Tech 147: Unit 1

1. Tech 147: Unit 1 The Nature and Role of Analysis and Management in Green Manufacturing Systems

2. Effectively using constrained resources is the task of operations planning personnel in a manufacturing organization

3. What We Are Dealing With Are... • Constrained Resources • Green and Sustainability • Efficiency • Cost

5. Areas for Analysis • Products • Equipment and tools • Personnel • Facilities • Materials • Material handling • Processes • Instruments

6. Analysis Leads To: • Improvement options • Implementation of options • Measurements • Management

7. Sample Green Analysis • Product = Car • Objective = Greener, Simpler, Cheaper • Analysis = 1000 Parts + 20 Toxic Elements + Extra Weight + Extra Processes + Extra Cost + Extra Time • Results = 500 Parts + 4 Toxic elements + Less Weight + Fewer Processes + Lower Cost + Less Time

8. Is concerned with overseeing, designing, and redesigning business operations in the production of goods and/or services. Involves the responsibility of ensuring that business operations are efficient in terms of using as little resources as needed, and effective in terms of meeting customer requirements. Concerned with managing the process that converts inputs (in the forms of materials, labor, and energy) into outputs (in the form of goods and/or services). Operations management programs typically include instruction in principles of general management, manufacturing and production systems, plant management, equipment maintenance management, production control, industrial labor relations and skilled trades supervision, strategic manufacturing policy, systems analysis, productivity analysis and cost control, and materials planning. Operations Management

9. Jacobs et al Chapter 4: Sales and Operations Planning • Sales and operations planning fundamentals should consider the following: • Balance between demand and supply • Volume of products to be produced • Mix of products to be produced

10. Sales and Operations Planning and Management

11. The Sales and Operations Planning Process

12. Sales and Operations Planning Displays

13. Defining Green Manufacturing Green Manufacturing means manufacturing that employs less energy, uses eco-efficient materials, and better use of resources which will result in lower costs and increased revenues for businesses

14. Sustainability Means development that meets the needs of the present without compromising the ability of future generations to meet their own need The goal of sustainable design is to produce products that reduce use of non-renewable resources, minimize environmental impact, and relate people with the natural environment

15. Green and Sustainability

16. Facilities Equipment Tools Workers Parts & Materials Products & Scheduling Operations & Processes Energy Green Manufacturing Touches:

17. Analysis Is: The process of breaking a complex topic, device, product, system, group or substance into smaller units or parts to gain a better understanding of it.

18. Analysis of: Facilities Equipment Tools Workers Parts & Materials Products & Scheduling Operations & Processes Energy Green Manufacturing Analysis Involves:

19. Sample Tool Locator Tool Crib No. Total Adjustable Die Stocks 2, 6 6 Allen Wrenches 2, 5 6 Angle Plate 4 7 Arbors 16 2 Arbor Supports 16 29 Awls 2 3 Band Saw Blades 8 16 Benders 3 0 Bevel Protractors 1 1 Bolts 16 111 Boring Bar Tools 2 3 Brissel Pads 3 1 Brooms 20 3

20. Product Analysis Areas 1. Parts2. Prices3. Materials4. Processes5. Suppliers6. Supply chain7. Design8. Function9. Durability10. Weight11. Volume12. Others

21. 1. Parts2. Cost3. Materials4. Processes5. Suppliers6. Speed7. Weight8. Tooling9. Automation10. Weight11. Volume12. Location13. Energy usage14. Condition15. Function16. Others Equipment Analysis Areas

22. Workers Analysis Areas 1. Number2. Training3. Skills4. Diversity5. Rank6. Schedule7. Sex8. Tasks or responsibilities9. Age10. Education11. Location or office

23. Facility Analysis Areas 1. Space2. Contents3. Energy usage4. Processes5. Workstations6. Schedule7. Cribs and storage8. Layout9. Ergonomics10. Location11. Output or takt time12. Others

24. Materials Analysis Areas 1. Types2. Quantity3. Sources4. Cost5. Suppliers6. Supply chain7. Inventory8. Storage9. Shapes10. Forms11. Green12. Manufacturing properties13. Others

25. Material Handling Analysis Areas 1. Types2. Quantity3. Automation4. Energy usage5. Suppliers6. Cost7. Design8. Others

