Industrial Management

By Dr .R.S.R
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UNIT-I
Q1.Define Industrial Engineering? Explain the Evolution of Industrial Management?

Industrial Engineering/Management: industrial Engineering is the science or discipline

dedicated which deals with the optimization of complex processes, systems, or organizations. It
works to eliminate waste of time, money, materials, person-hours, machine time, energy and
other resources that do not generate value, with application of technology that analyses the
factors linked to the production of goods and services. Simply it is a systems that improve
quality through design, planning, control and optimization of industrial process,
Definition of Industrial Engineering/Management: According to Frederick Taylor Industrial
Engineering is the ``Discipline of utilizing and coordinating humans, machines, and materials to
attain a desired output rate with the optimum utilization of energy, knowledge, money, and time.
It employs certain techniques (such as floor layouts, personnel organization, time standards,
wage rates, incentive payment plans) to control the quantity and quality of goods and services
produced.
Development/Evolution of Industrial Engineering
The evolution of the Industrial Engineering has been studied with the following decades
1. 1700`s Craftsman area: craftsman system based on customs which means that something is
built or done with quality—each step is completed correctly, and no corners are cut. This is a
definition that applies to most roles where something is being created, from furniture
construction.
2. 1800`sEnglish System: Under English system concentrated general purpose machines.
Measurement consists of standardized weights and measurements developed out of archaic
approximations, such as a human foot equating to a standardized ''foot.'' Dive into its
advantages and disadvantages, tracking this measurement system through history.
3. 1850`s American System: During this time precision and interchangeability was given
importance for industrialization.. The U.S. military expanded upon several existing
manufacturing methods to produce a new, more efficient system. Known as both “army
practice” and the “American system of manufacturing,” the new manufacturing system
incorporated two main elements: the use of interchangeable parts as well as the use of
mechanization.
4. 1900`s Scientific Management :Prespecified workers motions to analyzes and synthesizes
workflows. Its main objective is improving economic efficiency, especially labor
productivity. It was one of the earliest attempts to apply science to the engineering of
processes to management.
5. 1950`s Process improvement : Process Improvement is the proactive task of identifying,
analyzing and improving upon existing manufacturing processes within an organization for
optimization and to meet new quotas or standards of quality.
6. 1970`s Numerical Control : During this time industrialization goes on control of special
purpose machines. It is a Machine processes i.e. a piece of material to meet specifications by
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 following coded programmed instructions and without a manual operator directly controlling
the machining operation.
7. 1980`s Computor Integrated Manufacturing : industrialization through CIM and Robotics.
It is the manufacturing approach of using computers to control entire production process. This
integration allows individual processes to exchange information with each part towards less
error-prone by the integration of computers.
8. 1990`s Logistices :During this period supply chain mangement was developed, the flow of
goods and services between businesses and locations. This can include the movement and
storage of raw materials, work-in-process inventory, finished goods, and end to end order
fulfillment from point of origin to point of consumption.
9. 2000`s Enterprise Engineering :During this period entriprise ,ERP integration. It is the body
of knowledge, principles, and practices used to design all or part of an enterprise. An
enterprise is a complex socio-technical system that comprises people, information, and
technology that interact with each other.

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Q.2.What is Industrial Engineering? Explain the Applications/focus Areas of Industrial
Engineering

Applications/focus Areas of Industrial Engineering

1. Industrial Automotive Engineering: IE focuses on Industrial automotive engineering on the tasks
and concepts in the automotive industry from manufacturers and suppliers to service providers for
both engineering and business decision-making
2. Manufacturing Systems: IE basically fours on Manufacturing Systems.It can help to understand the
global relationships that exist among manufacturers, suppliers, engineers, researchers, marketers, and
managers and govern the modern manufacturing process. Systems engineering and integrated design
approaches are used to achieve manufacturing excellence.
3. Quality & Reliability: IE focus on Effective quality/reliability improvement programs provides a
significant competitive advantage. The Quality and Reliability concentration integration of modern
quality concepts, tools, and techniques to develop, implement and maintain systems. Lean, six sigma
and continuous improvement are addressed as well.
4. Supply Chain and Logistics: IE applicable to supply chain Management .It focuses on a foundation
in supply chain and logistics systems with a national and global perspective. It provides proficiency
in problem solving, and decision making .This includes manufacturing, retail, logistics, distribution,
healthcare, defense, service, and software.

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 5. Engineering Management: IE canalso focus area provides graduates with both excellent technical
and managerial skills. It combines a classic engineering education with technical skills and key
elements of a typical business/management education (managerial). Engineering management focuses
on preparing engineers for leadership roles in technology-based organizations.
6. Product Development: IE applied in the area of product development. It emphasizes product
lifecycle management (PLM), computer aided manufacturing, computer aided engineering, digital
manufacturing and sustainability. Therefore, automotive product development would be a key focus
area.
7. Human Factors & Ergonomics: IE focus area emphasizes improving the ergonomic design,
performance, air quality, lighting, noise and long term effects in the work environment. Students
learn theories and application of tools to reduce injuries, improve productivity and increase quality of
service/goods in industry. Students can choose ergonomics related classes for their technical
electives.
8. Policy planning: IE can also applied for industrial policy and planning on state power that influences
the distribution of income among industries. We describe some of its major tools and the way they
impact industry’s inputs, outputs, governance, and coordination.

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Q 3.What is Industrial Engineering? Explain Principles/ features of Industrial Engineering?

Principles/ features of Industrial Engineering/Management:

1. Productivity Science: Develop science for each element of a man - machine system's work
related to efficiency and productivity. Manage productivity at system level.
2. Standardization of Operating Methods: Engineer methods, processes and operations to
use the laws related to the work of machines, man, materials and other resources. or
Fundamentally, process standardization describes the establishment of a set
of rules governing how people in an organization are supposed to complete a given task
or sequence of tasks.
3. Applicable to all Branches of Engineering: Application of Engineering methods that help
industrial engineers to set system parameters that result in minimum costs or maximum
profits with the given data (cost and return figures and alternative values . Application of
statistical tools such as probability distribution, bar diagrams, histogram and other graphical
aids.
4. Machine utilization and economy: IE utilization the capacity of machines is the extent to of
installed productive capacity. It is the relationship between output that is produced with the
installed equipment. On the other hand Economy as the amount a company or
an economy can produce using its current equipment, workers, capital and other resources at
full tilt
5. Industrial engineering optimization: Industrial engineering is an engineering profession
that is concerned with the optimization of complex processes, systems, or organizations by
developing, improving and implementing integrated systems of people, money, knowledge,
information, equipment, energy and materials.
6. Incentive Systems and Job Evaluation: Incentives – IEM concentrate on monetary on
non-monetary incentives in order to motivate them to work more efficiently. While at the
same time job evaluation to be done for determining the value/worth of a job in relation to
other jobs with systematic comparison for establishing a rational pay structure.

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7. Team membership and leadership: should be stated here emphatically that there is
nothing that can permanently bring about results from scientific management, and the
economies that it is possible to effect by it, unless the organization is supported by the hearty
co-operation of the men. Without this there is no scientific management. - Gilbreth in
Applied Motion Study, Book.
8. Process and Operation Analysis: Operations analysis uses data to assess and
improve processes and systems. There are many operations measures or metrics that can
provide information relevant to decision making. An operations analysis requires
understanding the process and identifies ways to measure what is occurring.
9. Productivity training and education : The productivity of an employee only increases
when he knows what exactly he is supposed to do and providing training to them to perform
the activity delegated to him. Training boost up the confidence of employees which makes
them more productive.
10. Work measurement: It is an important measure in industrial engineering to select the best
work method for machine elements, purely manual work elements or a combination of man-
machine work elements. It is useful to set day’s task for an operator

Fig: Principles of Industrial Engineering

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Q.4.What is industrial Engineering/ Management? Explain the Significance /functions
/Role of Industrial Engineering or Engineer?

Role/ Significance /functions Engineering or Engineer / Management

1. Expert: Engineer is a Industrial Expert to add meaningful value to the lives of a specific
community in some shape or form. Guidance and knowledge brought by experts can
possibly even alter the direction of an entire industry. The following are the other roles
played by engineer.
i. Decision making: Engineers are decision makers often affect his or her job security,
income and opportunity for advancement, they impact the profitability or performance
of the engineer’s employer, and they often impact the environment and our safety.
ii. Designing the system: The design of engineering systems is a formal process which
invokes both technical and human elements to provide the blueprint for systems which
simultaneously provide for the needs of a system's stakeholders while not harming the
environment or living beings.
2. Adviser and consultant: Advice and consulting engineer is an engineer that specializes
in project design, coordination and analysis. These highly skilled professionals provide
their expertise during the planning, designing, supervising of public and private
infrastructure projects. The following are the other roles played by engineer.
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 i. Interpret Data: The process of using diverse analytical methods to review data and
arrive at relevant conclusions. The interpretation of data helps to subordinates for
categorize, manipulate, and summarize the information in order to answer critical
questions.
ii. Reviews Data: Data review is an activity through which the correctness conditions
of the data are verified. It includes the specification of the type of the error or
condition not met, and the qualification of the data
3. Analyst of System: Systems analysts may serve as change agents who identify the
organizational improvements needed; design systems to implement those changes, and
train and motivate others to use the systems. to solve business problems by using
technology. The following are the other roles played by engineer.
i. Systems Faults: He analyzes the System Fault includes malfunction or error in
employed system such that the System is unable to perform the functions it is
required to perform for the time being.
ii. Analyses the jobs: It is the process of gathering and analyzing information about the
content and the human requirements of jobs, as well as, the context in which jobs are
performed. This process is used to determine placement of jobs.
4. Trainer: Engineer gives practical training to workers or an industrial environment that
helps the workers in developing the required skills which will help them in becoming a
professional of the future. The following are the other roles played by engineer.
i. Motivates the workers: Engineers inspires individuals for putting in their efforts
towards the attainment of the organizational goals. Engineers try to influences people
to act and arousal, direction, and maintenance of behaviors relevant to work.
ii. Work Study: Engineer analytically studied the job or operation.” Work study helps
to increase productivity. Engineers form the basis for work system design. Identify
the most effective means of achieving necessary functions.
5. Decision Maker: Engineer is decision maker who is responsible for making strategically
important decisions based on a number of variables, including time constraints, resources
available, the amount and type of information available and the number of stakeholders
involved. The following are the other roles played by engineer.
i. Use OR and QT: While taking the decisions Engineer take the help from operational
research and quantitative techniques. Operations research uses mathematical methods
to find the right decision among a series of potentials. Quantitative techniques uses
the decision makes a systematic and powerful means of analysis, based on
quantitative data.
ii. Decision Tools: Engineer using the tolls such as Marginal Analysis. Marginal
analysis weighs the benefits of input or activity against the costs, SWOT Diagram,
Decision Matrix, Pareto Analysis, and Reviewing Your Decision & Making
Adjustments.
iii. Computer and MIS: CS uses by engineers more on technology and about math and
coding, CS is more oriented towards theory.MIS focuses more on business
application and about solving business needs using IT and coding. MIS is more
oriented towards application
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 Fig: Significance /functions /Role of Industrial Engineering or Engineer
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Q.5. what is industrial Engineering? State the Tools/Technique/Methods of Industrial

Engineering:

1. Production, Planning and Control: Planning for the resources (like men, materials and
machine) proper scheduling and controlling production activities to ensure the right quantity,
quality of product at predetermined time and pre-established cost.
2. Inventory Control: To find the economic lot size and the reorder levels for the items so that
the item should be made available to the production at the right time and quantity to avoid
stock out situation and with minimum capital lock-up.
3. Job Evaluation: This technique used to determine the relative worth of jobs of the
organization to aid in matching jobs and personnel and to arrive at sound wage policy.
4. Material Handling Analysis: To scientifically analysis the movement of materials through
various departments to eliminate unnecessary movement to enhance the efficiency of material
handling.
5. Ergonomics (Human Engineering): It is concerned with study of relationship between man
and his working
6. Method study: To establish a standard method of performing a job or an operation after
thorough analysis of the jobs and to establish the layout of production facilities to have a
uniform flow of material without back tracking.
7. Time study (work measurement): This is a technique used to establish a standard time for a
job or for an operation.
8. Motion Economy: This is used to analyses the motions employed by the operators do the
work. The principles of motion economy and motion analysis are very useful in mass
production or for short cycle repetitive jobs.
9. Value Analysis: It ensures that no unnecessary costs are built into the product and it tries to
provide the required functions at the minimum cost. Hence, helps to enhance the worth of the
product.
10. Financial and non-financial Incentives: These helps to evolve at a rational compensation
for the efforts of the workers.
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 Q.6.What is Production management? Distinguish between Production Mgt and IE?
Production Management: Production management means planning, organizing, directing and
controlling of production activities. It deals with converting raw materials into finished goods or
products. It brings together the Six M's i.e. men, money, machines, materials, methods and
markets to safety the wants of the people.

Production management Industrial Management

1. planning and control: planning and
control of manufacturing processes to
ensure to move smoothly at the required
level
2. Activities authorization :The production
manager must plan, control the process of
production
3. Integration: Integrate men, machines,
methods, materials, and money.
4. Maintenance : Maintaining the raw
materials, components parts, work in
process, finished goods, packaging
materials, and general supplies
5. Cost Structure : Labor costs, must first
measure the amount and type of work
required to produce a product, then specify
well-designed, methods
6. Tools and techniques :Specialists in these
fields are increasingly using computers
and information process to solve the
production problems
1. planning and control focused on
manufacturing systems and finding ways
to improve the system to ensure optimum
output
2. The industrial engineer will always have
options to explore plan control work and
authority person for process
3. Integrate people, money, knowledge,
information, equipment,
4. Maintenance time, money, materials,
person-hours, machine time, energy and
other resources of work measurement
,method study, motion study
5. The cost structure mainly focused on
eliminates waste of time, money,
materials, energy and other resources with
ensuring cost reduction.
6. Industrial engineers use computer and
statistical tools for simulation, especially
discrete event simulation, for system
analysis and evaluation.

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Q.7. what is Productivity /Explain reasons for Low productivity?
Productivity: Productivity is computed by dividing average output per period by the total costs
incurred or resources (capital, energy, material, personnel) consumed in that period. Productivity
is a critical A measure of the efficiency of a person, machine, factory, system, etc., in converting
inputs into useful outputs determinant of cost efficiency.
Reasons for low Level Productivity:
1. Lack of big-picture view: To feel that what they do is important; employees need to know
how their work contributes to the overall success of the company. Every company should
identify components called key performance indicators (KPIs) , but Non availability of big-
picture view.
2. Poor supervision: If a group’s productivity is lagging, consider a closer look at the
supervisor. Managers sometimes miss the mark by: Not being consistent or transparent
Micromanaging or not giving enough supervision,

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3. Poor communication: Communication is a two-way street. You need to communicate with
employees, but you also need to provide opportunities for employees to voice opinions and
concerns. Communication failure leads poor productivity.
4. Lack of delegation: The manager or supervisor is not able to guide and direct his employees
or subordinates well, he will not delegate authority. It is his fault since he is not well-versed
with the function of direction which leads poor productivity.
5. Inconsistency: When a work group, policies and rules are always changing, employees may
be too. Inconsistency at the top has a downstream impact on every department, and
consequently on the productivity.
6. Inappropriate behavior: Actions that violate company policy or corporate integrity,
including sexual harassment, discrimination, stealing, breaking the dress code, and
even coming to work late or starting rumors, can cause discomfort and distraction.
7. Inadequate technologies: Technology changes quickly, and if your employees are working
with old tools they will not be as effective as they could be. Stay up with the trends used by
your customers and competitors. Ask your employees what they need to be more effective
and efficient.
8. Lack of acknowledgement: When one member of a team goes above and beyond, co-
workers see that. They also see if it isn’t acknowledged and figure, “Why bother?”The stellar
employee feels it, too, and most likely will be sending out resumes soon.We all like a pat on
the back when we’re doing a good job
9. No Direction: It’s reasonable to expect employees to have a certain level of autonomy, but if
supervisors fail to give them any guidance whatsoever, staff members will find it difficult to
manage their time and prioritize tasks appropriately.
10. Inadequate Training: Companies won't hire candidates without the requisite skills for the
position, but each business has their own unique standards and processes. Insufficient training
leads to (sometimes costly) errors, errors lead to anxious employees and anxious employees
make more errors--a vicious cycle.
11. Poor Work-Life Balance: A standard workweek is 40 to 45 hours, but sometimes working
late or on the weekends is necessary, but when staff members must constantly sacrifice their
personal time, they're more likely to get burned out and look for opportunities elsewhere.
12. Unrealistic Expectations: Staring at a to-do list and knowing, without a doubt, it isn't
humanly possible to complete every task by its assigned deadline is disheartening. How can
an employee be motivated and productive when they're facing an insurmountable mountain of
work?
13. Outdated Systems: A system that was once widely used from a long period but was not
replaced with new one .i.e. newer version has not been released

Fig: Reasons for Low Productivity

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Methods for Measuring the Productivity:
1). Light and Dark Bottle Method 3).Radioactive Tracer Method 5 Dioxide Flux
2). Chlorophyll Concentration 4.Harvest Analysis 6.Dimension Analysis
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Q .8.What is Management? Explain Nature of management?

Management: Management (or managing) is the administration of an organization. The

activities of setting the strategy of an organization and coordinating the efforts of
its employees to accomplish its objectives through the application of available resources, such
as financial, natural, technological, and human resources. The term "management" may also
refer to those people who manage an organization. Simply "management is what a manager
does”. In other words “Management is a distinct process consisting of activities of planning,
organizing, actuating and controlling, performed to determine and accomplish stated objectives
with the use of human beings and other resources.”.
Characteristics/Features/Nature of Management
1. Management is goal oriented process: Management always aims at achieving the
organizational objectives. The functions and activities of manager lead to the achievement of
organizational objectives; for example, if the objective of a company is to sell 1000 computers
then manager will plan the course of action, motivate all the employees and organize all the
resources keeping in mind the main target of selling 1000 computers.
2. Management is Pervasive: Management is a universal phenomenon. The use of management
is not restricted to business firms only it is applicable in profit-making, non-profit-making,
business or non-business organizations; even a hospital, school, club and house has to be
managed properly. Management is used in the whole world whether it is USA, UK or India
3. Management is Multidimensional: Management does not mean one single activity but it
includes three main activities All organizations are set up to perform some task or goal.
Management activities aim at achieving goals or tasks to be accomplished. People refer to
Human resources and Human resources are the most important assets of an organization.
4. Management is a continuous process: Management is a continuous or never ending function.
All the functions of management are performed continuously, for example planning, organizing;
staffing, directing and controlling are performed by all the managers all the time. Sometimes,
they are doing planning, then staffing or organizing etc. Managers perform ongoing series of
functions continuously in the organization.
5. Management is a Science as well as an Art: Management is an art because there are definite
principles of management. It is also a science because by the application of these principles
predetermined objectives can be achieved.
6. Management is a group activity: Management always refers to a group of people involved in
managerial activities. The management functions cannot be performed in isolation. Each
individual performs his/her role at his/her status and department, and then only management
function can be executed. Even the result of management affects every individual and every
department of the organization so it always refers to a group effort and not the individual effort
of one person.
7. Management is a dynamic function: Management has to make changes in goal, objectives
and other activities according to changes taking place in the environment. The external
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 environment such as social, economical, technical and political environment has great influence
over the management. s changes take place in these environments, same are implemented in
organization to survive in the competitive world.
8. Management is Intangible: Management function cannot be physically seen but its presence
can be felt. The presence of management felt by seeing the orderliness and coordination in the
working environment. It is easier to feel the presence of mismanagement a leads to confusion.
9. Composite Functions: Management consists of series of functions which must be performed in
a proper sequence. These functions are not independent of each other. They are inter-dependent
on each other. As the main functions of management are planning, organizing, staffing, directing
and controlling; organizing etc all these functions inter-dependent on each other so management
is composite process of all these functions
10.Management is a system of authority: Authority means power to make others act in a
predetermined manner. Management formalizes a standard set of rules and procedure to be
followed by the subordinates and ensures their compliance with the rules and regulations. Since
management is a process of directing men to perform a task, authority to extract the work from
others is implied in the very concept of management.
11. Management involves decision-making: Management implies making decisions regarding the
organization and operation of business in its different dimensions. The success or failure of an
organization can be judged by the quality of decisions taken by the managers. Therefore,
decisions are the key to the performance of a manager.
12. Management is a universal activity: Management is not applicable to business undertakings
only. It is applicable to political, social, religious and educational institutions also. Management
is necessary when group effort is required.

Fig : Characteristics/Features/Nature of Management

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Q .9.What is Management? Explain Importance of management?

Importance /Objectives of Management

1. Proper Utilization of Resources: It is to use various resources of the enterprise in a most
economic way. The proper use of men, materials, machines and money will help a business to
earn sufficient profits to satisfy various interests, these interests will be satisfied only when

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 physical resources of the business are properly utilized.
2. Proving Performance: Management should aim at improving the performance of each and
every factor of production. The environment should be so congenial that workers are able to
give their maximum to the enterprise. The fixing of objectives of various factors of production
will help them in improving their performance.
3. Mobilizing Best Talent: The management should try to employ persons in various fields so that
better results are possible. The employment of specialists in various fields will be increasing the
efficiency of various factors of production. There should be a proper environment which should
encourage good persons to join the enterprise. The better pay scales, proper amenities, future
growth potentialities will attract more people in joining a concern.
4. Planning for Future: Another important objective of management is to prepare plans. No
management should feel satisfied with today’s work if it has not thought of tomorrow. Future
plans should take into consideration what is to be done next. Future performance will depend
upon present planning. So, planning for future is essential to help the concern.
5. Initiative and innovation encruages: Initiative means to do the right thing at the right time
without being told or influenced by the superior. The employee also encourages innovation in
the organization. Innovation brings new ideas, new technology, new methods, new products,
new services, etc. This makes the organization more competitive and efficient.
6. Growth and expansion: Management makes optimum utilization of available resources. It
reduces wastage and increase efficiency. It encourages team work and motivates employees. It
also reduces absenteeism and labor turnover results growth, expansion diversification of the
organization.
7. Employee’s motivation: Management motivates Employees with providing financial and non-
financial incentives. These incentives increase the willingness and efficiency of the employees.
This results in boosting productivity and profitability of the organization.
8. Reduce the wastage: Management reduces the wastage of human, material and financial
resources. Wastage is reduced by proper production planning and control. If wastage is reduced
then productivity will increase.
9. Increases efficiency: Efficiency is the relationship between returns and cost. Management uses
many techniques to increase returns and to reduce costs. Higher efficiency brings many benefits
to the organization.
10. Human relations improved: Management improves relations between individuals, groups,
departments and between levels of management. Better relations lead to better team work. Better
team work brings success to the organization.
11. Absenteeism and labor turnover reduced: An Absenteeism mean the employee is absent
without permission. Labor Turnover means the employee leaves the organization. Labor
absenteeism and turnover increases the cost and causes many problems in the smooth
functioning of the organization. Management uses different techniques to reduce absenteeism
and labor turnover in the organization.
12. Team Work enrages: Management encourages employees to work as a team. It develops a
team spirit in the organization. This unity brings success to the organization.

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 Fig: Importance /Objectives of Management
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Q.10.What is Management? Explain various functions of Management?
Management: Management is a distinct process consisting of activities of planning, organizing,
actuating and controlling, performed to determine and accomplish stated objectives with the use
of human beings and other resources.
Functions of Management
1. Planning : It is the basic function of management. It deals with chalking out a future course of
action & deciding in advance the most appropriate course of actions for achievement of pre-
determined goals. According to KOONTZ, “Planning is deciding in advance - what to do, when
to do & how to do. It bridges the gap from where we are & where we want to be. Planning is a
systematic thinking about ways & means for accomplishment of pre-determined goals. It
involves what to do, where to do, when to do, whom to do and so on. It is an intellectual activity
and it also helps in avoiding confusion, uncertainties, risks, wastages etc.
2. Organizing: It is the process of bringing together physical, financial and human resources and
developing productive relationship amongst them for achievement of organizational goals.
According to Henry Fayol, “To organize a business is to provide it with everything useful or its
functioning i.e. raw material, tools, capital and personnel’s”. To organize a business involves
determining & providing human and non-human resources to the organizational structure.
Organizing as a process involves:
1. Identification of activities. 2. Classification of grouping of activities.
3. Assignment of duties. 4. Delegation of authority and creation of responsibility.
5. Coordinating authority and responsibility relationships.
3. Staffing: It is the function of manning the organization structure and keeping it manned.
Staffing has assumed greater importance in the recent years due to advancement of technology,
increase in size of business, complexity of human behavior etc. The main purpose o staffing is to
put right man on right job i.e. square pegs in square holes and a round peg in round holes
i.e.staffing involves manning the organization structure through proper and effective selection;
appraisal & development of personnel to fill the roles designed un the structure”. Staffing
involves:
 Manpower Planning (man power searching; choose the person giving the right place).

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  Recruitment, Selection, Placement, Training.
 Remuneration and Performance Appraisal and Promotions & Transfer.

4. Directing: It refers to instructing, guiding, communicating and inspiring people in the

organization. Under directing following four activities are included
i. Supervision- implies overseeing the work of subordinates by their superiors. It is the act of
watching & directing work & workers.
ii. Motivation- means inspiring, stimulating or encouraging the sub-ordinates with zeal to
work. Positive, negative, monetary, non-monetary incentives may be used for this purpose.
iii. Leadership- may be defined as a process by which manager guides and influences the work
of subordinates in desired direction.
iv. Communication- It is the process of passing information, experience, opinion etc from one
person to another. It is a bridge of understanding.

5. Controlling: It implies measurement of accomplishment against the standards and correction of

deviation if any to ensure achievement of organizational goals. The purpose of controlling is to
ensure that everything occurs in conformities with the standards. An efficient system of control
helps to predict deviations before they actually occur. Controlling is the process of checking
whether or not proper progress is being made towards the objectives and goals and acting if
necessary, to correct any deviation i.e. Controlling is the measurement & correction of
performance activities of subordinates in order to make sure that the enterprise objectives and
plans desired to obtain them as being accomplished”. Controlling has following steps:

Fig: Functions of Management

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Q.11.What is Scientific Management? Explain Taylor principles of scientific management?

Scientific management: It implies the art of knowing exactly what is to be done and how it is to
be done. Under this approach, scientific techniques are applied in the recruitment, selection and
training of workers and are also used in tackling various industrial problems. i.e. Two fold
techniques applied Such as one is the discovery of the best method of performing a particular
work second one is the best method for meeting a given situation.

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 According to F.W. Taylor: It is the “knowing exactly what you want people to do and knowing
that they do in the best and the cheapest way possible“.
Features/Elements/Principles/Taylor principles of Scientific Management
1. Science, Not Rule of Thumb: In order to increase organizational efficiency, the ‘Rule of
Thumb’ method should be substituted by the methods developed through scientific analysis of
work. Rule of Thumb means decisions taken by manager as per their personal judgments. A
small production activity loading iron sheets into box cars can be scientifically planned.
2. Harmony, Not Discord: Taylor emphasized that there should be complete harmony between
the workers and the management since if there is any conflict between the two, it will not be
beneficial either for the workers or the management. Both the management and the workers
should realize the importance of each other. In order to achieve this state, Taylor suggested
complete mental revolution on the part of both management and workers .
3. Mental Revolution: The technique of Mental Revolution involves a change in the attitude of
workers and management towards each other. Both should realize the importance of each other
and should work with full cooperation. Management as well as the workers should aim to
increase the profits of the organization. so that the company makes profit and on the other hand
management should share part of profits with the workers
4. Cooperation, Not Individualism: This principle is an extension of principle of ‘Harmony, not
discord’ and lays stress on mutual cooperation between workers and the management.
Cooperation, mutual confidence, sense of goodwill should prevail among both, managers as well
as workers. The intention is to replace internal competition with cooperation.
5. Development greatest efficiency and prosperity: Efficiency of any organization also depends
on the skills and capabilities of its employees to a great extent. This can be, providing through
the use of scientific approach. Employees should be scientifically selected.
6. Match workers to their jobs: Rather than simply assign workers to just any job, match workers
to their jobs based on capability and motivation, and train them to work at maximum efficiency.
7. Monitor worker performance: Monitor Worker performance and provide instructions and
supervision to ensure that they're using the most efficient ways of working.
8. Allocate the work: The work allocation between managers and workers so that the managers
spend their time planning and training, allowing the workers performs their tasks efficiently.

Fig: Principles /Components of Scientific Management:

………………………………
14
Q.12.What is Scientific Management? Explain Significance of scientific Management?

Significance /Objectives of scientific Management:

1. Better management: This theory gained wide popularity in the managerial world, in both
business and non-business organizations. It introduced better management through scientific
methods such as work study, incentive plans, rest hours etc.
2. Optimum allocation of resources: Scientific management eliminates wasteful time and
motions in performing various activities. It introduced time and motion studies to increase
contribution to goals. Determined true capacity on a day’ work for fair wage’.
3. Scientific approach: It emphasized on scientific selection, education and development of
workers so that problem-solving is not based on random decision-making. It advocated selection
on the basis of job requirements. Select the right person to a right job.
4. Work specialization: He identified planning and execution as two distinct jobs. People
responsible for planning and execution belong to separate departments. Instructions are given by
foremen specialized in their areas. This results in smooth business operations.
5. Mental revolution: He advocated mental revolution on the part of both employers and
employees. This revolution changed the attitude of management and workers towards work.
6. Productivity: Better management and optimum allocation of resources result in high
productivity, high profits and high wages. It improves economic performance of both
management and workers.
7. Harmonious relationships: Since management and workers cooperate and relationship between
the two tends to be harmonious. It reduces interpersonal conflicts and promotes unity.
8. Improved standards of living: Improved profits and wages improve the living standards of
managers and workers.
9. Industrial prosperity: High productivity, profits and wages promote industrial peace. This
promotes industrial prosperity and image in international markets.
10. Incentive for high production: Rather than treating all workers at par, the theory rewards
efficient workers (those who produce more than the standard output) by paying them a higher
rate and lower rate to inefficient workers (those who produce less than the standard output). This
motivates workers to increase efficiency in order to make financial gains.
11. Job satisfaction: Scientific methods, order in the areas of production planning, analysis of
costs, wage systems, rest pauses etc. are used to promote job satisfaction amongst workers.
……………………………
Q.12. what are the Principles of Management? Henry Fayol 14 Principles of management?
Principles of Management: Management is an organized body of knowledge consisting of
principles of generalizations. These principles constitute management theory. A principle is a
fundamental statement of truth. It established cause and effect between two or more variables. A
principle may also be regarded as a guide to action.

15
 Fig: Principles of Management/ Fayol fourteen Principles of Management
1. Division of Work: In practice, employees are specialized in different areas and they have
different skills. Different levels of expertise can be distinguished within the knowledge areas.
According to Henry Fayol specialization promotes efficiency of the workforce and increases
productivity. In addition, the specialization of the workforce increases their accuracy and speed.
2. Authority and Responsibility: In order to get things done in an organization, management has
the authority to give orders to the employees. Of course with this authority comes responsibility.
The responsibility can be traced back from performance and it is therefore necessary to make
agreements about this. In other words, authority and responsibility go together and they are two
sides of the same coin.
3. Discipline: This third principle of the 14 principles of management is about obedience. It is often
a part of the core values of a mission and vision in the form of good conduct and respectful
interactions. This management principle is essential and is seen as the oil to make the engine of
an organization run smoothly.
4. Unity of Command: The management principle ‘Unity of command’ means that an individual
employee should receive orders from one manager and that the employee is answerable to that
manager. If tasks and related responsibilities are given to the employee by more than one
manager, this may lead to confusion which may lead to possible conflicts for employees.
5. Unity of Direction: This management principle of the 14 principles of management is all about
focus and unity. All employees deliver the same activities that can be linked to the same
objectives. All activities must be carried out by one group that forms a team. The manager can
only ultimately responsible for this plan and he monitors the progress of the defined and planned
activities.
6. Subordination of Individual Interest: There are always all kinds of interests in an organization.
In order to have an organization function well, Henri Fayol indicated that personal interests are
subordinate to the interests of the organization (ethics). The primary focus is on the
organizational objectives and not on those of the individual. This applies to all levels of the
entire organization, including the managers.
7. Remuneration: Motivation and productivity are close to one another as far as the smooth
16
 running of an organization is concerned. There are two types of remuneration namely non-
monetary (a compliment, more responsibilities, credits) and monetary (compensation, bonus or
other financial compensation). Ultimately, it is about rewarding the efforts that have been made.
8. The Degree of Centralization: Management and authority for decision-making process must be
properly balanced in an organization. This depends on the volume and size of an organization
including its hierarchy. Centralization implies the concentration of decision making authority.
9. Scalar Chain: Hierarchy presents itself in any given organization. This varies from senior
management (executive board) to the lowest levels in the organization. Henri Fayol ’s
“hierarchy” management principle states that there should be a clear line in the area of authority
(from top to bottom and all managers at all levels. Each employee can contact a manager or a
superior in an emergency situation without challenging the hierarchy.
10. Order: According to this principle of the 14 principles of management, employees in an
organization must have the right resources at their disposal so that they can function properly in
an organization. In addition to social order work environment must be safe, clean and tidy.
11. Equity: The management principle of equity often occurs in the core values of an organization
i.e. employees must be treated kindly and equally. Employees must be in the right place in the
organization to do things right. Managers should supervise and monitor this process and they
should treat employees fairly and impartially.
12. Stability of Tenure of Personnel: This management principle of the 14 principles of
management represents deployment and managing of personnel and this should be in balance
with the service that is provided from the organization. Management strives to minimize
employee turnover and to have the right staff in the right place. Focus areas such as frequent
change of position and sufficient development must be managed well.
13. Initiative: Henri Fayol argued that with this management principle employees should be
allowed to express new ideas. This encourages interest and involvement and creates added value
for the company. Employee initiatives are a source of strength for the organization. This
encourages the employees to be involved and interested.
14. Esprit de Corps: The management principle ‘esprit de corps’ of the 14 principles of
management stands for striving for the involvement and unity of the employees. Managers are
responsible for the development of morale in the workplace; individually and in the area of
communication. Esprit de corps contributes to the development of the culture and creates an
atmosphere of mutual trust and understanding.
Other principles of management: Some other principles also formulated, in addition to the above
principles of Hennry Fayol. Those are discussed under
1. Harmony of objectives 3. Principles of planning 5. Principle of balance
2. Principle of co-ordinations 4. Principle of exception 6.Principle of accountability.
-------------------------------------
Q.13.what are the Motivational Theories? State the Maslow’s Need Hierarchy Theory?

Motivation: The motivation is a drive that forces an individual to work in a certain way. When
the establishment of human organizations, people tried to motivates an employee in the
organization. Stimulate the employee towards successfully complete the given work or task. The
theories of motivation can be broadly classified as:

17
 Fig: Theories of Motivation
I. Maslow’s Need Hierarchy Theory:. He classified all human needs into a hierarchical manner
from the lower to the higher order. He believed that once a given level of need is satisfied, Then,
the next higher level of need has to be activated in order. The human needs follow a definite
sequence of domination. Maslow identified five levels in his need hierarchy as shown in
following figure.

Fig : Maslow’s Need Hierarchy Theory/Model

1. Physiological Needs: These needs are basic to human life and, hence, include food, clothing,
shelter, air, water and necessities of life. These needs relate to the survival and maintenance of
human life. They exert tremendous influence on human behavior. These needs are to be met first
at least partly before higher level needs emerge. Once physiological needs are satisfied, no
longer motivate the man.
2. Safety Needs: After satisfying the physiological needs, the next needs felt are called safety and
security needs. These needs find expression in such desires as economic security and protection
from physical dangers. Meeting these needs requires more money. When physiological needs
satisfied these become inactive..
3. Social Needs: Man is a social being. He is, therefore, interested in social interaction,
companionship, belongingness, etc. It is this socialising and belongingness why individuals
prefer to work in groups and especially older people go to work.
18
4. Esteem Needs: These needs refer to self-esteem and self-respect. They include such needs
which indicate self-confidence, achievement, competence, knowledge and independence. The
fulfillment of esteem needs leads to self-confidence, strength and capability of being useful in
the organization. However, inability to fulfill these needs results in feeling like inferiority,
weakness and helplessness.
5. Self-Actualization Needs: This level represents the culmination of all the lower, intermediate,
and higher needs of human beings. In other words, the final step under the need hierarchy model
is the need for self-actualization. This refers to fulfillment. The term self-actualization was
coined by Kurt Goldstein and means to become actualized in what one is potentially good at. In
effect the person’s motivation to transform perception of self into reality.
Maslow’s further classified needs into –
1. Lower order needs 2. Higher order needs
…………………………………..

Q.14. Discuss the Douglas McGregor's theory 'x' and theory ‘y’?

Douglas Mc Gregor in 1960 stressed the importance of understanding the relationships between
motivation and behavior. He believed that managers motivate employees by one of two basic
approaches. Which he termed as theory X and theory Y

Theory X
This is the traditional theory of human behavior. The assumptions about the human
behavior are stated as negative in this approach. Based on this assumption organization and
managers who believes on theory X kind of human nature attempt to structure, control and
closely supervise their employees.
The General traits/ Assumptions of Theory X
1. Laziness 7. Less motivated 13. Lack of initiation
2. Dependent 8. Avoids taking risks 14. Never own activity
3. Relies on superiors 9. Power is supreme 15. Inherently dislike work.
4. Lack of ambition. 10. Constant guidance. 16. Resist changing.
5. They avoid responsibility. 11. No scope for R&D 17. They tend to work slowly.
6. Motivated at money. 12. Man to be indolent. 18. Lack of self control.

Theory Y
This theory emphasizes the need for a cooperative effort from management and employees.
This theory highlights the requirement of today i.e. to get maximum output with minimum
input, control and direction.
The General traits/ Assumptions of Theory Y
1. Active 6. Takes initiative 11.Highly motivated
2. Takes risks 7. Work is play or rest 12. They like the work.
3. Goal-oriented 8. Inventor/creator/discover. 13. Independent
4. Work source satisfaction 9. Face challenges. 14. Feel responsibilities.
5. High degree of imagination. 10. They exercise self control. 15. Committed to Work
……………………

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 UNIT-II

Q.15.What is plant Location? Explain the Factors governing the plant location?

Plant location: It refers to the choice of region and the selection of a particular site for setting
up a business or factory. But the choice is made only after considering cost and benefits of
different alternative sites. It is a strategic decision that cannot be changed once taken.

