Manufacturing Management - Introduction

Planning, organizing and controlling manufacture of goods is manufacturing management. Chase et al. define operations management as the design, operation, and improvement of the systems that create and deliver the firm's primary products and services. Operations management is a discipline that includes production of goods and services.

Once the company decides to manufacture and sell a product, the specialized responsibility of the manufacturing management starts. But the decision to manufacture a product is based on feasibility analysis. During this analysis also manufacturing management issues are involved. Therefore, the persons doing strategic analysis or corporate planning analysis include persons from manufacturing management discipline with manufacturing management knowledge and bring into the analysis or decision making process the manufacturing view point.

Manufacturing is carried out through processes. A process is any activity or group of activities that takes one or more inputs, transforms them, and provides one or more outputs. The output could be for an external customer for sale or for an internal customer to use for further processing. In some cases it can be for consumption in the same process or by the consumption by the producer himself. Manufacturing processes convert materials into goods that have a physical form. The transformation processes change the materials on one or more of the following dimensions:

1. Physical properties
2. Shape
3. Fixed dimension
4. Surface finish
5. Joining parts and materials.

The outputs from manufacturing processes can stored and transported in anticipation of future demand (Krajewski et al. 2007).

Important Developments in Manufacturing Management

Developments in manufacturing management include certain technical developments that made manufacturing systems more productive and flexible.

Shop Management - F.W. Taylor

Shop floor management guidelines provided by F.W. Taylor were landmarks in the field of manufacturing management. Taylor further development Scientific management philosophy. Taylor also brought out the importance of scientific studies in manufacturing processes improvement or design. His studies on machining were considered a very important research contribution. Taylor also introduced time study based best practice identification and training all operators in the best practice. He advocated that manufacturing managers have the responsibility of developing manufacturing methods and training operators in best methods.

Frank Gilbreth developed study of motions of operators to develop efficient operator movements either to do manual work or to operate machines. He and Lilian Gilbreth also introduced the concept of fatigue and proposed ways to prevent the negative consequences of fatigue in operators as well as in manufacturing systems.

Henry Ford introduced moving assembly lines that revolutionized the production systems. Henry Gantt developed charts that helped scheduling production activities.

Harry Emerson wrote a book on principles of efficiency and it became part of industrial engineering and scientific management literature. Focus on efficiency in systems in general and especially manufacturing systems sharpened.

F.W. Harris developed theory of batch quantities in production and purchase. Walter Shewart developed procedures for using statistical thinking in process control. He created methods for determining when to change machine setups based on the measurements of samples taken at random intervals.

Hawthorne studies became another landmark development in manufacturing management. They brought out the importance of psychological variables in improving or decreasing productivity of operators. Unfortunately, the proponents of this line of thought have not integrated their conclusions with the ideas of scientific management appropriately. They chose to attack themes of scientific management. Manufacturing management might have had a different state today, if scientific management movement that had engineering foundations and human relations school of thought that had psychology as its foundation were appropriately integrated by human relations school.

Operations Research

Development of operations research (OR) helped manufacturing managers to understand and optimize their systems better. Study of operations research became a part of studies of manufacturing managers. Use of computers was started in recording store related transactions and data and it was extended to shop floor transaction data. The use was further extended to calculation of batch quantities and preparation of loading sheets and schedules. MRP and MRP II came into existence and they got extended into ERP systems.

The domain of production and operations management and the role of Elwood Buffa in its delineation

Kalyan Singhal, Jaya Singhal, Martin K. Starr

https://doi.org/10.1016/j.jom.2006.06.004   

Production and operations management (POM), as we know it today, was established in the 1960s in response to various drivers. Elwood Spencer Buffa first published his textbook, Modern Production Management, in 1961. Buffa coined the term operations management and consolidated knowledge from various streams of production management, including operations research and industrial engineering, into a coherent managerial framework.

