HOMEWORK CHAPTER 5

MKMI 1803:
PRODUCTION AND
OPERATIONS
MANAGEMENT
Nurfarina Hussein (MKM151044)
Assoc. Prof. Dr. Adnan Hassan

1. Discuss what are documents for production and give examples for each document.
A variety of documents are assisting the production after a product was selected, designed
and ready for production. The documents are including the assembly drawing, assembly chart,
route sheet, work order and engineering change notices (ECNs).

Figure 1: Assembly Drawing

Assembly drawing is an exploded view of the product. It is usually an isometric drawing

(3D view) where the relative locations of components are drawn in relation to each other to show
how to assemble the unit.

Figure 2: Assembly Chart

Assembly chart shows in schematic form how a product is assembled. It may show the
manufactured components, purchased components, or a combination of both. It identifies the
point of production at which components flow into subassemblies and ultimately into a final
product.

Figure 3: Route Sheet

The operation necessary to produce the component with the material specified in the bill
of material is listed in the route sheet. The route sheet for an item will have one entry for each
operation to be performed on the item. It is known as process sheet if it includes the specific
methods of operation and labor standards.

Figure 4: Work Order

Work order is an instruction to make a given quantity of a particular item to a given

schedule. In a hospital or factory, it is more to a formal document that provides authorization to
draw items from inventory, or to perform various functions and operations, or to assign personnel
to perform those function and operations.

Engineering change notices (ECNs) change some aspect of the products definition or
documentation, such as an engineering drawing or a bill of material. For a complex product that
has a long manufacturing cycle, such as a Boeing 777, the changes may be so numerous that no
two 777s are built alike.

2. Case study : Green Manufacturing and Sustainability at Frito-Lay

a) What are the sources of pressure on firms such as Frito-Lay to reduce their
environmental footprint?
To reduce their environmental footprint, the sources of pressure for Frito-Lay are come
from both external and internal sources. External sources that force them are including the
government, forces driving the environmental laws and regulations. While, society, pollution,
climate, culture and competition that acted as the internal sources are playing a major role.
To make a sustainable society and environment, government and environmental drivers
always pressurize such companies to minimize their waste. No one in this world that wants to
live in a polluted environment due to the harmful chemicals, wastage and gages which was
coming from the manufacturing unit. Thus, they prefer these manufacturing units to be
constructed and built somewhere out of the city.
Competitors also play a significant role because if one of the competitors are being aware
of the environment sustainability and adopting the minimum wastage and green policies, the
other companies related also have to do the same in order to be stay in the market with
safeguarded reputation.

b) Identify the specific techniques that Frito-Lay is using to become a green

manufacturer.
To become a green manufacturer, Frito-Lay has done many approaches. One of the
approaches was engaging their employees in the energy management program. In this
program, the employees are needed to reduce their energy consumption and elements such
scorecards and customized action plans are used to empower and recognized the employees
achievements.
Other than that, Frito-Lay also plans to take the plant off the power grid and run it almost
entirely on renewable fuels and recycled water. The manager at the Casa Grande plant have
also installed skylights in the conference rooms, offices and a finished goods ware house to
reduce the need for artificial light. More fuel-efficient ovens recapture heat from exhaust
stacks. Vacuum hoses that pull moisture from potato slices to recapture the water and to
reduce the amount of heat needed to cook the potato chips are also being used.
In addition, in order to generate solar power, Frito-Lay has built over 50 acres of solar
concentrators behind their plant in Modesto, California. The solar power is being converted
into hear and used to cook Sun Chips. A biomass boiler, which will burn agricultural waste,
is also planned to provide additional renewable fuel. High-tech filters also installed by FritoLay to recycle most of the water used to rinse and wash potatoes. It also recycles corn byproducts to make Doritos and other snacks.

At Frito-Lays Florida plant, only 3.5% of the waste goes to the landfills, and their goal is
zero waste to landfills. Substantial resource reductions have been made in the production
process, with an energy reduction of 21% across Frito-Lays 34 U.S. Frito-Lay is also
moving toward biodegradable packaging and seasoning bags and cans and bottles.

c) Select another company and compare its green policies to those of Frito-Lay.
The Body Shop and Frito-Lay are very similar in their ways considering for the
environmental sustainability. The Body Shop are very committed in sustaining environment
on their business operations as they use the energy, water and other resources for their
product.
Recently, they have installed one of the largest, self-funded roof mounted solar PV
systems in the UK. The installation comprises 3,840 solar panels and will generate around
900,000 kWh of electricity a year, which is more than 25% of their head offices energy
requirements.
More than 500 of their stores run on Green Energy. 100% of their palm oil is from
sources certified as sustainable by the Roundtable on Sustainable Palm Oil (RSPO). Also,
100% of their wooden accessories are form sources certified as sustainable by the Forest
Stewardship Council (FSC). Their head office as well recycles all waste, therefore no waste
goes to landfill and they also compost all their food waste. Their targets for the green
environment are as follows: