INDIAN INSTITUTE OF MANAGEMENT, LUCKNOW POST GRADUATE PROGRAMME COURSE OUTLINE COURSE: MANUFACTURING SYSTEMS DESIGN Term IV,

2012-2013 FACULTY: Prof. Rajiv K. Srivastava 2nd Year Elective 1.0 INTRODUCTION AND OBJECTIVES

In today's world of ever-increasing domestic and global competition, it has become apparent that for significantly improving productivity and quality, it is no longer sufficient to exercise greater control over existing manufacturing systems: the improvements must begin from system design. The success achieved by world class manufacturers, notably those in Germany and Japan, has shown that well conceived and executed manufacturing can be used as a strategic weapon for achieving corporate and national prosperity. The managers of tomorrow must be aware of the changes that are taking place in the nature of the manufacturing function worldwide. This course provides a focus on the design aspects of manufacturing systems as distinct from the planning and control issues normally addressed in most Operations Management courses. It seeks to present together the concepts, techniques and solutions relating to manufacturing systems design based on the choice of competitive priorities. The objectives of the course are: 1. 2. To introduce and familiarize students with contemporary manufacturing systems. To acquaint students with the tools and techniques used in the analysis, design and evaluation of different types of manufacturing systems. To provide an understanding of the issues involved in the integration of different aspects of manufacturing, with special reference to the changing competitive priorities.

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Literature and computer based assignments will be used from time to time to supplement and reinforce the concepts and techniques discussed in class.

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SOURCE BOOKS

2.1 Course Book 1. Hopp, W.J., & Spearman, M.L., "Factory Physics: Foundations of Manufacturing Management", 3rd Edition, McGraw Hill International Edition, 2008. Main Reference Books Askin, R.G., & Standridge, C., "Modeling and Analysis of Manufacturing Systems", John Wiley, 1993. Cohen, M.A., & Apte, U.M., "Manufacturing Automation", Irwin, 1997. Goldratt, E., and Cox, J., "The Goal: A Process of Ongoing Improvement", 3 rd Revised Edition, Productivity & Quality Press Pvt. Ltd. Madras, 2005. "The Toyota Production System: An Integrated Approach to Just- In- Time" (4th Edition), by Y. Monden, Productivity Press, 2010

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Supplementary Reference Books Blackburn, J.D. (Ed.), "Time-Based Competition: The Next Battle Ground in American Manufacturing", Irwin, 1991. Hall, R.W. & Nakane,J., "Flexibility: Manufacturing Battlefield of the 1990's", Association for Manufacturing Excellence, 1990. Harmon, R.L., & Peterson, L.D., "Reinventing the Factory", Free Press, 1990. Heragu, S., "Facilities Design", PWS Publishing, 1997. Hirano, H., "JIT Factory Revolution", Productivity Press, 1988. Hitomi, K., "Manufacturing Systems Engineering", 2nd Edition, Taylor & Francis, 1996. Miltenburg, J., "Manufacturing Strategy: How To Formulate and Implement a Winning Plan", Productivity Press, 1995. Moody, P.E., "Strategic Manufacturing: Dynamic New Directions for the 1990's", Irwin, 1990. Nyman, L.R. (Ed.), "Making Manufacturing Cells Work", Society of Manufacturing Engineers, 1992. Pine, B.J., "Mass Customization", Harvard Business School Press, 1993. Rembold, U., Nnaji, B., & Storr, A. "Computer Integrated Manufacturing and Engineering", Addison Wesley, 1993. Sekine, K., "One Piece Flow", Productivity Press, 1990. Suri, R., "Quick Response Manufacturing: A Companywide Approach to Reducing Lead Times", Productivity Press, 1998. Tompkins, J.A., & White, J.A., "Facilities Planning", 2nd Edition, John Wiley, 1996. Upton, D.M., "Designing, Managing, and Improving Operations", Prentice Hall, 1998.

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EVALUATION Assignments, Quizzes, Class Participation/ Viva Mid-Term Examination Term-End Examination 35% 30% 35%

4.0 SESSION DETAILS __________________________________________________________________________________ Session No. Topic __________________________________________________________________________________ 1 2 Course Overview and Contemporary Manufacturing Concepts Principles and Types of Manufacturing Systems: Relationship to Manufacturing Strategy; Taxonomies; Features and Applicability of Different Systems; Flow Line & Assembly Systems: Design Issues in Flow/Assembly Lines; Choice of Cycle Time; Mixed Model Line Balancing/Sequencing; Coping With Variability; Layout, Handling & Work In Process Management

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Group Technology and Cellular Manufacturing Systems: Grouping Methods; Cell Design; Cell Implementation and Operation __________________________________________________________________________________ MID-TERM EXAMINATION __________________________________________________________________________________ 11-12 13-14 Factory Physics Concepts in Manufacturing Systems Analysis Time Based Manufacturing: Lead Time Constituents & Reduction; Improving Speed & Dependability Flexibility & Customization in Manufacturing: Flexibility Concepts; Flexible Manufacturing Systems (FMS); Customization & Mass Customization Designing Material Flow & Information Systems One Piece Flow and Facilities Design; Material Handling; Information & Decision Technologies in Manufacturing, Computer Integrated Manufacturing (CIM);

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Evaluation, Selection & Implementation of Manufacturing Systems (with Manufacturing Systems "classic" cases) __________________________________________________________________________________ TERM-END EXAMINATION __________________________________________________________________________________ Session duration: 90 minutes

MSD Topic-Wise References/ Readings Mapping 2012-13 __________________________________________________________________________________ Topic References Readings __________________________________________________________________________________ Manufacturing Concepts Manufacturing Strategy Manufacturing Systems Overview Flow Line & Assembly Systems Group Technology and Cellular Manufacturing Systems C1; M2, 3 S7, 8, 15 M1, 2; S3, 6 C1; M1, 3, 4 M1, 2, 4; S3-5, 9, 13 1-2 3-4

--------------------------------------------------------------------------------------------------------------------------Factory Physics Concepts Time Based Manufacturing Flexible Manufacturing & Mass Customization Material Flow Systems Manufacturing & Support Technologies C1 M3; S1, 13 S2, 10 M1, 3, 4; S4, 12, 14 M2; S11, 14 5 6 7-8

Evaluation, Selection & Implementation of Manufacturing Systems S5, 15 9-10 __________________________________________________________________________________ Notes: The References column lists books with one or more chapters containing material related to the topic coverage. C in the column means titles listed as Course Books M in the column means titles listed as Main Reference Books in the Course Outline. S in the column means titles listed as Supplementary Reference Books. The number in the References column refers to the serial number of the book within the category (Main or Supplementary). The Readings column lists the supporting material included in the polycopy. The number in the Readings column refers to the serial number on the Contents page (the Course Outline is un-numbered)