Production Planning

Definition:​
Production Planning means deciding in advance what to produce, how much to produce,
when to produce, and how to produce it.​
It helps to make sure that the right materials, machines, and workers are ready before
production starts.

Example:​
If a company wants to make 100 bikes next month, production planning will decide the steps,
like ordering parts, scheduling workers, and checking machine availability.

✅ Production Control
Definition:​
Production Control means monitoring and guiding the production process while it is
happening. It makes sure everything is going as per the plan and fixes problems if anything
goes wrong.

Example:​
If a machine breaks down during bike production, production control will quickly take action to
fix it or shift work to another machine to avoid delays.

✅ Production Planning – 7 Roles (Each with 4 Points)

1. Product Selection and Design

●​ Chooses what product to make based on market demand.​

●​ Consider customer needs and preferences.​

●​ Designs the shape, size, and features of the product.​

●​ Make sure the design can be made with available tools.​

🪑 Example: A company selects a new plastic chair design that is lightweight, stackable, and
fits current trends.

2. Process Planning

●​ Breaks the job into step-by-step processes.​

●​ Selects machines and tools for each step.​

●​ Defines the operations in a proper sequence.​

●​ Aims to reduce process time and cost.​

🛠 Example: Making a table: Cutting → Drilling → Assembling → Polishing.

3. Material Planning

●​ Estimates the quantity of raw materials needed.​

●​ Ensures timely availability to avoid delays.​

●​ Avoids excess stock which can increase storage cost.​

●​ Works with suppliers to place advance orders.​

📦 Example: For 500 shoes, plan for 500 soles, 1000 laces, and leather sheets.

4. Capacity Planning

●​ Checks how much production can be done with current resources.​

●​ Matches workload with available machines and manpower.​

●​ Avoids overloading or underusing equipment.​

●​ Plans for extra capacity if demand increases.​

🏭 Example: If a company has 3 machines that can make 50 products/day, the total capacity is
150/day.

5. Routing

●​ Sets the path the product will follow inside the factory.​

●​ Decides the department-wise flow of work.​

●​ Reduces unnecessary movement or waiting time.​

●​ Ensures a smooth and logical work sequence.​

🔄 Example: A metal rod goes from cutting → shaping → welding → painting in that order.

6. Scheduling

●​ Fixes when each task should begin and end.​

●​ Ensures timely use of all machines and workers.​

●​ Avoids production clashes or idle time.​

●​ Keeps the overall timeline under control.​

📅 Example: Monday for cutting, Tuesday for assembly, Wednesday for testing.

7. Cost Estimation and Budgeting

●​ Predicts total cost including materials, labor, and electricity.​

●​ Helps decide the selling price of the product.​

●​ Avoids overspending by tracking the budget.​

●​ Improves profitability by reducing unnecessary costs.​

💰 Example: Budget per chair = ₹200 (materials) + ₹100 (labor) + ₹50 (overhead) = ₹350.

✅ Production Controlling – 7 Roles (Each with 4 Points)

1. Implementation of Plan

●​ Starts the production as per the planning schedule.​

●​ Ensures all departments follow the plan correctly.​

●​ Coordinates workers and machines at the right time.​

●​ Uses checklists or control sheets to guide the process.​

🛠 Example: Starts production of toy cars on Monday exactly as planned with raw materials
ready.

2. Dispatching

●​ Issues work orders and job instructions.​

●​ Authorizes departments to begin work.​

●​ Assigns duties to operators and supervisors.​

●​ Provides tools, drawings, and materials needed.​

📝 Example: The assembly team is given a work order to assemble 100 fans today.

3. Progress Monitoring

●​ Keep track of work status at each stage.​

●​ Checks if tasks are completed on time.​

 ●​ Identifies reasons for any delay or stoppage.​

●​ Updates management regularly about progress.​

📈 Example: If painting is delayed by one day, the schedule is updated and corrective action is
taken.

4. Quality Control

●​ Checks whether the product meets quality standards.​

●​ Uses tools like inspection and testing.​

●​ Rejects or reworks defective products.​

●​ Maintains customer satisfaction and brand trust.​

🧪 Example: A phone is tested for display, battery, and speaker function before packing.

5. Inventory Control

●​ Ensures enough materials are available for production.​

●​ Prevents overstocking or shortage.​

●​ Keeps track of usage and storage levels.​

●​ Works closely with the stores department.​

📦 Example: If only 20 screws are left but 100 are needed, the control team places a quick
order.

6. Corrective Actions

●​ Quickly fixes issues like machine breakdown or absenteeism.​

 ●​ Shifts workload to other machines or workers if needed.​

●​ Minimizes production loss or delay.​

●​ Avoids repeating the same problem.​

🔧 Example: If Machine A stops, Machine B is used for emergency backup.

7. Delivery and Feedback Handling

●​ Ensures products are packed and delivered on time.​

●​ Tracks shipping and transport arrangements.​

●​ Collects customer feedback to improve production.​

●​ Communicates feedback to the planning team.​

🚚 Example: Orders reach retailers on Friday, and feedback says packaging needs
improvement.

✅ STEPS IN PRODUCTION PLANNING (Deeper

Explanation)

🔹 1. Forecasting Demand
Forecasting means predicting how many units of a product customers will likely buy in the
future. This helps the company prepare early. It avoids problems like making too many products
that don’t sell or too few that can't meet customer needs.

🧾 Example: A fan manufacturing company checks last year's summer sales and predicts that
25,000 fans will be needed this year between April and June.

🔹 2. Product and Process Planning

In this step, the company finalizes the product’s shape, size, features, and material. Once that is
ready, the company plans each step of making it — from cutting raw material to final packaging.
Every machine and worker is assigned a specific task.

🛠 Example: For a washing machine, the process includes motor fitting, wiring, drum
installation, outer body fixing, testing, and packaging.

🔹 3. Material Planning
This involves calculating how many raw materials (like parts, components, or packaging items)
are required to meet the production target. The company ensures all materials arrive before
production begins, so there’s no delay.

📦 Example: To produce 500 refrigerators, the company needs 500 compressors, 2000 feet of
copper tubing, 1000 doors, and insulation foam in advance.

🔹 4. Routing
Routing is the step where the exact path or sequence is decided for the product as it moves
through the factory. It shows which department or machine will handle which part of the work.
This avoids confusion and saves time.

🔁 Example: In a bike factory, the routing could be: welding frame → fixing wheels → engine
installation → fuel tank mounting → painting → testing.

