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Solved, MB0044 – Production Operations Management

Solved, MB0044 – Production Operations Management

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Published by Arvind K
Solved, MB0044 – Production Operations Management
Solved, MB0044 – Production Operations Management

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Published by: Arvind K on Nov 25, 2011
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Master of Business Administration - MBA Semester IIMB0044
Production & Operations Management - 4 Credits(Book ID: B1133) Assignment Set- 1 (60 Marks)Note: Each Question carries 10 marks. Answer all the questions.Q1. Explain in brief the origins of Just In Time. Explain how JIT is implemented.
Time (JIT) manufacturing is a process by which companies don’t keep lots of excess
inventory; instead, they manufacture a product as an order comes in. It is a management philosophy of continuous and forced problem solving.The objective of JIT manufacturing system is to:
· Eliminate waste that is, minimise the amount of equipment, materials, parts, space, and worker’s
time, which adds a great value to the product 
· Increase productivity
JIT means making what the market demands when it is in need. It is the most popular systems that incorporate the generic elements of lean systems. Lean production supplies customers with exactlywhat the customer wants, when the customer wants, without waste, through continuousimprovement.Deploying JIT results in decrease of inventories and increases the overall efficiencies. Decreasinginventory allows reducing wastes which in turn results in saving lots of money. There are manyadvantages of JIT. JIT:· Increases the work productivity· Reduces operating costs· Improves performance and throughput · Improves quality· Improves deliveries· Increases flexibility and innovativenessFor industrial organisations to remain competitive, cost efficiencies have become compulsory. JIThelps in this process. It is extended to the shop floor and also the inventory systems of the vendors.JIT has been extended to mean continuous improvement. These principles are being applied to thefields of Engineering, Purchasing, Accounting, and Data processing.However, for organisations to completely implement JIT manufacturing system, they need to have aproper commitment along with the following basic facilities - proper material, quality, equipment,and people involvement.
Characteristics of JIT
In this section, we will study different methods by which inefficiency is reduced and unproductivetime is minimised. The consequent savings are to be utilised for reducing cost and rendering betterservice to the customer. Shigeo Shingo an authority on JIT at Toyota classifies the wastes to beeliminated as follows. The seven wastes to be eliminated according to JIT are:1. Over production2. Inventory3. Waiting time4. Movement 5. Effort 6. Defective products7. Over processing
Seven wastes
ForCompleteSolvedSMU Assignment @1000 Rs  Email:mba8182@gmail.comPh:09873669404 
Over production
Over production is to manufacture products before it is actually needed. If thedemand for that product decreases, the extra parts or products produced may not be useful orneeded. Also over production results in high storage costs and is also difficult to detect defects. So,over production is considered a waste.2.
Excess procurement or production builds up stock of materials which are not immediately used, thus locking space and funds carrying heavy costs. The figure 13.2, illustrates theinventories at different levels of an organisation
Supplier distribution, Production, and Customerdistribution.
Inventories in an organisation
Waiting time:
Waste of time happen when goods are not moving or being processed. Theoperator, the machine or the part will either be not working or be worked upon. The duration of waiting is can be said to be unproductive and may create more serious consequences.4.
Any unnecessary movement is a waste of energy; it causes blockages, disruptingmovements and delaying the flow of other items creating delays.5.
The people, who work, do not make a study as to how the products on which they aremaking are utilised and do not realise the purpose for which they are made. This lack of educationwill lead to waste of resources. Finally, they end up in shortage of resources when needed.6.
Defective products:
The defective products lead to a tremendous loss to the company. This isbecause they use up the same equipments, workmen and the time that would be used to make goodproducts. Thus defective products use up resources and result in losses.
ForCompleteSolvedSMU Assignment @1000 Rs  Email:mba8182@gmail.comPh:09873669404 
Over Processing:
Some steps like unnecessary processing or production do not add value to thefinal output. As a result, it is waste of all the inputs that go into the process.Since these wastes have to be eliminated, a thorough study of how they occur and what steps wouldresult in their elimination is of paramount importance. The next section focuses on some of them.
13.3 Key Processes to Eliminate Waste
 The key processes to eliminate the wastes are listed below:

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