Factors Governing the Plant Location: The following figure explaining the factors

1. Law and order situation: Plant location must be at that place where law and order situation
is in control. If a state has bad or unfavorable acts , laws and government order situation,
then the business must not be located within that state, unless other important factors such as
availability of heavy or bulky raw materials.
2. Availability of infrastructure facilities: Plant location which is selected must have proper
infrastructure facilities such as Transport and communications, Banking and insurance
services, Regular fuel supply, Continuous supply of electricity and water, etc.
3 Good industrial relations: Entrepreneurs do not want to locate their business at places
where anti-social elements are rampant, although there are other favorable factors such as
good infrastructure facilities, cheap labor, etc.
4. Availability of skilled workforce: Plant location must be convenient and easily accessible to
skilled workforce. Most businesses require skilled-labor force such as engineers,
management experts, computer programmers, etc.
5. Social infrastructure:. There is a need of suitable social infrastructure facilities like;
Education institutions, Hospitals and health centers, Community centers like worship place,
garden, meditation center, etc. Recreation facilities like theaters, clubs, communication
facilities, etc.
6. Investor friendly attitude: Plant location must be in those states whose governments have an
investor-friendly attitude. Government must give attractive incentives and concessions to
those who start business units in their states. There must not be any bureaucratic control for
starting a business. An investor-friendly attitude will not only attract investment, but will
also result in the overall development.
7. Nearness to market: Plant location must be near a market. Every business unit depends on a
market for selling its goods and services. The goods and services must reach the market on
time, and it must be available to the consumers at a low price.
8. Nearness to raw-materials' source
Plant location must be usually near to the source of raw-material. Raw-materials' costs are
about 50% of the total cost. Therefore, a business must be located close to the source of raw
material, especially in the case of “Gross Materials and Pure Materials
9. Nearness to supporting industries: Plant location must be near its supporting industries and
services. If it purchases spare parts from an outside agency, then these agencies must be
located very close to the business. If not, the business will have to spend a lot of
extra money on transport. It will also be difficult, to control the quality of the spare parts
because of the distant location.

20
 10. Must meet safety requirements: Plant location must meet all essential safety requirements.
Due to air, water and sound pollution, some factories have a bad effect on the health of the
people. Therefore, these factories must be located away from residential areas. Safety of
environment must also be given priority in this regards.
10. Miscellaneous factors: Following miscellaneous factors also affect a plant location
 Availability and cost of land,
 Suitability of land - soil and topography,
 Climatic conditions,
 Location of a similar unit, etc.

Fig: Factors Governing the Plant Location

……………………………
Q.16. Define plant layout? Explain the principles of plant layout?

What is Plant layout: It is the overall arrangement of the production processes, storeroom, tool-
room, immaterial handling equipment, aisles, racks and sub-stores, employee services and all
other accessories required for facilitating the production in the factory.
Definition: According to James Lundy, Plant layout is the`` most effective physical
arrangement, either existing or in plans of industrial facilities i.e. arrangement of machines,
processing equipment and service departments to achieve greatest co-ordination and efficiency
of 4 M’s (Men, Materials, Machines and Methods) in a plant`
Principles of Plant Layouts `
1. Principle of Minimum Movement: Materials and labor should be moved over minimum
distances; saving cost and time of transportation and material handling.
2. Principle of Space Utilization: All available cubic space should be effectively utilized –
both horizontally and vertically.
3. Principle of Flexibility: Layout should be flexible enough to be adaptable to changes
required by expansion or technological development.
4. Principle of Interdependence: Interdependent operations and processes should be located in
close proximity to each other; to minimize product travel.
5. Principle of Overall Integration: All the plant facilities and services should be fully
integrated into a single operating unit; to minimize cost of production. Integration of
production facilities like men, machinery, raw materials, supporting activities and any other
such factors which result in the best compromise.

21
 6. Principle of Safety: There should be in-built provision in the design of layout, to provide for
comfort and safety of workers.
7. Principle of Smooth Flow: The layout should be so designed as to reduce work bottlenecks
and facilitate uninterrupted flow of work throughout the plant.
8. Principle of Economy: The layout should aim at effecting economy in terms of investment in
fixed assets.
9. Principle of Supervision: A good layout should facilitate effective supervision over workers.
10. Principle of Satisfaction: A good layout should boost up employee morale, by providing
them with maximum work satisfaction
……………………………………
Process /Steps Involved Designing a Plant Layout
1. Collection of required data: Data about the size of the plant, type of products to be produced,
method of production to be adopted, extent of space available, extent of mechanization etc are
to be collected.
2. Preparation of blueprint for the floor plan: Based on the data gathered, a blue print has to
be prepared for the floor plan. Care should be taken to ensure, that the layout provides for
unhindered movement of men and materials with minimum possible effort and time.
3. Preparation of process chart and flow diagram: The process chart and flow diagram
depicting the various activities to be performed and the linkages between them has to be
prepared.
4. Preparation of draft layout: A draft layout needs to be prepared clearly depicting the
positioning of men and materials and the process flow. The draft layout should be circulated
and discussions held with employees inviting suggestions for improvement.
5. Test run: A test run is important to understand the efficiency of the layout in a real time work
environment. Problems not noticed in the earlier stages can occur at this stage. The initial
problems noticed need to be modified and test runs should be continued for at-least a few
times to ensure that the layout.
………………………………
Q.17. Define plant layout? Explain the objectives of plant layout?

Objectives/Significance plant layout

1. Minimize the cost of material handling: Reducing the time and distance it travels, paring
equipment costs, avoiding damage and boosting storage capacity. Ultimately,
controlling material-handling costs increases productivity and brings a company more profit
2. Avoid industrial accidents: Best plant layout preventing the industrial accidents through
Proper safety measures, Proper selection and safety conscious. Enforcement of discipline,
Safety committees, and Proper maintenance of machines, equipment and infrastructural
facilities.
3. Eliminate bottlenecks of plant capacities: There are several ways to eliminate bottlenecks.
Some means of doing so are: Adding resources to the bottleneck operation (more people),
minimizing downtime, eliminate non-value activities, investing in more machinery which
completes the same action and optimizing the bottlenecks operation
4. Increase material turnover: In accounting, the Inventory turnover is a measure of the number
of times inventory is sold or used in a time period such as a year. The equation for inventory
turnover equals the cost of goods sold divided by the average inventory. Inventory turnover is
22
 also known as inventory turns; merchandise turnover, stock turn, stock turns, turns, and stock
turnover.
5. Utilize the cubic area of the factory effectively: Quantify the factory area profile in terms
of capacity and utilization. Thoroughly understand the flow and utilization of the current
layout, including rack configuration, slotting/pick philosophy, receiving, put away,
replenishment, inventory management and packing Include seasonal peak trends of inbound
and outbound product manufacturing flow.
6. Improve objectionable operation: The main characteristic of the factory operation is the use
of machinery, originally powered by water or steam and later by electricity.
Other characteristics of the operation mostly derive from the use of machinery or economies of
scale, the centralization of factories, and standardization of interchangeable parts.
7. Increase returns on the investment: One way to increase your return on investments is to
generate more sales and revenues or raise your prices. If you can increase sales and revenues
without increasing your costs, or only increase your costs enough to still provide
8. Utilization of installed capacity: Capacity utilization or capacity utilization is the extent to
which an enterprise or a nation uses its installed productive capacity. It is the relationship
between output that is produced with the installed equipment, and the potential output which
could be produced with it, if capacity was fully used.
9. Utilize man-power resources effectively: Manpower utilization is a production concept that
describes how effectively a manufacturer uses its manpower or workers. Manufacturing
commonly use the concept of manpower utilization to evaluate output in relation to labor costs.
10. Elimination of idle time: Layout helps to planned production and proper supervisions, so that
idle time will be reduced to a minimum level. Instructions and drawing must be clear so that the
workers are not confused or have to wait for clarifications.
…………………………………………..

What are the symptoms/characteristics of bad plant layout?

1. Material Congestion 4.Excessive WIP 7.Poor Space Utilization
2. Long Transportation lines 5. Production bottlenecks 8.Machines are idle
3 .Excessive handling 6.Long Production Cycle 9 .Mental and Physical Strain.
……………………………………
Q.18. Explain the quantitative techniques for optimal designing the plant layout?

Some of the important techniques of plant layout are:

1. Process chart: It is a graph containing details regarding various activities and operations
taking place in the organization from start to the last stage of the work.
2. Process flow diagram: This is an aid to process chart. This relates to details regarding
position of machines, area covered by each machine, internal transportation and other
operations pertaining to production. This model diagram is prepared on the paper.
3. Templates: The area covered by a machine is cut to scale from a thick paper to form a
template. Not only machines but space covered by furniture, equipment and other
components can also form a template. These can be well arranged representing the actual
plan of layout to be undertaken.
4. Models: Three dimensional wooden models of machinery, equipment and other devices and
components can be prepared. By seeing these models even a layman can form an idea about

23
 the layout of the plant. But this technique is very costly and only big concern can afford to
install such a measure.
5. Drawings: Layout drawings can be got prepared by drafts men showing walls, stairways,
machines and equipment etc.
6. Machine data card: These cards are tied with different machines operating in the plant.
These obtain valuable information regarding various salient features or characteristics of
machines viz., efficiency, capacity space area covered by the machine and technique of
operating the machine etc.
……………………………….
Q.19.Explain the various types of Plant Layouts?
Four basic plans of the arrangement of manufacturing facilities

………… ……………
Q.20.What is Product Plant Layout? Explain advantages and disadvantages?
Product /line plant Layout: all the machines are arranged in the sequence, as required to
produce a specific product. It is called line layout because machines are arrange in a straight
line. The raw materials are fed at one end and taken out as finished product to the other end.
According to Merrick Product Plant Layout is ``machines that are needed to produce a
product are arranged sequentially in a continuous line and the raw materials are fed into the first
machine and the final product comes out of the last machine.``

Fig: Product Plant Layout

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Advantages/ Suitability of Product Plant Layouts

1. Smooth flow of production: The entire production process is integrated. Therefore the
possibility of stoppage of production at different stages of production is eliminated. Hence
smooth flow of production is ensured.
2. Lower material handling costs: Since machines are arranged based on the sequence of
operations, there is no backtracking (back and forward movement) or criss-crossing of
materials. Therefore, cost and time involved in handling of materials is minimized.
Transportation cost involved in transporting materials from one machine to another is
eliminated.
3. Lesser work-in-progress: Since the production process is continuous and uninterrupted,
work-in-progress is less. Investment in work-in progress is less and the storage space
required is also minimized..
4. Optimum space utilization: Since all machines are arranged sequentially, space available
can be utilized in an optimum manner. Even in case of congested space, arrangement of
machines would not be a problem, because the machines can be arranged in U shape.
5. Effective utilization of resources: Product layout ensures effective utilization of resources
by ensuring: Minimum movement of workers, continuous production process and reduced
wastage,less working-progress and mechanization of materials handling,
6. Effective supervision: Since production process is integrated and
continuous, supervision and control of the manufacturing process is easy. Inspection points
are integrated into the production line.
7. Production control: Since the production process is continuous, production control is
facilitated. The management can plan for the operations and adopt measures to complete the
work according to the plans.
8. Savings in time: Time spent for transporting materials can be minimized. Since machines
are arranged based on the sequence of operations, mechanized equipment such as conveyor
belts can be used for transporting materials. This results in significant saving of time.
9. Removal of obstacles in production: Product layout ensures unrestricted and continuous
production thereby minimizing bottlenecks in the process of production; this is because work
stoppages are minimum under this method.
10. Lesser manufacturing time: Under this method (as already pointed), backward and forward
handling of materials is not involved; it leads to considerable saving in manufacturing time.

Disadvantages Of Product Layout

1. Rigidity: The layout is not flexible. Since the operations are performed in a sequential
manner, adjustments in the course of production cannot be made.
2. Expansion is difficult: It is difficult to expand production beyond the capacity of each line
of production.
3. Costly: This type of layout is costly. Machines in this type of layout are arranged on the
basis of sequence of operations and not according to functions. Therefore it results in
duplication of similar type of machines needed for different lines of production.
4. Supervision difficult: Under this layout, there are no departments for various types of work.
Therefore specialization in supervision is difficult.
25
 5. Complete stoppage during breakdown: Since output of one machine is the input of the
next machine, any breakdown of one machine results in the complete stoppage of work.
6. Monotony: Since workers are engaged in repetitive nature of work, it results in monotony.
Workers may lose interest in the job. The labor force has very little opportunity to display its
talent.
7. High labor cost: Since workers work on specific machines, they lack knowledge to work on
other machines. Therefore in case of absenteeism of a worker engaged in any particular
work, the entire workflow may get affected.
8. Lesser flexibility: As work is carried in sequence and process arranged in a line, it is very
difficult to make adjustments in production of operations. Sometimes, certain changes under
this method become very costly and impractical.
9. Interruption due to breakdown: If one machine in the sequence stops on account of
breakdown, other machines cannot operate and work will be stopped. The work stoppage
may also take place on account of irregular supply of material, poor production scheduling
and employee absenteeism etc.
10. Lack of specialization in supervision: Supervision of different production jobs becomes
difficult under this method as there is absence of specialized supervision as the work is
carried on in one line having different processes and not on the basis of different departments
for different specialized jobs.
…………………………..
Q.21.What is Process Plant Layout? Explain advantages and disadvantages?

Process Layout (or Functional Layout) In this type of layout, all machines performing similar
type of operations are grouped at one location i.e. all lathes, milling machines etc. are grouped in
the shop and they will be clustered in like groups.

Typical process layout is depicted below:

Fig: Process Plant Layout

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Advantages of Process Plant Layout

1. Flexibility: It is more flexible when compared to a product layout. Changes in operations as

well as their order can be made without disturbing the existing layout. Any new operation can
be added.
2. Lower investment: General purpose machines which are usually of low cost are used.
Duplication of machinery is avoided. Further general purpose machines do not become
obsolete as rapidly as special purpose machines.
3. No stoppage of production: Incase of Machine was breakdown; the whole process does not
come to a standstill. Work of the machine which suffers from breakdown can be transferred to
the other machines.
4. Scope for expansion: Different capacity lines can be expanded under this type of layout. New
machines and labor can be added without upsetting the existing order of arrangement.
5. Full utilization of equipment: Process layout facilitates full utilization of equipment. General
purpose machines are used in each department which can perform a variety of jobs. There is
no need to provide a separate machine for each product line.
6. Better supervision: Because of specialization in operation, an efficient and better supervision
is possible.
7. Better utilization of workers. The special abilities of the workers and supervisors can be
utilized better if the machines ate arranged according to their functions.
8. Adaptability in case of breakdowns: Unlike the line layout, a breakdown of a machine does
not disrupt the whole work.