🔹 5. Scheduling
Scheduling means fixing a clear timetable for when each task should start and finish. This
ensures there are no delays and every department knows what to do at what time.

📅 Example: Assembly starts Monday morning at 9 a.m., painting begins Tuesday afternoon,
and final inspection is scheduled for Thursday.

🔹 6. Capacity Planning
This step checks if the factory has enough machines, workers, and space to complete the
planned production. If not, additional resources or shifts may be arranged in advance.

🏭 Example: If one machine can make 50 units per day and the target is 100 units/day, then
the company must use two machines or arrange for overtime.
🔹 7. Cost Estimation and Budgeting
This step calculates how much the whole production will cost — including raw materials, labor,
machine use, electricity, and packaging. A fixed budget is made to avoid overspending and to
ensure the product remains profitable.

💰 Example: The estimated cost for each LED TV is ₹10,000. If the selling price is ₹14,000, the
profit per unit is ₹4,000. This step ensures the cost stays within budget.

✅ STEPS IN PRODUCTION CONTROLLING (Deeper

Explanation)
Production Controlling starts once the factory begins making products. Its goal is to keep things
on track, maintain quality, and solve any problems quickly.

🔹 1. Dispatching
Dispatching means giving the final “go-ahead” for production to start. It includes issuing work
orders, sending required materials, giving instructions, and assigning jobs to workers or
machines.

📝 Example: The production manager hands out job cards to the motor assembly section to
begin work on 200 motors with tools and parts ready.

🔹 2. Executing Production
This is where actual production takes place. Machines are run, workers start assembling or
processing, and the product begins to take shape. The goal is to follow the plan as closely as
possible.

🛠 Example: In a toy factory, workers assemble plastic parts, insert batteries, and perform the
programmed steps designed during planning.

🔹 3. Monitoring Progress
The progress of production is continuously watched to ensure work is happening as per the
schedule. If there's any delay or issue, it is reported immediately. This avoids piling up
problems.

📈 Example: If only 80 machines are completed instead of 100 by end of day, the supervisor
investigates the cause and updates the manager.

🔹 4. Inspecting Quality
At different stages, quality checks are done to make sure the product meets required standards.
Any product with errors is fixed (reworked) or rejected. The aim is to avoid faulty items reaching
customers.

🧪 Example: Each finished water purifier is tested to ensure no leaks, proper filtration, and
electric safety before packing.

🔹 5. Inventory Control
This involves keeping track of how much raw material is used, how much is left, and how much
finished product is in stock. It helps avoid shortages and also prevents wastage or overstocking.

📦 Example: If the store has only 50 motors left and 200 are needed next day, a new order is
placed immediately to avoid production stoppage.

🔹 6. Corrective Actions
If any problem arises during production — like a machine breaking down, a worker being
absent, or parts missing — this step is about solving it quickly to avoid delay.

🔧 Example: A wire-cutting machine fails; the production team shifts that job to another
machine or sends it to an outside vendor for temporary help.

🔹 7. Delivery and Feedback

Once the product is ready, it is packed and delivered to customers or warehouses. After that,
feedback is collected to improve the next batch or correct any flaws noticed by customers.
🚚 Example: Fans are delivered to a retailer. The seller says packaging was weak and motors
overheated. This feedback is shared with the planning team to make improvements in future
production.

✅ What is Work Measurement? (Expanded)

Work Measurement is the science of finding out how long a task should take when performed by a
trained worker, using a standard method, under normal working conditions.

It is used to:

●​ Improve planning and scheduling

●​ Set performance standards
●​ Identify delays and inefficiencies
●​ Support cost estimation and budgeting
●​ Fix incentives or wages fairly

📌 Importance of Work Measurement

1.​ Better Time Management: Helps fix how much time each task should take.
2.​ Avoids Idle Time: Identifies where workers or machines are idle.
3.​ Increases Output: Encourages faster, smoother production.
4.​ Supports Fair Wages: Helps reward workers based on real effort.
5.​ Improves Efficiency: Highlights unnecessary steps and helps remove them.

✅ Objectives of Work Measurement

●​ Set standard time for tasks.
●​ Improve workflow and production planning.
●​ Reduce labor cost and material waste.
●​ Use workers and machines to their full potential.

✅ Detailed Explanation of Types of Work Measurement

🔹 1. Time Study (Stopwatch Study)
Definition:​
Measuring the time taken by a skilled worker to perform a job repeatedly using a stopwatch.

How it works:

●​ The job is divided into small elements or steps.

●​ A stopwatch is used to time each element.
●​ Performance rating is used to adjust for speed.
●​ Allowances are added for fatigue, rest, and delays.
●​ The result is the standard time for the job.

Applications:

●​ Ideal for repetitive and short-cycle jobs.

●​ Used in assembly lines, packaging, machining.

Example:​
If a worker takes 5 minutes to drill holes on a plate, and the observer watches 10 such cycles, the average
time is calculated, adjusted, and finalized as 5.5 minutes including allowances.

Advantages:

●​ Accurate and reliable for short, repetitive jobs.

●​ Easy to use for direct observations.

Limitations:

●​ Not suitable for long or varied jobs.

●​ Observer presence may disturb worker’s natural speed.

🔹 2. Work Sampling (Activity Sampling)

Definition:​
Involves checking what a worker is doing at random times during the day to calculate how time is
divided between activities.

How it works:

●​ Random checks (say, every 10 minutes).

●​ Activity is noted: working, idle, maintenance, etc.
●​ Large sample size gives time distribution.

Applications:
 ●​ Best for long-cycle, non-repetitive jobs.
●​ Used in maintenance departments, administrative offices.

Example:​
In 200 observations:

●​ 160 times the worker was active

●​ 40 times he was idle​
Then, working efficiency = (160/200) × 100 = 80%

Advantages:

●​ No need for continuous observation.

●​ Can cover many workers at once.

Limitations:

●​ Less accurate for small jobs.

●​ Needs large number of observations for reliable results.

🔹 3. Predetermined Motion Time Systems (PMTS)

Definition:​
Assigns standard times to basic human motions (e.g., reach, grab, twist) using pre-calculated data
tables.

Common PMTS systems:

●​ MTM (Methods-Time Measurement)

●​ MOST (Maynard Operation Sequence Technique)

How it works:

●​ Analyze job into small body motions.

●​ Use standard motion time tables to assign time.
●​ Add all values = Total job time.

Applications:

●​ Used in high-volume industries, like electronics and automotive assembly.

