Production And Operations Management
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Question paper 1
SECTION-A
1. What is the difference between production management and operations management?
Answer:
Production management
Separation management
(i)
Old term that wall used when laser soul and operation was small and complexity and competition was less.
(i)
Modern term as it include organisation that deal in supply of services and also watch overall operation of the organisation.
(ii)
Focus on products .
(ii)
Focus on both product and service.
(iii)
Construct confused only 2 conservation of raw material into finishing goods.
(iii)
Broad concept that include planning designing development, conservation and distribution.
(iv)
No customer contact.
(iv)
Continuous customer contact.
2. Explain the meaning of Product Development
Answer:
Product Development it is an activity attempted to increase the usefulness of existing product by improving the feature aur function full stop it is the process of orating a new product to be sold by a business or Enterprise to its customer. Product development means formation of of a product IE including a brand new product in the market for addition of refresher product to an existing line of products.
For eg:- any addition to the functions revision of book by inserting new information, modification of an engineered products such as a computer.
A good product development helps to
1. Create new business opportunities and bring growth.
2. Boost productivity and profitability of the Enterprises.
3. Enhance the satisfaction levels of the customers.
3. Difference between Process Layout and Product Layout
3. Difference between Process Layout and Product Layout
Answer:
Process Layout
Product Layout
1.
Many products are produced in small quantity
1.
Large number of one or few products are produced.
2.
Less automation and dependency on skilled workers.
2.
Hi automation and dependency on money.
3.
Amount of work in progress is more.
3.
Work in progress is less.
4.
Non repetitive worker leading to more interest of workers.
4.
Repetitive work leading monitory .
5.
Suitable for batch production.
5.
Suitable for mass production.
4. What do you mean by the concept of six sigma ?
Answer:
Six Sigma Six to improve the quality of process, output by identifying and removing the causes of defect. 6 sigma approach is a collection of managerial and statistical concept and techniques that focus on reducing variation in process and preventing defence or or in product.
Six Sigma is a methodology for improving the quality of operation management by ultimate eing errors and defeats comma reducing cost, saving time. It is primary attendant for hire and Engineering and manufacturing where comparing seek Six Sigma quality but it can be adopted for other product and service industries.
5. Explain the types of stores.
Answer:
Different types of stores are
i. Speciality store:- it carry very limited product lines with deep assortment.
ii. Department store:- it is a large retail outlet that handle a wide variety of lines of product.
iii. Super market:- a Supermarket is designed to serve the total need of food, laundry and household maintenance product.
iv. Convenience Store:- it is located near residential area. It is relatively small and kept open for long hours.
v. Discount store:- IT sales standard merchandiser at lowest prices. Higher volume of sales compensate lower imagines and increase the overall profitability.
6. ABC manufacturing company uses cetrain component at a conatant rate of 4000 units per year. Cost per unit is Rs. 2. The company spends Rs. 50 to place an order and the carrying cost is 20% per year. Find the optimum size of each order.
Answer:
D = Annual usage or demand
O = Ordering cost Per order
C = Carrying cost per unit per year
According to question
D= 4,000 units
O=Rs 50
C=20%x2
=Rs 0.20
Thus , Optimum size of each Order =
=1414.21
Or
=141511Units
SECTION-B
7. Explain the various types of production system.
Answer:
Types of production system
1. Intermittent production system
2. Continuous production system
1. Intermittent production system:- it is that system which starts and stop at regular interval. In this production system, the goods are manufactured at regular intervals as per the specification and demands of customers. the production is is undertaken in small quantities .
Example of intermittent production system are jewellery designing, tailors, bakery etc.
Intermittent production system further two types:-
(i) Job production
(ii) Batch production:-
(i) Job production:- in this system the goods are product in local quantities such as a maximum Lord Mein Institute one item. In this production system goods are produced as per requirement and specification of the customers.
Advantage:-
Less damage of resources.
It is very flexible method.
Give job satisfaction to the workers.
Disadvantage:-
It result in underutilized of plant and machinery.
IT results in less productivity.
The hiring of workers required in fields prove to be costly.
(ii) Batch production:- the production process is divided into various operation. A group of products of similar nature moves through one operation in batches before they moved to next operation.