Modern business education had started to emerge around 1959 after reports from the Carnegie Corporation and the Ford Foundation recommended improving research and analytical approaches. Many business schools created courses in POM. At the time, no single book covered what we now call production and operations management. The POM faculty at most business schools, including Columbia's Graduate School of Business, adopted Buffa's book enthusiastically when they introduced courses in “production management”. Buffa covered supply chain management, design for manufacturing, quality management, service operations, and computer applications and the automated factory. The POM community pursued these issues more actively 2 or 3 decades later.

https://onlinelibrary.wiley.com/doi/10.1016/j.jom.2006.06.004

https://openlibrary.org/authors/OL1193811A/Elwood_Spencer_Buffa

Elwood Buffa's pioneering contributions to production and operations management

Authors: Sushil Gupta and Martin K. Starr

From: Production and Operations Management,  Summer 2006 (Vol. 15, Issue 2)

1. Introduction

The first three editions of his textbook, Modern Production Management (Buffa 1961a, 1965, 1969), played a major role in the evolution of an integrated and coherent discipline that has come to be known as production and operations management (P/OM). Although P/OM has existed for centuries and the work of Smith (1937, originally published in 1776) and is widely regarded as its formal beginning, Buffa's book marked the founding of this discipline. It immediately became the dominant book for introductory P/OM courses all over the world.  While Modern Production Management created an identity for our discipline in 1961, the P/OM community still remained fragmented into several interest groups and societies until 1989, when the Production and Operations Management Society (POMS) was founded. Later, the European Operations Management Association (EuROMA) was formed in 1993.

2. Teaching and Textbooks

 Although Buffa's books covered a wide range of areas, such as general business, management science, production and operations management, and strategy, all of them evolved from his interest in production and operations management.

While the series of books written by Buffa were becoming standard texts for introductory P/OM courses, several other books were published in the early 1960s that introduced the field of P/OM to students at an advanced level (Fetter and Dalleck 1961; Hanssmann 1961; Miller and Starr 1962). Buffa also published an advanced level book, Production and Inventory Systems: Planning and Control in 1968, and wrote its second edition with William Taubert (Buffa and Taubert 1972), and the third edition with Jeffrey Miller (Buffa and Miller 1977). These advanced level books, written by several P/OM thought leaders at that time, were used as texts for a second course in production and operations management. 

Japanese Contribution to Production Management

In 1970s, scholars in USA recognized that Japanese had used their manufacturing management philosophies, strategies and techniques as a strategic capability to win market shares in global markets. A new era of manufacturing strategy thought developed in manufacturing management. Automation increased in factories. With this multi-skilling of operators came into picture as now operators have more time and can operate more machines. As group layout became more popular, an operator was required to operate different machines which were in series. Total quality management, total productive maintenance, total cost management became the strategies. JIT or lean systems became the best practice production systems. While improvement everywhere reached its zenith, the important idea that it is improvement in bottleneck that has the most value was highlighted by Goldratt in the name of 'Theory of Constraints.'

Many new technologies came into existence and were adopted into manufacturing processes. The existing ideas regarding technology adoption did not emphasize the suboptimal use of technology. The full power of technology was not being put to use by many. Theory of BPR brought this into focus and helped systems become more productive by utilizing the power and potential of the new technologies more. Ability to look at bigger and bigger systems using OR models and system dynamics models and the ability to access data anywhere using internet based data communication systems made coordination across distributed national and global facilities. This led to the development of theory of supply chain wherein information can be made visible to anybody and optimization can be done from the point of origin or raw materials to its dumping point. Manufacturing facilities are now a part of supply chains wherein information is available to both suppliers and potential customers in real time and purchasing is done through electronic orders. In a century, manufacturing management theory and practice developed immensely.

Industry 4.0 - Japanese Attempt to Master Implementing New Technologies and Equipment

Machine Work Study - Machine Improvement in Toyota Production System (TPS)

Chase, Richard, B., F. Robert Jacobs, Nicholas J. Aquilano , Operations Management, 11th Edition, McGraw-Hill, New York, 2006.
Krajewski, Lee et al., Operations Management: Processes and Value Chains, 8th Edition, Prentice Hall, Upper Saddle River, 2007.

________________________________________________________________________

Early Books on Manufacturing Management

Learning from the first Operations Management textbook

Christopher A. Voss

//doi.org/10.1016/j.jom.2006.05.013

De Re Metallica by Georgius Agricola was published in 1556. It is arguably the first Operations Management textbook. In it the author describes the management and technologies of the mining and metallurgical industry of the period. There is a  translation by Herbert and Lou Hoover. Many areas which we see as contemporary, such as ethical and environmental issues, are explicitly addressed in the book.  The book describes how the operations should be organized and managed, the role of the foreman, and the education and training required.  The most enduring lesson from this remarkable book is the importance of systematic capture and dissemination of knowledge in Operations Management.