●​ Ideal for repetitive and short operations.

Example:​
Picking a component:
 ●​ Reach = 0.2 sec, Grasp = 0.3 sec, Move = 0.5 sec → Total = 1 sec

Advantages:

●​ Very detailed and accurate.

●​ Used in automated planning and simulation.

Limitations:

●​ Requires training and software.

●​ Not suitable for unique or flexible jobs.

🔹 4. Standard Data or Synthetic Data Method

Definition:​
Uses pre-recorded and stored time values from previous similar jobs to estimate new job times.

How it works:

●​ Maintain a database of standard task times.

●​ Match new task with similar past task.
●​ Apply the stored time directly.

Applications:

●​ Useful in batch production, machining, inspection.

●​ Speeds up estimation where time study is not possible.

Example:​
If drilling a 10mm hole in mild steel took 25 seconds in a previous job, use the same time for a similar
hole in the new job.

Advantages:

●​ Fast and saves effort.

●​ Helps in consistent costing and quoting.

Limitations:

●​ Needs regular updating.

●​ Not useful for new or uncommon jobs.

🔹 5. Analytical Estimating (Expert Judgment)

Definition:​
Time is estimated based on the experience of engineers or supervisors, especially when it’s difficult to
measure.

How it works:

●​ Experienced staff break the job into small elements.

●​ Assign approximate time to each step based on past knowledge.
●​ Add to get total job time.

Applications:

●​ Used in maintenance, tool making, construction, repair works.

Example:​
An expert estimates it will take 45 minutes to replace a broken machine belt, based on similar tasks done
before.

Advantages:

●​ Very useful when measurement is difficult.

●​ Fast decision-making in emergency work.

Limitations:

●​ Less accurate.
●​ Depends on the skill and judgment of the expert.

✅ Advantages of Work Measurement

1.​ Improves labor productivity
2.​ Helps plan accurate delivery times
3.​ Supports performance-based pay systems
4.​ Assists in machine and manpower allocation
5.​ Reduces cost by identifying idle times and waste

❌ Limitations of Work Measurement

1.​ Not accurate for creative or irregular jobs
2.​ Observer presence may change worker behavior
3.​ Requires skilled and trained staff
4.​ Time-consuming in detailed studies
5.​ Errors in recording can lead to incorrect results
✅ Work Allowances
🔷 Definition:
Work Allowances are the extra time added to the basic or normal time of a task to cover rest breaks,
personal needs, unavoidable delays, or multitasking effects.​
They help make the standard time realistic and achievable for workers under actual working conditions.

📌 Formula:​
Standard Time = Normal Time + Work Allowances

✅ Types of Work Allowances

(Each with 4 expanded points and example)

🔹 1. Relaxation Allowance
📝 Description: Time given to workers to recover from physical and mental tiredness caused by
continuous work.

4 Key Points:

1.​ This allowance helps the worker recover from muscle strain, eye strain, and general fatigue
during the shift.
2.​ It is necessary even in light jobs and more for jobs involving heat, noise, or high physical effort.
3.​ The value is typically between 4% to 10% of the normal time, depending on the nature of the
work.
4.​ This ensures steady performance, fewer mistakes, and reduced accidents.

✅ Example: In metal forging, workers receive extra breaks due to high-temperature conditions and
heavy physical effort.

🔹 2. Personal Needs Allowance

📝 Description: Time provided for attending to natural human needs like using the toilet, drinking
water, or stretching.

4 Key Points:

1.​ It applies to all workers, regardless of job or department, since personal needs are universal.
2.​ Normally, a standard 4% to 5% of the job time is added.
3.​ It does not depend on job type or workload, unlike fatigue-related allowances.
4.​ It promotes worker dignity and comfort in the workplace.

✅ Example: A factory worker is allowed short breaks to use the restroom or get a drink during their
8-hour shift.

🔹 3. Contingency Allowance
📝 Description: Time added to account for irregular or unpredictable delays that may occur
occasionally in a job.

4 Key Points:

1.​ It includes delays like machine adjustments, waiting for tools, material mix-ups, or minor
communication with supervisors.
2.​ It is not added to every job — only where such disturbances are known to happen occasionally.
3.​ The allowance is generally in the range of 2% to 5%.
4.​ Helps avoid unfair penalties when workers face small unexpected problems.

✅ Example: During machine setup, sometimes the right wrench is missing, so extra time is allowed to
fetch it.

🔹 4. Interference Allowance
📝 Description: Time allowed when one worker handles more than one machine, and sometimes must
wait between operations.

4 Key Points:

1.​ It applies when the worker’s task depends on machine cycles that cause short idle periods.
2.​ The worker can't operate all machines at the same time, so waiting or shifting occurs.
3.​ Interference time is measured or estimated and added as part of standard time.
4.​ It is common in automated or semi-automated processes with machine dependency.

✅ Example: A CNC operator managing three machines may need to wait for one machine to finish
before starting another.
✅ Advantages of Work Allowances
1.​ 🎯 Fair Work Standards: Allowances make standard time realistic by considering human

2.​ ⏳ Accurate Planning: Helps in planning realistic production schedules and delivery dates.
limitations and job-related delays.

3.​ 💰 Balanced Wages: Workers are paid fairly, and performance is judged accurately.
4.​ 🛠 Improved Morale & Safety: By preventing fatigue and overwork, allowances protect health
and reduce errors.

❌ Disadvantages of Work Allowances

1.​ ⚠️ Overestimation Risk: If allowances are too high, it may lead to low productivity and idle

2.​ 📉 Inaccurate Costs: Too much allowance can inflate labor cost and affect pricing and
time.

3.​ 🧾 Misuse Possibility: Workers might misuse relaxation or personal time if not monitored
budgeting.

4.​ 🕵️ Difficult to Calculate: Exact values need proper studies; guessing can make the system
properly.

unfair or unproductive.

✅ Process Chart
🔹 Definition (with Example):
A Process Chart is a visual tool used to represent all steps involved in a task, job, or process using
standard symbols. These steps can include operations (doing work), inspection (checking), movement
(transport), delays, and storage. It helps in understanding the sequence and flow of activities in a
process.

The main aim is to analyze and improve work methods by finding unnecessary steps, reducing delays,
and improving efficiency.

🛠 Example:​
Let’s say a company is assembling a table:
 1.​ Cutting wood – operation
2.​ Checking size – inspection
3.​ Moving it to next station – transportation
4.​ Waiting for next machine – delay
5.​ Assembling parts – operation
6.​ Storing finished product – storage

Each step would be shown using different symbols in a process chart.

