https://www.yourarticlelibrary.

com/production-management/production-
management-its-meaning-definition-function-and-scope/27925

Production Management refers to the application of management principles to the

production function in a factory. In other words, production management involves
application of planning, organizing, directing and controlling the production process.

https://www.managementstudyhq.com/production-and-operations-management-functions-
importance.html

The role of Production Management is quite elaborate. But the sole aim is to ensure the
business produces quality products that can satisfy the needs of customers on a regular
basis. Below are the functions of production management.

 Production Control – Here the manager supervises and directs the production

process. He or she also must find out and ensure the right production plan is
followed during the production process. If there are deviations, the
production manager has to take the right steps to correct them.
 Scheduling – This function is critical in every organization. It has to do with
planning when the actual production would begin and ends.
 Cost and Quality Control – Every company knows how essential quality control
and price are. Customers are not just looking for the best products. But they also
want to have them at the lowest possible price. Quality control is an essential
duty the production manager has to perform. It entails multiple checks
performed on the product to ensure quality is intact.
 Maintenance of Machines – Production management also entails making sure
that instruments used are in good working condition. And that means replacing
the ones that are underper forming or changing damaged parts to enable the
machine to function optimally.
https://www.roarwap.com/pom/difference-between-production-and-operations-management/

The main purpose of production and operations management

is to effectively manage and utilize the resources of the
company which is essential for the production of goods and
services. Production management refers to managing the
activities related to the production of goods.

The main difference between production and operational

management is that production management focuses on the
production of goods and services. Operational management,
on the other hand, involves activities such as supervision,
planning, and designing business activities. Production
management is also part of operational management.
Conclusion
Both are relevant to an establishment. They both help
the firm to accomplish its objectives. In the past, the
mindset people had was that operation management
isn’t pertinent. But if you read this post carefully, you will
discover how important the role of the operations
manager is. It is best for companies to implement both
management concepts and ensure they are run
efficiently to achieve business growth and customer
satisfaction.
 Answer 2 ka a wala

https://www.textilesphere.com/2020/06/factory-building-construction-textiles.html

advantages and disadvantages of both single storage and multi-storage

buildings. 

Advantages of Single storage building:

 Requires lighter foundations with less variation.
 Maintenance and the changes in equipments can be carried out easily.
 Heavy machines can be installed easily with quickness in construction.
 As there is no requirement of lifts or stairs it saves the floor spacing and cost of life
operation.
 Construction cost per square foot is lower.
 Shows good efficiency in routine and material handling.
Disadvantages of single storage building:
 Require more land compared to that of multi- storage building.
 The plant layout is not compact
 The production space is generally occupied by offices and stores.
 Gravity can not be employed in material handling and more roof spaces are required.
Advantages of Multi-storage building:
 More compact layout.
 Less roof repairs.
 Less cost of land in rural areas and gravity can be employed.
 Material handling distance I reduced considerably.
Disadvantages of multi-storage building:
 Requires high cost for foundation
 Floor expansion is not possible and natural illumination in center is poor.
 Space is wasted in construction of staircase or lifts.
 Handling of bulky materials is expensive.
Answer no 2 ka b wala

https://www.businessmanagementideas.com/project-management/plant-location/plant-
location-importance-techniques-and-procedure/6658

Introduction:
Location of an industry is an important management decision. It is a two-step decision:
first, choice of general area or region and second, the choice of site within the area
selected. Location decision is based on the organisations long-term strategies such as
technological, marketing, resource availability and financial strategies.

The objective of plant location decision-making is to minimise the sum of all costs
affected by location.

Plant location is important because of the following:

(i) Location influences plant layout facilities needed.

(ii) Location influences capital investment and operating costs.

Location decisions are strategic, long-term and non-repetitive in nature. Without sound
and careful location planning in the beginning itself, the new facilities may create
continuous operating problems in future. Location decision also affects the efficiency,
effectiveness, productivity and profitability.

