ASSIGNMENTS

Subject code: MB0028

Set 1
SUBJECT NAME: PRODUCTION & OPERATIONS MANAGEMENT

Question: 1. Explain the various automated system for transform of

materials in the production plant? Illustrate your answer by
considering on example of an automobile showroom.

Answer: Basically, automation system comes to reduce labour power and time in
the production. Here we can see the evolution systems with some examples. The
goods requited by society were produces in small quantities by craftsman who
would know the need of the community and produced them by their own hands
with simple tools. The apprentices or by another craftsman, who would make
them to meet the requests made.

The parts and components used to make these machines had to be replaced when
they wore making parts so that interchangeability was achieved made setting up
standards and specifications important for meeting

The craftsmen gave way to engineers, workers, superiors and inspectors. Division
of labour became necessary to achieve efficiencies and the jabs that became
specialized. Competition has necessitated improved quality, reduced sates and
better services to the customer.

Automation systems cost huge sums of money and therefore a deep analysis of
the various factors has to be done. For services, automation usually means labour
saving devices in education, long distance learning technology helps in
supplementing class room instruction. The facilitating goods that are used are
web site and videos.

Automation in the banking sector has resulted in ATMs which same the banks a
huge amount customer satisfaction. Automation is ideas when the service
provided or the product manufactured is highly standardized.

Some extent of automation can be designed even with customization i. e. product

or service a meant to produce or deliver low volume specific to a requirement.
The advantages of automation is it has low variability and will be more consistent
on a repetitive basis

The machines have sensing and control devices that enable them to operate
automobile. The simplest of them called machine attachments replace human
effort. They guide, locate, move and achieve revise position by means of came,
optical sensing. Load sensing mechanisms and activate the controls to remove
human intention.

Robots are higher in the order of automation as they perform a variety of tasks.
They are designed to move movements according to programmers written into
the computer that inside them.

With the help of automation, inspection of component can be done 100% ensures
highest quality identification and movement of materials are helped by bar codes
which are read and fed into the system far monitoring quantity, location,
movement etc. They help the automated systems to start information and provide
information for effecting any changes necessary. To make effective use of
automated machines, we need to have the movement of materials from and to
different time as stores, automated, Automated storage and Retrieval systems-
ASRS- receive orders for materials from anywhere in the production area, collect
materials in the works times. Computers and information systems are used for
placing orders for matters, give commands adjust inventory records which show
the location and quantity of materials needed.

Automated guided vehicle systems- AGVS – are pallet trucks and unit load
carriers follow embedded guide wires or paint strips to destinations as
programmed.

In an automobile showroom we can see all the work automatically with latest
machine.

Question 2. Sate the important consideration for locating an

automobile plant? Collect information on layout planning of an
automobile plant from various services and furnish the same.

Answer: To locate an automobile company or plant many thing should be

consider. For an automobile plant automated flaw lines, automated assembly
lines, flexible manufacturing systems, global transition rapid prototyping.
Building manufacturing flexibility things are necessity.

About the automated flow lines we can say it is a machine which is linked by a
transfer system which moves the parts by using handling machines which are
also automated, we have an automated flow line.

Human intervention ma is needed to verify that the operations ate taking place
according to standards. When these cab be achieved with the help of automation
and the processes are conducted with self regulation, we will have automated
flow lines established.

In fixed automation or hard automation, where one component is manufactured

using services operations and machines it is possible to achieve this condition.
We assume that product life cycles are sufficiently stable to interest heavily on the
automate flow lines to achieve reduces cast per unit.

Product layouts ate designed so that the assembly tasks are performed in the
sequence they are designed at each station continuously. The finished item came
out at the end of the line.

In automated assembly lines the moving pallets move the materials from station
to station and moving arms pick up parts, place them at specified place and
system them by perusing, riveting, & crewing or even welding. Sensors will keep
track of there activities and move the assembles to the next stage.

The machines are arranged in a sequence to perform operations according to the

technical requirements.

The tools are loaded, movements are effected, speeds controlled automatically
without the need for worker’s involvement.

The flexibility leads to better utilization of the equipments. It reduces the

numbers of systems and rids in reduction of investment as well as a space needed
to install them. One of the major cancers of modern manufacturing systems is to
be able to respond to market
Demands which have uncertainties.

Prototyping is a process by which a new product is developed in small number so

as to determine the suitability of the materials, study the various methods of
manufactured, type of machinery required and develop techniques to over come
problems that my be encountered when full scale manufacture is undertaken.

Prototypes do meet the specification of the component that enters a product and
performance can be measured on these.

It helps in con be reforming the design and any shortcomings can be rectified at
low cost.