Advantages of Process Layout

1. Inefficient material handling: Materials have to be carried forward and backward quite
frequently. Mechanization of material handling becomes difficult. Fixed path material
handling equipment like conveyor belts, chutes etc cannot be used and cost of material
handling is quite.
2. High space requirement: Space requirement is more than product layout. More storage space
is to be provided around machines for waiting material to be processed.
3. High investment in inventory: Due to the lack of continuous flow of production there is high
in-process inventory. Frequently materials have to be carried back and forth. This results in
delays and therefore the investment in inventory is high.
4. High supervision cost: Cost of supervision is high because the number of employees per
supervisor is less resulting in reduced span of control. Further, the work is to be checked after
each operation.
5. Longer production time: Time required for production is more in the case of product layout.
6. Skilled labor required: Skilled labor needs to be employed to perform variety of operations
in general purpose machine
7. Difficulty in the use of machines: The mechanical devices for material handling, cannot be
conveniently employed.
8. Dis-economy of floor space: This type of layout requires more floor space than the product
layout.
9. Wasteful hauling of materials: The materials have to be carried forward and backward quite
frequently. This means both delay and waste.
27
 10. Difficulty of production control: Production control is difficult to enforce under such layout
and is both costly and complex.
……………………….
 Combination Layout:
In practice, plants are rarely laid out either in product or process layout form. Generally a
combination of the two basic layouts is employed; to derive the advantages of both product
and process layout systems. For example, refrigerator manufacturing uses a combination
layout.

 Fixed Position Layout:

It is also called stationary layout. In this type of layout men, materials and machines are
brought to a product that remains in one place owing to its size. Ship-building, air-craft
manufacturing, wagon building, heavy construction of dams, bridges, etc. are typical examples
of such layout.
…………………………………………..
Q.22. Explain the difference between product plant layout and process plant layout?

………………………………………..
Q.23.What is Plant maintenance? Explain various types of Plant Maintenance?

Plant maintenance: It is usually refers to the methods, strategies, and practices used to keep an
industrial factory running efficiently. This can include anything from regular checks of
28
equipment to make sure they are functioning properly, to cleaning garbage bins and toilets. The
general aim of plant maintenance is to create a productive working environment that is also safe
for workers.
Objectives/Importance of Plant Maintenance
1. Machines condition: Machines and other facilities should, be kept in such a condition which
permits them to be used as their optimum (profit making) capacity without any interruption
or hindrance.
2. Achieve minimum breakdown: The objective of plant maintenance is to achieve minimum
breakdown and to keep the plant in good working condition at the lowest possible cost.
3. Ensures the availability of the machines: Maintenance division of the factory ensures the
availability of the machines, buildings and services required by other sections of the factory
for the performance of their functions at optimum ret.
4. Minimize the total production cost: Minimize the total production or operating costs
directly attributed to equipment service and repair.
5. Prevent the loss of production: Equipment breakdown leads to an enviable loss of
production. If a piece of equipment goes out of order in a flow production factory, the whole
line will soon come to a halt. Plant maintenance prevents the loss of production.
6. Remove the expensive and frequent repairs: An un-properly maintained or neglected plant
will sooner or later require expensive and frequent repairs. With the passage of time all
machines or other facilities (such as transportation facilities, buildings etc.) wear out and
need to be maintained to function properly.
7. Properly maintained the process materials: When ever plant was properly maintained the
equipments will reduce the loss in production time & spoiled materials (because sudden
stoppage of process damages in-process materials).
8. Affects production management: plant breakdown creates problems such as loss in
production time, increase in spoilt materials form sudden stoppage of process damages in-
process materials, failure to recover overheads.
………………………………………
Types of Plant Maintenance:

Fig: Types of Plant Maintenance

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Q.24. Define Preventive Maintenance? Explain the process of preventive maintenance?

Preventive Maintenance : The care and servicing by personnel for the purpose of maintaining
equipment in satisfactory operating condition by providing for systematic inspection, detection,
and correction of incipient failures either before they occur or before they develop into major
defects.
According to Taylor Preventive maintenance refers to maintenance action performed to keep or
retain a machine/equipment or asset in a satisfactory operating condition through periodic
inspections, lubrication, calibration, replacements and overhauls.

Importance /Objectives of Preventive Maintenance

1. Prevent major repairs: Reacting once a problem occurs is often very costly. All
maintenance issues worsen over time and the longer an issue waits to be fixed, the more
damage can occur. It can be frustrating when equipment breaks down and what could have
been a minor fix is now a major repair.
2. Improve safety: If the equipment isn’t working optimally, it can create unsafe working
conditions and workers may be injured. Depending upon the type of equipment you work
with, a complete failure could easily cause bodily harm to employees.
3. Increase efficiency: Routine maintenance in the form of inspections, oil changes, parts
replacements and more help equipment to run more efficiently. When equipment slowly
deteriorates, you’re probably not likely to notice a drop in the production.
4. Reduce downtime: Maintenance tasks do require some downtime but a preventative
maintenance program decreases and optimizes any downtime. Using CMMS software enables
pre-planned maintenance at times when it has less of an impact.
5. Improve reliability: Customers need to be able to count on a business to deliver products,
materials or services on time without any unnecessary delays. If you wait until an asset breaks
down altogether before performing necessary maintenance, you could find that a critical piece
of equipment becomes unusable for a significant period of time.
6. Conserve assets: Equipment doesn’t come cheap and the better it’s cared for, the longer it
lasts. Neglecting equipment and not keeping it properly maintained can drastically reduce its
lifespan. As preventative maintenance prolongs equipment life, this results in decreased costs
and increased profit.
7. Maintenance Scheduling: In general, equipment comes with recommended maintenance
tasks and the frequencies at which those tasks should be completed. Therefore, when a new
piece of equipment is implemented in a process, it is useful to incorporate the recommended
maintenance tasks into your overall maintenance schedule.
8. Process Monitoring: The Fourth Industrial Revolution increasing focus on process
optimization and data acquisition. Equipment monitoring devices help ensure that users are
aware of the status of their equipment, and alert users at the first sign of device failure or
insufficient performance.
9. Inspect and Adjust Components Regularly: Over the lifespan of a piece of equipment,
normal wear and tear are inevitable. However, improper use can cause equipment to wear
much more quickly than expected. Therefore, it’s important to regularly inspect, lubricate,
and align components with moving parts.
……………… ……………. RSR

30
Q.25. what is Break down maintenance? Explain Causes/reasons break down of machines?

Breakdown maintenance:
It is a form of material or equipment remediation that is performed after the equipment or material
has lost its functioning capabilities or properties i.e. Repairs or replacements performed after a
machine has failed to its functional state following malfunction or shutdown.
Maintenance performed on equipment that has broken down or unusable.

Causes/reasons break down of machines

1. Not reading the operator's manual:"Some workers have never even opened the owner’s
/work manual. Most of what they need to know is in there."Owner’s manuals cover
everything from maintenance checklists to calibration instructions.
2. Improper maintenance: Skipping daily maintenance is another mistake that can cause
downtime. It is important to grease all lube points daily and check engine oil and fluids such
as transmission fluid and urea or diesel exhaust fluid.
3. Poor electrical connections: This problem is becoming more commonplace as more
machinery is electronically controlled cleaning away dust and dirt around the connectors can
help. Cleaning, use compressed air instead of water to keep moisture away from the wires.
4. Overrunning machines: Some operators/workers out there that push the machines too hard
for too long and try and force them to do things they weren’t designed for. Run machines just
under their intended maximum performance level and not than more.
5. Not replacing worn parts: When a part on a machine breaks, some customers will replace
only that part and not check or replace other parts that may have caused the initial failure.
Don’t replace all the things we recommend need replacing,
6. Misaligned tighteners: Tighteners that are not tracking straight with the belt or chain in
relation to the main drives can put tension on the belt or chain, causing it to break or wear
excessively. It’s important to replace worn bushings in the tightener pivot that may be
pushing the belt or chain sideways. "
7. Improper storage: Combines and planters can build up dust and debris, which attract
rodents. Rodents gnaw on wires and the dust itself can interfere with electrical connections.
Storing machinery inside and cleaning around all electrical connections and other areas of
buildup before parking it inside.
8. Weather-related issues: Operating in wet, muddy conditions can put strain on equipment.
Understanding the weather-related issues can alert you to problems to look for. Heavy rains
.Dirty air .Lack of humidity in the atmosphere are weather problems.
9. Ignoring warning signals: Warning lights on screens are there for a reason, often signaling
issues that need to be addressed, such as low hydraulic pressure, high engine temperature or a
shaft that isn’t turning.
10. Untrained operators Lack of training can result in abused machinery and costly
breakdowns."We see that fairly often," Bates says. Time invested in training can make your
machinery last longer.
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31
Q.26. Distinguish with Preventive Maintenance Breakdown maintenance?
The following are the Differences between Preventative and Breakdown maintenance

UNIT-III

Q.27.what is production? Explain the importance of production?

Production: Production is the organized activity of transforming resources into finished

products in the form of goods and services the objective of production is to satisfy the demand
for such transformed resources for creating utility towards satisfying the human needs.
Importance of Production:
1. Production helps to improve our standard of living: Economic growth is defined as
an increase in the productive potential of an economy. Growth can lead to higher living
standards because if GDP rises, there is more money in the domestic economy.
2. Provision of employment opportunity: production creates employment opportunities for
individuals because it accomplishes many things such as establish a baseline for acceptable
behavior, which is important considering the vast array of lifestyles, values, and attitudes
individuals have.
3. Production makes goods and services available: production is the act of creating an output,
a good or service which has value and contributes to the utility of individuals. They are
improving quality-price-ratio of goods and services and increasing incomes from growing and
more efficient market production.
4. Production helps to increase export potentials: here are several ways to evaluate the export
potential of your products. questions about how exporting will enhance your company's goals
can help to management and personnel, production capacity, and financing,
5. Production increases the wealth of the people: Distribution of wealth and income, the way
in which the wealth and income of a nation are divided among its population, or the way ...

32
 One classification system categorizes wealth and income on the basis of the ownership of
factors of production.
6. Production helps people to acquire special skills: Drawing from our experience, below we
review some of the skills that manufacturing hiring managers are looking for in prospective
employees for attention to detail, critical thinking, Strong Communication, Interest and
Aptitude for Technology.
7. Production can lead to specialization: job/work specialization is its potential to increase
worker productivity and output. While productivity tends to benefit the employer of
workers, specialization can also be advantageous to workers in that it may improve
employment prospects.
8. Expansion of the Firm: The production helps the firm to get bigger and grow. This is
often as a result of it tries to enhance quality and cut back prices. This helps the firm to
earn higher profits. These profits facilitate the firm to expand and grow.
9. Minimizes price of Production: Production facilitates to reduce the value of production.
It tries to maximize the output and minimize the inputs. This helps the firm to attain its
price reduction and potency objective.
10. Reputation, Goodwill and Image: Production management helps the firm to satisfy its
customers. This will increase the firm’s name, goodwill and image. an honest image helps
the firm to expand and grow.
11. Helps to Face Competition: Production helps the firm to face competition within the
market. This can be as a result of production management produces product of right
amount, right quality, and right value and at the correct time.
12. Optimum Utilization of Resources: Production facilitates optimum utilization of
resources like work force, machines etc. therefore the firm will meet its capability
utilization objective; this may bring higher returns to the organization.
……………………………
Q.28.what is production? State the different Types of production?

Types of production
1. Job Production: Under this method peculiar, special or non-standardized products are
produced in accordance with the orders received from the customers. As each product is non-
standardized varying in size and nature, it requires separate job for production.
2. Batch production: It refers to the production of goods, the quantity of which is known in
advance. It is that form of production where identical products are produced in batches on the
basis of demand of customers’ or of expected demand for products.
3. Mass or flow production: This method involves a continuous production of standardized
products on a large scale. Under this method, production remains continuous in anticipation
of future demand.
4. Continuous production or Process production: The materials, either dry bulk or fluids that
are being processed are continuously in motion, undergoing chemical reactions or subject to
mechanical or heat treatment. Continuous production system involves a continuous or almost
continuous physical flow of materials

33
 5. Direct Production: This involves production of goods and services on a small scale. It is
usually done by an individual for the purposes of his/her family use or consumption. The
goods produced are meant for the family use alone and not for sale.
6. Indirect Production: Goods and services are produced on a large scale. Indirect production
is sub divided into: a. Primary Production. b. Secondary Production. c. Tertiary Production.
a. Primary production: Primary production refers to the extraction of basic raw materials
from their natural location as provided by nature. Examples of primary production are
agriculture, fishing, mining etc.
b. Secondary Production: Secondary production involves the transformation or conversion
of raw materials or semi-finished goods into final forms that are acceptable to the
consumers. Examples are houses, cars, food, etc.
c. Tertiary Production: This ensures goods produced at the primary and secondary levels
are distributed to the final consumers. This also includes all kinds of service industries
such as transportation, communication and tourism.
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Q.29.Define work study? Explain the objectives of work Study?