✅ Types of Process Charts

Each type of chart focuses on a different part of the process, depending on what or who is being
studied.

🔷 1. Outline Process Chart (also called Operation Process Chart)

📌 Detailed Description:
The Outline Process Chart is the simplest form of process chart. It only shows the main operations
and inspections in a process. It doesn’t show the movement of materials or workers, waiting time, or
storage — just the key actions.

It is used in the early stages of process planning to get an overview of how a product is made or how a
job is done.

🔣 Symbols Used & Meanings:

Symbol Meaning

● Operation – A task is being performed (e.g., cutting, shaping, painting)

☐ Inspection – The item is being checked or tested for quality or accuracy

🧠 Used In:
 ●​ Product design phase
●​ When creating routing sheets in manufacturing
●​ Giving managers a quick view of how the product is made
●​ Used for decision making and simplifying the process

🛠 Example:
Making a simple bolt:

csharp

CopyEdit

● Cut steel rod

● Turn rod on lathe

☐ Measure diameter

● Thread the rod

☐ Final inspection

Only main actions and checks are shown here — nothing else.

🔷 2. Flow Process Chart

📌 Detailed Description:
This is a very detailed chart that shows every step in a process including:

●​ Operations (doing work)

●​ Inspection (checking)
●​ Transport (movement)
●​ Delays (waiting)
●​ Storage (temporary keeping)

Flow process charts can be created for:

●​ Man – showing what a person does

●​ Material – showing how the materials move
 ●​ Machine – showing machine activity

This chart helps us find waste, like too many movements, waiting times, or repeated inspections.

🔣 Symbols Used & Meanings:

Symbol Meaning

● Operation – Doing something (e.g., machining, assembling)

☐ Inspection – Checking quality, size, or finish

→ Transport – Moving material or worker from one place to another

D Delay – Waiting due to unavailability, queue, or breakdown

∆ Storage – Putting something in a store or keeping it aside

🧠 Used In:
●​ Manufacturing, assembly, packing, and service industries
●​ To identify non-value-adding steps
●​ To study movement of materials and people
●​ For process improvement and layout design

🛠 Example:
Suppose you are preparing a steel pipe:

1.​ ● Cut the pipe

2.​ → Move to bending station
3.​ ● Bend the pipe
4.​ D Wait for inspection
5.​ ☐ Inspect bend accuracy
6.​ ∆ Store the pipe in finished goods area
This chart will clearly show where time is wasted, and how the flow can be made smoother.

🔷 3. Two-Hand Process Chart

📌 Detailed Description:
This chart is used to study manual jobs where both hands of the worker are involved. It records each
movement of the left and right hands, side-by-side, to see if:

●​ One hand is idle while the other is working

●​ Both hands are being used efficiently
●​ The job can be done faster or better

It is part of motion study, often used to improve assembly or tool handling jobs.

🔣 Symbols Used & Meanings (Same for both hands):

Symbol Meaning

● Operation – Hand doing work (e.g., screw, fit, press)

☐ Inspection – Hand checking something

→ Transport – Hand moving or reaching for an item

D Delay – Hand waiting (idle time)

∆ Hold – Hand holding an item (temporary hold position)

🧠 Used In:
●​ Assembly line work
●​ Tool or part handling
 ●​ Packaging
●​ To reduce fatigue and speed up manual tasks

🛠 Example:
Time Right Hand Left Hand

0 sec → Reach for bolt → Reach for wrench

2 sec ● Pick bolt ● Pick wrench

4 sec ● Place bolt in part ∆ Hold part steady

6 sec ● Tighten bolt D Idle

In this chart, we can see the left hand is idle while the right hand works — showing an area for

Chart Using Time Scale

🔹 Definition (with Example):

A Chart Using Time Scale is a process chart where time is shown along the horizontal axis, and the
steps of the process are arranged based on how long each activity takes.​
It helps in visually comparing the time spent on different activities such as operations, inspection,
transport, delays, and storage.

This type of chart is useful to identify:

●​ Which steps are time-consuming

●​ Where waiting or delays occur
●​ Opportunities to balance work between man, machine, or processes
✅ 1. Multiple Activity Chart
🔹 Definition (with Example):
A Multiple Activity Chart is a time-based chart used to study and compare the activities of two or
more resources (people, machines, or both) over a period.​
It helps identify who is working, who is waiting, and how to improve the coordination between them.

🛠 Example:​
A worker operates two machines. The chart shows what the worker is doing and what each machine is
doing during each minute of work.

🔹 Detailed Description:
●​ The chart is usually arranged in rows, where each row represents a person or a machine.
●​ The horizontal axis represents time.
●​ Activities are shown as blocks, either shaded (working) or empty (idle).
●​ Helps to reduce idle time, balance workloads, and improve productivity.

🔹 Symbols and Their Meanings:

Symbol or Format Meaning

█ (dark block) Operation/working

▒ (light block) Idle or waiting

→ Transport or movement

Blank No activity

🔹 Used In (Applications):
●​ When one operator manages multiple machines
 ●​ Assembly lines with multiple workers
●​ In manufacturing plants to coordinate labor and machines
●​ For layout planning and efficiency improvement

✅ 2. Gang Process Chart

🔹 Definition (with Example):
A Gang Process Chart is a special type of multiple activity chart that shows the activities of a group
(gang) of workers working together on a single operation or machine.​
It is used to balance work among team members doing the same or related tasks.

🛠 Example:​
Five workers lifting and assembling a large pipe together — the chart shows who is doing what during
each minute.

🔹 Detailed Description:
●​ Each row in the chart represents one worker in the group.
●​ The columns represent time units (seconds or minutes).
●​ The chart identifies when workers are active, idle, or helping others.
●​ The goal is to make sure everyone contributes equally and no one remains idle unnecessarily.

🔹 Symbols and Their Meanings:

Symbol Meaning

█ Worker is performing an operation/task

▒ Worker is idle or waiting

↔ Coordination or teamwork activity

🔹 Used In (Applications):
●​ Team-based jobs such as lifting, construction, heavy machine handling
●​ Maintenance teams or repair crews
●​ To analyze labor efficiency in group tasks
●​ To redesign team work structure for better use of manpower

✅ 3. SIMO Chart (Simultaneous Motion Chart)

🔹 Definition (with Example):
A SIMO Chart (SIMultaneous MOtion chart) is a detailed micro-motion study chart that records very
small hand and body movements of a worker in real-time, often using a time measurement unit like
"therbligs."​
Used to optimize manual operations by finding and removing unnecessary motions.

