Pom Lecture (28)

Unit 2 Management of Conversion System Chapter 9: Project Scheduling

Lesson 28 -Tutorial 8 Case

Scheduling at Bellop INTRODUCTION

Bellop Ltd. established in the early 1960s as a private firm, is manufacturing a number of electronic equipment items. The organization, being a fairly large one, is a pioneer in the range of products manufactured by it. The technological excellence of its products has gained it a place among organizations, which undertake complex design _d development work for the electronic industry as a whole. During the late eighties, the company established a unit within its present manufacturing premises, exclusively dedicated to such developmental tasks. The unit was organized to produce fabricated components on the cellular manufacturing principle. Currently, its fabrication shop is divided into five work cells. These cells are, more or less, divided on the basis of operation layouts for components. Each cell processes a group of similar products, due to which, flexibility and economy are achieved in manufacturing. Material flow is shown in Fig. 14.1. Approximately 50 to 70 per cent of mechanical parts go

1

1

Work cell

Work cell ----.

1 l

I I

Work cell --

2

1

Work cell --.

3

Work cell I--

4

5

Plating shop

shop

Assembly

Fig. 14.1 Material flow through the paint shop to the assembly; hence, the importance of the paint shop. The present trenc indicates that about 70 per cent of the load in the paint shop is due to jobs related to PRC and RRA projects .A job which takes the longest production route is shown in Fig. 14.2 as a process flow. The Workcell or slores

To assembly / slores

Fig. 14.2 Process flow.

sequence is maintained for all the jobs but some operations may be skipped depending upon the, routing of a job. More details about various operations in their sequence for the jobs of the particular month studied, are given in Table 14.1. The paint shop can be considered as a job shop with inputs coming in batches of different quantities and of different types at different points in time. The overall information system existing; in the organization, with a specific reference to paint shop and its interface with other work cells i shown in Fig. 14.3. Yearly forecast/order booking is done by the Sales Department. The forecast gives an idea 0 how many jobs per project are to be processed during the current year. It includes any backlog 0 the previous orders as well. This forecast is considered by various project cells so as to make quarterly schedule for the number of jobs. There are five project cells which monitor the progress of various jobs produced against their requirements. These

cells expedite the production in the pair shop on the basis of assembly requirements. The job plan is divided into the categories: 1. Monthly production. 2.

Quarterly

production. 3.

Yearly

production. The quarterly plan is broken into a monthly plan or monthly list for the parts to be delivered (which are in short supply) for the assembly requirements.

Table 14.1

Sequence of Operations for Jobs Sand Make Applying Putty

Part number 2016496501

Name Housing

Quantity Mask Demask Blast

Seal

putty rubbing

Primer

Final

Sten-

Screen

Letter

coat

coat

cilling

Printing

Painting

G

245

.103

.22

.045

.053

1

210004960133 Housing

275

.1027

.21

.043

.054

1

475612420122 Knob

539

.0031

.005

.0057

35001035022

244

.0044

.007

.009

Clamp

.004 2 .003 6

110000403272 Heatsink

30

.035

.047

.036

.017

.0.17

110000403175 Heatsink

30

.035

.047

.036

.017

.017

110000045245 Frame

12

.084

.081

.039

.042

210002360145 Box assembly

50

.078

.085

.406 .047

.054

20162300234

Clamping frame

33

.031

.046

.021

.024

130384

Window

45

250010360213 Clamp

500

210001600150 Capnut

952

11000253795

Box

.47 .0765

.52

.141

.047 7 .0083

.002 7 .001 9

.0051

.0056

.0061

.0023

.0042

.0052

31

.082

.094

4

.014

.0267

.0517

.053

210001610184 Cavity tube

14

.023

.05

.0048

.0052

110000023323 Radiator holder

15

.116

.067

.673

.1152

100004700324 Reflector

21

.014

.267

.0517

.053

.275

.091

.097

.0834

.375

.0416

.029

.033

1.00004700324 Reflector

.

.082

.44

.130

.412 .058

1

.062

.066

assembly .23

assembly 110000020122 Radiator wing 35001037024

Plate

110.00'0072114 Device panel

7 131 1

.066 7 .031 .061 6

.82 .033

.029

.068

.05

110000023226 Spine

13

.064

110000024487 Frame

9

.094

11000002019

Radiator

139

110000041268 Site cover

31

11000032221

Box cover

.004 2

.085

.029

2016201180164C. bar

19

.038

110000024681 Device 4 box

35

.084

.083

.078 .051

18

.078

.091

16

.031

.1033 .108

104

100004524366 Device 2 cab

19

210002950165 Flange

80

.0633

.017

.1 J5

.012

.021

.002 7 .001 9 .022

.1416

.011 .04

100004512532 Device 1 cab

210001810155 Sub panel

.033 .03

.017

110000128374 Device 2 panel

300

.021 .112

6 .035

.5

.324

.003

275

1000047000309 Angle

.1083

.43

.061

.066

.2523 .021

.031

.3

.074

.093

.011

.062

.003

.004

.0491

.0035

.0042

.091

.052

.059

.091

.0183

.023

. .046

.05 .0375

.129

.084

.066

.3

.37

4