Flexibility has three dimensions in the manufacturing field. They are variety,
volume and time. There demands will have to be satisfied. In that sense they
become constraints which restrict the maximization of productivity. Every
business will have to meet the market demands of its various products in variety
volumes of different time.

Flexibility is also needed to be able to develop new products or make

improvements in the products fast enough to cater to shifting marker needs.

Manufacturing systems have flexibility built into them to enable organization

meet global demand. You have understood how the latest trends in
manufacturing when implemented help firms to stay a head in business.
Question 3. Who are the players in a project management? What are the
various roles and responsibilities of the players in a project management?

Answer. At first we will discuss about project management then we will discuss
about players in project management. Project management is the practice of
controlling the use of resources, such as cost, time manpower, hardware and
software involved in a project. That starts with a problem statement and end with
delivery of a complete product.

Here we will see the participants of project management:

In the project management players individual and organizations both are

involved-

That is actively involved in the project whose interests may be affected by the
outcome of the project.

Exert influence over the project and its results players or also called “stake
holders’’ of the project
Project manager- the individual responsible for managing the project.

Customer- the individual or organization that will use the product- the end result
of the project.

Performing organization- the enterprise whose employees are mast directly

involved in doing the work of the project.

Sponsors- the individual or group within or external to the performing

organization that funds the project.

Now, we will define the role and responsibilities of project management. Here are
some roles and responsibilities:

There are number of projects which an organization works on. It is not possible
for one individual to manage all the projects.

There is a team of mangers who manage the projects.

There may be different teams working an different projects.

An experienced project manager and this team may manage more than one
project at a time.

The project team is responsible for ensuring that the project upon completion
shall deliver the gain in the business for which it is intended for.
-the project team has to properly co-ordinate with each other working on
different aspects of the project.

-the team members are responsible for the completion of the project as per the
plans of the project.

Characteristics of project mindset: - some of the characteristics of project

mindset are the following –

Time - it is possible to improve the pace of the project by reducing the time frame
of the process. The mindset is normally to work in a comfort made by stretching
the time limits.

Responsiveness – it refers to quickness of response of an individual. The vibrancy

and livens of an individual or an organization are proportional to its capability of
evolving process and structure for superior responsiveness time constant.

Information sharing – information is owner information is the matter key to

today’s business. Information sharing is the characteristic of the project mindset
today.

Process – project mindset lays emphasis on flexible process. The major difference
in a process and a system is in its capabilities of providing flexibility to different
situational encounters. Flexible process possesses greater capabilities of
adaptability.

Structured planning – structure planning based a project management life cycle

enables one to easily and conveniently work according to the plan.

Question 4. What are the various steps in project monitoring and controlling a
project?

Answer: Here we elaborate the project monitoring and control.

Any project aimed at delivering a product or a service has to go through phases in

a planned manner in order to meet the requirements. It only by careful
monitoring of the project progress. It required establishing control factors to
keep the project on the track of progress. The results of any stage in a project,
depends on the inputs to that stage. It is therefore necessary to control all the
inputs and the corresponding outputs from a stage. A project management may
use certain standard trolls to keep the project on track. The project manager and
the team members should be fully aware of the techniques and methods to rectify
the factors influencing delay of the project and its product. The methodology of
PERT (programmer Evolution Review Technique) and CPM (critical path
method) may be used to analyze the project. In the PERT method one car find out
the variance and use the variance to analyze the various probabilistic estimates
pertaining to the project. Using the CPM one can estimate the start time and the
finish time for every event of the project in its WBS (work Breakdown Structure).

The analysis charts can be used to monitor, control, track and execute a project.
Typical PERT/ CPM exercise of a project are worked out at the end of this sub
unit- 9.2. The various steps involved in monitoring and controlling a project from
start to end are as follows-

1. Perlirninary work- the team members understand the project plans, project
stage schedule, progress controls, tracking the dules. Summary of the members
have to understand the tolerances in any change and maintain a change control
log. They must realize the need and importance of quality for which they have to
follow strictly quality agendas. They must understand the stage status reposes,
stage and reports, stage end approval reports.

2. Project progress- The members must keep a track of the project progress and
communication the same to other related members of the project. They must
monitor and control project progress, through the use of regular check points,
quality charts. Statistical tables, control the quality factors which are likely to
deviate from expected values as any deviation may result in change to the stage
she duel

3. Stage control- The manager must establish a project check paint cycle. For this
suitable stage version control procedure may be followed.