The location decision should be taken very carefully, as any mistake may cause poor
location, which could be a constant source of higher cost, higher investment, difficult
marketing and transportation, dissatisfied and frustrated employees and consumers,
frequent interruptions of production, abnormal wastages, delays and substandard
quality etc.

https://myventurepad.com/plant-location-decisions-factors-affecting-plant-location/
the steps for plant location decision are

Decisions regarding selecting a location need a balance of several factors. These are divided into primary
factors and secondary factors; here both the factors can influence the business in the long run.

Primary factors:

Availability of raw materials---

Availability of raw materials is the most important factor in plant location decisions. Usually,
manufacturing units where there is the conversion of raw materials into finished goods is the main task
then such organizations should be located in a place where the raw materials availability is maximum
and cheap.

Nearness to the market---

Nearness of market for the finished goods not only reduces the transportation costs, but it can render
quick services to the customers. If the plant is located far away from the markets then the chances of
spoiling and breakage become high during transport. If the industry is nearer to the market then it can
grasp the market share by offering quick services.

Availability of labor ---

Another most important factor which influences the plant location decisions is the availability of labor.
The combination of the adequate number of labor with suitable skills and reasonable labor wages can
highly benefit the firm. However, labor-intensive firms should select the plant location which is nearer to
the source of manpower.

Transport facilities---

In order to bring the raw materials to the firm or to carrying the finished goods to the market, transport
facilities are very important. Depending on the size of the finished goods or raw materials a suitable
transportation is necessary such as roads, water, rail, and air. Here the transportation costs highly
increase the cost of production, such organizations can not complete with the rival firms. Here the point
considered is transportation costs must be kept low.
Availability of fuel and power--

Unavailability of fuel and power is the major drawback in selecting a location for firms. Fuel and power
are necessary for all most all the manufacturing units, so locating firms nearer to the coal beds and
power industries can highly reduce the wastage of efforts, money and time due to the unavailability of
fuel and power.

Availability of water--

Depending on the nature of the plant firms should give importance to the locations where water is
available.

For example, power plants where use water to produce power should be located near the water bodies.

Secondary factors:

Suitability of climate-

Climate is really an influencing factor for industries such as agriculture, leather, and textile, etc. For such
industries extreme humid or dry conditions are not suitable for plant location. Climate can affect the
labor efficiency and productivity.

Government policies-

While selecting a location for the plant, it is very important to know the local existed Government
policies such as licensing policies, institutional finance, Government subsidies, Government benefits
associated with establishing a unit in the urban areas or rural areas, etc.

Availability of finance-

Finance is the most important factor for the smooth running of any business; it should not be far away
from the plant location. However, in the case of decisions regarding plant location, it is the secondary
important factor because financial needs can be fulfilled easily if the firm is running smoothly. But it
should be located nearer to the areas to get the working capital and other financial needs easily.
Competition between states-

In order to attract the investment and large scale industries various states offer subsidies, benefits, and
sales tax exemptions to the new units. However, the incentives may not be big but it can help the firms
during its startup stages.

Availability of facilities-

Availability of basic facilities such as schools, hospitals, housing and recreation clubs, etc can motivate
the workers to stick to the jobs. On the other hand, these facilities must be provided by the
organization, but here most of the employees give preference to work in the locations where all these
benefits/facilities are available outside also. So while selecting plant location, organizations must give
preference to the location where it is suitable for providing other facilities also.

Disposal of waste-

Disposal of waste is a major problem particularly for industries such as chemical, sugar, and leather, etc.
So that the selected plant location should have provision for the disposal of waste.

