UNIT - 1

2 Marks questions

A1. What do you understand by ‘Production”   P2

            Production is the process by which raw materials and other inputs are converted into finished goods.

A2. What are the sub-systems of Production system?  P1

                Production system has two subsystems - Conversion system, and Control sub system.

A3. List the three types of decisions, an operations manager takes    P3 last para

                An operations manager takes three kinds of decisions - strategic decisions, operating decisions, and control decisions

A4. List any four characteristics of Modern Manufacturing   P 48-49

            The characteristics of Modern manufacturing are - 1. Specialisation, 2. Mechanisation, 3. Use of technology of Industrial Engineering, 4. Increasing use of Computers and data processing equipment, and 5. Use of the Scientific Method.

A5. List four primary characteristics of Services.  P 50

                The primary characteristics of Services are - 1. Intangibility, 2. Perishability, 3. Inseparability, and 4. Variability
       

A6. List problems caused by intangibility of Services.  P 51

            Problems caused by Intangibility are - 1. Purchasing service does not result in ownership, 2. Lack of ability to store, 3. Lack of protection by patents, 4. Difficulty in displaying or communicating services, and 5. Difficulty in pricing services.

A7. List different methods of Manufacturing.  

                Different methods of manufacturing are - 1. Flow shop, 2. Job shop, 3. Batch processing, 4. Projects

A8. What is a flowshop?

                Here, successive units of output undergo the same sequence of operations, using specialised equipment, usually positioned along a production line. Eg assembly of cars, televisions, scooters, motor cycles, etc.

A9. What is a continuous process?

                It is an extreme kind of flow shop, where there is a constant flow of materials as in oil refining, chemical processing etc.

A10. What is job shop?

                This is a conversion process in which units of different types of products follow different sequences through different shops. This type of system has more flexibility.But this

system has more set up time, more in process inventory, complex scheduling etc.

A11. What is batch manufacturing?

                When the volumes of any single product is not sufficient to justify the use of flow shop, production is taken up in batches. The whole process and machine settings are changed for each batch. It is in between a job shop and flow shop.

A12. What is a project?

                A project refers to the process of creating a complex one of a kind product or service with a set of well defined tasks in terms of resources required and time phasing. Some examples are large bridges, dams, starting new industries, etc.

A13. Define productivity.

                Productivity is the relationship between inputs and outputs of a system.

Productivity  =  Output / Input

Higher the productivity, higher will be efficiency of a process.

B1. Define conversion sub-system   Table 1.1

            Conversion subsystem is a subsystem of a larger production system where inputs are converted into outputs.

B2. Define control sub-system     Table -1.1

            Control subsystem is a subsystem of a larger production system where a portion of the output is monitored for feedback signals to provide corrective action if required.

8 MARK QUESTIONS

A 1. What are the differences between (goods) Manufacturing and Services   P 50

Sl No	Manufacturing	Services
1	Goods can be resold	Reselling services is unusual
2	Goods can be invetoried	Services can not be iventoried
3	Some aspects of quality are measureable	Many aspects of quality are difficult to measure
4	Selling is distinct from production of goods	Selling is often a part of services.
5	Goods are transportable	Services provider and not services  are transportable
6	Location can be far from customer	Location is often close to customer
7	Often easy to automate operations	Services are often difficult to automate

               

B1. What are the advantages and disadvantages of Process Layout? P 146

Process layout involves grouping together of like machines at one department.

The advantages of process layout are

1.      Reduced investment in machines as they are general purpose machines.

2.      Greater flexibility in the production.

3.      Easier to handle breakdown of machines, as jobs and men  can be moved easily to other machines.

4.      Most suited for job shops.

5.      Adding capacity is easier as machines can be added to departments that are critical.

The disadvantages are

1.      Movement of material is more compared to product layout.

2.      This kind of layout needs more space.

3.      Work in progress gets accumulated at different departments.

4.      Difficulty in production planning and control.

5.      Production time is more asmaterial has to move between departments

B2. What are the advantages and disadvantages of Product Layout? P 147

                Product layout involves the arrangement of machines in one line depending upon the sequence of operations.

The advantages of product layout are

1.      This kind of layout avoids production bottlenecks, and hence suitable for high production levels.

2.      Materials are moved mostly mechanically and hence,  time and energy is saved in material handling.

3.      Requires less floor area.

4.      Better production control

5.      Work in progress is reduced to minimum

6.      Defects can be detected early, as inspection can be planned after each stage.

The disadvantages are

1.      Product layout is known for its inflexibility

2.      This type of layout is expensive.

3.      Expansion of capacity is difficult and expensive.

4.      Break down of any equipment can disrupt the whole production.

15 Marks Questions

A1. List duties and responsibilities of a Production Manager.   P10

The following are duties and responsibility of production manager in manufacturing organisations:

1.Planning the geographical location of the factory.

2.Purchasing production equipment .

3.Layout of equipments within the factory.

4.Designing production process and  equipments.

5.Product design.

6.Designing production work and establishing work standards.

7.Capacity planning .

8.Production planning and scheduling.

9.Production control.

10.Inventory management.

11.Supply chain management.

12.Quality control.

13.Production equipment maintenance and repair.

14.Measurement and monitoring of productivity.

15.Industrial Relation.

16.Health and safety.

17.Staff selection and liaisoning & Budgeting and capacity planning.