Introduction

A few years ago, I published a paper reviewing the history of Operations Management from Taylor to Toyota (Voss, 1995). Like many in the field, the work was based on the underlying assumption that Operations Management started with Frederick W. Taylor. However, as many have pointed out, it is possible to trace the field much further back.

https://www.sciencedirect.com/science/article/abs/pii/S0272696306000684

De Re Metallica by Georgius Agricola - published in 1556.

Translation by Herbert and Lou Hoover.

https://www.gutenberg.org/files/38015/38015-h/38015-h.htm

Shop Management
Frederick Winslow Taylor, 1903
http://www.archive.org/stream/shopmanagement00taylgoog#page/n10/mode/2up

Shop Management - Themes

1. Definition of Management 

2. Difference in Production Quantity between a first class man and an average man

3. Developing and Employing First Class People in an Organization

4. Confronting Soldiering - Slow Pace of Work

5. Halsey Plan - F.W. Taylor's Comments

6. Task Management

7. Investment for Increasing Productivity or Efficiency

8. Importance of people - organization

9. Modern Engineering and Modern Shop Management

10. Task Management - Starting and Ending Times

11. Task Work - Some More Thoughts

12. Usefulness of Gantt's system

13. Time Study - Part 1- F.W. Taylor in Shop Management

14. Bicylcle Ball Inspection Case Study

15. Need for Functional Foremanship or Functional Organisation of Foremen

16. Functional Foremanship

17. Production Planning and Control

18. Role of Top Management in Managing Change to High Productive Shop

19. Train Operators in High Productivity One by One and Then in Small Batches

20. Organizing a Small Workshop for High Productivity

21. Introducing Functional Foremanship

21a. Time Study - Part 2 - Shop Management 1903 Explanation by F.W. Taylor

22. Personal Relations Between Employers and Employed

23. Don't be in a hurry - It Takes Time to Manage Change

24. Best Practices in Shop Management

Profit Making in Shop and Factory Management
Charles U. Carpenter, 1908
http://www.archive.org/stream/cu31924002748576#page/n1/mode/2up

Factory Organization and Administration
Hugo Dimer, First Professor of Industrial Engineering, Pennsylavania State College
First edition: 1910
Third edition digital copy
http://www.archive.org/stream/factoryorganiza00diemgoog#page/n10/mode/2up



Factory and Office Administration
Lee Galloway, 1918
http://www.archive.org/stream/factoryofficeadm00galliala#page/n3/mode/2up

Factory Management Wastes: And How to Prevent Them
James F. Whiteford, 1919
http://www.archive.org/stream/factorymanagemen00whit#page/n7/mode/2up

Plant Management
Dexter S. Kimball, 1919
http://www.archive.org/stream/cu31924031222627#page/n7/mode/2up

__________________________________________________________________________

1958

https://books.google.com/books?id=J5pZAAAAMAAJ

1962

https://books.google.com/books?id=OgocWwOBxs4C

Introduction to Manufacturing Management

Ivan R. Vernon

American Society of Tool and Manufacturing Engineers, 1969 - Technology & Engineering - 301 pages

Clarifies the managerial and operational responsibilities of manufacturing.

https://books.google.co.in/books/about/Introduction_to_Manufacturing_Management.html?id=z9JTAAAAMAAJ

1974

https://books.google.com/books?id=RZRZAAAAMAAJ  

1987

https://books.google.com/books?id=juJTAAAAMAAJ

1993

Manufacturing Organization and Management

Harold T. Amrine et al.

