Production Planning and Control Mukhopadhyay PDF Free: The Ultimate Book for Industrial Engineers

Production Planning And Control : Text And Cases by MukhopadhyayBook Summary:This comprehensive and up-to-date text, now in its Third Edition, describes how the latest techniques in production planning and control are applied to contemporary industrial setups so as to meet the ever-increasing demands in industrial organizations for better quality of services, for faster delivery of products and for adapting to the rapid changes taking place in the industrial scenario. With the demands in the industrial arena increasingly tending to be lumpy, the most effective strategy for planning and controlling production processes cannot be a static, preconceived one. Instead, it is one that is flexible and is capable of adapting to the erratic changes in demand patterns. Evolving such a strategy requires more of practical skill than mere theoretical knowledge of the subject.

In industry 4.0, shop floor management teams are increasingly focused on developing an unprecedented strategy to avoid financial losses and address the challenges and problems encountered in operations management. In the present scenario, the management teams use various process optimization approaches for operational control, including lean manufacturing, smart manufacturing, the internet of things, and artificial intelligence. The process optimization approach is used to maximize productivity within limited constraints on the shop floor. The present research aims to develop a smart production management system and suggest an efficient process optimization approach to enhancing industrial sustainability by identifying problems and challenges encountered in the complex shop-floor conditions in industry 4.0. The developed production management system has been prepared by classifying the challenges and problems found in the previous research work and organizing brainstorming sessions. The developed management system has been validated by a comprehensive investigation of a case study of an earthmoving machinery manufacturing unit. The analysis showed that the developed system could enhance operation excellence and industrial sustainability in industry 4.0 by optimizing the utilization of resources on the shop floor within limited constraints. The authors of the present article strongly believe that the developed production management system will improve operational excellence and would be beneficial for industry personnel and researchers in controlling operations management in shop floor management of heavy machinery manufacturing, including industry 4.0.

production planning and control mukhopadhyay pdf free

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To evaluate the efficiency of production processes, overall production processes and activities are categorized. The categorization helps know if the activities involved contribute to the production process; if so, the activity adds value to the production and is known as value-added activities; and if not, the activity is non-value-added (NVA) and known as non-value-added activities (NVAA) [6]. The elimination of non-value-added activities continuously improves production processes and makes it easier to control production performance for shop floor management [7].

The shop floor management team encourages the synergistic implementation of the Lean concept with industry 4.0 technologies to eliminate waste and enhance industrial sustainability. For this, new models and strategies have been developed by previous researchers to strengthen operational performance and to know the present condition of industry 4.0 technologies. Sony et al. [8] proposed an integration model of industry 4.0 and lean management. The model was developed by reviewing previous literature, and in the study, vertical, horizontal, and end-to-end engineering models were integrated with the lean management methodology. This study provided 15 research propositions to advance the integrative mechanism of industry 4.0 and lean management for enhancing financial profitability by better utilization of resources. Tortorella et al. [9] examined the role of industry 4.0 technologies on the relationship between operational performance and lean production within Brazil. The study has organized a survey on implementing lean and industry 4.0 technologies by performance indicators, including productivity, quality, delivery, safety, and inventory. The collected data has been collected through questionnaires and analyzed by multivariate analysis and contingency theory. The result of the study revealed that entirely technological adoption could not be able to enhance operational performance. However, lean helps in process improvement and support in controlling operation management in industry 4.0. Kamble et al. [10] combined the empirical and exploratory research design to develop a framework for identifying and validating the performance measure for evaluating smart manufacturing systems in Indian small, medium, and microenterprises of auto-components. The data was collected by questionnaire on ten performance dimensions: flexibility, cost, quality, integration, time, optimized productivity, computing, real-time diagnosis and prognosis, and social and ecological sustainability. The result of the study revealed that the proposed performance system was proved able to evaluate the smart manufacturing system and its investments.

However, only a few studies have been done on the methodology developed to identify an efficient process optimization technique for enhanced productivity within restricted resources. Here, constraints mean the availability of resources for shop floor management. To improve the process, it is necessary to get rid of the challenges and difficulties faced by the industry [20]. Typically, a production system is developed to identify the challenges and difficulties associated with production in the industry, which helps know where to get rid of the challenges and difficulties of production have to improve [21]. Through this system, information about the processes is collected so that the level of the processes can be evaluated and the production can be improved. The objective of the present article is to develop a smart production management system to identify the problems and challenges encountered on the production shop floor in industry 4.0 and suggest an efficient process optimization approach for industrial sustainability. The present article provides a systematic functional approach to provide a sustainable shop floor management system and to further enhance operational excellence within limited constraints. The proposed methodology has been described in Figure 2. There are five stages in the proposed methodology. The first stage focuses on layout draw and preparing a checklist of ergonomics issues by considering shop floor factors, including workplan, working environment, and workload distribution according to different departments. In the second stage, the production conditions are analyzed by calculating different parameters and resources condition by considering shop floor factors, including time, cost, worker, and shop floor congestion in various departments. The third stage reviews the machinery conditions and availability by observing and analyzing different departments and using advanced condition monitoring systems to improve machinery efficiency and utilization. In the fourth stage, the production shop floor planning is modified by brainstorming, meeting, conversations with production management teams, and using the internet of things, digitization, and data acquisition system. Finally, in the fifth stage, production shop floor improvement is validated by comparing proposed, observed, and previous results by considering product performance, approach, throughput, and shop floor management in different departments. As this methodology comprises nineteen different factors and each and every respective factor is crucial while implementing the same in various departments likes in inspection, quality, production, and design in industry 4.0, for example, the work plan sector is highly significant in the inspection department, quality department, and industry 4.0 department. The same other factors are very much prominent the same in the different departments that will provide a sustainable shop floor management system within available resources.

The development of research methodology is a systematic way to implement process optimization methods that the elimination of waste in production can be possible. In previous researches, few researchers developed a methodology to improve the effectiveness of process optimization methods for shop floor management. In methodologies, emphasis was laid on determining the consumption of resources according to production and improving the production process. The following features distinguish the developed methodologies and prove to be important for the implementation of process optimization techniques.(i)The developed methodology helps understand the reason of source of waste and investigated impact of working production processes on productivity in industry 4.0(ii)The developed methodology provides a systemic illustration of material-flow, process-flow, time parameters (CT, LT, IT, and TT) to control the uncertainty in an advanced production environment(iii)The developed methodology identifies problems and challenges by systematic analysis and helps provide an efficient action plan at beginning of production in industry 4.0(iv)The developed methodology can be applied to any type of shop floor management in industry 4.0 and control overall process activities within available resources

The process optimization approach is mostly preferred in industry 4.0 because it is capable of achieving production improvements with confined assets on automated production lines [26] and serves the purpose of process optimization while other techniques can be used in limited production conditions. Process optimization as an approach uses limited constraints that include the use of machinery, shop floor area, investment, production, process planning, and time [27]. The objective of process optimization is the minimization of waste in terms of time, manpower, machinery, and shop floor area. The concept of process optimization has been implemented by different techniques in industry 4.0; the techniques used in previous decades and in industry 4.0 are illustrated in Figure 4.

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