🛠 Example:​
During assembly of a watch, every movement of both hands (reach, pick, hold, press) is recorded for a
few seconds.

🔹 Detailed Description:
●​ The chart has two vertical columns: one for the right hand, one for the left hand.
●​ Each movement is recorded second by second or using frame-by-frame film.
●​ A timing device like a microchronometer or video is used.
●​ Each motion is broken down into basic units (therbligs) such as reach, grasp, hold, use, inspect,
etc.
●​ The chart helps eliminate wasted motion and rearrange the workplace for better efficiency.

🔹 Symbols and Their Meanings (Therbligs):

Symbol or Term Meaning

R Reach
G Grasp

H Hold

P Position

U Use

I Inspect

A Assemble

D Delay (involuntary or voluntary)

R' Release

Note: Therbligs are not graphical symbols but coded letters representing motions.

🔹 Used In (Applications):
●​ Assembly line jobs requiring high precision
●​ Watch-making, electronic device repair, microsurgery, etc.
●​ Where repetitive manual motions need optimization
●​ In time and motion study labs
 UNIT 3

🧾 Definition:
Value Analysis is a systematic and creative method used to improve the value of a product or service by
analyzing its functions and costs. The goal is to reduce or eliminate unnecessary costs without
compromising performance, reliability, or quality.

💡 Key Concepts (Direct Points):

1.​ Value = Function / Cost – Value increases when the function is improved or the cost is reduced.
2.​ Function Focused – Emphasis is on what the product does (primary and secondary functions).
3.​ Elimination of Waste – Identifies and removes components or processes that do not add value.
4.​ Customer-Centric – Ensures that the final outcome aligns with customer expectations.
5.​ Team-Based Approach – Relies on cross-functional collaboration for better decision-making.

🎯 Objectives (Direct Points):

1.​ Reduce overall product or process cost without compromising on quality.
2.​ Identify and eliminate unnecessary components or operations.
3.​ Enhance the performance or utility of a product.
4.​ Improve overall design efficiency and resource utilization.
5.​ Increase customer satisfaction by offering better value at a lower cost.

🛠️ Steps Involved in Value Analysis (with expanded content and examples):

1. Information Phase

●​ Collect complete information about the product’s components, material, manufacturing process,
and cost breakdown.
●​ Understand customer needs and expectations regarding the product.
●​ Study the purpose of the product and its usage in real-world conditions.
●​ Identify stakeholders involved in design, production, and sales.
●​ Create a structured overview of the current product or service as a baseline.
📌 Example: For an electric kettle, engineers study materials used (metal, plastic), energy consumption,
heating element cost, and customer usage data.

2. Function Analysis Phase

●​ Identify all primary and secondary functions using a verb-noun format (e.g., “boil water”, “hold
liquid”).
●​ Classify functions as essential (primary) or optional (secondary).
●​ Assign cost to each function to see which ones are expensive.
●​ Question the necessity of each function in delivering core performance.
●​ Analyze which functions contribute most to value and which ones can be simplified.

📌 Example: In a washing machine, “wash clothes” is a primary function, while “play music” during
operation may be a costly, unnecessary secondary function.

3. Creative Phase

●​ Brainstorm multiple ideas to achieve each function at lower cost or better efficiency.
●​ Use techniques like brainwriting, mind maps, or reverse thinking to generate alternatives.
●​ Explore changes in design, materials, components, and processes.
●​ Include suggestions from various departments (design, production, marketing).
●​ Document all ideas without immediate judgment to encourage innovation.

📌 Example: Instead of metal hinges in a chair, the team proposes strong plastic hinges which are cheaper
and equally durable.

4. Evaluation Phase

●​ Filter the brainstormed ideas by analyzing feasibility, performance, safety, and cost-effectiveness.
●​ Check for compatibility with existing systems or manufacturing processes.
●​ Perform a cost-benefit analysis for each shortlisted idea.
●​ Consult experts to ensure quality, reliability, and customer impact aren’t compromised.
●​ Finalize the best options that offer maximum value improvement.

📌 Example: From 15 redesign ideas for a smartphone case, the team chooses 2 that reduce cost by 30%
and pass all durability tests.

5. Development & Implementation Phase

 ●​ Convert the selected ideas into detailed plans, engineering drawings, or prototypes.
●​ Conduct tests to ensure the redesigned product meets specifications.
●​ Estimate potential savings and document benefits for final approval.
●​ Present the proposal to stakeholders or decision-makers.
●​ Once approved, integrate the new design/process into full-scale production.

📌 Example: A redesigned printer ink cartridge using fewer components is prototyped, tested, and
introduced into production after approval, saving 15% in cost.

✅ Benefits of Value Analysis:

1.​ Reduces Manufacturing Cost – Identifies and eliminates cost-heavy components or processes.
2.​ Improves Product Functionality – Enhances the main functions while removing unnecessary
features.
3.​ Enhances Customer Satisfaction – Better design at a lower price increases customer value.
4.​ Encourages Innovation and Creativity – Promotes out-of-the-box thinking across departments.
5.​ Optimizes Resource Usage – Makes better use of materials, time, and labor for efficiency.

Process Planning
🧾 Definition:
Process Planning is the detailed method of deciding how to manufacture a product in the most efficient
and cost-effective way. It determines what operations are needed, which machines will be used, what
tools are required, and the sequence in which operations should occur to convert raw material into a
finished product as per design specifications.

🔁 Steps Involved in Process Planning (With Expanded Explanation + Importance):

1. Analyze Product Design & Specifications

●​ This step involves thoroughly reviewing engineering drawings, 3D models, technical

specifications, and design documents of the product.
●​ It focuses on understanding key features like dimensions, surface finish, material type, tolerance
limits, and functional purpose of the product.
 ●​ A feasibility check is also done to ensure the product can actually be manufactured with existing
technologies and facilities.
●​ Collaboration may happen with the design team if any changes or clarifications are needed.

✅ Importance:​
Avoids manufacturing errors and reduces the chances of rework. It ensures that production teams clearly
understand what needs to be made and how critical features must be achieved.

📌 Example: For a precision gear with 0.01 mm tolerance, the planner ensures tight control of process
parameters.