4. Resources- Plan the resources required for various stage of the project. Brief
both the project team and the key resources about the objectives of every stage,
planned activities, products, organization. Metrics and project controls.
5. Quality control- This is very important in any project: Quality control is
possible if the project member’s follow-

Schedule quality review, Agenda for quality review, conduct quality review and
follow up.

6. Progress control- It is the main part at assessment-

Progress control assesses- monitor performance, update schedule, update casts,

Re-plan stage schedule, conduct team status review etc.

Along with we create status report, create flash reports, project status reports etc.

7. Approvals - lastly, project sage reviews and the decisions taken and actions
planned need to be approved by the top management. The goals of such review
are to improve quality by finding defects and to improve productivity by finding
defects in a cost effective manner. The group review progress includes several
stage like planning, preparation and overview, a group review meeting and
rework recommendation and follow-up.
Question 5. Explain the necessity and objectives a SCM?

Answer. SCM is the abbreviation of supply chain Management. It is considered by

many express worldwide as the ultimate solution towards efficient enterprise
management.

Now, we explain the necessity and objectives of SCM-

SCM is required by and enterprise as a tow to enhance management effectiveness

with a following organizational objective:

Reduction of inventory

Enactment in functional effectiveness of existing systems like ERP, Accounting.

Software and Documentation like financial reports statements ISO 9000
Documents etc.

Enhancement of participation level and empowerment level

Effective integration of multiple systems like ERP, communication systems,

documentation system and secure, Design R&D systems etc.

Better utilization of resources- men, material, equipment and money.

Optimization of money flow cycle within the organization as well as to and from
external agencies.

Enhancement of value of products, operations and services and consequently,

enhancements of profitability.

Enhancement of satisfaction level of customer and clients, supporting

institutions, statutory control agencies, supporting institutions, statutory control
agencies, suppliers and vendors, employees and executives.

Enhancement of flexibility in the organization to help in easy implementation of

schemes involving modernization, expansion and divestment, merges and
acquisitions.

Enhancement of coverage and accuracy of management information systems.

With the objectives of SCM its implementation are required. Implementation is
in the form of various functional blocks of an organization interpenetrated
through which a smooth flow of the product development is possible.

A relatively new SCM option involves web based software with a browser
interface. Several electronic marketplaces for buying and selling goods and
materials.
Question.6 - What are the steps involves in SCM implementation?

Answer- There is many steps which involved in SCM implementation are-

Business Process, sales and marketing. Logistics, costing, demand planning,
trade- off analysis, environmental requirement, process stability, integrated
supply, supplier management, product design, suppiers, customers, material
specifications, etc.

Some important aspect of SCM-

The level of competition existing in the market and the impact of competitive
forces on the product development.

Designing and working on a strategic logic for better growth through value
invention.
Working out new value curve in the product development along with necessary
break point.

Using it to analyses markets and the economies in product design. Tine,

customer, quality of product and the concept of survival of fittest.

Steps of SCM principals:

Group customer by need: Effective SCM groups, customer by tietinct service
meeds those particular segment.

Customize the logistics networks: In designing their logistics network, companies

need to focus on the service requirement and profit potential of the customer
segments identified.

Listen to signals of market demand and plan accordingly- sales and operations
planners must monitor the entire supply chain to detect early warning signals of
changing customer demand and needs.

Differentiate the product closer to the customer-companies today no longer can

afford to stock pile inventory to compensate for possible forecasting errors,
instead, they need to postpone product differentiation in the manufacturing.
Process closer to actual customer demand.

Strategically manage the source of supply-by working closely with their key
suppliers to reduce the overall casts of owning materials and services; SCM
maximizes profit margins both for themselves, and their supplies.

Develop a supply chain wide technology strategy- as one of the cornerstones of

successful SCM information technology must be able to support multiple levels of
decision making.Adopt channel spanning performance measures- Excellent
supply performance measurement systems do more than just monitor internal
functions. They apply performance criteria that embrace bathe service and
financial metrics, including as such as each accounts true profitability.
 ASSIGNMENTS
Subject code: MB0028
Set 2
SUBJECT NAME: PRODUCTION & OPERATIONS MANAGEMENT

Question.1. Explain how material flow information helps in work center

decision. Consider the example of a shopping center to illustrate your answer.

Answer: The decision which involves during uses of material flow information
has below-

A work center is a production facility comprising of one or more machines and

one or more workmen considered as a single unit for purposes of estimation of
capacity. This unit may have a single operation or a number of them conducted
on the input items. In the pipeline of production, each work center’s contribution
is vital as materials are scheduled, routed and loads to be sent to it.

In most organization, they are even considered as cash centers. Location trust
means relative position of different centers so as to minimize the movement of
materials, meet technological sequences, to reduce congestion, maximize
throughput, improve part tracking ability and avoid repetitive movements. In
addition another consideration is to provide for expansion of production.

