specified targets/standards of performance, analyzing the variances between
actual achievement and the set targets/standards, evolving and taking corrective
action in case of shortfalls in achievements when compared with the set
targets/standards.
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2. ORGANISATION OF PPC
The production engineering department of a division of a company engaged in
aircraft production is typically organized as follows:
• Central or Programme Planning Group
This group is responsible for issue of the aggregate plan which specifies what
products are to be produced in the next 1-3 years, the resources required to launch and
sustain production, the broad assignment of tasks and the targets/standard of
performance to be achieved by the groups engaged in execution and control. It
derives the requirement of products to be produced from the marketing, R&D,
personnel, purchase and finance departments. The programme planning group is also
responsible for design of the plant layout and for taking “Make or Buy” decisions.
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• Planning Breakdown
An aircraft comprises thousands of individual parts suitably assembled in
stages. The “Planning Breakdown” defines the major structural components of the
aircraft, their individual parts, sub assemblies and the systems installed in each
major component, the sequence of manufacture of the individual parts and the
stages of assembly. The Planning Breakdown is derived from a study of the
manufacturing drawings.
• Man Hours for Manufacture
Man hours is the time required under specified conditions expressed in hours
by an average worker/group of workers to execute a given job with or without the
assistance of tools and production aids such as machine tools, production tools,
standard tools, and other production equipment.
In the execution of jobs there are four major time elements:
(i) Set up time i.e. preparing for executing the job which includes setting up
of jigs, tools, fixtures.
(ii) Time for loading the job onto the jig/fixture/machine.
(iii) Time for carrying out the operation.
(iv) Time for unloading the job.
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Work study provides a scientific basis for establishing the work content
involved in fabrication of individual parts and assembling them. Work-study
comprises of Methods Study and Work Measurement. ‘Method study’ is defined
in the British standards “The systematic recording and critical examination of the
factors and resources involved in existing and proposed ways of doing work, as a
means of developing and applying easier and mire effective methods and reducing
costs”. Work measurement “is defined by the same British standards as, “The
application of techniques designed to establish the time for a qualified worker to
carry out a specified job at a defined level of performance”. Methods engineer or
process planner studies the design drawings and arrives at a process of
manufacture largely based on past experience. He will be familiar with the various
manufacturing processes and associated materials, production tools, machine tools
and standard tools.
The process planner writes out in detail the instructions for each of the
operations, indicating the sequence of operations, the material, production and
machine tools to be used, speeds, feeds, and other machine parameters controlling
the operation, stages of inspection and testing to ensure conformance with the
design specifications, the work centre in which the work is to be accomplished.
The process sheet indicates the previous assembly in which the part assembly will
be used. The information given in the process sheet guides the operators in
executing the given job.
Work measurement is carried out in terms of “Standard Man Hours “
(SMH) which can be defined as the average time taken by a qualified worker
working at average pace to perform a given job, due allowance being made for
relaxation and other contingencies. Time study observed can arrive at a standard
time by applying rating factor to the observed times based on their large
experience. Willful idle time and enforced idle time when the worker has to
remain failure etc are excluded in the computation of SMH.
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The plant facilities include machinery, equipment and associated building and
services. The requirement of plant facilities is established from a consideration of the
following:
(a) For production shops with reference to the manufacturing processes adopted,
(b) For indirect departments with reference to the job design, systems and procedures
adopted,
(c) The stabilized production rate
(d) The type of plant layout adopted
(e) Provision for expansion if this is envisaged in the long term plan.
The major objectives of designing the plant layout are the following:
(a) Optimum utilization of the facilities,
(b) Providing a smooth flow of materials
(c) Ease of material handling
(d) Access for installation, maintenance and removal of machinery and equipment
(e) Providing a comfortable and safe environment for working.
The principal types of layouts are the following:
(a) Product layout
Where different items of machinery and equipment are arranged in the sequence
of operations. For example, a product may require turning as the first operation, milling
as the second operation and drilling as the third and final operation. The lathes, mills and
drills are arranged in this sequence, all jobs moving from lathes to mills to drills.