Answer no 3 ka a wala

https://asq.org/quality-resources/total-quality-management

TQM can be summarized as a management system for a customer-focused

organization that involves all employees in continual improvement. It uses
strategy, data, and effective communications to integrate the quality discipline
into the culture and activities of the organization. Many of these concepts are
present in modern quality management systems, the successor to TQM. Here
are the 8 approaches of total quality management:
1. Customer-focused: The customer ultimately determines the level of quality.
No matter what an organization does to foster quality improvement—
training employees, integrating quality into the design process, or upgrading
computers or software—the customer determines whether the efforts were
worthwhile.
2. Total employee involvement: All employees participate in working toward
common goals. Total employee commitment can only be obtained after fear
has been driven from the workplace, when empowerment has occurred, and
when management has provided the proper environment. High-performance
work systems integrate continuous improvement efforts with normal business
operations. Self-managed work teams are one form of empowerment.
3. Process-centered: A fundamental part of TQM is a focus on process thinking.
A process is a series of steps that take inputs from suppliers (internal or
external) and transforms them into outputs that are delivered to customers
(internal or external). The steps required to carry out the process are defined,
and performance measures are continuously monitored in order to detect
unexpected variation.
4. Integrated system: Although an organization may consist of many different
functional specialties often organized into vertically structured departments, it
is the horizontal processes interconnecting these functions that are the focus
of TQM.
 Micro-processes add up to larger processes, and all processes aggregate into
the business processes required for defining and implementing strategy.
Everyone must understand the vision, mission, and guiding principles as well
as the quality policies, objectives, and critical processes of the organization.
Business performance must be monitored and communicated continuously.
 An integrated business system may be modeled after the Baldrige
Award criteria and/or incorporate the ISO 9000 standards. Every organization
has a unique work culture, and it is virtually impossible to achieve excellence
in its products and services unless a good quality culture has been fostered.
Thus, an integrated system connects business improvement elements in an
attempt to continually improve and exceed the expectations of customers,
employees, and other stakeholders.
5. Strategic and systematic approach: A critical part of the management of
quality is the strategic and systematic approach to achieving an organization’s
vision, mission, and goals. This process, called strategic planning or strategic
management, includes the formulation of a strategic plan that integrates quality
as a core component.
6. Continual improvement: A large aspect of TQM is continual process
improvement. Continual improvement drives an organization to be both
analytical and creative in finding ways to become more competitive and more
effective at meeting stakeholder expectations.
7. Fact-based decision making: In order to know how well an organization is
performing, data on performance measures are necessary. TQM requires that
an organization continually collect and analyze data in order to improve
decision making accuracy, achieve consensus, and allow prediction based on
past history.
8. Communications: During times of organizational change, as well as part of
day-to-day operation, effective communications plays a large part in
maintaining morale and in motivating employees at all levels. Communications
involve strategies, method, and timeliness.

Answer no 3 ka b wala

https://www.managementstudyguide.com/capacity-planning.htm

Capacity is defined as the ability to achieve, store or produce. For an organization, capacity

would be the ability of a given system to produce output within the specific time period.
In operations, management capacity is referred as an amount of the input resources available to
produce relative output over period of time.

Capacity planning is essential to be determining optimum utilization of resource and

plays an important role decision-making process, for example, extension of existing
operations, modification to product lines, starting new products, etc.

Strategic Capacity Planning

A technique used to identify and measure overall capacity of production is referred to as
strategic capacity planning. Strategic capacity planning is utilized for capital intensive
resource like plant, machinery, labor, etc.

Strategic capacity planning is essential as it helps the organization in meeting the future
requirements of the organization. Planning ensures that operating cost are maintained
at a minimum possible level without affecting the quality. It ensures the organization
remain competitive and can achieve the long-term growth plan.

Capacity Planning Classification

Capacity planning based on the timeline is classified into three main categories long
range, medium range and short range.

Long Term Capacity: Long range capacity of an organization is dependent on various

other capacities like design capacity, production capacity, sustainable capacity and
effective capacity. Design capacity is the maximum output possible as indicated by
equipment manufacturer under ideal working condition.

Production capacity is the maximum output possible from equipment under normal
working condition or day.

Sustainable capacity is the maximum production level achievable in realistic work

condition and considering normal machine breakdown, maintenance, etc.

Effective capacity is the optimum production level under pre-defined job and work-
schedules, normal machine breakdown, maintenance, etc.

Medium Term Capacity: The strategic capacity planning undertaken by organization

for 2 to 3 years of a time frame is referred to as medium term capacity planning.

Short Term Capacity: The strategic planning undertaken by organization for a daily

weekly or quarterly time frame is referred to as short term capacity planning.

