kishor dadmal sfcs

8/7/2019 kishor dadmal sfcs

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SHOP FLOOR CONTROLSHOP FLOOR CONTROL

SYSTEMSYSTEM

Presented by:Presented by:--

KISHOR L. DADMALKISHOR L. DADMALRoll no. 20,Roll no. 20,

Marathwada Institute of Technology,Marathwada Institute of Technology,

Aurangabad.Aurangabad.


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Introduction:Introduction:--

Production management systems are concernedProduction management systems are concernedwith two related objectives; planning and controlwith two related objectives; planning and controlof the manufacturing operations. The functionsof the manufacturing operations. The functionsof production planning, development of theof production planning, development of themaster schedule, capacity planning and MRP allmaster schedule, capacity planning and MRP all

deal with planning objective. System thatdeal with planning objective. System thataccomplished this objective termed as Shopaccomplished this objective termed as Shopfloor control .floor control .

Shop Floor Control System


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Major FunctionsMajor Functions

1. Assigning priority of each shop order1. Assigning priority of each shop order

2. Maintaining work2. Maintaining work--inin--process quantityprocess quantityinformationinformation

3. Conveying shop3. Conveying shop--order status information to theorder status information to the

officeoffice


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Major FunctionsMajor Functions

4. Providing actual output data for capacity control4. Providing actual output data for capacity control

purposespurposes

5. Providing quantity by location by shop order for5. Providing quantity by location by shop order for

WIP inventory and accounting purposesWIP inventory and accounting purposes

6. Providing measurement of efficiency, utilization,6. Providing measurement of efficiency, utilization,

and productivity of manpower and machinesand productivity of manpower and machines


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Shop floor control systemShop floor control system

The shop floor control system consists of threeThe shop floor control system consists of three

steps.steps.

1.Order release.1.Order release.

2.Order scheduling2.Order scheduling

3.Order progress.3.Order progress.


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Order ReleaseOrder Release

The purpose of order release is to provide theThe purpose of order release is to provide thenecessary documentation that accompanies annecessary documentation that accompanies anorder as it is processed through the shop.order as it is processed through the shop.

The shop packet for an order consists of :The shop packet for an order consists of :

1.Route sheet.1.Route sheet.

2.Material requisitions.2.Material requisitions.

3.Job cards.3.Job cards.

4.Move ticket.4.Move ticket.

5.Parts list.5.Parts list.


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Order SchedulingOrder Scheduling

The purpose is to make assignment of the order toThe purpose is to make assignment of the order tothe various machines in the factory.the various machines in the factory.

It is the function of priority control to schedule theIt is the function of priority control to schedule theorder for production according to their priorities.order for production according to their priorities.

The basic document prepared by the orderThe basic document prepared by the orderscheduling module is dispatch list.scheduling module is dispatch list.


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Order ProgressOrder Progress

The purpose of the order progress module is toThe purpose of the order progress module is to

accomplish the remaining three function of shopaccomplish the remaining three function of shop

floor control;floor control;

To provide data relative to work in progress.To provide data relative to work in progress.

Shop order status.Shop order status.

Capacity control.Capacity control.


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Order SchedulingOrder Scheduling

It reports the job that should be done at each workIt reports the job that should be done at each work

center and certain details about the routing of the part.center and certain details about the routing of the part.

The dispatch list is generated each day or each shiftThe dispatch list is generated each day or each shift

In an effective shop floor control system, documentsIn an effective shop floor control system, documents

represents to the foreman or production supervisor therepresents to the foreman or production supervisor thebest way for accomplishing the master schedulebest way for accomplishing the master schedule


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Order ProgressOrder Progress

The order progress module is designed to accept dataThe order progress module is designed to accept data

collected from the shop floor and to generate reports thatcollected from the shop floor and to generate reports that

can be assist production management.can be assist production management.

The various documents contained in the shop packetThe various documents contained in the shop packetprovide the means to identify the jobs.provide the means to identify the jobs.

When a machine operator completes a particular processWhen a machine operator completes a particular process

specified in the root sheet, relevant data to indicate thespecified in the root sheet, relevant data to indicate the

completion are entered into the order progress module.completion are entered into the order progress module.

The order progress module maintains a file of theThe order progress module maintains a file of the

transactions reported on each of the uncompleted jobs.transactions reported on each of the uncompleted jobs.


