4[1]. automation and mechanization

Duties and responsibilities of an Operations
Manager
Presented by
Anupama Naik
Roll.no.4

“automatic-without the use of manpower “
 It is the use of machines and equipments in performing mental and
physical operations in a production process.
 It is the use of control systems such as computers to control
industrial machinery and processes, replacing human operators.
 It is an electronic brain with the capability of taking routine and
logical decisions connected with control and planning.
 It is considered a step beyond mechanization. Mechanization
reduces physical requirements of work and automation reduces
need for human, sensory and mental requirement.

 A system of doing work where material handling, production
processes and products are integrated through mechanization of
thoughts (logic) and efforts (routine) to achieve a self regulating and
controlling system.
 The machines and equipments required to perform various
operation of production process are sequentially arranged in order
of the hierarchy of operations.
 Electronic devices are used to record, store, process and interpret
information at various stages of production.
 The process of having a machine or machines accomplish tasks
performed wholly or partly by humans.

 The fundamental constituents of any automated process are
(1) a power source,
(2) a feedback control mechanism, and
(3) a programmable command
While feedback is usually associated with more advanced forms
of automation, so-called open-loop automated tasks are
possible. Here, the automated process proceeds without any
direct and continuous assessment of the effect of the automated
activity.
Example: for a manufacturing unit automation includes machining ,
structural fabrication ,assembly, material handling , inspection
and
testing,maintenance,tooling,turning,boring,drilling,shaping,grindin
g etc.

 Technological advances in both hardware and software industry has
primarily resulted greater automation of processes.
 Hardware technologies include numerically controlled machine
tools, industrial robots, automated materials handling systems,
machining centres and flexible manufacturing systems.These
devices are used in the manufacturing of products.
 And software based technologies aid in the design of manufactured
products and in the analysis of planning of manufacturing activities.
 Software technologies include computer aided design and
automated manufacturing, planning and control systems.

 Specialized hardened computers, referred to as programmable logic
controllers (PLCs), are frequently used to synchronize the flow of
inputs from physical sensors and events with the flow of outputs to
actuators and events.
 Human-machine interfaces(HMI) or computer human interfaces
(CHI), formerly known as man-machine interfaces, are usually
employed to communicate with PLCs and other computers, such as
entering and monitoring temperatures or pressures for further
automated control or emergency response. Service personnel who
monitor and control these interfaces are often referred to as
stationary engineers.

 A separate form of automation involving computers is
test automation, where computer-controlled automated
test equipment is programmed to simulate human
testers in manually testing an application.
 Another separate field of automation is Home
automation. This type of automation emerged in the
early 1990s. This type of automation is concerned with
the controls of everything in a house, from lights and
blinds through security and access system to heating,
cooling, water supply and home theater systems.

 Cost reduction:
1. Labor cost
2. Material cost
3. Inventory cost
4. Quality cost
5. Maintenance cost
 Increased product variety
 Improved product features
 Shorter cycle times
 Greater product output
 Effective control on operations
 Improved working conditions
 Safe working environment
 Improve quality of work

 Automated manufacturing includes automated machine tools,
assembly lines, robotic assembly machines, automated
storage-retrieval systems, integrated computer-aided design
and computer-aided manufacturing (CAD/CAM), automatic
inspection and testing, and automated agricultural equipment
(used, for example, in crop harvesting).
 Automated information processing and control includes
automatic order processing, word processing and text
editing, automatic data processing, automatic flight control,
automatic automobile cruise control, automatic airline
reservation systems, automatic mail sorting machines,
automated planet exploration, automated electric utility
distribution systems, and ATMs.

 Technological risk:
a. The risk of acquiring an untested technology whose problems could disrupt
the firm’s operations.
b. Risk of obsolescence
 Operational risk :
a. Installation of a new technology generally results in significant disruptions.
b. Delays and errors in the production process.
c. Uncertain and sudden change in demands.
d. larger inventories and continuous power supply.