Advantage:-
Plant and machinery is is better utilized.
Workers are better utilized.
Variety of product can be offered to customer.
Disadvantage:-
Creates co-ordination problem between various processes.
Determining the the optimum batch size is not easy.
2. continuous production system:- goods are not produce as per the order of customer as was the caves in intermittent production system. The production happens continuously on large scale on the basis of focusing made by the business. The inputs used in this system is standardized nature.
The system in further classified into two types
(i) Mass production
(ii) Blow production
(i) Mass production:- in this production system is very large quantity of goods are produced. These goods are of standard size specification and quality. The machines are set in such a manner that does are proved with raw material of predefined quality to get specific quality of such goods.
Advantage:-
Lesser time required for production as its happen through fully automatic machines.
Chance of errors are less as human ultimate is less involved.
Quickly control and in controlling is easy as output of standard specification.
Disadvantage:-
It is a less or flexible system
As a workers Honda one job over a long period of time it create boredom and mandatory.
In case of dramatic downfall in demand heavy losses may occur.
(ii) Blow production:- in the floor productions the goods are moved from one processor to another and production happens in a continuous flow.
Advantage:
The the use of heavy automatic machinery is made.
The resources such as Man, material and machines are used optimally.
As material is handled by machine, chances of loose handling is reduced.
Disadvantage:-
It is very difficult to addition for butt duct and process in this system.
The slowest machine will determine orsat the production speed.
8. Write in detail Product Development Process.
Answer:
product development is an activity attempted to increase the usefulness of mystery product by improving the feature or function. It is the process of a new product to be sold by business or Enterprises to its customers.
For example any additun to the furniture revision of book by interesting new information, modification of an imaginary products such as computer.
A good product development help to
To create more business opportunities and bring growth
Boost productivity and profitability of the interprenesurs.
Enhance the satisfaction level of the customer.
Product development process:-
1. Idea Generation:- it is the first step in the new product development process. New ideas are normally generated by a group of experts about the design of product. In order to focus on the creation of an idea imagination. Various factor are taken into consideration the designers for the engineer.
(a) conduct market research in order to find out the need of a wants of the customers.
(b) invite suggestions from customers and the employees of the organisation
(c) organized brainstorming season to get suggestions for new product ideas
2. Idea screening:- the ideas which are generated in step number 1 are screened in this chapter. The ideas are Rand in descending order of their importance and utility and among-st them the most promising ideas are selected for further reviews.
3. concept testing:- after having selected the idea for the new product a rough design of product is tested in terms of its shape and size. In this stage the concept testing, the company find out
(a) whether the customer understand the product Idea or not question
(b) Whether the customer need the new product or not?
(c) Whether the customer will accept the product or not?
4. Business Analysis:- business analysis is an in-depth study of the product Estimated contribution to the organization sales, cost and profit. it is an of the economic feasibility of the product, the company find out whether the new product is is commercially variable and economically feasibility or not.
5. Product Development:- at this stage, the company will first find out whether it is technically feasible to produce the product or not. This frame will take all unnecessary stepper to produce and distribute the new product.
6. Test marketing :- test making means to introduce the new product on a very small scale in a particular geographical area fusion to experiment the interdepartmental a very small market so as to judge the excite to which the potential customer can buy.
7. Commercialization/ product launch:- if the test tube making is successful, product launch is the final step of which into launched the product on very large scale into the market. it advertise the new product on mass media like TV, radio, newspaper and magazine Etc.
9. Explain in detail various methods of evaluation of location of a business.
Answer:
Location Evaluation Methods:- if any industry, organization or business is considering setting up a new manufacturing location, it must follow the following three steps
i. identify Nominator location factor
ii. develop location alternative.
iii. evaluate location alternatives:- various quantitative and qualitative methods have been developed by experts over a period of time in order to select the most suitable location for manufacturing operation of an organization.
(A) Qualitative Method:- it makes an attempt to measure and analyses non monetary qualitative factor in order to reach to a conclusion. there are two such method available for that can help to Decide about manufacturing location.
(i) Judgement Method :- under this method the efforts is made to identify most of the qualitative factor, that are important while taking location decision. These factor are taken in comparison to each other on scale for different locations under consideration.