A2. Describe the recent trends in Production and Operations Management.  P11-12

RECENT TRENDS IN PRODUCTION/OPERATION MANAGEMENT:

Many recent trends in production/operations management relate to global competition and the impact it has on manufacturing firms .Some of the recent trends are :

1.Global market Place :Globalisation of business has compelled many manufacturing firms to have operations in many countries where they have certain economic advantage.This has resulted in a steep increase in the level of competition among manufacturing firms throughout the world

2.Production/Operation Strategy: More and more firms are recognising the importance of production/operations strategy for the overall success of their business and the necessity for relating it to their overall business strategy.

3.Total Quality Management:TQM approach has been adopted by many firms to acheive customer satisfaction by a never-ending quest for improving the quality of goods and services.

4.Flexibility:The ability to adapt quickly to changes in volume of demand,in the product mix demanded,and in product design or in delivery schedules, has become a major competitive advantages and a competitive advantages to the firms.This is sometime called agile manufacturing.

5.Time Reduction:Reduction of manufacturing cycle time and speed to market for a new product provide competitive edge to a firm over others firms.When companies can provide products at the same price and quality,quicker delivery(Short lead times) provide one firm competitive edge over the other.

6.Technology: Advances in technology have led to a vast array of new products ,new processes and new materials and components.Automation,Computerisation,Information, and communication technologies have revolutionised the way companies operate.Techonological changes in products and processes can have great impact on competetiveness and quality,if the advanced technology is carefully integrated into the existing system.

7.Work Involvement:The recent trends is to assign responsibility for decision making and problem soving to the lower levels in the organisation.This is known as employee inolvement and empowerment.Examples of worker involvement are quality circles and use of work teams or quality improvement teams.

8.Re-engineering:This involves drastic measure or break -through improvements to improve the performance of a firm.It involves the concept of clean-slate approach or starting from scratch in            redesigning the business processes.

9.Environmental issues:Today’s production managers are concerned more and more with pollution control and waste disposal which are key issues in protection of environment and social responsibility. There is increasing emphasis on reducing waste,recycliong waste,using less toxic chemicals and using biodegreadable material for packaging.

10.Corporate Downsizing (or Rightsizing):Downsizing or rightsizing has been forced on firms to shed their obesity.This has become necessary due to competition,lowering productivity,need for improved profit and for higher dividend payment to shareholders.

11.Supply Chain Management:Management of supply-chain,from suppliers to final customers reduces the Cost of transpotation,warehousing and distribution throughout the supply chain.

12.Lean Production: Production system have become lean production systems which use minimal amounts of resources to produce a high volume of high quality goods with some variety.These system use flexible manufacturing system and multi-skilled workforce to have advantages of both mass production and job production.   

A3. Describe the different types of production systems.

                The production systems are classified based on the type of output, flow, and service.

Basis	Classifications	Examples
Types of output	Products	Consumer goods like TVs, Producer goods like lathes etc.
	Services	Transportation, health, entertainment, banking etc.
Types of Flow	Projects	Roads, bridges, dams etc.
	Job shop	Hospitals, machine shop, auto repair etc.
	Flow shop	High volume production of cars, motor cycles, TVs etc.
	Continuous process	Oil refinery, chemical plant etc
Service type	Customised	Medical care, legal services
	Standardised	Insurance, banking etc.

B1. Write( preferably in a tabular form) different types of  Production and Operations Management decisions and their applications.   P 4  Table 1.2

POM Decision and their Applications

Types of Decision Strategic Decisions: (Planned Products) Processes and Facilities)	Area of involvement 1.Production Processes 2.Production Technology 3.Facility Layout 4.Allocation Resources to strategic alternatives. 5.Long range Capacity Planning and Facility location.	Nature of activities Development long range production plans including design process . Selecting and managing production technology. Planning and arrangement facilities, Planning for the optimal distribution of scarce resources among product lines or business units. Answering the ‘how much’ and where questions about long range production capacity.
2.Operation Decisions (Planning production to meet demand)	1.Production planning Systems 2.Independent demand     Inventory systems 3.Resources Requirements Planning systems. 4.Shop floor planning and control at each work centre. 5.Materials manageent.	Aggregate planning and master production scheduling Planning and controlling finished goods inventories. Planning material and capacity requirements. Short range decisions about what to produce and when to produce Managing all facets of material system.
Control Decisions (Planning and Operations)	1.Productivity and Employees 2.Total Quality control 3.Project Planning and control techniques 4.Maintenance Management and Reliability.	Planning for the effective and efficient use of human resources in operations. Planning and controlling the quality of products and services. Planning and controlling projects Planning for maintaining the machines and facilities of production.

C1. List the areas of productivity of Production function.   P 6  Box 1.1

Production Function -Area Of Productivity

1.Improving volume of production. 2.Reducing reduction rate . 3.Minimising rework rate. 4.Maintaining Delivery Schedule. 5.Controlling idle machine and manpower hours. 6.Establishing/Updating/Improving/Setting industrial engineering norms. 7.Updating Processes and procedures. 8.Maintaining Accuracy and timeliness of Management Information System. 9.Decreasing Machine set- up time. 10.Controlling Over Time. 11.Good housekeeping. 12.Checking absenteeism,thefts/pilferage and misconduct. 13.Eliminating accidents. 14.Effective grievance-handling. 15.Efficient training and team building 16.Minimising inventory and achieving better yields. 17.Enhancing customer satisfaction. 18.Total Quality Management. 19.Business Process Re-engineering (BPRE). 20.Automation..