2. Select Raw Materials

●​ Identify the most suitable raw material required for the product considering mechanical properties
(strength, hardness, thermal resistance), chemical properties (corrosion resistance), and
manufacturability.
●​ Evaluate the availability of the material in standard market sizes to reduce wastage and cost.
●​ Consider cost, supplier reliability, lead time, and environmental impact as well.

✅ Importance:​
Choosing the right raw material directly affects the functionality, durability, cost, and ease of
manufacturing.

📌 Example: Aluminum alloy is chosen instead of steel for a drone body to reduce weight and improve
flight time.

3. Determine Manufacturing Operations & Sequence

●​ Identify all the necessary operations like turning, milling, drilling, welding, heat treatment,
grinding, painting, etc., needed to shape the product.
●​ Decide the best logical order (sequence) to perform these operations for minimal movement and
time.
●​ Ensure compatibility between operations to avoid complications like hardening before machining.

✅ Importance:​
Helps in achieving a smooth workflow, reduces downtime, and ensures a logical progression of work
that supports high productivity.

📌 Example: Machining flat surfaces before boring holes helps in holding the workpiece properly and
ensures accuracy.
4. Select Machines & Equipment

●​ Choose the most appropriate machines for each operation based on capability, tolerance range,
production volume, and machine availability.
●​ Consider whether the operations need CNC machines, manual lathes, grinding machines, or
special-purpose machines.
●​ Decide on the required fixtures, jigs, gauges, and work-holding devices to support efficient
machining.

✅ Importance:​
Ensures that the selected machine can handle the complexity and precision required for the operation
without overloading or underutilizing capacity.

📌 Example: Selecting a CNC vertical machining center instead of a manual milling machine for
complex 3D components with tighter tolerances.

5. Determine Cutting Parameters & Tools

●​ Fix the optimum cutting speed, feed rate, depth of cut, and coolant use for each operation based
on material and machine capability.
●​ Choose appropriate cutting tools like carbide inserts, HSS tools, diamond tools, or drills based on
material hardness and finish requirements.
●​ Plan for tool changes and determine tool life to avoid sudden tool failure.

✅ Importance:​
Reduces cycle time, improves surface finish, extends tool life, and ensures safe and efficient material
removal.

📌 Example: For machining stainless steel, slower speeds and a suitable coolant system are selected to
avoid tool overheating.

6. Plan for Inspection & Quality Control

●​ Identify the quality checks required during and after manufacturing to ensure all critical
dimensions and tolerances are met.
●​ Select proper measuring tools like micrometers, calipers, CMMs, gauges, or optical devices.
●​ Define checkpoints (in-process, final inspection) and the frequency of inspections.

✅ Importance:​
Ensures defect-free production, reduces rejections, and helps maintain product consistency and
customer trust.
📌 Example: In automotive engine parts, a 100% inspection is planned for crankshaft alignment and hole
accuracy.

7. Estimate Time & Cost

●​ Calculate how long each operation will take, including machine time, setup time, and idle time.
●​ Include labor cost, machine cost per hour, tool cost, and material cost.
●​ Add overheads and contingency costs to prepare an accurate production budget.

✅ Importance:​
Provides a clear production schedule, helps in pricing decisions, and supports management in cost
control and capacity planning.

📌 Example: Estimating that producing one unit of a shaft takes 45 minutes and costs ₹320 allows
planners to budget for large orders.

8. Prepare Process Sheet / Route Sheet

●​ Create a detailed document listing all operations, machines, tools, time required, safety
instructions, and quality checks.
●​ It acts as a manufacturing blueprint or instruction manual for the shop floor team.
●​ This document ensures consistency in production even if the operator changes.

✅ Importance:​
Acts as a standard reference, ensures accurate repetition of the process, and helps with traceability in
case of product issues.

📌 Example: A route sheet shows:​

Op1 – Milling (20 mins)​
Op2 – Drilling (10 mins)​
Op3 – Inspection (5 mins)

Machine Capacity
🧾 Definition:
Machine Capacity refers to the maximum amount of output a machine can produce within a specific
time period under normal working conditions. It determines how much work a machine is capable of
handling and plays a critical role in production planning, resource allocation, and scheduling in
manufacturing systems.

🎯 Importance of Machine Capacity:

1.​ Efficient Production Planning – Helps allocate jobs based on available machine power.
2.​ Avoids Overloading/Underloading – Ensures optimal use of machines without causing wear or
idle time.
3.​ Improves Delivery Commitments – Ensures realistic timelines and meets customer deadlines.
4.​ Helps in Investment Decisions – Guides whether to purchase new machines or upgrade existing
ones.
5.​ Reduces Cost and Wastage – Prevents excess capacity and optimizes labor, power, and time.

📊 Types of Machine Capacity (with Examples):

Type Description Example

1. Design Maximum possible output as per A CNC lathe designed to produce 60

Capacity machine specifications. parts/hour under ideal conditions.

2. Effective Realistic output considering Same lathe produces only 45 parts/hour

Capacity maintenance, fatigue, downtime, etc. due to tool changes and rest.

3. Actual Output the machine truly produces Due to material delay, only 35 parts/hour
Capacity during a specific period. were produced today.

⚙️ Factors Affecting Machine Capacity:

1.​ Machine Type & Age – New or upgraded machines have better performance.
2.​ Operator Skill Level – Skilled workers can maximize machine performance.
3.​ Tooling & Setup Time – Frequent setups reduce actual working hours.
4.​ Maintenance Schedule – Regular maintenance keeps machines running longer.
5.​ Material Supply – Delay in raw materials results in unused machine time.
6.​ Shift Hours – More shifts mean higher daily capacity.
7.​ Production Volume & Product Type – High mix or complex products slow down output.
🔁 Steps Involved in Machine Capacity Planning (Expanded with Examples):
1. Identify Available Machines

●​ Begin by creating a comprehensive list of all machines involved in the production process.
●​ For each machine, record its type, capabilities, rated speed, size, tool compatibility, and other
relevant specifications.
●​ Also document historical data like average output, breakdown frequency, and previous utilization
records.

✅ Why important:​
Knowing what resources are available is the foundation of capacity planning. It helps you understand
your plant’s limits and production potential.

📌 Example: A shop floor has 3 CNC milling machines and 2 conventional lathes. Each has different
production rates and setup times.

2. Determine Available Working Time

●​ Calculate how much time each machine is available for productive work over a given period
(daily, weekly, or monthly).
●​ Subtract non-working hours like break time, scheduled maintenance, or shift changes.
●​ Consider how many shifts are operated (1-shift, 2-shift, or 24/7 system).