Definition of work study: According to ILO — International Labor Organization — work

study is “a term used to embrace the techniques of method study and work measurement which
are employed to ensure the best possible use of human and material resources in carrying out a
specified activity.” In other words, “work study is a tool or technique of management involving
the analytical study of a job or operation.” Work study helps to increase productivity. It
examines the method and duration involved in the process.

Fig: Techniques of Work Study

Objectives /Significance of Work Study:

1. Cost Reduction: The study results in lowering of cost of manufacturing as it eliminates

unnecessary movements in work or job or motions.
2. Productivity Improvement: It enhances the efficiency of the production and hence increases
the productivity.

34
 3. Profitability: It raises the profitability without raising the sales price of the product. For
example, a product manufactured at Rs. 100 and sold at Rs. 120 will give a profit of Rs. 20,
which is 20%. If the same is able to be manufactured at Rs. 80 by using work study and is
sold at Rs. I00 gives a profit of Rs. 20 but it is 25%.
4. Standardization: The work study standardizes the work by which the employees get job
security and the customer finds reliability and interchangeability. The target or task
performance of the worker will be his weapon to safeguard his job while customers get
delighted by getting a standard product.
5. Easier Work: The purpose of the work study is fulfilled if the job is made easier even though
it couldn't reduce the cost nor increase the production. Because the ease in doing the job will
automatically raise the productivity by reducing the fatigue in the employee.
6. Fair Day Wage: As the work is timed and based on this, the target is fixed, the operator gets
a "fair day wage" as explained in Taylor's approach. This not only regulates the employee but
also provides the employer a good control over the workmen. So also it builds up a fair
relationship between the employer and employee.
7. Better Working Conditions: An Overview Work study provides good working conditions
by which the worker would love to work in the environment. It also makes the work place
clean. neat and tidy and thus brings out a good working culture.
8. Deterministic Production Schedules: The work study proves the job to be practicable and
hence results in exactness in the production by which the production schedule can be met as
per the plan. This makes the producer to satisfy the customer by meeting the delivery
schedules accurately.
9. Increased efficiency: Track and limit how much time you're spending on tasks. Take regular
breaks. Set self-imposed deadlines. Follow the "two-minute rule." Just say no to meetings.
Hold standing meetings. Quit multitasking. Take advantage of your commute.
10. Choose the fastest method to do a job: There are many different ways to engage the public
with your work. Explore a range of methods and techniques that might be suitable for
different purposes and effectively complete the job.
--------------------
------------------RSR

Q: 30.Define Work study and method Study? Explain Process /Steps for both of them?
Method Study : A procedure for examining the various activities associated with the problem
which ensures a systematic, objective and critical evaluation of the existing factors and in
addition and imaginative approach while developing improvements. i.e. 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.
Process /Steps involved for work Study/Method Study: following is the procedure.

Fig: Process /Steps involved for work Study/Method Study

35
1. Select: The appropriate job or process to be filled and selected for the purpose of work study
with aims to achieve the better method of doing work and analyses the work on
selected way is to be applied for completing with effectively.
2. Record: All the details concerning job should be recorded with a systematic manner by
using various recording techniques.
3. Examine :There must be a strict consolidated examination to be introduced to know the
depth of the work on recorded facts by asking questions like who, what ,when ,where ,why.
4. Develop: The most reasonable, purposeful economical method to be developed to carrying a
work study a part from various available word study methods.
5. Measure: The amount of Work Involved and set standard time to do with the application of
techniques designed to establish the time taken for a qualified worker to carry out a
specified job (task) at a defined level (rate) of performance.
6. Define: The new method and standard time through procedure oriented and
systematic study to establish the one best way (standard) method of doing an operation by
investigation and analysis of all the details regarding the job or operation carried out as per
the established standard method.
7. Installed: Install the new method and train personnel so that it conforms to the agreed
standard practices through required resources and materialize the best work study method.
8. Maintain: The installed work study techniques to be maintained with ergonomics,
operations research, work study and time-and- motion study. Apply the orderly and
systematic approach to planning, organizing, monitoring and
evaluating maintenance activities and their cost.
------------------
Q: 31.Define Work Measurement? Explain Process /Steps involved in work Study?

Work Measurement: The application of techniques designed to establish the time for a
qualified worker to carry out a specified job at a defined level of performance. It is concerned art
of observing and recording the time required to do each detailed element of an Industrial
activity/operation for the determination of the amount of time required to perform a unit of
work.
Objectives /Significance /Purpose of Work Measurement.

1. Manpower planning: Work measurement data is used for manpower planning. This is
because it gives information about the total hours required to perform the job. This helps to
estimate the number and type of employees who are required to do the job. It ensures that
there will not be any excess staff.
2. Production planning and scheduling: Work measurement data is used for production
planning and scheduling. This is because this data is used for making production standards.
This data is also used for scheduling. Scheduling means to fix starting and finishing time for
each job. This cannot be done without work measurement data.
3. Estimating productions costs: Work measurement data helps to estimate the production
cost. This is because it gives management accurate data about production time. This data
helps to estimate the labor costs. Secondly, indirect costs such as fuel and power
consumption, rent and salaries of staff, etc. also depends on the production time factor.

36
 4. Cost reduction and control: The data is used to reduce and control costs. This is because it
provides a guideline to the employees to work efficiently and effectively. This helps to make
optimum use of the available manpower. So labor cost and material costs reduce..
5. Rational basis for incentives:. The efficient employees are rewarded by giving them a higher
wage rate. Work measurement fixes the standard-time for doing the work. Who complete
work within a standard or before standard-time rewarded with higher wages.
6. Performance appraisal: It is done to find strengths & weaknesses of employees. Work
measurement helps to do performance appraisals. This is because it fixes the standard-output
and standard-time for each employee.
7. Training of employees: It helps to train the employees, especially the new employees. It
divides the full job into small elements (parts). It gives complete details about each element of
the job. It gives details about; how to do each element, the time taken for each element, the
machines and tools involved in each element, etc.
8. Comparing alternative methods: There are many methods for doing a job. Work
measurement data helps to choose the best method for doing a job.
9. Accepting new orders: Work measurement data tells us when each job will be completed.
So, it helps the company to decide whether to accept new orders or not. In other words, it
helps to find out whether the new-order will be completed within a specific time limit.
10. Fixing the selling cost: Work measurement data also helps to fix the selling cost of product.
This is because it estimates the cost of production, especially the labor cost. Selling cost is
decided after fixing the estimated production cost.
*******
 Methods of work Measurement:

…………………
Q.32. what is Time Study? Explain the process of time study?

What is Time Study: Time study is concerned with the determination of the amount of time
required get form a unit of work. It consists of the process of observing and recording the time
required to perform each element of an operation so as to determine the reasonable time in
which the work should be completed.

37
 Formulation /Process / of Time study:

………………………………
Q.33.What is Wok Sampling? Explain need and Procedure to conducting work Sampling?

Work sampling: work sampling is a technique of determining the percentage occurrences of a

certain activity (a group of processes, machines, or workers) with the help of statistical sampling
and random observations. When the sample size is large enough and random observations are
made indeed, there is quite a high probability that the observations would reflect the real
situation plus minus a certain margin of error.
Procedure /Steps involved in Work sampling

……………………………………..

38
 Q. 34.What is predetermined motion time system (PMTS)? Explain Merits and demerits?

Predetermined motion time system (PMTS): It may be defined as a procedure that analyzes
any manual activity in terms of basic or fundamental motions required to perform it. The main
use of PMTS lies in the estimation of time for the performance of a task before it is performed.
Advantages/uses/purpose/Merits of PMTS
1. Eliminates in accuracies associated: No timing is required so it eliminates inaccuracies
associated with stop watch time study.
2. Remove the performance rating: The use of PMT eliminates the requirement of
troublesome and controversial performance rating. So performance rating is not required.
3. Analyses the method conscious: The use of PMTS, force the analyst to be method conscious
and to take care of method in detail. This sometimes helps to further improve the method.
4. Useful in methods design, equipment selection: Since times can be calculated before
starting the work, this procedure is useful in methods design, equipment selection and design
and production planning and control.
5. Production planning and control: Production planning and control involves generally
the organization and planning of the manufacturing process. Specifically, it consists of
the planning of the routing, scheduling, dispatching and inspection, co-ordination and
the control of materials, methods, and machines, tooling and operating times.
6. Time standard arrived: PMTS is frequently used to perform wage-rates in labor (labour)
oriented such as apparel and footwear. Industries by quantifying the amount of time required
to perform specific tasks. This topic comes under wider industrial and production
engineering.
7. Improving and modifying work methods: This method suggested improvement in job
performance. The technique specially designed for improving work method through
eliminates the unnecessary activities.
8. Set time standards for various jobs: Set a time standards towardes specification for
measuring time: either the rate at which time passes or points in time; or both. In modern
times, several time specifications have been officially recognized as standards, where
formerly they were matters of custom and practice.
9. Estimation of labor cost and wage plans: Estimating on-site labor costs and wage plans are
very straightforward by PMTS. It describing the job content of the work, by indicating the
skill, knowledge etc. Matching the jobs with the employees.
10. Facilitate training of the workers and supervisory staff: PMTS provide training to
enhancing the skills, capabilities and knowledge of employees for doing a particular job.
Training process moulds the thinking of employees and leads to quality performance of
employees.
……………………..
Q.35. Discuses about the Methods time Measurement (MTM)?

Methods-Time Measurement (MTM) : It was developed by H.B.Maynard, USA in the 1940s

This is a predetermined motion time system that is used primarily in industrial settings to
analyze the methods used to perform any manual operation or task and, as a product of that
analysis, set the standard time in which a worker should complete that task. In other words the
time required to perform a specific task depend on the method chosen for the activity.
Need /Purpose of MTM:
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 1. Analyzing manual work processes: Using MTM work process analysis helps you identify
the detrimental elements in an operation and identify how to overcome obstacles. Without a
proper analysis, your teams will waste a lot of time and effort solving the wrong problems
2. Process block systems were developed: Process that is blocked is one that is waiting for
some event, such as a resource becoming available or the completion of an I/O operation. In a
multitasking operating system, individual tasks, or threads of execution, must share the
resources of the system.
3. Application in different process types: In manufacturing, process types can be considered as
project, jobbing, batch, mass and continuous. A description of each process is used to make a
one-off product to a customer specification with MTM technique.
4. Describing manual work processes: The process for payroll creation requires the input of
multiple factors like hours worked, vacation time, sick days, and statutory holidays. A
payroll clerk would then use the time input from the employees across the organization to
determine a pay cheque for each employee after applying rules the company.
5. Supports the design of work processes : Work process design is key to efficiency,
scalability, and competitiveness. While analyzing your processes recognize redundancies,
inefficiencies, areas of risk, lack of succession planning, and more. Standardization helps in
achieving consistency across the organization.
6. Systematically organizes processes: organizing process, managers coordinate employees,
resources, policies, and procedures to facilitate the goals identified in the plan to get the
quality products and services
7. Factors control them transparent: Factor Control system cannot operate in isolation. A
number of other functions are also requires to be performed for making be control effective.
such as Planning, action, delegation of a authority and flow of information
………………………
Q.36.What is Work Factor System? Explain Types of work factor system?

Work Factor System: It is a detailed system of Method study and Time study for analyzing the
actions and motions of workers. It is a system of pre-determined times, also called a P.E.M.T.S.,
Predetermined Elemental Motion Time System. It is an elemental time systems for compiling
time standards to establish the expected productivity of the human when performing useful
manual and mental work.

Types of work factor system/areas of work factor system.

1. Detailed Work-Factor: It is utilizing for operation which needs accurate time standards and
savings resulting from the use of accurate time standards are greater than the cost of
determining these standards.
2. Simplified Work Factor System: It is quite effective in preparing estimates before actual
production starts. Like other higher level systems it is easier and is rapidly used. Time units
used in Work Factor Table are in ten thousandths of a minute.
3. Abbreviated Work Factor System: This is a higher level system developed to fill a need for
a very simple system of predetermined time standards. They provide a rapid measurement
procedure, in as much as they make use the time data.

40
 4. Ready Work Factor System: It is normally utilized in evaluating manual work in industry
and other similar places. This technique has been developed to satisfy the requirement for a
simple method of evaluating measuring and comparing the time required for manual motions.
5. Brief work Factor System: Brief system is relatively new and like the Abbreviated Systems
uses a Time Unit of 0.005 minute (recorded as 5). It was developed to make the format
conform with the Detailed, and to the Ready Systems.
6. Mento-Factor System: It is a basic level system which is used for measuring mental
processes such as inspection, proof reading, color matching, and calculations and virtually any
repetitive or semi repetitive and predominantly mental operation.
………………………….
Q.37. Explain the Principles of Ergonomics?

Ergonomics: It is the science which deals with the relationship between man and his working
environments. It takes care of factors governing the physical and mental strains. Simply,
ergonomics is the branch of science that deals with the people and their working environment.

Principles of Ergonomics.