Goal of Capacity Planning

The ultimate goal of capacity planning is to meet the current and future level of the
requirement at a minimal wastage. The three types of capacity planning based on goal
are lead capacity planning, lag strategy planning and match strategy planning.

Factors Affecting Capacity Planning

Effective capacity planning is dependent upon factors like production facility (layout,
design, and location), product line or matrix, production technology, human capital (job
design, compensation), operational structure (scheduling, quality assurance) and
external structure ( policy, safety regulations)

Forecasting v/s Capacity Planning

There would be a scenario where capacity planning done on a basis of forecasting may
not exactly match. For example, there could be a scenario where demand is more than
production capacity; in this situation, a company needs to fulfill its requirement by
buying from outside. If demand is equal to production capacity; company is in a position
to use its production capacity to the fullest. If the demand is less than the production
capacity, company can choose to reduce the production or share it output with other
manufacturers.

Answer no 4 ka a wala

http://www.simplynotes.in/e-notes/mbabba/productivity-management/work-study-meaning-
and-its-components/
 Answer no 4 ka b wala

What is Method Study?

Method study deals with analysing every topic/chapter and identifying
the strong and weak points in that. Then studying in a pattern in which
maximum topics are covered in a minimum time span. Simply put,
method study is when each and every piece of study material or work
is put through thorough scrutiny in order to ensure that every word is
understood and retained by you. This is also advantageous as it
prevents any kind of error or misleading information from getting
through as it detected and conveniently omitted in the learning
process. Method study is the best way to go about your studying to
achieve better results and productivity. Being meticulous with your
study materials or work is beneficial because you can make less errors
and improve stronger retention abilities.

Method study is the systematic recording and critical examination of

existing and proposed ways of doing work, as a means of developing
and applying easier and more effective methods and reducing costs.
So it is the process of analyzing the methods involved in work flow to
increase productivity. It deals with doing the work in a better way, with
less time and effort. That is why it is also termed as work simplification.

Method study procedure  is an organized approach and its

investigation rests on the following six basic steps:

1. Select the work to be analyzed.

2. Record all facts relating to the existing method.
3. Examine the recorded facts critically but impartially.
4. Develop the most economical method commensurate with plant
requirements
5. Install the new method as standard practice.
6. Maintain the new method.

1. Selection of the Job

Selections of the jobs to be studied for methods improvement by the
method study practitioner is a managerial responsibility and it
(selection) may be based on economic technical or human
consideration.   Economic consideration justifies selection based on
the economic worth (i.e. money saving potential) of the job. Technical
consideration identifies jobs, which require studies to overcome
manufacturing difficulties (excessive rejection, relaxation in prefixed
performance standards, inability if the shops to stick to specified
machining parameters such as speeds, feeds, depth of cut etc.,
inconsistent quality etc.) Human consideration in job selection is
usually given weight-age while introducing method study practices for
the first time.

2. Recording of Facts
Systematic recording is the most crucial step in method improvement.
Since recording by long hand (or by descriptive method) has its
limitations, it is not recommended for use in method study. Instead,
five symbols and eight charting conventions are used to record facts
relating to the job under study.   Five typical symbols are O, ||, à, D
and V and eight charting conventions concern composition of the
chart, reject, rework, repletion, change of state, introducing of new
material, combined events and numbering of events. The document
on which details of the process are recorded by the above referred
symbols and conventions is called chart.

3. Critical Examination
Critical examination aims to analyze the facts critically and thereby
give rise to alternatives, which form the basis of selection and
development of easier, and effective methods. Critical examination is
conducted through a systematic and methodical questioning process.
Each activity recorded on the chart, whether it relates to processing or
inspection, or material handling, or to any other aspect, is picked up
one at a time and is examined minutely.   The questioning process is
considered under five major heads, namely the purpose, the place, the
sequence, the person and the means.   These five aspects in critical
examination are referred to as five governing considerations.

4. Development and Selection

Development and selection stage concerns short listing of ideas
generated at the critical examination stage, testing each short listed
idea for its technical and economic feasibility, and making selection
among the alternatives wherever choice exists.   To develop ideas and
to ascertain their technical and economical feasibility, the method
study practitioner needs to solicit the cooperation of personnel from
different departments of the company.   Various techniques available
for the development and selection purpose are: cost benefit analysis,
break-even analysis, investment analysis and critical path analysis.

