Short Answer:

Routing is the process of determining the exact path or sequence of operations that a product must follow during manufacturing. It specifies the machines, tools, materials, and operations required to produce the component efficiently.

The main aim of routing is to ensure smooth and systematic movement of materials through different work centers. It helps in reducing production time, avoiding delays, and ensuring better utilization of resources by defining the best possible route for manufacturing.

Detailed Explanation:

Routing

Routing is an essential function of production planning and control that defines the detailed route or path which materials or components must follow during manufacturing. It involves planning the sequence of operations, selecting suitable machines, tools, and work centers required to produce a product efficiently. Routing provides a clear and systematic layout of the operations, starting from the raw material stage to the final product.

In simple terms, routing answers three main questions:

1. What work is to be done?
2. Where should the work be done?
3. In what sequence should the work be carried out?

Routing ensures that every operation is properly planned and that the production process flows smoothly without unnecessary movement or delays. It helps in optimizing the use of machines, tools, and manpower to achieve higher productivity.

Objectives of Routing

The main objectives of routing are:

1. Efficient Production Flow: To ensure that materials move smoothly through all stages of production without unnecessary handling or delay.
2. Proper Resource Utilization: To make the best use of available machines, equipment, and workers.
3. Reduction of Idle Time: To minimize machine and worker idle time by planning operations in advance.
4. Improved Production Planning: To support production scheduling and control by providing a clear operation plan.
5. Product Quality and Cost Control: To maintain product quality while reducing production costs through well-organized operation sequences.

Routing provides the foundation for production scheduling and control, as it specifies how and where production activities will be performed.

Elements of Routing

Routing generally includes the following important elements:

1. Operations to be Performed: Listing of all manufacturing operations required for making a product.
2. Sequence of Operations: Arrangement of operations in the correct order to ensure smooth production.
3. Work Center Identification: Selection of machines, departments, or workstations where each operation will be performed.
4. Tools and Equipment: Identification of the tools, jigs, and fixtures needed for each operation.
5. Inspection Stages: Indicating the points where inspection and quality checks are required.
6. Material Flow: Defining the path of materials from one operation to the next until completion.

These elements together make up a complete route sheet, which acts as a guide for production.

Steps Involved in Routing

1. Product Analysis: Study the design and specifications of the product to identify the operations required.
2. Operation Breakdown: Divide the entire process into individual operations.
3. Selection of Work Centers: Decide which machines or departments will carry out each operation.
4. Determining Operation Sequence: Arrange operations in the most efficient order to minimize time and cost.
5. Preparation of Route Sheet: Prepare a detailed document listing the sequence of operations, tools, and machines.

A route sheet serves as a written plan for production workers and supervisors, helping them follow the proper workflow.

Importance of Routing

• Ensures Smooth Production Flow: Routing minimizes confusion by clearly defining the order of operations.
• Reduces Production Time: Well-planned routing minimizes delays between operations.
• Improves Efficiency: Helps achieve better use of machines and manpower.
• Supports Scheduling and Control: Provides essential data for creating production schedules.
• Improves Quality: Proper routing helps maintain consistency and product standards.
• Reduces Cost: Efficient routing reduces material handling, idle time, and production waste.

By ensuring a systematic approach to production, routing enhances both efficiency and productivity.

Factors Affecting Routing

1. Type of Product: Complex products may require multiple operations and work centers.
2. Production Volume: Large-scale production requires more standardized and fixed routes.
3. Plant Layout: The physical arrangement of machines affects the movement of materials.
4. Availability of Machines and Tools: Routing may need adjustment based on available resources.
5. Skill of Workers: The level of skill determines which operations can be assigned to whom.

Understanding these factors ensures that routing remains practical and effective under actual production conditions.

Advantages of Routing

• Helps in systematic planning of manufacturing operations.
• Reduces production cost and material handling.
• Increases machine and labor efficiency.
• Ensures proper quality control and product standardization.
• Helps in identifying bottlenecks and improving workflow.

Routing thus plays a key role in improving overall manufacturing performance.

Conclusion:

Routing is a fundamental part of the production process that determines the path and sequence of operations for manufacturing a product. It provides a detailed plan that ensures smooth workflow, efficient utilization of resources, and timely completion of production. Proper routing reduces idle time, improves product quality, and supports production control. Hence, routing is essential for achieving efficiency, productivity, and cost-effectiveness in manufacturing operations.