1. Work in Neutral Postures: Your posture provides a good starting point for evaluating the
tasks that you do. The best positions in which to work are those that keep the body "in
neutral.
2. Reduce Excessive Force: Excessive force on your joints can create a potential for fatigue and
injury. In practical terms, the action item is for you to identify specific instances of excessive
force and think of ways to make improvements.
3. Keep Everything in Easy Reach: The next principle deals with keeping things within easy
reach. In many ways, this principle is redundant with posture, but it helps to evaluate a task
from this specific perspective.
4. Work at Proper Heights: Working at the right height is also a way to make things easier.
5. Reduce Excessive Motions: The next principle to think about is the number of motions you
make throughout a day, whether with your fingers, your wrists, your arms, or your back.
6. Minimize Fatigue and Static Load: Holding the same position for a period of time is known
as static load. It creates fatigue and discomfort and can interfere with work.
7. Minimize Pressure Points: Another thing to watch out for is excessive pressure points,
sometimes called "contact stress. So minimize excessive pressure points.
8. Provide Clearance: Having enough clearance is a concept that is easy to relate to. Work area
should have enough clearance. Let the worker not worry about the bumps that they have to
encounter on daily basis.
9. Move, Exercise, and Stretch: To be healthy the human body needs to be exercised and
stretched. Better to take intervals between the works and stretch and move along. Stretching
technique may differ and depend on the work one does
10. Maintain a Comfortable Environment: This principle is more or less a catch-all that can
mean different things depending upon the nature of the types of operations that you do. It is
concerned about the lightening, space, cool air and many more
…………………

41
Q.38. what is a Flow process chart? Explain Its Benefits to the organization?
Flow process chart: Graphical and symbolic representation of the activities performed on the
work piece during the operation. It represents an algorithm, workflow or process, showing the
steps as boxes of various kinds, and their order by connecting them with arrows. The Flow
process Chart is a simple half-text, half-picture method of showing the steps in a process, using
symbols to indicate the type of action being taken and text to give details of the action. The
chart can selectively be used to show what happens to selected people, materials or equipment.

Fig: Flow Process Chart Model (Example Egg Try production)

Benefits of Flow Process Chart:

1. Communication- Flowcharts are better way of communicating the logic of a system to all
concerned. The old saying “a picture is worth a thousand words” holds true for flowcharts. It is
easier to explain the logic through the flowchart rather than the program itself.
2. Proper documentation- Digital flowcharts serve as a good paperless documentation, which is
needed for various purposes, making things more efficient.
3. Effective Coding- The flowcharts act as a guide or blueprint during the system analysis and
program development phase.
4. Proper Debugging- Debugging is the process of detecting and removing of existing and
potential errors (also called as ‘bugs. Debugging is used to find and resolve bugs or defects.
5. Efficient Program Maintenance- The maintenance of operating program becomes easy with
the help of flowchart. It helps the programmer to put efforts more efficiently on that part.
6. Visual Clarity: One of the biggest benefits of a flowchart is the tool's ability to visualize
multiple progresses and their sequence into a single document. Stakeholders throughout an
organization can easily understand the workflow while finding out which step is unnecessary
and which progress should be improved.

42
 7. Effective Coordination: For project managers and resource schedulers, the benefits of a
flowchart include the ability to sequence events and reduce the potential for overburdening
team members. Eliminating the unnecessary steps help to save time and resources.
8. Efficiency Increase: The flowchart lists each step necessary to perform a process. The
flowchart helps designer remove unnecessary steps in a process, as well as errors. Flowchart
should only include the steps are requirements to reach endpoint of the process.
9. Effective Analysis: It specifically shows what type of action each step in a process requires.
Generally, a rectangle with rounded edges defines the beginning or end of the process, a
diamond shape shows the point at which a decision is required, and a square block shows an
action taken during the process.
10. Problem Solving: Flowcharts break a problem up into easily definable parts. The defined
process displayed by the flowchart demonstrates the method of solving a complex problem. A
flowchart reduces the chance that a necessary step for solving a problem.
……………………
Q.39. what is Therbligs? Discuses the basic motion element of Therbligs?

Therbligs
:Therbligs are used in studying the relationship of the activities of the operator and the machine
as a means of timing operations. In obtaining motion time data for time standards. Acts as a
permanent record of the method and time of activities of the operator and the machine. study of
motion economy in the workplace. A workplace task is analyzed by recording each of the
therblig units for a process, with the results used for optimization of manual labour by
eliminating unneeded movements.

Basic 18 motion elements of Therbligs

1. Transport empty 6.Grasp 11. Transport loaded 16.Hold
2. Release load 7.Preposition 12. Position 17. Use
3. Assemble 8.Disassemble 13. Search 18. Select
4. Plan 9.Inspect 14. Rest
5. Unavoidable delay 10.Avoidable delay 15. Find
……………………………………….

UNIT –IV

Q.40. what is quality Control? Describe Importance/purpose of Quality control /TQM?

Quality control (QC):

Quality control is a process by which entities review the quality of all factors involved in
production. ISO 9000 defines quality control as "A part of quality management focused on
fulfilling quality requirements. It is a procedure intended to ensure that a manufactured product
or service to a defined set of quality criteria or meets the requirements of the client or customer.

Importance /Advantages /Need of /Objectives of Quality Control/TQM

1. Encourages quality consciousness: The most important advantage derived by introducing
quality control is that it develops and encourages quality consciousness among the workers in
the factory which is greatly helpful in achieving desired level of quality in the product.
43
 2. Satisfaction of consumers: Consumers are greatly benefited as they get better quality
products on account of quality control. It gives them satisfaction.
3. Reduction in production cost: By undertaking effective inspection and control over
production processes and operations, production costs are considerably reduced. The inferior
products and wastages thereby bringing down the cost of production considerably.
4. Most effective utilization of resources: Quality control ensures maximum utilization of
available resources thereby minimizing wastage and inefficiency of every kind.
5. Reduction in inspection costs: Quality control brings about economies in inspection and
considerably reduces cost of inspection.
6. Increased goodwill: By producing better quality products and satisfying customer’s needs,
quality control raises the goodwill of the concern in the minds of people. A reputed concern
can easily raise finances from the market.
7. Higher morale of employees: An effective system of quality control is greatly helpful in
increasing the morale of employees, and they feel that they are working in the concern
producing better and higher quality products..
8. Improved techniques and methods of production: By supplying technical and engineering
data for the product and manufacturing processes, improved methods and designs of
production are ensured by quality control.
9. Facilitates price fixation: By introducing quality control measures, uniform products of
same quality are produced. This greatly facilitates the problem of price fixation. One price of
standard products becomes prevalent in the market.
10. Increased sales: TQM ensures production of quality products which is immensely helpful in
attracting more customers for the product thereby increasing sales. It is greatly helpful in
maintaining existing demand and creating new demand for the product.
11. Adaptability to changing: Adaptability in the workplace is when an employee can be
flexible and have the ability to adapt to changing quality conditions. When a quality problem
occurs, TQM Develop solution to overcome up with change of production system.
12. Enhanced market image: It is a strategic step to develop the existing market rather than
looking for a new market. The company looks for new buyers to pitch the product to a
different segment of consumers in an effort to increase quality of product with TQM..
13. Increased customer loyalty and retention: Retention is a measure of whether an existing
customer continues to do business. Loyalty measures a customer's predisposition to select a
business entity as a preference indicates certain resistances to competitor’s both are by TQM.
…………………………

Q.41.What is Quality Assurance? Explain Difference between Quality assurance and quality
control?
Quality assurance:
It is the term used in both manufacturing and service industries to describe the systematic efforts
taken to insure that the product(s) delivered to customer(s) meet with the contractual and other
agreed upon performance, design, reliability, and maintainability expectations of that customer. It
is a Part of quality management focused on providing confidence that quality requirements will be
fulfilled.

44
 Differences between Quality Assurance and Quality Control:

……………………………………
Q.42. what is Total Quality Management? Explain methods and techniques of TQM?

Total Quality Management (TQM): Planning, maintaining, improving and controlling of

product quality with structured approach through continues improvement internal practices. It
provides a framework for implementing effective quality and productivity initiatives that can
increase the profitability, customer satisfaction and competitiveness of organizations. Simply
use the statistical methods for monitoring and maintaining of the quality of products / services.

Types /Techniques of Quality control charts: The following are the charts were practiced.

Fig : Techniques of SQC

45
 1. X-bar chart. In this chart, the sample means are plotted in order to control the mean value of
a variable (e.g., size of piston rings, strength of materials, etc.).
2. R chart. In this chart, the sample ranges are plotted in order to control the variability of a
variable.
3. S chart. In this chart, the sample standard deviations are plotted in order to control the
variability of a variable.
4. S**2 chart. In this chart, the sample variances are plotted in order to control the variability of
a variable. For controlling quality characteristics that represent attributes of the product, the
following charts are commonly constructed:
5. C chart. In this chart (see example below), we plot the number of defectives (per batch, per
day, per machine, per 100 feet of pipe, etc.).
6. U chart. In this chart we plot the rate of defectives, that is, the number of defectives divided
by the number of units inspected (the n; e.g., feet of pipe, number of batches
7. Np chart. In this chart, we plot the number of defectives (per batch, per day, per machine) as
in the C chart. However, the control limits in this chart are not based on the distribution of
rare events, but rather on the binomial distribution.
8. P chart. In this chart, we plot the percent of defectives (per batch, per day, per machine, etc.)
this chart is most applicable to situations where the occurrence of defectives is not rare (e.g.,
we expect the percent of defectives to be more than 5% of the total number of units
produced).
……………………….

Q.43.What is Sampling Inspection? Explain advantages of sampling Inspection?

Sampling inspection: is a technique to determine whether a lot or population should be

rejected or accepted on the basis of the number of defective parts found in a random sample
drawn from the lot. If the number of defective parts exceeds a predefined level, the lot is
rejected.
Advantages/Purpose /Significance /Merits/Objectives of sampling inspection

1. Less amount of inspection: Inspection to achieve a pre-decided degree of certainty about the
quality. Whenever started doing sampling inspections quality manager was interchangeably
mentioning possible level which leads to reduced the amount of inspection.
2. It consumes less time, and is less expensive: Although inspection has proven to be effective
at finding defects early in product development with less cost and time. Therefore, several
new variations have been attempted.
3. Improvement of operating efficiency: Fatigue and boredom incurred is much less
inspection, hence their operating efficiency remains high to provide easy access to real-time
data. Improve internal and external operating efficiency and customer satisfaction.
4. More accurate information: It is more accurate because in 100 percent inspection, errors get
introduced because of the fatigue and boredom incurred by the inspectors due to large
inspection work of repetitive nature.

46
 5. Control the further damage: Since fewer pieces are inspected, no damage is done to the
remaining pieces of the lot as they are not handled. It is much better to prevent further defects
rather than finding and removing them from products.
6. Quality rejection policy: Rejection of a complete batch on the basis of a sample inspection
decidedly pressurizes for improvements in quality. This Quality Rejection and Compensation
Policy have been established by sample inspection committee to provide guidelines on
acceptability.
7. Help to follow the Mass production procedure: SI applicable in those industries where
there is mass production and the industries follow a set production procedure. Sampling
inspection help to reduce labor costs, material costs and other resources costs.
8. Easily imparted training: impart training to staff employees to enable the employees to
assume new responsibilities.SI provide effective training to support career progression and
ensure employees have the knowledge and skills to perform well in their new assignments.
9. Identity the Products of destructive nature: The distractive nature products are generally
lower molecular weight. Cracking feedstock’s into liquid and volatile compounds, and
polymerizing and solids, may both occur in the Sampling inspection process.
10. Delivery times are improved: Due to quick sample inspection process, scheduling and
delivery times are improved. Supplier has consistently delivered acceptable products the SI
provides Feedback to drive improvements in products offered on Pre Delivery Inspection.
………………………………………..
Q.44.What is Sampling Inspection? Explain Types/Methods /Single and Double sampling?

Types/Methods of Sampling Inspection

1. Single Sampling: One sample of items is selected at random from a lot and the disposition of
the lot is determined from the resulting information. These plans are usually denoted as
(n,c) plans for a sample size n, where the lot is rejected if there are more than c defectives.
2. Double sampling plans: Here sample is drawn in two stages. The second sample is drawn
only when clear cut decision cannot be drawn from the first sample. Let c1 and c2be the
specified defectives in first and second samples respectively After the first sample is tested,
3. No Sampling Inspection: It only checks the outer carton and random check the packages, but
it can’t get any idea about the garment workmanship. They choose this sampling method in
some container loading inspection.
4. Full Inspection):100% inspection also calls full inspection, which means every unit must be
inspected. In this method, every piece of the garment would be granted or rejected instead of a
lot of garments to be granted or reject ted.
5. Spot Checking: Inspector will inspect the shipment goods randomly. In this method, the result
is found minimum. Some customers also choose it to check the raw materials, semi-finished
products, or container loading inspection.

