Routing_ppt by Gopal k. Dixit

8/3/2019 Routing_ppt by Gopal k. Dixit

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ROUTING,PROGRESS REPORTINGAND EXPEDITING

PRESENTED BY:

GOPAL KRISHAN DIXIT


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ROUTING: Definition and Meaning

Routing involves the:-

The determination of which machines or work centers will be used

to manufacture a particular item. Routing is specified on a routesheet, the route sheet identifies operations to perform, sequence and

materials, tolerances, tools and time allowances.

Routing includes the planning of: what work shall be done on the

material to produce the product or part, where and by whom the

work shall be done. It also includes the determination of path that the

work shall follow and the necessary sequence of operations which

must be done on the material to make the product.


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Routing means determination of the route to be followed by

each part/component being transformed from input/raw

material into final product. Following questions decide how

the job is routed.

If a job has a number of operations which can be done in

different orders, which ordering should be used?

If an operator has choice of many machines with different

process time and machine time, which machine should be chosen?

Should a job be sent to the flexible manufacturing cell or be

done by an expert on a manual all purpose machine?

ROUTING: Definition and Meaning


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ROUTING PROCEDURE INVOLVES FOLLOWING DIFFERENT

ACTIVITIES.

(1) Analysis of the article to determine what to make and what to buy.

(2) To determine the quantity and type of material

(3) Determining the manufacturing operations and their sequence.

(4) Determination of lot sizes

(5) Determination of scrap factors

(6) Organization of production control forms

(7) Analysis of cost of the article


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The product is analyzed to determine its components/parts and decision is

made whether to manufacture all its parts in the factory or to be purchased

from outside. For example a bicycle company may decide to manufacture all

its parts/components by itself or buy some of them like chains, tyres, tubes etc

from outside. The decision to make or to buy is in view of the following facts:

Cost comparison for making and buying

Whether the available man power can be utilized for the purpose of making with the

plant.

Whether the existing machines which are idle can be utilized.

Whether the input materials and machines are available in the plant for

manufacture or require procurement.

Capital funds

MAKE AND BUY DECISION


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-Bill of Materials (BOM) describes all the components/parts (purchased and to be

manufactured) at every level of manufacturing process, that are needed to make a

product of desired quantity.

-Bill of Material is a listing of all of the assemblies, intermediates, parts and raw

material that go into a parent assembly showing the quantity of each required to

make that assembly

- From BOM the quantity of material required for each part is known and

accordingly can be procured. Some firms prepare separate lists for finished

components and raw materials. To know how much material is to be purchased or

procured, the amount of materials in the stores should be known.

QUALITY, QUANTITY AND TYPE OF MATERIAL


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S.No

.

Part

No.

Name

of thePart

Drg.

No.

Input Material No.

Of

Wt/.

Piece

Total Remarks

Finished

ComponentsRaw

Material

Name Specifications Name Specifications Length Width Thickness

BILL OF MATERIALDate: __________ Ref. Drg. No.____

Part No.________

QUALITY, QUANTITY AND TYPE OF MATERIAL


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DETERMINING THE MANUFACTURING OPERATIONS

AND THEIR SEQUENCE

Routing section analyses the product to determine the operations

involved in manufacturing of each of its parts, sub-assemblies and

assemblies. These operations are then analyzed to determine their

sequence. The routing decision establishes the operations necessary for

processing the product and lists them in their sequence on route sheet

and operation sheet


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DETERMINATION OF LOT SIZE

Routing section also determine the number of units to be

produced in one lot. The lot size is generally determined

by the economic order quantity. These quantities are of

course affected by other factors such as availability of

production capacity and other resources.


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-Scrap factor is the percentage factor in the product structure used to

increase gross requirements to account for anticipated loss within the

manufacturing of a particular product.

-The scrap factor is inverse of a yield percentage, whereas the yieldpercentage indicates the quantity of good material from a process.

Following are the formulas used for adjusting the planned quantity

Quantity Planned=Quantity Needed + Yield percentage

=Quantity Needed + (1-Scrap Factor)

-The usual practice should be to establish these factors from past experience,

to determine the manpower, the essential machines/equipment and the

materials. This scrap factor plays an important role in the determination of

man power requirements and loading of various machines

DETERMINATION OF SCRAP FACTOR


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In order to carry out routing as planned, various forms

and procedures are required which furnish necessary

information for the purpose. Various forms used e.g.

production order, job ticket, inspection ticket, move order,

tool ticket and equipment ticket are also prepared in this

process.

