Subject Code: IMT-15

Subject Name : Production

and Operation Management

Objective: 1. To provide an awareness of the role of Operations Management in the functioning of a business organization. 2. To give an insight into the relationships that exist between various factors that affect the operations of a business organization- manufacturing or service 3. To equip students with a tools and techniques for analyzing, designing and improving the functioning of an operations system. Contents : Introduction to Operations Management -Operations management as a system - Operations strategy Products and services system - Competitive priorities-order winners and qualifiers Product design - Process of new product development - Implications of product life cycle to operations management - CAD and concurrent engineering - Reliability, maintainability and safety - Designing for manufacturability - Value analysis - Modular design Process selection - Generic manufacturing process and their choice - Hybrid processes including flexible manufacturing systems - Flow strategies - Process Mapping Facility decisions - Layout design Location analysis Capacity planning - Design, effective and actual capacity - Determinants of effective capacity - Economies of scale - Estimating equipment requirements - Capacity strategies Aggregate Planning - Strategies for meeting demand - Techniques for aggregate planning Supply Chain Management - Introduction to the concept of supply chain - Make or buy decisions - Vertical integration Inventory management - Dependent and independent demand inventories - EOQ model - Non instantaneous replenishment - Reorder point model - Periodic review model - Single period model. ABC analysis Material Requirement Planning - Inputs for MRP system - MRP processing, reports and record updating Lot sizing rules Scheduling - criteria for evaluating performance of a schedule - Scheduling in line, batch and job type production systems Single, two processor and multi processor scheduling - Personnel scheduling Synchronous manufacturing and introduction to Theory of Constraints. Just in Time System - Characteristics of JIT including Kanban system - JIT vs traditional system Quality Management - Definition of quality - Role of employee involvement and continuous improvementCosts associated with quality - Tools for TQM - Introduction to six sigma

Notes:
a. b. c. d. Write answers in your own words as far as possible and refrain from copying from the text books/handouts. Answers of Ist Set (Part-A), IInd Set (Part-B), IIIrd Set (Part C) and Set-IV (Case Study) must be sent together. Mail the answer sheets alongwith the copy of assignments for evaluation & return. Only hand written assignments shall be accepted. 5 Questions, each question carries 1 marks. 5 Questions, each question carries 1 marks. 5 Questions, each question carries 1 marks. Confine your answers to 150 to 200 Words. Two Case Studies : 5 Marks. Each case study carries 2.5 marks.

A. First Set of Assignments: B. Second Set of Assignments: C. Third Set of Assignments: D. Forth Set of Assignments:

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ASSIGNMENTS
FIRST SET OF ASSIGNMENTS Marks Assignment-I = 5

PART A
1. What is Production Management? What is Operations Management? Production is the heart of an organization Comment . 2. Explain how the following factors help improve the competitiveness of a manufacturing organization . a. Low production costs b. Fast delivery of products/Services. c. On-time deliveries d. High quality products/services e. Flexibility 3. Bring out the stages in the development of a new product. Explain each stage in brief. How QFD technique helps in product and process design . 4. What is process selection ? Why is it essential for a successful organization ? Explain Criteria for process selection ? 5. a). Steps in process design. b). Product-process matrix .
SECOND SET OF ASSIGNMENTS Assignment-II = 5 Marks

PART B
1. Define location. Discuss the factors which determine the location of a plant .How is location for a plant selected ? Discuss simple median model for selected plant location with and example . 2. What is layout planning ? What are its objectives. In brief give the relevance of group technology in plant layout in todays situation .Under what conditions is G.T. layout appropriate . 3. Compare product and process layouts and under what circumstances product and process layouts can be used. Explain with the help of an example how travel chart method helps in selecting the best layout among several alternatives ? 4. Define the term capacity planning . How plant capacity is related with plant layout , process design and equipment selection ? 5. The processing time and due dates for 5 jobs A,B,C,D and E are given in the table below : Job A B C D E Processing Time (days ) 10 8 6 12 7 Due date (days from now) 18 22 27 17 42

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Sequence these jobs according to EDD Evaluating Sequencing Rules and Calculate . a) Total Completion Time b) Total Flow Time c) Average Flow Time d) Average number of jobs in the system. e) Average job lateness
THIRD SET OF ASSIGNMENTS Assignment-III = 5 Marks

PART C
1. What is master production Schedule and what are its inputs? Describe the process of preparing a MPS. How MPS differ between produce-to-stock and produce-to-order firms. 2. Describe the various phases in a project life cycle .What is a network diagram? Distinguish between PERT and CPM and state where they are used .Explain steps in network crashing? 3. What is Quality? How it is insured? Explain Quality control techniques. Bring out the famous Deming principles of Quality. How far Quality circles ensure workers participation? 4. What are the trends in maintenance management? Outline the various types of maintenance. What is predictive maintenance? What is its advantages .Explain the bath tub curve? 5. Define the terms Inventory and Inventory management Why are inventories held in business? Explain the various techniques of inventory control a factory uses
FOURTH SET OF ASSIGNMENTS Assignment-IV = 2.5 Each Case Study

CASE STUDY - I
ABC Company Ltd, a manufacturer of floppy disks, inspects a sample of 50 disks from each day's output. A quality inspector of the company decides on the acceptability or otherwise of the disks based on a variety of attributes.

Date 18.02.2010 19.02.2010 20.02.2010 21.02.2010 22.02.2010 23.02.2010 24.02.2010

No of Defectives 3 10 13 4 12 14 08

Date 25.02.2010 26.02.2010 27.02.2010 28.02.2010 29.02.2010 01.03.2010 02.03.2010

No. of defectives 7 18 1 0 4 9 22

Date 03.03.2010 04.03.2010 05.03.2010 06.03.2010 07.03.2010 08.03.2010

No of defectives 7 6 19 3 9 7

Data relating to the number of defectives in the sample over the past 20 days are given above. The production manager suspects that the variation in quality was due to deputing an inexperienced substitute operator instead of a regular one, on three days during the period. With the use of a fraction defective chart, specifying the upper and lower control Limits or otherwise, determine the days of poor quality which can be traced or assigned to the inexperienced operator. Do the number of such days, match the number of points indicating out of control situations .

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CASE STUDY-II
The activities of a project and their time estimates are given below : Activity 1-2 1-4 1-5 2-3 2-6 3-6 4-6 5-7 5-8 6-8 7-8 a) b) c) d) e) Estimated duration of activity (in weeks) Optimistic time (to) Most likely time(tm) Pessimistic time (tp) 2 5 8 4 19 28 5 11 17 3 9 27 3 6 15 2 5 14 3 6 15 1 4 7 2 5 14 6 12 30 2 5 8

Draw the PERT network Diagram Determine the mean time and standard deviation of each activity Determine the critical path and the standard deviation for the critical path Calculate the slack for the events Calculate the total float, free float and independent float for each activity .

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