Pearson Education India, 1993 - 640 pages

https://books.google.co.in/books?id=LzfVL6ge_MwC

See page 109 for the chapter Design of Manufacturing Processes

1995

https://books.google.com/books?id=xnxPAAAAMAAJ

2000

Encyclopedia of Production and Manufacturing Management

Paul M. Swamidass

Springer Science & Business Media, 30 Jun 2000 - Business & Economics - 979 pages

The Encyclopedia of Production and Manufacturing Management is an encyclopedia that has been developed to serve this field as the fundamental reference work. Over the past twenty years, the field of production and operations management has grown more rapidly than ever and consequently its boundaries have been stretched in all directions. For example, in the last two decades, production and manufacturing management absorbed in rapid succession several new production management concepts: manufacturing strategy, focused factory, just-in-time manufacturing, concurrent engineering, total quality management, supply chain management, flexible manufacturing systems, lean production, and mass customization, to name a few. This explosive growth makes the need for this volume abundantly clear.

Preview

https://books.google.com/books?id=BWQ597fj44QC

2006

Strategic Manufacturing Management: Strategies to Achieve Managerial Competitiveness

Thomas J. Sowell

Xlibris Corporation, 28 Feb 2006 - Business & Economics - 163 pages

The economic interdependence amongdeveloping and established industrializednations, and the disintegration of barriersto the flow of capital, information andtechnology across national borders facilitatesinternational market integration andglobalization. These market conditionsforce manufacturing companies to seriouslyconsider the strategies they need to implementif they are to develop competitive advantages. Very often the strategies that are executedwill result in a sustained competitiveadvantage through which a firm becomesleaner, more flexible, and more focused onproviding cost-effective goods and services tosophisticated customers. This book providesmanufacturing business strategies to assistcompanies to meet those requirements.

Preview

https://books.google.com/books?id=SXnI8FvnNqMC

2013

Industrial Production Management in Flexible Manufacturing Systems

Dima, Ioan Constantin

IGI Global, 31 Jan 2013 - Business & Economics - 512 pages

Industrial Production Management in Flexible Manufacturing Systems addresses the present discussions surrounding flexible production systems based on automation, robotics and cybernetics as they continue to replace the traditional production systems. The book also covers issues related to the use of multi-servicing in the operational management of the industrial production and its scheduling systems.

Preview

https://books.google.com/books?id=esaeBQAAQBAJ  

2017

https://books.google.com/books?id=ekZqswEACAAJ

Advances in Production Management Systems. Initiatives for a Sustainable World: IFIP WG 5.7 International Conference, APMS 2016, Iguassu Falls, Brazil, September 3-7, 2016, Revised Selected Papers

Irenilza Nääs, Oduvaldo Vendrametto, João Mendes Reis, Rodrigo Franco Gonçalves, Márcia Terra Silva, Gregor von Cieminski, Dimitris Kiritsis

Springer, 15-Mar-2017 - Computers - 962 pages

This book constitutes the refereed post-conference proceedings of the International IFIP WG 5.7 Conference on Advances in Production Management Systems, APMS 2016, held in Iguassu Falls, Brazil, in September 2016.

The 117 revised full papers were carefully reviewed and selected from 164 submissions. They are organized in the following topical sections: computational intelligence in production management; intelligent manufacturing systems; knowledge-based PLM; modelling of business and operational processes; virtual, digital and smart factory; flexible, sustainable supply chains; large-scale supply chains; sustainable manufacturing; quality in production management; collaborative systems; innovation and collaborative networks; agrifood supply chains; production economics; lean manufacturing; cyber-physical technology deployments in smart manufacturing systems; smart manufacturing system characterization; knowledge management in production systems; service-oriented architecture for smart manufacturing systems; advances in cleaner production; sustainable production management; and operations management in engineer-to-order manufacturing. 

https://books.google.co.in/books?id=khBhDgAAQBAJ

2018

https://books.google.com/books?id=zbSKDwAAQBAJ

Global Manufacturing Management

From Excellent Plants Toward Network Optimization

© 2021

Editors:

Thomas Friedli, Gisela Lanza, Dominik Remling

Features the St. Gallen Network Management approach, enhancing it with key practice-relevant facets

Highlights the scarcely investigated performance perspective in the field of international manufacturing networks

Combines outstanding world-class research with real-world evidence, including case studies

https://link.springer.com/book/10.1007/978-3-030-72740-6

2024

10 articles

https://books.google.co.in/books?id=HQkcEQAAQBAJ

Gavriel Salvendy

Professor Emeritus

salvendy at purdue.edu

Article originally posted in
knol   nrao 3309

Updated  19.9.2024,   15 November 2019,  22 October 2017, 13 October 2014