TO PROVIDE NECESSARY INFORMATION

AND FORMS


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AND FORMS

MANUFACTURING ORDER

These orders for parts are both instructions

and authorization to perform operations. As

parts are different, each lot of parts has itsown manufacturing order. So, there may be

many manufacturing orders to support one

assembly order.

Manufacturing orders include the order no.,

the identification no. and description of part

to be made, the quantity to make, the wanted

date, material to be used and department

which has to carry each operation


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AND FORMS

JOB ORDER/TICKET

If the copies of the manufacturing orders

are not used to direct and authorize

production, this can be done by the means

of individual job orders. Job orders are

individual operation assignments. A

manufacturing order may list dozen or

more operations to be performed, but joborder covers only one operation.

Job orders are generally small,

lightweight cardboard forms.


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AND FORMS

TOOLTICKET/ORDER

Ordinary tools in general use are

usually issued to person in

exchange for tool ticket. Worker

decides or finds from the

manufacturing order what tool

he needs, then he goes to the tool

room and ask for it


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AND FORMS

INSPECTION REPORT

This is a quality check documented

used by the quality and inspectiondepartment. It is filled by the

inspector for each lot on the basis

of the inspection results of the lot

sample


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AND FORMS

Move Order

Generally in plants, various orders follows

different paths. Therefore the material is

moved by hand truck or power truck. This

means the trucker should know what

material to move and where to take it, move

orders are used for this purpose. Move orders

tells what the material is , where it is now and

where it is to go. It is also used to tell

production control that material has been

moved and its location


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STANDARD ROUTING DOCUMENTS:

The two important documents of routing are:

Route Sheet or Route Card

Operation Sheet


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A Route Sheet or Route Card lists manufacturing operations in proper

sequence and associated machine tools for each part.

It also indicates the department in which a particular operation is to be

done on a part/ parts, and to which department the parts must go to for the

next operation.

It also include the set-up time and operation time for the machines.

A route sheet travels with the parts which move in batches between the

processes from one point in the plant to another.

ROUTE SHEET


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ROUTE SHEET

Name of part_______ Part No.________ Drawing No.________

Product___________ Product No._____ Quantity____________

Material___________ Economic lot size____

Order No.__________ Due Date________

OperationNo.

Descriptionof Operation

Machines orEquipments

Department Tooling Set-up Time OperationTime


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ROUTE SHEET


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The operation sheet lists the various operations in sequence, required for

producing a part.

Operation sheets vary greatly as to details. A simpler operation sheet

specifies only the operation and the machines to be used. Cutting speeds,

feeds, and depths of cut are left to the discretion of the operator,

particularly if he is skilled and small quantities of parts are involved.

However, in more common operation sheets complete details are given

regarding cutting speeds, feeds, depth of cut and tools, Often, the time

analysis for each operation is also included in the sheet.

OPERATION SHEET


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OPERATION SHEET

Name of part__________________ Part No.___________________

Material______________________ Quantity___________________

OperationNo.

Description ofOperation

MachinesTools

CuttingTools

CuttingSpeed

Feedmm/rev

DepthOf cut,

mm

TimeAnalysis


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ROUTING IN

JOB ORDER PRODUCTION

BATCH/INTERMITTENT PRODUCTION

CONTINUOUS PRODUCTION


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ROUTING IN JOB ORDERPRODUCTION:

In job order production, the machines are arranged according to the process

type of layout.

In this type of production since every time there is new job, the operations

change from job to job according to varying specification. Thus the number of

operations and their sequence vary considerably. The route sheet is prepared for

implementation of each order and hence requires a greater amount of work

experience. The product passes through a larger shop floor involving back

tracking. The routing is also subjected to production bottlenecks, waiting and

rushing according to the work back logs and the machine loads available for

them. Thus in job order production, the routing procedure is most difficult and

complex.


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ROUTING IN BATCH ORDER PRODUCTION:

In Batch order/ intermittent production also generally the equipment is

arranged in process type layout. The operations and their sequence differ

from batch to batch. The route sheets would require revision whenever

the production of the batch changes. Thus is relatively simpler as

compared to job order production.


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ROUTING IN CONTINUOUS/ MASS MANUFACTURING:

In mass/ continuous manufacturing does not present any problem due to

product type of layout, where the machines are arranged according to the

sequence of operations which are to be performed on the components. The

routing becomes a routine and mechanized function. Production requires

special attention to route sheets in following cases

Interruption to production flow due to certain factors like machine

breakdown or power cuts and shortages of materials.