Steps:-
(a) make a list of all Qualitative factor affecting location decision.
(b) rank these on scales for various location under consideration
(c) Present them a graph or chart or diagram in compare the difference with one another.
(d) make a judgment on the basis of analysis.
(ii) point or factor Rating method:- there may be number of qualitative factors that have the season where more than one alternative location has been shortlisted
(a) find the main quality factor required to be analysed
(b) assign weight to each factor as per its relative important to all other factor
(c) determine are scale to evaluate each factor
(d) multiply factor weight with factors code to calculate weighted score for each alternative and Europe for each location
(B) Quantitative Method:- this method used mathematical equation and modeling to reach to a conclusion. All the factor that can be expressed in Oracle terms are to drink in this method
(i) Long Distance Method:- in long distance method help in finding a suitable location that minimizes its load weighted distance from a supplier of raw material, market, warehouses or any other facilities.
(ii) Centre of gravity Method:- location where travel time for transportation cost among st various location is least near the center of gravity. The center of gravity method to find out coordinates of sate locations.
(iii) Break even Analysis:- Breakout analysis gives us a level of output or scale value at which cost will be covered. break over. Is a level of number profit no loss for the organization. If information regarding all the coast associated with different location is available, the alternative with lowest break even point should be selected.
10. Write in detail yarious functions of Production Planning and Control.
Answer:
Functions of production planning and control
I. Routing:- routing is the foremost step in production planning and its form the basis for the other functions of function of planning department. Routing is the process of planning the travel path through which the raw material is converted into finished good in the maximum time involving minimum cost.
According to H.N. Broom, " Roti is a product of finding the path the sequence of operations which a factory order will follow through the process".
Steps of routing:-
(i) true analysis of product.
(ii) estimation of input requirements.
(iii) establishing sequence of operations.
(iv) determination of production lot size.
(v) estimation of scarf.
(vi) estimation of cost.
(vii) preparation of production control form.
(viii) preparation of route sheet
II. Scheduleling:- it involves the determination of the starting and completing time for each of the question forming the part of production process. The sequence of various square operations is established in the way that result in minimum idle time of labour and machines.
Scheduling is of three types
(a) Matter scheduling:- it is a plane showing the number of units of each product compound to be produce in the specific period of time in in future.
(b) manufacturing scheduling:- these schedules are prepared in case of process industries where the production is continuous and the product passes through a number of change before being converted into finished product.
(c) detail operation scheduling:-it shows that time required for each of production operation forming part of the manufacturing process.
III . Loading:- load refers to the quality of work. Loading is the process of allocating specific Quality of work job to man, machine or work Center involved in the manufacture of particular product. Loading aimed at machine the balance between the load allocated and the capacity available at various work center and these help in titanium utilization of resource of the organization.
IV. Dispatching:- it is concerned with the implementation of product as laid down in routing and scheduling. It involves spline material, tools and equipment and also order and instructions necessary to carry out production process in conformity with the Production plan.
Steps:-
(i) issue of material at actual production centers.
(ii) ensuring the timely available of tool and equipment at the production centers.
(iii) giving the necessary instruction and guideline to the personnel involved in carrying out the production operation.
(iv) when the work is completed the necessary chapter is applied to ensure the timely return of Toll and drawing to the the insurance department.
V. Follow up:- it involves regular evaluation of production activities I. Analyzing the progress of work at regular comparing the actual output with the target set finding the division and analyzing the resource for the same and taking timely corrective action.
VI. Inspection:- it is concerned with the quality of the product being manufactured during the production process for stop regular instruction is the undertaking at various stage of production so as to ensure that the finished product confirm to the specific quality standard Inception is carrot but the quality of raw material work in progress equipment machine used in a production process as well as the finishing process the.
SECTION-C
11. Discuss in detail various Productivity Techniques.
Answer:
Various productivity techniques
1. Demand forecasting:- it is an essential part of production management as production planning, implementation and control is dependent on it. An organization cannot manage to resources, man material machine and money without having an idea of future demand.
2. Linear programming:- it helps in determining production schedule. The object of the model is to plan production in such a manner that production schedule is carried out with minimum possible currentiry and setup cost.