Each work center receives information along with material that enter it the
material also leaves the word center with information. The route sheet contains
information about the material, process, quantities, and inspection procedures.
Etc. the drawings or instructions tell the condition of the malarial of entry and
the required condition at exit.

In this sense every operation consists of material transformation occurring on the

basis of information. Activities conducted are on the basis of information that
flows with material. Different locations have to accommodate the constraints of
the basis of darning maximums benefit of the information that is available.
Basically, each location is determined on the basis of from and to: where does it
receive material goes. Some centers have to close as a matter of necessity, some
need not to be and some need to be as for away as possible.

This aspect has been given a rating scale in terms of alphabets as under:

Absolutely necessary to be close

Essential to be close
Ordinary closeness
Ordinary closeness
Unimportant that they are close or not
Not desirable that the centers are close

It can be seen that this is only a guide for Indian location as the work centers as
there will many competing factors that have to be accommodated.

Question.2. what are the reasons for failure of a project? Give suitable
examples.

Answer: Before knowing the reasons of failure we have to know about project.
Project is a set of activities which are networked in order and aimed towards
achieving goal of a project.

Now, the reasons are project failure:

Incidence of Project failure

Projects being initiated of random at all levels
Project objective not in line with business objective
Project management not observed
Project manager with no prior experience in the related project
Non- dedicated team
Lack of complete support from clients

Factors contributing to project success not emphasized:

Project objective in alignment with business objective

Working within the framework of project management methodology
Effective scoping planning, estimation, execution, controls and reviews, project
bottlenecks
Communication and managing expectations effectively with clients, team merits
and stake holders
Prior expectance of PM in a similar project

Overview of information and communication Technologies (ICT)

project:

Involve information and communication technologies such as the word wide web,
e-mail, fiber-optics satellites
Enable societies to produce, access, adapt and apply information in greater
amount, more rapidly and at reduce casts
Offer enormous opportunities for enhancing business and economic viability
Common problems encountered during projects
No prioritization of project activity from an organizational position
One or more of the stages in the project mishandled
Less qualified non-dedicated manpower
Absence of smooth flow of communication between the involved parties

These basic reasons lead a project to failures. In the project failures business
management and project management is directly involved. From the
management point of view it is basic things to care above topics to success of a
project. Project is the core business of a company.

Question-3. Explain the various phases in project management life cycle?

Answer: This is the initial phase of any project. In this phase information is
collected from the customer pertaining to the project and the requirements are
analyzed. The entire project has to be planned and it should be done in a strategic
manner. The project manager conducts the analysis of the problem and submits a
detailed report to the top project justification, details on what the problem is a
method of solving the problem, list of the objectives to be achieved, project
budget and the success rate of completing the project. The report must also
contain information and the project feasibility, and the risks involved in the
project.

Project management life cycle is the integrated part of management. It is attach

with project responsibility. It is the most valuable chapter in production
management.

The important tasks of this phase are as follows:

Specification Requirements Analysis (SRA): It has to be conducted to determine

the essential requirements of a project in order to achieve the target.

Feasibility study: To analyze whether the project is technically, economically and

practically feasible to be undertaken.

Trade off analysis: To understand and examine the various alternatives which
could be considered.

Estimation: To estimate the project cost, effort requires for the project and
functionality of various process in the project.

System design: Choose a general design that can fusil the requirements.

Project evolution: Evaluate the project in terms of expected profit, cost and risks
involved marketing phase.

A project proposal is prepared by a group of people including the project

manager. This proposal has to contain the strategies adopted to market the
product to the customers.

Design phase: This phase involves the study of inputs and outputs of the various
project stages.

Execution phase: In this phase the project manager and the teams members work
on the project objectives as per the plan. At every stage during the execution
reports are prepared.

Control – Inspecting, Testing and Delivery phase during this phase. The project
team works under the guidance of the project manager. The project manager has
to ensure that the team working under his, implements the project designs
accurately, the project manager has to ensure ways of managing the customer,
perform quality control work.

Closure and post completion analysis phase upon satisfactory completion and
delivery of the intended product or service the staff performance has to be
evaluated. Document the lessons from the project. Prepare the reports on project
feedback analysis followed by the project execution report.

The phase which involve in the above are:

The preparation stage involves the preparation and approval of project outline,
project plan and project budget.

The next stage involves selecting and briefing the project team about the
proposals followed by discussions on the roles and responsibility of the project
member and the organization.