✅ Why important:​
Gives you a realistic view of how much time each machine can actually be used, avoiding
overestimation.

📌 Example: If a machine runs 2 shifts per day (8 hours each), the available time is 16 hours/day minus 1
hour for cleaning and changeover.

3. Assess Machine Efficiency

●​ Evaluate how efficiently the machine performs during working hours.

●​ Include downtime due to breakdowns, tool changeover, and operator fatigue.
●​ Use efficiency ratings (e.g., 80%, 90%) based on historical data or OEE (Overall Equipment
Effectiveness).
✅ Why important:​
Machines never run at full rated capacity due to real-world constraints. Considering efficiency ensures
realistic planning.

📌 Example: A machine may be available for 16 hours, but due to tool changes and minor stoppages, its
actual working time is only 13.5 hours (i.e., 85% efficient).

4. Estimate Production Time Per Unit

●​ Calculate the cycle time, i.e., the time it takes for the machine to produce one unit of the product.
●​ Include the time taken for loading/unloading, machining, and minor inspections.
●​ If multiple products are made, compute cycle time for each.

✅ Why important:​
Cycle time tells you how many units a machine can realistically produce, which is essential for
production planning.

📌 Example: If a lathe takes 10 minutes to produce one shaft, it can produce 6 shafts per hour under ideal
conditions.
6. Match Capacity with Demand

●​ Compare the calculated machine capacity with the production requirement (customer demand or
forecast).
●​ If capacity is lower than demand, consider overtime, outsourcing, or machine upgrades.
●​ If capacity exceeds demand, optimize scheduling or divert machine for other jobs.

✅ Why important:​
Aligning machine capacity with production demand prevents delays, bottlenecks, or idle machines,
ensuring smooth operations.

📌 Example:​
If customer order requires 40 units/day, but capacity is only 36, the planner may schedule overtime or
split the job across two machines.

✅ Benefits of Machine Capacity Planning:

1.​ Better Resource Utilization – Avoids both overuse and underuse of machines.
2.​ Improved Productivity – Reduces idle time and ensures smooth production flow.
3.​ Lower Operational Costs – Saves energy, time, and labor by avoiding inefficiencies.
 4.​ Informed Expansion Decisions – Data helps decide when to add more machines.
5.​ Accurate Delivery Commitments – Realistic timelines increase customer satisfaction.

Process capability
🧾 Definition:
Process capability in a multi-product system refers to the ability of a production process to efficiently
and consistently produce different products (varying in design, size, or material) using the same set of
machines, tools, labor, and production lines, all while meeting quality standards, minimizing
downtime, and optimizing resources.

🎯 Importance:
1.​ Supports Product Variety​
– Essential for industries that manufacture a range of products using shared equipment (e.g., auto
parts, FMCG, electronics).
2.​ Maximizes Machine and Labor Utilization​
– Machines and manpower are used more efficiently across different jobs.
3.​ Reduces Setup Time and Costs​
– Proper planning minimizes changeovers between different product types.
4.​ Improves Responsiveness to Market Needs​
– The system can handle sudden changes in demand across multiple products.
5.​ Enables Lean Production​
– Reduces waste, improves flow, and supports batch-level efficiency.

📊 Types of Process Capability in Multi-Product Systems:

Type Description Example

1. Product-Mix Ability to produce multiple product A bakery producing bread, cakes,

Capability types on the same line with varying and cookies on the same line.
operations.
2. Volume Flexibility Ability to increase or decrease the A bottling plant adjusting
number of products produced per type. production from 500 ml to 1L
bottles.

3. Customization Ability to produce standard and custom A car plant making standard and
Capability versions of the same product efficiently. premium variants on the same
line.

⚙️ Factors Affecting Process Capability in Multi-Product Systems:

1.​ Product Design Variability – Greater differences in design, shape, and tolerances increase the
complexity of process planning.
2.​ Tooling and Fixture Requirements – Unique tools for each product type may increase setup
time and tool costs.
3.​ Machine Flexibility – Machines must be programmable or reconfigurable to adapt to different
product types.
4.​ Skilled Labor – Operators should be trained to handle multiple operations and understand varied
instructions.
5.​ Quality Control Requirements – Different products may require different inspection criteria and
equipment.
6.​ Inventory and Material Handling – Managing multiple raw materials and semi-finished
products adds complexity to logistics.

🔁 Steps Involved in Evaluating and Managing Process Capability in Multi-Product Systems:

1. Analyze Product Requirements

●​ Begin by listing each product manufactured in the system.

●​ Understand the unique design features, dimensional tolerances, quality standards, and materials
used for each product.
●​ Identify which processes are common across products and which are unique.
●​ Group products based on similar process requirements to simplify planning.

✅ Importance:​
Provides clarity on the production needs of each product, enabling smart grouping and reducing
unnecessary variation in the production flow.
📌 Example: In a footwear unit, shoes and sandals may share cutting and stitching operations but differ in
assembly and finishing.

2. Assess Machine and Tool Compatibility

●​ Review each machine and its ability to handle various product types.
●​ Check for compatibility in terms of size range, material type, and tooling setup.
●​ Ensure tooling like dies, jigs, and fixtures can be reused or changed easily across products.
●​ Identify where machine reprogramming or adjustments are needed.

✅ Importance:​
Ensures that machines can switch between products quickly and efficiently, reducing idle time and
ensuring smooth transitions.

📌 Example: A CNC machine that can switch between programs for metal and plastic parts with only a
tool change.

3. Measure Process Capability (Cp, Cpk) for Each Product

●​ Use statistical quality control methods to calculate Cp (process capability) and Cpk (process
performance) for each product.
●​ Collect data on key quality characteristics and compare them to specification limits.
●​ Identify whether the process can consistently produce products within tolerance levels.

✅ Importance:​
Helps in understanding how well the process performs for each product, enabling focused improvements
and quality assurance.

📌 Example: A drilling process for Product A has Cpk = 1.4 (good), but for Product B it’s only 0.8 (needs
improvement).

4. Evaluate Setup and Changeover Times

●​ Record the time and steps involved in switching from one product to another (tool change,
machine programming, part positioning).
●​ Analyze how frequent these changes occur and their impact on productivity.
●​ Use techniques like SMED (Single-Minute Exchange of Dies) to reduce setup times.