(b) Process layout
Here the machinery and equipment are arranged in groups, each group relating to
a particular process. For example, in a machine shop all lathes may be grouped together
and so on. The job moves from one work centre to another depending on the sequence of
operations required in the process chosen for the products. The sequence of operations
may vary from one product to another.
(c) fixed position layout
In this, the item to be worked on is stationary and all resources required to do the
jobs on it are taken to this fixed location. This kind of layout is of limited application to
series production of aircraft and is more applicable to R&D work. Costly test facilities
are often arranged in a fixed location. A product layout is favored when the product mix
is limited to a few basic types, the products have a high degree of standardization of
parts, the production volumes are high and period of production long.
The process layout is preferred when there is a need for flexibility to handle a
large variety of products with different sequence of operations, when there is little
standardization of parts and when production volumes are low. Under these conditions
the process layout offers high utilization of the facilities and low investment costs.
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8. SCHEDULING
The next step in PPC is to formulate schedules or short term plans, each schedule
covering a period of a month, week or day. Scheduling breaks down the requirements of
the aggregate plan and gives the item wise details of individual parts, sub-assemblies,
major assemblies, and aircraft final assemblies to be started and completed in each
month/week/day. Aggregate plans represent planning at the “macro” level, whereas
scheduling represents planning at the “micro” level.
Scheduling is a dynamic activity in that schedules for successive periods need to
be updated and revised, taking into account the following:
(a) Actual extent of execution of the schedules of the previous period,
(b) Additional orders placed or cancellation of existing orders,
(c) Changes in priorities of products to be delivered,
(d) Availability of input resources, which include product design specifications,
drawings, schedules, process instructions, production jigs, fixtures, tools, machine
tools, standard tools, energy, materials, manpower and funds. Prompt feedback
(e) reports on the above mentioned factors is essential for formulating the schedules
for the next period.
The basic aims of scheduling are to meet the customer’s requirements in
terms of delivery periods of the products and at the same time ensure optimum
utilization of resources. Scheduling determines the following:
(a) Itemised list and quantities of “jobs” which have to be loaded on the
manufacturing / assembly / overhaul shops in each scheduled period,
(b) Itemized list and quantities of jobs to be completed by the shops in
each scheduled period.
(c) The sequence in which the jobs are to be loaded and completed,
(d) The supporting schedules for making available the required input
resources.
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9. SHOP PROGRESS
The progress staffs are located in each of the manufacturing and assembly shops.
The functions are as follows:
(a) Load the jobs to be performed on the designated work centre in each shop in
accordance with the starting schedules. Loading of the jobs involves collection of
required materials, production and standard tools, drawings, test schedules,
process instructions, inspection schedules and documentation and supplying these
to the individual or group of workers of the designated work centre.
(b) Follow the progress of execution of the jobs and report when each part or
assembly is completed to the scheduler.
(c) Arrange to provide assistance to the shops when problems arise in
manufacture/assembly. Solution of the problems may require co-ordinated action
by design liaison staff, process planners, tool designers, quality control staff and
shop supervision. Shop progress will assist in assembling the required personnel.
(d) Credit the completed parts/assemblies to holding stores or directly to the next
shop here further work may have to be done.
(e) Move material, tools, documents from work center to work center with in the
shops and between stores and shops.
Job preparation involves collection of materials, tools, documents etc.,
well in advance of loading. Several alternate jobs will be kept ready for loading
for each work center. If for any reason a particular job cannot be loaded strictly in
accordance with the set schedule the next job can be loaded without loss of time.
Kit marshalling for assembly shops involves collection of all the component parts
of the assembly in the form of a set or kit, well in advance of scheduled date of
loading the parts for assembly. This serves the same purpose as job preparation
for manufacturing shops.
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Effective “man management” is the essence of good shop management. The shop
manager should possess leadership qualities, namely self confidence, ability to analyze
and take decisions promptly, inspire and motivate the group reporting to him, be
receptive to new ideas, encourage participation, be good at communication, have
persistence in following through implementation of jobs, a balanced temperament.
The workers in the shops, suitably grouped for convenience of control, will report
to a first line shop supervisor. A first line shop supervisor may be in charge of 10-20
workers. Where the work centers are large in size, they will be further subdivided, and
each subdivision placed in charge if a first line supervisor. Where the work centers are
small, two or more work centers may be placed in charge of a first line supervisor.