 Organizational risk :
a. Lack of top management commitment to absorb the short term
disruptions associated with adopting a new technology.
b. Tendency of employees or managers to resist changes or
abandon the technology due to short term failures.
 Environmental or market risk:
a. market forces make the investment worthless.
b. any breakdown anywhere would lead to complete shutdown.
c. can create unemployment.

 Mechanization was the next logical step in the substitution
of chemical for muscle power once small and light enough
power sources became available.
 The process of having a machine or machines accomplish
tasks performed wholly or partly by humans. As used here,
a machine refers to any inanimate electromechanical
device such as a robot or computer.
 It provides the self regulating property by performing
manual operations by means of mechanized operations for
example-material handling etc., self control can be
introduced in the process.

 Manual(By using hands, hand tool, powered level
tool hand control) and
 Mechanical (power tool program control cycle,
power tool system remote controlled, activated by
introduction of workpiece or material)

 Operations management is concerned with the
production of goods and services. Everyday we come in
contact with a an abundant array of goods or services,
all of which are produced under the supervision of
operations managers.
 The different operations managers are-
1. Production manager
2. Inventory control managers
3. Quality managers
4. Line supervisors

 Assembling appropriate resources and direct use of
these resources, by the people, machines,
processing etc. in transforming material and time of
people into products and services.
 Managers pay attention on what customers want to
buy and work according to government regulations
and behaviour of consumer and environmental
protection groups.

 Channelize the production process to ensure
efficient use of the resources to the best advantage
for the enterprise.
 Production of right quantity of material at right time.
 Ability to do something real and constructive about
production problems.
 He should be well conversant with the ways and
means to attain the desired goals

Personal
noneconomic
impact
Engineering
marketing &
Equipments PR
economic
Finance
impact
Human, goods &
Material & capital services
Transformation
activities
I
N
P
U
T
S
Control
O
U
T
P
U
T
S

1. Operation manager should concern himself with
production planning: he is required to produce required
quantity of product in time to meet the stipulated delivery
date. This can be done by-
a) assessing the requirements of various factors of production on the
basis of demand forecasting.
b) formulating demand schedule for factors of production to permit
purchase of raw material.
2. Production control: it is the duty of the production
manager use the resources at his disposal in best possible
manner and regulate the operation to maintain the desired
delivery schedule.

3. OM should concern himself with Quality control: it is
the duty of the production manager to manufacture the goods
and services of desired specifications.
4.Method analysis: there are a number of ways in which an
operation can be executed. Operation manager should select
the most efficient and economical method to perform the
operation.
5.Plant layout and material handling: the physical
arrangement of the manufacturing components and the
equipment for handling the material during production process
has considerable effect on cost of production. So, the material
handling system and the plant layout should be most efficient
for the given situation.

6.Proper inventory control: inventory implies all the materials ,
parts,supplies,tools and in-process or finished products kept in
stocks for sometime. The procurement policy of these items require
careful consideration and analysis. The purchases should be
planned in economic lot sizes and the time of purchase should be
so scheduled that the investment in the inventory is at the lowest
possible level. This implies determination of economic lot sizes and
re-order level.
7.Work study: method study and measurement techniques are
applied to find the relationship between output of goods and
services and input of human and material resources . The operation
manager should try to find the most appropriate method of
performing various operations involved in a production process so
as to obtain the optimum use of the resource as well as increasing
the productivity.

8. Production manager should be able to generate the interest
of the workers to increase their efforts by providing them
wage incentives.
9. The cost of production varies with different methods of
production. The production manager is responsible to follow a
systematic approach to control capital and expenditure
designed in a way that desired profit is ensured.
10. The operation manager should have the capability as well
as the aptitude to use the qualitative and quantitative methods
of analysis to get the desired solution.

 Operations management- theory and problems by
Joseph G. Monks.
 Operations management- decision making in the
operation functions by Roger G. Schroeder.
 Production operations management by Dr. B.S.
Goel.
 Internet

4[1]. automation and mechanization

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4[1]. automation and mechanization