3. PERT and CMP:- PERT and CMP are the techniques used for planning scheduling and controlling large and complex project. Many production activities are viewed and encrusted in the form of projects such as Dam construction, shipbuilding, missile program, satellite launching design and development and launching of product, repair, maintenance of Refineries and Research and Development.
4. Sequencing:- A sequence referred to the order of programming various task and jobs. Sequencing problem are generally faced by a manufacturing unit receiving number of different customer order which are to be proceed through different Machine repair and maintenance department with the factory dealing with the maintenance of large number of equipment and machinery.
5. Inventory management:- it is the most important consistent of a supply chain network of an organization. The production manager has to monitor the struck off material, work in progress and finished goods in order to ensure smooth functioning of production process.
The following tools under inventory management help the overall production process.
(a) economic order quantity:- in the number of units that organization should order each line and requesting for material is to be made to the supplier. Generally in an organization buying raw material was a routine decision.
(b) just in time inventory:- it is philosophy that concentrate on supplying product of best quality in extra quantity at right time and place.
(c) production Run model:- in the inventory is purchased immediately from outside and received in the store
(d) ABC classification:- there are many types of items available in the Inventory of any manufacturing organization. Some of of them are more costly than other.
6. Work study:- it is an important technique to achieve in increased productivity. It is a collection of method, tool and particular used to analyses what and how the work will be to ensure that all the factor of production are utilized in an organized manner. Work study can be divided into two parts
(a) method study
(b) work measurement:-
7. Gantt chart:- these charts are primarily used in scheduling and loading production processes. These are also very useful as production control tool. Does at any specific date, the actual performance status can be quickly analyses and delay in the particular activity can be reported.
12. Explain the Procedue of Purchasing.
Answer:
Produce of purchasing process of purchasing involve service of step starting with receipt of purchase free question by the purchase department and ending with recording the book in the store. Purchase products vary with the nature and availability of materials suppliers.
1. Purchase requisition:- the purchase department does not imitate any purchase activity e at its over. The organization main need different type of material, tool or equipment for its smooth functioning the items can be divided into two categories protein and special.
2. Selection of method of purchase:- number of purchase method are available in the purchase department can follow. Choice of method depend on many factors such as type of material urgency of needs nature of supplier and overall economic condition.
3. Receipt of quotation:- before receipt of quotation the list of suppliers is shortlisted from all sources. The information regarding suppliers is available form database of trades Association trade journalist newspaper and magazine offline database bi website like Just dial and yellow page, recommendation of the employees are associated.
4. Making comparative statement:- what's the bird are are received the pressures committee decide to open technical first in the order to evaluate the specification offered by supply full stop the suppliers that meet the specification and shortlisted and their financial Birds are opened. The supply that quotes the lowest bed is generally selected.
5. Negotiation:- in case of new supplier the Mega ration are done for favorable term and condition and price. It is an art which is conducted by enterprise knowledgeable and full time Purchase Manager. The purpose of whole purchase process is is defeated if an organization fail to ensure the contact on term that are favorable to it.
6. Issues of purchase order:- in the next step in purchase produce is issue of supply work or purchase order to the suppliers who have been has been selected to supply the material full stop in a purchase order is a work order given by the buyer the supplier to supply a specific quantity of good with specific dissolved at a price agreed price.
7. Monitoring the purchase order:- the duty of purchase department is not finished by placing A purchase order full stop it has to be in sure that the order is closely monitored and supplier is is pressure your to make timely delivery.
8. Receipt and Inception:- it is essential to receive good as per the purchasing order. Generally store keeper receive the goods and math it with quantity and specification of purchase order. Sometime as a separate section or unit is is with the duty of receiving the goods.
9. Maintenance of records:- the goods which are receive upper order and sent to store and entry of the source is made in stock register. All the detail of the goods are entered into the resistor. The person in charge generally the store keeper or caretaker, make a good receive vote and make frame copy of it.
10. Payment to supplier:- this is the last step in the whole purchase. The goods received are checked with the bill sent by the supplier for stop all the documents such as purchase order, delivery note and good receive on Note are compared with each other for mathematically accuracy.