Depending on the size and complexity of operation, there may be one or two
levels of middle supervisors, through whom the first line supervisors will report to the
shop manager. In a shop with say 200 workers, there may be 10-15 work centers each in
charge if a first line supervisor and there may be 4-5 middle level supervisors. The duties
of the different levels of supervision are as follows:
(A) First line supervision
Assign work. Clarify instructions contained in drawings, process sheets, test
schedules. Assist workers in solving problems encountered in execution e jobs
assigned. Where required, demonstrate how the job is to be performed. Carry out
first off-inspection (i.e. inspection of the first part made in a batch). Maintain
safety precautions. Ensure healthy work discipline. Invite and be receptive to
workers suggestions. Counsel workers on measures to improve quality and
efficiency, if found wanting,
(B) Middle level supervision:
The emphasis is on problem solving beyond the competence of the first line
supervision and in coordinating the supporting services so as to ensure that
workers are not kept idle for reasons beyond their control. Middle level
supervision will report to the Shop Manager.
(C) Shop Manager:
The shop manager is ultimately responsible for the proper performance and
administration of the shop. He will closely monitor shop performance, review and
take corrective action so as to maintain the set schedules. The shop manager has
to design and maintain an environment in which workers in which workers put in
their best efforts keeping in view the management’s objectives of efficient
resource utilization and economic production.
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The aircraft industry has costly machinery and other production equipment. If
these are not maintained in a serviceable condition, cost of production will increase,
quality deteriorate and skilled workers will idle. To ensure proper condition, preventive
maintenance schedules are drawn up according to which the machine tools and
production equipment are inspected and serviced at periodic intervals. Where possible the
maintenance is carried out in the third shift. Maintenance is also carried out in holidays.
The object of preventive maintenance is to avoid machine breakdown. If despite all
precautions the machine does breakdown, arrangements are made in advance to carry out
repairs expeditiously. A norm generally achieved in well maintained facilities is that
machine breakdown should not exceed 2% of the gross available hours, Periodic
performance capability studies are carried out on each of the machine tools, say once a
year, in which the machine performance is critically examined and a record maintained of
the dimensional tolerances achieved under actual conditions of usage by a skilled worker.
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Incentive schemes belong to two broad categories, one financial and the other
non-financial. In financial incentive schemes the worker is rewarded by payment of a
sum of money for performance above a set level. In non-financial incentive schemes, the
reward is by way of recognition and appreciation, not involving any direct payment of
sums of money, non-financial incentive schemes rely on principles of motivation and
human behavior.
Financial incentives for direct workers
Financial incentive schemes for direct workers are basically related to the
performance efficiency achieved by individual direct workers or group of direct workers.
The performance efficiency is determined by dividing the SMH content of all jobs
completed by a direct worker in a defined period divided by the man hours booked on
production during the same period. Where the jobs are performed by a group of direct
workers, the numerator and denominator are those pertaining to the whole group. The
SMH content of only those operations , parts or assemblies which have been accepted
after inspection during the specified period is taken into consideration in determining the
SMH output. The hours booked on production will include all hours spent on rework up
to the stage of rejection. In other words, the incentive reward is only for quality output.
The level of performance efficiency achieved by a direct worker will determine his
incentive payment.
For a financial incentive scheme to work satisfactorily certain conditions should
be satisfied.
(a) The SMH content of all jobs should be scientifically determined and man hours
booked in production correctly recorded,
(b) There should be adequate work load to utilize the available capacity,
(c) Job preparation should be done so that the direct workers are not kept idle,
(d) The average incentive payments should be of the order of 25-35% of the normal
salaries / wages of the direct workers,
(e) The incentive payments should be clearly distinguished from the normal salary /
wage payments so that the workers are aware that the incentive payments are for
their extra effort. This is often arranged by making the incentive payments on a
date separate from the normal salary / wage payments.
(f) The incentive payments for a month should be paid in the following month.
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REFERENCES
1. Aircraft production technology & management, S.C Keshu & K.K Ganapathy
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