✅ Importance:​
Minimizing changeover time improves uptime, reduces labor fatigue, and allows for smaller batch sizes.
📌 Example: Reducing changeover time on a stamping machine from 40 minutes to 10 minutes using
quick-release dies.

5. Optimize Scheduling and Workload Balancing

●​ Plan production sequences smartly to reduce frequent switches between different product types.
●​ Use scheduling tools like Gantt charts or ERP systems to allocate machine and labor efficiently.
●​ Balance workloads across workstations based on demand, capability, and operator skill.

✅ Importance:​
Ensures a smooth and uninterrupted workflow, meeting delivery targets without overloading specific
machines or stations.

📌 Example: Producing products with similar processes back-to-back before switching to a completely
different product line.

6. Standardize Work Instructions and Operator Training

●​ Create Standard Operating Procedures (SOPs) for each product or product group.
●​ Train operators to be multi-skilled, so they can handle a variety of products and machines.
●​ Use visual aids and product-specific checklists to reduce confusion and ensure uniformity.

✅ Importance:​
Maintains consistent quality and reduces errors, especially when switching between diverse product
types.

📌 Example: Visual SOP boards showing steps for assembling Product X and Product Y side-by-side for
easy reference.

✅ Benefits of Strong Process Capability in a Multi-Product System:

1.​ Increased Production Flexibility – Easily shift between product types based on demand.
2.​ Efficient Utilization of Equipment – Same machines can handle multiple jobs, reducing capital
investment.
3.​ Improved Customer Responsiveness – Ability to deliver multiple product variants faster.
4.​ Cost Reduction – Reduces waste, setup costs, and labor idle time.
5.​ Standardization and Quality Assurance – Maintains uniform standards across products while
handling variation
Machine Balancing
🧾 Definition:
Machine Balancing is the process of evenly distributing workload across all machines or
workstations in a production line so that each operates efficiently without being overburdened or
underutilized. The main objective is to maintain a smooth and continuous flow in production by
minimizing idle time and bottlenecks.

🎯 Importance of Machine Balancing:

1.​ 🔁 Improves Workflow Continuity​

2.​ ⏱️ Reduces Idle Time​

– Prevents production delays by maintaining a steady rhythm across machines.

3.​ 💰 Lowers Production Costs​

– Machines aren’t left waiting for input or delayed by slower preceding processes.

4.​ ⚙️ Optimizes Resource Utilization​

– Efficient machine use reduces energy costs and operational waste.

5.​ 📦 Increases Output and Quality​

– Ensures both machines and manpower are used to their full capacity.

– Balanced systems ensure smoother production, leading to better quality and faster delivery.

📊 Types of Machine Balancing:

Type Description Example

Static Balancing Based on fixed task times and sequences; Traditional conveyor
assumes stable conditions. assembly lines.

Dynamic Adjusts in real-time based on feedback, sensors, Smart automated

Balancing or system variability. manufacturing units.

⚙️ Factors Affecting Machine Balancing:

1.​ Task Time Variation – Different tasks take different times, causing load imbalances.
 2.​ Machine Speed Differences – Some machines naturally process faster than others.
3.​ Human Operator Skill – Skilled operators might complete tasks faster, impacting overall
balance.
4.​ Tool/Setup Time – Machines requiring frequent adjustments reduce efficiency.
5.​ Product Design Complexity – Complex components need more processing time on certain
machines.
6.​ Material Movement Delays – Slow transport between machines causes idle time.

🔁 Steps Involved in Machine Balancing (Expanded):

1. Identify and List All Tasks and Operations

●​ Break the entire manufacturing process into discrete tasks (cutting, drilling, painting, etc.).
●​ Record the sequence and dependencies between operations.
●​ Include both manual and machine-driven steps for each product.

✅ Why it matters:​
A clear breakdown helps in identifying how tasks can be allocated efficiently.

📌 Example: Making a cycle: frame welding → painting → tyre fitting → brake assembly.
2. Measure Time for Each Task (Cycle Time)

●​ Use time-motion study or digital tools to find how long each task takes.
●​ Factor in machine time, operator involvement, and setup time.
●​ Include a buffer for variation and errors.

✅ Why it matters:​
Exact timing prevents overload and underload in any workstation.

📌 Example: Cutting: 3 mins, drilling: 2 mins, painting: 4 mins, fitting: 2.5 mins.
3. Determine Takt Time (Based on Demand)

●​ Takt Time = Available Time / Customer Demand

●​ Helps define the maximum time allowed per task to meet customer requirements.
●​ Guides how tasks should be grouped to match flow speed.
✅ Why it matters:​
Keeps the production speed aligned with market needs.

📌 Example: 480 mins/day and 120 units/day → Takt time = 4 mins/unit.

4. Assign Tasks to Machines Based on Balance Logic

●​ Group tasks so total task time at each machine is close to takt time.
●​ Use balancing methods like:
○​ Ranked Positional Weight
○​ Largest Candidate Rule
●​ Avoid overloading or starving any workstation.

✅ Why it matters:​
Prevents bottlenecks and ensures each machine contributes equally.

📌 Example: If Machine A = 3.9 mins, Machine B = 4.1 mins → good balance.

5. Calculate Line Efficiency and Balance Delay

●​ Line Efficiency (%) = (Sum of Task Times / (Number of Stations × Cycle Time)) × 100
●​ Balance Delay (%) = 100 – Line Efficiency
●​ A high efficiency means good balance; low delay shows optimal machine use.

✅ Why it matters:​
Quantifies how well-balanced the production line is.

📌 Example: If line efficiency = 85%, then balance delay = 15% (wasted time).
6. Implement, Test, and Improve

●​ Start the production run and monitor machine performance.

●​ Look for overloaded or idle machines and adjust the assignments.
●​ Use feedback to refine task groupings, improve setup, and upgrade operator training.

✅ Why it matters:​
Real-world trials reveal issues that planning may miss, enabling continuous improvement.

📌 Example: If painting station delays flow, consider pre-coating or split workload.

✅ Benefits of Machine Balancing:
1.​ 🏭 Increases Production Throughput​

2.​ ⚖️ Even Load Distribution​

– More units are produced per shift with fewer delays.

3.​ 💡 Improves Worker Morale​

– Prevents wear and overuse of specific machines or operators.

4.​ 📈 Boosts Overall Efficiency​

– Balanced tasks reduce fatigue and stress.

5.​ 🛠️ Reduces Machine Downtime​

– Better flow leads to cost savings and improved customer satisfaction.

– No machine is idle for long, enhancing lifespan and reliability.