13. Explain the various techniques of Statistical Quality Control.
Answer:
1.Probabilty Concept:- the probability concept is important for end elastic engineer as it forms the basis of statistical quality control. The understanding of the probability theory become in necessary in order to follow sampling Inception and quality of control chart.
2. The poisson Distribution:- it appears frequently in the literature of Management. And funds a large number of applications. it is used to describe a number of managerial situation including the arrivals of patient at health clinic, the distribution of telephone call going through a cultural Switching System coma the arriving of vehicle ad troll booth.
3. Normal Distribution:- an important continuous probability distribution is normal distribution stop this distribution has systematic shaped form and tends to infinity in both direction.
4. Confidence Limits:- the confidence or control limits are calculated with the help of statistical measure known as standard division.
5. Measures of central tendency:- most frequency distributions habit a a central tendency i, a shape such that the bulk of the observation peel up in the area between two entrance. the measure of this culture tendency is one of the two most fundamental measures in cost statistical analysis.
6. Estimation:- sentences cal quality control tells what should be sample size and how much reliable will be that sample. in other words, a criteria can be decided on the basis of which lot will be Accepted or rejected.
7. Significance Testing:- significance test are employed. to make decisions on the basis of small information available from the samples. With all Sachs decision and amount of risk is involved. Consider a lot or batch of Piston pins to be inspected for this diameters. Lastly the whole lot is intercepted as regards its diameter and means a lot diameter Is found out.
8. Analysis of variance:- it is a very powerful technique in the discipline of experimental statistics. it's also those problem where even test is unable to make clear which, of the many significant difference. More over, analysis of variance can be very much used for analyzing the result inquiry is conducted in the field of industrial engineering, agriculture etc.
9. Control Charts:- these are are based on statistical sampling theory, according to which an adequate sized sample drawn at random, form a lot represents the lot.
10. Life testing:- the life of a part in one of its quality criteria. The life of a Pound mint it may be defined as the time period during which the part remains it quality cried characteristics.
11. Reliability and Reliability production:- the study of reliability Is important because it is related to the quality of product. Generally impediment having low reliability and of poor quality but extra high quality does not always make a product of higher reliability.
14. What do you mean by maintenance management ? Explain its objectives and functions.
Answer:
Maintenance management is all about status maintaining the resource of the company so that production produce effectively and that no money is waste on inefficiency. These objectives are to control cost, to schedule work properly and expectantly and to ensure that the company E with all regulation.
Objectives Of Maintenance Management:-
1. Minimizing the loss of productive time because of equipment failure to maximize the availability of plant, equipment and machinery for productive utilization through planned maintenance.
2. To extend the useful life of the plant, machinery and other facilities by minimizing their wear and tear.
3. Minimizing the loose due to production stoppages.
4. To ensure operational readiness of all equipment in deed for emergency purpose at all time such as fire fighting equipment.
5. Efficient use of maintenance equipment and personal first ok
6. To ensure safety of personnel thought regular inceptions and maintenance of facilities such as blower compressor and material handling equipment etc.
7. To maximizing efficiency and economy in production through optimum utilization of available facilities.
8. To improve the quality of products and improve the productivity of the plant.
9. To minimize the total maintenance cost which may consist of cost of repairs, cost of prevent you are maintenance.
10. To improve reliability, availability and maintainability.
Functions Of Maintenance Management:-
1. To develop maintenance policies, products and standard for the plant maintenance system.
2. To schedule the maintenance work after due consultation with the concerned production departments.
3. To carry out Re repairs and rectify or over help planted equipment facilities for achieving the required labor of availability and id.mi.com operational efficiency
4. To ensure scheduled Inception liberation oil checking comma and adjustment of plant machinery and equipment.
5. To document and maintain record of each maintenance activity.
6. To maintain and carry out repairs of buildings, utilities, material handling equipment and other service facilities.
7. To prepare inventory list of spare part and material required for maintenance.
8. To ensure cost-effectively maintenance.
9. To forecast the maintenance and prepare a budget and to ensure that maintenance is as per planned budget.
10. To recruit and trained personnel to prepare the maintenance workforce for effective and effect and plant maintenance.