26. Processes Analysis Areas 1. Machines2. Automation3. Cost4. Layout5. Efficiency6. Cycle time7. Types8. Green9. Compatibility with personnel10. Compatibility with materials11. Others

27. Instruments Analysis Areas 1. Types2. Quantity3. Locations4. Inventory5. Cost6. Dealers7. Parts8. Status9. Condition10. Others

28. Hardware Analysis Areas 1. Types2. Quantity3. Locations4. Inventory5. Cost6. Dealers7. Parts8. Status9. Condition10. Others

29. Management Means: • Checking current performance of a system against pre-determined or set standards • Ensuring that tasks are being carried out according to a set plan. • Measurement and correction of performance in order to make sure that enterprise objectives and the plans devised to attain them are accomplished.

30. Sample Tool Locator: From Analysis to Management Tool Tool Crib No. Total Busy Adjustable Die Stocks 2, 6 6 5 Allen Wrenches 2, 5 6 4 Angle Plate 4 7 1 Arbors 16 2 0 Arbor Supports 16 29 2 Awls 2 3 3 Band Saw Blades 8 16 5 Benders 3 0 0 Bevel Protractors 1 1 1 Bolts 16 111 25 Boring Bar Tools 2 3 1 Brissel Pads 3 1 1 Brooms 20 3 1

31. Management Comprises: • Planning • Organizing • Staffing • Leading Or Directing • Controlling

32. Management of: Facilities Equipment Tools Workers Parts & Materials Products & Scheduling Operations & Processes Energy Green Manufacturing Management Means:

33. And keep it green and sustainable?

34. Machine Analysis Involves: • Parts or components of machine tools • Cost or prices of equipment and parts • Green content of equipment and parts • Weights of equipment and parts • Ease of design of equipment and parts • Appraisal of equipment and parts

35. Partial Structure of Machine Analysis

36. Use of BOM for material costing Use of process charts in labor costing & planning Use of the Internet for equipment & part pricing Using forecasting models in calculating needed quantities Use of scheduling formulas Use of green factors in calculating green content Analytical Calculations Include:

37. Analytical Calculations Include: • Use of facility analysis spreadsheet • Use of equipment analysis spreadsheet • Use of product analysis spreadsheet • Use of personnel analysis spreadsheet • Use of process analysis spreadsheet • Use of green and sustainability analysis spreadsheet

38. Forecasting: Basic forecasting techniques Basic forecasting models Scheduling: Basic MRP record Daily production schedule Generic scheduling JIT MRP Gantt charts PERT Others Purchasing, leading to: Inventory management Material management Hiring and Training, leading to: Personnel management Operations management Financial management Facility management Production management Product management Quality management Others Management Tasks Include:

39. Jacobs et al Chapter 10A: Management of Supply Chain Logistics Supply chain management is the management of a network of interconnected businesses involved in the ultimate provision of product and service packages required by end customers. Supply chain management spans all movement and storage of raw materials, work-in-process inventory, and finished goods from point of origin to point of consumption.

40. The Breath of Supply Chain Logistics Supply chain management (SCM) encompasses all material flow decisions, from raw materials to final consumption.

41. Structure of Supply Chain Management

42. Supply Chain Example: Tin Mining and Supply

43. Logistics The detailed organization and implementation of a complex operation. • The management of the flow of things between the point of origin and the point of consumption in order to meet requirements of customers or corporations. • The resources managed in logistics can include physical items such as food, materials, animals, equipment, and liquids; as well as intangible items, such as time and information. • The logistics of physical items usually involves: • The integration of information flow • Materials handling • Production • Packaging • Inventory • Transportation • Warehousing

47. Supply Chain Logistical Elements • Transportation • Water, Rail, Hand delivery, Highway, Pipeline, Air etc • Vehicle scheduling analysis • Warehouses • Replenishing systems: ROP/EOQ, Base stock, Distribution requirement planning • Location analysis: Simulation, heuristic, and programming procedures • Inventory

48. And keep it green and sustainable?

49. Obi, Chapter 1 Introduction to Industrial Ethics

50. Industrial Ethics and Values: Some Definitions Principles of right and wrong values in relation to the industrial worker whose initiatives affect productivity and quality of products and services.