5. Installation
Installation (or implementation) of the proposed method involves
preparation of project report on recommendations making oral
presentation to the top management, securing approval of the
decision maker, assisting line management during implementation,
arranging training of workmen, and getting jobs (operations) re-time
after implementation, arranging training of workmen, and getting jobs
(operations) re-timed after implementation.
6. Maintenance
Maintenance phase is the follow up phase after implementation, which
serves as a monitoring and control mechanism. It helps to ensure that
the revised methods are set into concrete and workmen do not revert
back to old methods. It also provides an opportunity to the
practitioner to assess the effectiveness of the approach followed by
him and makes changes in the methodology (if required).

The problem with expressing the procedure in such a simple manner is

that undertaking a method study appears to be a simple, linear and
mechanistic process. This description in six steps does however serve
to show the underlying simplicity of the concept of method study. In
practice, the method study procedure consists of a cyclical or iterative
process in which each step may be revisited according to the findings
of subsequent steps. For example,  collecting data  about a current
situation often enables us to discover the reality behind our first
perceptions and thus to refine our selection of what we are
addressing. Similarly, when we start to examine data, we sometimes
become aware that data are missing or incomplete and we need to go
back and collect (record) additional data. This cyclic process often
begins with a rough first pass, in which preliminary data are collected
and examined, and progresses to a more detailed and thorough pass
which results in the collection of more detailed and more complete
data which is the subject of a more rigorous scrutiny. The method
study procedure is thus a convenient representation of what may be a
complex process.
 Answer no 5 ka a wala

The functions of maintenance management is different from production management

are as follow:

1. Policies, rules, and regulations must be developed to make maintenance work more
efficient and more effective.
2. The procedure of maintenance operation shall be done on time so that maintenance
work is not delayed.
3. Ensure that organization complies as per the rules, regulations, and policies.
4. Ensure maintenance is effective and cost-efficient as well.
5. One of the main functions of maintenance management is to make sure that facility
parts such as elevators, escalators, sewers, electric store, HVAC (Heating ventilation air
condition) work fine.
6. Document all the maintenance activities that are done on each day including their
expenses. Documentation can help in keeping track of maintenance work.
7. To deliver effective maintenance work, the maintenance team needs inventories.
Therefore, maintenance management needs to ensure that inventory is available for the
maintenance team.
8. Forecasting demands and planning for maintenance expenditure are also significant.
9. Keeping track of assets, equipment, and machines so that they are secured from theft.
Theft is a big problem in all organizations, especially small equipment. Therefore, it is
the duty of management so that their machines and assets are protected.
10. The most important above all is to make sure that equipment is not neglected and
provided maintenance on time.

Answer no 5 ka b wala

https://www.safeopedia.com/definition/1052/industrial-safety

Industrial safety refers to the management of all operations

and events within an industry in order to protect its
employees and assets by minimizing hazards, risks,
accidents, and near misses.

Industrial safety is overseen by federal, state, and local laws

and regulations. The Occupational Safety and Health
Association (OSHA) is the primary regulatory body in the
United States dedicated to ensuring industrial safety

https://i-sight.com/resources/top-10-ways-to-prevent-workplace-accidents/

1. Discourage Risky Behavior

 
Sometimes workplace accidents result from employees pushing themselves too
hard. Maybe they want to impress their coworkers with their strength. Perhaps
they want to increase their output in hopes of a raise. They may even have been
injured before and begin working before they’ve fully recovered.
While you should encourage employees to be as productive and creative as
possible, employee relations expert Simon Sapper suggests that employers
“incentivize innovation, not accident-inducing risk.” Emphasize that employee
safety is worth far more to you than a boost in productivity.
 