As records of job conditions and methods

As reference when it is necessary to train new personnel in the standard

procedures of the job


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PROGRESS REPORTING- Shortage of parts and failure of production foremen to meet production schedules

are common. There are numerous reasons for these occurrences, for example, errors

in routing, scheduling and dispatching, lack of material, labor difficulties, breakdown

of equipments, lack of proper tools, jigs and fixtures and excessive rejections etc.

- Progress reporting is essential to the prevention of above delays. For this it is

necessary to check the progress of the order undertaken as it is being produced from

the first operation until the order is converted into final product.

- Progress reporting is checking the manufacturing activities systematically so that

production may be carried out according to the plan, analysis of performance for

shortcomings (if any) and following up the management in order to apply corrective

action to prevent excessive short fall. Thus Progress Reporting is a function by which

one can give early warning when the actual production divert from planned

production.


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TYPES OF PROGRESS REPORTS:

The progress reporting can be done by following

When the manufacturing within a department is completed, an

inspection is made to check quality and conformity of the product with

the specifications. The inspection ticket is prepared by the inspector and

sent back to the production control department. From the information on

the ticket, the progress of the order can be recorded. In this way

production department can follow every job.

Dispatch office get job information in several ways like through

returned job tickets, move orders, inspection reports etc. Dispatch office

send in to the central office all the written reports that they get which

serve as reporting of progress of jobs.


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Besides from written reports, foremen tell verbally if anything unusual

turns up. If anything goes wrong like unusual amount of scrap, foremen tell

it right way to the production control department.

Some Companies uses a dial system for reporting work done. Dials

similar to telephone dials are spaced around the plant. When a man gets an

order he dials in to the production control, giving the order no. and

operation no. When he finishes the order he dials out. This method keepsprogress reports in central production control department.

Tele control is relatively newcomer among devices to control shop

operations with minimum of paper work.

TYPES OF PROGRESS REPORTS:


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EXPEDITING

Expediting is determining the current status of a part which is on order or

a production order which is in process and initiating the efforts to speed up

operations when failure to meet schedules appears likely.

Follow up is the most important part of production control. This step is to

ascertain from time to time that the production operations are going on

according to the plan. The expeditor or chaser is meant for observing that

anything overlooked or not properly executed is set right. This ensures

proper coordination of production activities and plans in order to take

corrective action if necessary. Follow up functioning checks and measure

the effectiveness of previous production control functions like: routing,

scheduling and dispatching.


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Part I

Part II

It regulates the progress of material and parts through the production process. The

cause of delays or shortages may also be investigated and an attempt made to prevent

their recurrence.

This includes the physical tracing of the work in the plant and the contacting of the

vendors who provide outsource parts

Expeditor or stock chaser is a person who locates lost jobs and push late jobs

through to completion. He attempts to foresee and eliminate further delays.

Expediting is a special form of follow up or progress reporting. Expeditors are used

To help to eliminate particular difficulties which are throwing production off the

schedule?

To speed up the processing of certain orders.

EXPEDITING


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Expediting is divided into two categories:

Production operations inside the plant

The supply of the parts and materials from outside the plant

Inside expeditor must see that the material and tools are delivered to their scheduled

destination in time. He must be familiar with the plant operations and use this

knowledge to ensure a free flow of tools and materials to the production line. For the

parts and assemblies under this control, he must be familiar with the status of the

required materials, production tooling, cutting tools and in-process equipments.

The outside expeditor is usually a sales department representative operating in the

plants of vendors. His job is to see that the material and parts flow into the plant as

required

EXPEDITING


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REFERENCES

1. Operations Management by Monks

2. A Text Book of Production Engineering by P.C. Sharma

3. Industrial Engineering & Operations Management by S.K.Sharma , Savita Sharma

4. http://www.du.ac.in/course/material/ug/ba/esb/Lesson_8.pdf

5. Web: www.macro.o.za

6. Modern Production Management by Buffa Elwood.

7. Production Control by Franklin G. Moore

8. Industrial Engineering & Management System by Dalela, Aggarwal9. Production and inventory control handbook By James Harnsberger Greene, American

Production and Inventory Control Society. Handbook Editorial Board

10. Organization and ManagementBy R.D. Agarwal, Agarwal R D Staff
http://www.du.ac.in/course/material/ug/ba/esb/Lesson_8.pdfhttp://www.macro.o.za/http://www.macro.o.za/http://www.du.ac.in/course/material/ug/ba/esb/Lesson_8.pdf


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THANK YOU FOR ATTENDING MYSEMINAR

Routing_ppt by Gopal k. Dixit

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