The project management life cycle:

A Life cycle of a project consists of the following:

Understanding the scope of the project

Establishing objectives of the project

Formulating and planning various activities

Project execution and

Monitor and control the project resources

Question.4. What are the seven principles of SCM?

Answer: Seven principles of SCM are:

Group customer by needs- Effective SCM groups, customer by distinct service

needs, regardless of industry and then tailors services to this particular segment.

Customize the logistic network- In designing their logistics network; companies

need to focus on the service requirement and profit of the customer segments
identified.
Listen to signals of market demand and plan accordingly- Sales and operations
planners must monitor the entire supply chain to detect early warning signals of
changing customer demand and needs. This demand driven approach leads to
more consistent forecast and optimal resource allocation.

Differentiate the product closer to the customer- companies today no longer can
afford to stock pile inventory to compensate for possible forecasting errors.
Instead, they need to postpone product differentiation in the manufacturing
process closer to actual consumer demand. This strategy allows the supply chain
to respond quickly and cost effectively to change in customer needs.

Strategically manage the sources of supply- by working closely with their key
suppliers to reduce the overall costs of owning materials and services; SCM
maximizes profit margins both for themselves and their suppliers.

Develop a supply chain wide technology strategy- as one of the cornerstones of

successful SCM information technology must be able to support multiple levels of
decision making. It also should afford a clear view and ability to measure the flow
of products, services and information.

Adopt channel spanning chain performance measures- Excellent supply chain

performance measurement system do more than just monitor internal functions.
They apply performance criteria to every link in the supply chain-criteria that
embrace both service and financial metrics.

Question.5 .Explain what is meant by bullwhip effect and how it could be

prevented?

Answer: An organization will always have ups and downs. It is necessary that
the managers of the organization keep track of the market conditions and analyze
the changes. They must take decisions on the organization to meet the market
demands. Failing to do so may adversely affect the functioning of the
organization resulting in lack of coordination and trust among supply chain
members. The changes may effect the information and may lead to demand
amplification in the supply chain. The bullwhip effect is the uncertainty caused
from distorted information flowing up and down the supply chain. This has its
affect on almost all the industries, poses a risk to firms that experience large
variations in demand. And also these firms which are dependent on suppliers,
distributors and retailers.

A bullwhip effect may arises because of-

Increase in the lead time of the project due to increase in variability of demand.

Increase in the stock to stock to accommodate the increasing demand arising out
of complicated demands models and forecasting techniques .
Reduced service levels in the organization .

Inefficient allocation of resources .

Increased transportation cast .

How to prevent it?

Bullwhip effect may be avoided by one or more of the following measures- Avoid
multiple demand forecasting.

Breading the single orders into number of batches of orders

Stabilize the prices avoid the risk involved in overstocking by maintaining a

proper stock.

Reduce the variability and uncertainty in paint of sale (POS) and shaving
information.

Reduce the lead time in the stages of the project.

Always keep analyzing the past figures and track current and future levels of
requirements.

Enhance the operational efficient and outsourcing logistics to capable and

efficient agency.

Question.6. What do you understand by Line Balancing? What is the

importance of order picking in material handling? Give suitable examples.

Answer: Production lines have a number of work centers in a particular

sequence so that the material that gets proceed has to move further without
encountering any bottlenecks. The quantities produced the rate of production at
each center, the number of operations and the total production required are
factors taken into account.

The purpose of taking place between work centers and minimum inventory gets
created. We use the principles of JIT and lean Manufacturing to achieve these.
Linear programming, Dynamic programming and other mathematical models are
used to study these problems.

In order picking important pants are:

Order picking is a process by which items of products for supply is to be made

haves to be retrieved from specific storage location. It is found to take 60% of
labour activities in the warehouse. Since it is critical to the business to meet
customer’s demand expeditiously and accurately, lot of attention is being given to
this aspect of operations. In the manufacturing arena, we desire to move towards
small lot sizes and cycle time reductions.

Efficient order picking is necessary for being competitive. In the supply chain
Storage, retrieval and delivery do not add value to the product, but are necessary.

Material Handling:

The purpose is to take the job through the technological steps in which the
processing needs to be done for the transformation that is to be effected on the
material that is getting processed. The major concerns are about the quantities
that need to be processed and the time that the different operations required. In
case the product has to enter assembly, along with other parts that are being
manufactured parallel, will all the required parts arrive at that point at the same
time. Some components may be outsourced. To handle different parts, we have
material handling equipments such as cranes lifting forks, trucks etc.

The problem for the manager is the limited supply of these equipments and the
need to optimize utilization of the equipment and see that the manufacturing line
has smooth flow. Our concern is to reduced inventory, minimums movement and
timely availability.