2. Implement Control Measures

 

If you know the hazards that your workers face, make a plan to implement control
measures that will reduce the risk of them turning into workplace accidents. This
hierarchy of controls diagram shows the different categories of controls you can
use and their effectiveness.
Consider, for example, an employee who works on a computer and is at risk for
carpal tunnel syndrome. The least effective way to mitigate this risk is to offer
them a wrist brace (PPE). A better solution is to allow them short, frequent
breaks (administrative controls). Even better, vary their tasks so they are not
strictly doing repetitive typing motions for their entire shift (substitution).
 

3. Review Your Policies and

Procedures
 
Once per year, as well as after workplace accidents, review your organization’s
safety policies and procedures. Do they still apply to the risks your employees
face? If you have changed the way you perform a task, started using new
equipment or tools, or moved to a new location, your health and safety
committee should update these documents.
When and if you update safety protocols, communicate the changes to your
employees. Send a company-wide email detailing the changes for minor
updates, but provide updated training if a policy or procedure changes
significantly.
 
RELATED: Workplace Accident Investigations: The Definitive Guide
 

4. Provide Adequate Training

 
According to David Reischer, CEO of LegalAdvice.com, “A poorly trained
employee is not only a danger
to themselves but also to co-workers and other third parties.” Without proper
training, an employee may unknowingly put themselves and their coworkers in
danger.
Prevent workplace accidents by providing a thorough training program to every
new employee, no matter how experienced they are. Even though it might take a
little longer for them to start producing work, you’ll protect employees from harm
and yourself from a potential lawsuit. Also, conduct regular retraining sessions to
keep employees up-to-date on policies and procedures.
 

5. Perform Regular Inspections

 
In lines of work like construction, shipping, manufacturing and repair, using
dangerous equipment can’t be avoided. However, workplace accidents don’t
have to be an inevitable part of the job.
Perform regular inspections of machinery, equipment and tools. From each
worker’s hammer to large, shared machines, makes sure that the tools
employees use for their jobs are safe and function properly. When something
breaks, repair or replace it right away. Saving a few bucks on a machine part
could cost an employee their health or your company millions of dollars in legal
fees.
 

6. Supervise Employees
 
Whether you’re working on a construction site or in an office, it’s important to
provide all employees with adequate supervision. This ensures that employees
understand their tasks and have easy access to a supervisor when they have
questions.
Without a supervisor around, an employee who is unsure about their work might
“wing it,” which could cause injury, equipment damage or time lost to fixing a
mistake. Train supervisors to be open and communicate with their employees to
encourage dialogue.
 
RELATED: The Complete Guide to Workplace Incident Investigations
 
7. Use Employees’ Expertise
 
When creating a risk-management plan, control measures or safety policies,
consult with employees. No one knows the risks workers face better than the
workers themselves. Provide a suggestion box or hotline to help spot and
address potential issues.
 

8. Take a Risk Management

Approach
 
“Adopt a risk management approach to operations—that helps you understand
where danger is and work to mitigate or eliminate it,” suggests Sapper. In other
words, don’t be reactive when it comes to workplace accidents. Instead, find
ways to prevent them from happening in the first place. Don’t wait until it’s too
late to figure out what risks your workers face; seek them out and mitigate them
proactively.
 

9. Offer Different Types of

Support
 
Workplace accidents can be caused by the employee’s work environment, task
or materials. However, their education, experience, or physical or mental
condition may also factor in. When an employee is tired, overworked, sick or
having issues at home, their mind is elsewhere and they can’t perform their best
at work. This could result in reduced productivity at best and a serious workplace
accident at worst.
Offer employees a comprehensive list of physical and mental health resources
both at work and in your benefits plan. When an employee feels supported and
healthy all around, everyone is safer.
 

All workplace incidents need to be addressed, even if they

don’t result in harm to an employee or property. Use
our near miss reporting form template to get started.
 

10. Use Case Management

Software
 
Case management software makes it fast and easy to investigate and prevent
workplace accidents. Rather than having to gather information and documents
from all over the office, you can keep data and evidence right in the case file.
With the capability to create an instant report and file it directly with the
Occupational Safety and Health Administration (OSHA), you won’t waste time
doing paperwork. Finally, a case management solution can help you spot trends
and high-risk areas so you can take steps to reduce workplace accidents.