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Dispatch ListDispatch List

WORKWORK

ORDERORDER

LOTLOT

QUANTIQUANTI

TYTY

PRIORPRIOR

WORKWORK

CENTERCENTER

NEXTNEXT

WORKWORK

CENTERCENTER

STARTSTART

DATEDATE

DUEDUE

DATEDATE

REMAINREMAIN

INGING

HOURSHOURS

15731573 2525 370370 400400 11--1414 11--2525 27.627.6

16881688 300300 370370 400400 11--1414 11--2828 40.540.5

16921692 107107 265265 375375 11--1717 11--3131 13.613.6

16931693 1414 370370 342342 11--1717 22--44 12.012.0

20532053 2727 240240 375375 11--2020 11--2828 16.216.2


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Operations SchedulingOperations Scheduling

The nature and importance of job shopsThe nature and importance of job shops

JobJob--shop scheduling (shop scheduling (n jobs on one machinen jobs on one machine))

ShopShop--floor controlfloor control

Issues in scheduling service personnelIssues in scheduling service personnel


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Principles of SchedulingPrinciples of Scheduling

1. There is a direct equivalence between work flow1. There is a direct equivalence between work flow

and cash flow.and cash flow.

2. The effectiveness of any job shop should be2. The effectiveness of any job shop should bemeasured by speed of flow through the shop.measured by speed of flow through the shop.

3. Schedule jobs as a string, with process steps3. Schedule jobs as a string, with process steps

back to back.back to back.

4. A job once started should not be interrupted.4. A job once started should not be interrupted.


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Principles of SchedulingPrinciples of Scheduling

9. When seeking improvement in output, look for9. When seeking improvement in output, look for

incompatibility between engineering design andincompatibility between engineering design and

process execution.process execution.

10. Certainty of standards, routings, and so forth is10. Certainty of standards, routings, and so forth is

not possible in a job shop, but always worknot possible in a job shop, but always worktowards achieving it.towards achieving it.


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Priority Rules for Job SequencingPriority Rules for Job Sequencing

1. First1. First--come, firstcome, first--served (FCFS)served (FCFS)

2. Shortest operating time2. Shortest operating time

3. Earliest due date first3. Earliest due date first

4. Earliest start date first (due date4. Earliest start date first (due date--lead time)lead time)

5. Least slack time remaining first5. Least slack time remaining first


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Priority Rules for Job SequencingPriority Rules for Job Sequencing

6. Least slack time remaining (per operation as6. Least slack time remaining (per operation as

opposed to per job) firstopposed to per job) first

7. Smallest critical ratio first7. Smallest critical ratio first(due date(due date--current date)/(number of days remaining)current date)/(number of days remaining)

8. Smallest queue ratio first8. Smallest queue ratio first

(slack time remaining in schedule)/(planned remaining queue time)(slack time remaining in schedule)/(planned remaining queue time)

9. Last come, first served9. Last come, first served

10. Random order10. Random order


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Job Sequencing ExampleJob Sequencing Example

FirstFirst--Come FirstCome First--ServedServed

Jobs (i order Processi g Due Date low Time

of arrival) Time (days) (days e ce) (days)

A 4 5 4

B 7 10 11

C 3 6 14

D 1 4 15

FCFS Schedule

Late?

On-Time?

Orderssubmitted

at beginning of week

Jobs (i or er rocessi e te

of rri l) i e ( s) ( s e ce)

A 4 5

B 7 10

C 3 6

D 1 4n-jobs on one machine


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LastLast--Come FirstCome First--ServedServed

Orderssubmitted




A 4 5

B 7 10

C 3 6

D 1 4n-jobs on one machine

Last- ome First-Served Schedule

Jobs (i order Processi g Due Date low Time

of arrival) Time (days) (days e ce) (days)D 1 4 1

C 3 6 4

B 7 10 11

A 4 5 15

Late?

On-Time?


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Shortest Operating TimeShortest Operating Time

Orderssubmitted




A 4 5

B 7 10

C 3 6

D 1 4

Shortest Operating Time Schedule

Jobs (i or er rocessi e te low i e

of rri l) i e ( s) ( s e ce) ( s)

D 1 4 1

C 3 6 4

A 4 5 8

B 7 10 15

Late?

On-Time?

n-jobs on one machine


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Earliest Due Date FirstEarliest Due Date First

Orderssubmitted




A 4 5

B 7 10

C 3 6

D 1 4

Earliest Due Date First

Jobs (i or er rocessi e te Flow i e

of rri l) i e ( s) ( s e ce) ( s)D 1 4 1

A 4 5 5

C 3 6 8

B 7 10 15

Late?

On-Time?

n-jobs on one machine

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