47
 6. Arbitrary Sampling: This type of method is the most popular and widely used in the apparel
manufacturing sector. Whatever the lot size available is, a 10% sample of the lot is collected
and inspected and will decide the lot of garments to be granted or rejected.
7. Acceptance Sampling: In this sampling method, samples are collected and inspected by
statistically from the lot size and will decide the lot of garments to be granted or rejected. This
plan is used for inspection of raw materials before garments production.
……………………
Q.45. what is Zero Defect Concept? Explain advantages and Disadvantages?
Zero Defect Concept:. A product will be acceptable when it is free of defects. It is,
acceptable levels can be achieved for a product to maximization of profitability and
improvement in quality. Errors/problems free performance in providing goods or services.
There is no waste existing in a product. It is the concept of “doing it right the first time” to
avoid more expenses and time-consuming process. Simply it is a led program to totally
eliminate defects in industrial production.
Advantages/Merits/need/Principles of Zero Defect Concepts

1. Improves team morale and reputation with customers: It can changes the whole attitude
of the team and forces everyone to look in a more positive direction to eliminate all mistakes
from their workflow. Team members are have a huge impact on the way things get done.
2. Reputation with customers The same can be said for customers and the way they see your
business, as running a zero defects program can instill a lot of confidence in your
organization.
3. It eliminates hidden costs: Zero defects can help move away from that problematic state to
a great extent, while on the other hand, it can make it much more obvious what additional
costs you re incurring from post-release maintenance, and how they can be avoided.
4. Quality is defined as for requirements: Every product should have a requirement (a
description of what the customer expects to see). A product achieves quality when it meets
own set of standards i.e. predetermined requirements to achieve zero defects.
5. Defects prevention is better than quality inspection and correction: It is better to find a
defect in the process and fix it, rather than find the defect in the finished products. If you
spend time and money fixing the process instead of inspecting products for defects.
6. Quality standard means zero defects: Simply stated, any product that does not meet the
requirements set forth for that product will not be accepted by the customer and does not
satisfy the customers need
7. Quality is measured in terms of money: Every defect represents a hidden cost i.e.
inspection time, rework, revenue, wasted material, labor, and customer dissatisfaction. When
identified the costs can provide justification for spending money on steps to improve quality.
8. Ensuring higher profitability: ZD established that quality is the most important element for
ensuring higher profitability—and it’s the most important part of everyone’s job in the
manufacturing organization.
9. Striving for a perfect process: Announcing to your employees that you’re setting a goal of
Zero Defects could lead to a scenario where your team is striving for a perfect process. No
perfect process led to negatively impact performance and put a strain on employee attitude.

48
 10. Identify issues in real time: However, when you implement a program of continuous
improvement—and give your teams the tools they need to identify issues in real time and take
meaningful action to solve them with empowered and motivated to next improvement.

Disadvantages/Criticisms of Zero Defect Concepts

1. Ii is impossible to truly achieve: In many fields, the concept of zero defects is a more
abstract one and not something rooted in reality. It is impossible to completely eliminate
human error from all stages of product design and development.
2. It is outdated image: zero defects are actually seen as something outdated .This means that
continuing to use it while still engaged in those professional relationships can impact
negatively.
3. Over-engineered process: A process of over engineering in endeavoring to create a
situation of it increasing the time. And expense spent in an attempt to build the perfect
process that delivers a finished product.
4. Time and resources were twisted: The time and resources you dedicate to reaching zero
defects may get twisted, despite your efforts, negatively impact performance, and put a strain
on employee motivation i.e. failures can have the opposite effect.
5. Hamper the work culture More people and process might be involved to find out the
defects which will lead to extra cost. Also over strictness might hamper the work culture and
production in projects.
…………………RSR……………….
Q.46. Quality Circle? Mention the Advantages of quality circle?

Quality Circle:
Conceptually Quality Circles can be described as a small group of employees of the same work
area, doing similar work that meets voluntarily and regularly to identify, analyze and resolve
work related problems. The circle carries on the activities, utilizing problem solving techniques
to achieve control or improvement understanding in the work area and also help self and mutual
development in the process. It built mutual trust.
Objectives /Significance /role of Quality Circles:

1. To utilize human resources effectively: Develop, enhance and utilize human resources
effectively through Allotting them work in which they have an aptitude, Getting them
involved in the whole process, Motivating them to do their best, appreciating their every good
activity or accomplishment and not them.
2. To improve quality of products/services: improve quality of products/services productivity
and reduce cost of production per unit of output. Create a long-term plan
for quality improvement, break it in to small steps, and then make changes to achieve goals of
each step.
3. To satisfy the workers’ psychological needs: Satisfy the workers’ psychological needs for
self-urge, participation, recognition etc., with a view to motivating them. Accomplishment of
this objective will ensure enhancement of employee morale and commitment.

49
 4. To improve various supervisory skills: Improve various supervisory skills like leadership,
problem solving, and inter-personal and conflict resolution. use of the knowledge and skills of
the workers.
5. To utilize individual imaginative and creative: Utilize individual imaginative and creative
and innovative skills through participation, creating and developing work interest, including
problem solving techniques etc. quality circle promote something new and somehow
valuable is formed.
6. To develop good relations: Develop good relations between workers and managers: and
create cordial industrial relations through Develop your people skills, Identify the
relationship needs,. Schedule time to build relationships. Appreciate others and so on.
7. To overcome the barriers: overcome the barriers that may exist within the prevailing
organizational structure so as to foster an open exchange of ideas. The main challenges over
come with quality circles are additional costs, Unpopular market reception, Brand risk, Minor
increases in sales
8. To develop a positive attitude: Develop positive attitude and feel a sense of involvement in
the quality decision making processes of the services offered. Quality circles can give you
more confidence; improve your mood free from hypertension, depression and other stress-
related disorders.
9. To improve competence: An improving competency allows an organization to remain
adaptable and competitive, ultimately contributing to increased productivity and greater
revenue. This can easily be achieved with little to no expense, other than extra time and
attention.
10. To display human capabilities: Display human capabilities are totally in a long run.
Generally described as what people are effectively able to do or the positive freedom that
people have to enjoy valuable 'beings and doings'. Beings and doings are called 'functioning.
11. To make job satisfaction :quality circles Make everybody understand the contribution of job
satisfaction, job involvement which includes ,career planning ,an employee feels self-
motivated, content & satisfied with his/her job, having job stability, career growth and a
comfortable work life balance
……………………………………..
Q.47.What is six-sigma? Explain the process /phases of Six-Sigma Model?
Six-Sigma:
Six-Sigma is a set of management tools and techniques designed to improve business by
reducing the likelihood of error. It is a data-driven approach which uses statistical
methodology for eliminating defects i.e. It is the qualitative and quantitative techniques to
drive process improvement with the application of tools such as statistical process control
(SPC), control charts, failure mode and effects analysis, and process mapping for eliminating
the defects .

50
 Process /Phases/tool/Techniques/ Concepts of Six-sigma standard

1. Define: The Six Sigma process begins with a customer-centric approach. The business
problem is defined from the customer perspective. Goals are set. What do you want to
achieve? What are the resources you will use in achieving the goals? Map the process. Verify
with the stakeholders that you are on the right track.
2. Measure: The second phase is focused on the metrics of the project and the tools used in the
measurement. How can you improve? How can you quantify this? Measure your problem in
numbers or with supporting data. Define performance yardstick.
3. Analyze: The third phase analyzes the process to discover the influencing variables.
Determine if your process is efficient and effective. Does the process help achieve what you
need? Quantify your goals in numbers.
4. Planning: planning is a written summary of the process that lays out in detail the steps to be
taken to maintain a process or a device operating at the current level of performance. Control
plans ensure mean performance or variation in a batch of products.
5. Improve: This process investigates how the changes in “X” impacts “Y.” This phase is where
you identify how you can improve the process implementation. Identify possible reasons. Test
to identify one influenced by anther with establish process tolerance
6. Control: In this final phase, you determine that the performance objective identified in the
previous phase is well implemented and that the designed improvements are
sustainable. Validate the measurement system to be used. Establish process capability.
………………………………………..
Q.48. what is six-sigma? Represent the Advantages/Significance /importance of Six-Sigma?
Advantages/Significance /importance of Six-Sigma.
1. Achieve maximum satisfaction: Six-Sigma is driven by the customer and thus aims to
achieve maximum customer satisfaction and minimizing the defects. It targets the customer
delight and new innovative ways to exceed the customer expectations.
2. Improve profitability: Implementation of Six-Sigma methodology leads to rise of
profitability and reduction in costs. Thus improvements achieved are directly related to
financial results.
3. Implemented in every business: Six-Sigma is successfully implemented in virtually every
business category including return on sales, return on investment, employment growth and
stock value growth.

51
4. Prospective methodology: Six-Sigma is prospective methodology as compared to other
quality programs as it focuses on prevention on defects rather than fixing it. Provides
recommendations for potential problems before the company incurs any form of loss.
5. Attentive to the entire business processes: It is attentive to the entire business processes and
training is integral to the management system where the top down approach ensures that
every good thing is capitalized and every bad thing is quickly removed.
6. Adding value and ensuring quality: Six-Sigma has provided a proven-track record of
adding value and ensuring quality to the output of a business in the form of incremental
improvements to a product or service.
Disadvantages/ of Six-Sigma
1. Consume more time and less profitable: Applicability of Six Sigma is being argued among
the Six Sigma critics. They opined that the quality standards should be according to specific
task and measuring 3.4 defects per million as standard leads to more time spent in areas
which are less profitable.
2. Contradicts the innovation and kills the creativity: Six-Sigma gives emphasis on the
rigidity of the process which basically contradicts the innovation and kills the creativity. The
innovative approach implies deviations in production, the redundancy, the unusual solutions,
insufficient study which are opposite to Six Sigma principles.
3. Lack of accountability: People argue that Six Sigma is a bit gimmicky and simply a
rebranding of the continued improvement techniques and tools as practiced by Toyota. It thus
promotes outsourcing of improvement projects with lack of accountability.
4. Difficultly for regular implementation: The implementations of Six Sigma model require
skilled man force. Thus control and employee dedication are hard to accomplish if its not
implemented regularly.
5. Forgets specific mission statement or policies: It is also important to consider that when
Six-Sigma is implemented into a manufacturing process, problems arise as the company
focuses on Six Sigma endorsed policies only and forgets about its specific mission statement
or policies.
6. Increase in cost: Six-Sigma inspects the business processes minute-by-minute and generates
substantial amounts of empirical data, leading to time-consuming and complicated procedures
because its root, adoption of protocols often leads to an increase in costs.
…………………………………………
UNIT –V
Q.49. what is Human Resource management? Explain Scope/ Nature of HRM?
HRM: It is a process of procuring, developing and maintaining competent human resources in
the organization .HRM is an art of managing people at work in such a manner that they give
their best to the organization for achieving its set goals .i.e. HRM is the planning, organizing,
directing and controlling of the procurement development compensation integration,
maintenance, and separation of human resources to the end that individual, organizational and
social objectives are accomplished.
Scope/ Nature of HRM:

1. Human resources planning: - Human resource planning is a process by which the company
to identify the number of jobs vacant, whether the company has excess staff or shortage of
staff and to deal with this excess or shortage.
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2. Job analysis design: - Another important area of HRM is job analysis. Job analysis gives a
detailed explanation about each and every job in the company. Based on this job analysis the
company prepares advertisements.
3. Recruitment and selection: - Based on vacancies in the company prepares advertisements
and publishes them in the news papers. A number of applications were received interviews
are conducted and the right employee is selected.
4. Orientation and induction: - Once the employees have been selected an induction or
orientation program is conducted. The employees are informed about the background of the
company. They are told about the organizational culture
5. Training and development: Training program is also conducted for existing staff that have
a lot of experience. This is called refresher training. Training and development is one area
were the company spends a huge amount.
6. Performance appraisal: HR department checks the performance of the employee. Based on
these appraisal future promotions, incentives, increments in salary are decided.
7. Compensation planning and remuneration: -There are some rules were introduced to
calculate the compensation and other benefits..
8. Motivation, welfare, health and safety: - Motivation becomes important to sustain the
number of employees in the company. Apart from this certain health and safety regulations
have to be followed for the benefits of the employees.
9. Industrial relations: - Another important area of HRM is maintaining co-ordinal relations
with the union members. This will help the organization to prevent strikes lockouts and
ensure smooth working in the company.
---------------------------------
Q. 50. What is Human Resource management? Explain objectives and Limitations?
Objectives /Importance of HRM:
1. Effective Utilization of Resources: HRM teaches how to utilize human and non-human
resources so that the goals can be achieved. Organization aiming to utilize their
resources efficiently invites the HR department to formulate required objectives and policies.
2. Organizational Structure: Organizational structure defines the working relationship
between employees and management. It also defines positions, rights and duties,
accountability and responsibility, and other working relationships.
3. Development of Human Resources: Human resource management provides favorable
environment for employees so that people working in organization can work creatively. This
ultimately helps them to develop their creative knowledge, ability and skill.
4. Respect for Human Beings: It is to provide a respectful environment for each employee with
required means and facilitates employee along with an appropriate respect because the
dominating tendency develops that will result organizational crisis.
5. Goal Harmony: Bridges the gap between individual goal and organizational goal-thereby
resulting into a good harmony. If goal difference occurs, the employees will not be willing to
perform well. Hence, a proper match between individual goal and organizational
6. Employee Satisfaction: It provides a series of facilities and opportunities to employees for
their career development. This leads to job satisfaction and commitment with kind of
facilities and opportunities, they will be satisfied with their work performance.

53
 7. Employee Discipline And Moral: Human resource management tries to promote employee
discipline and moral through performance based incentives. It creates a healthy and friendly
working environment through appropriate work design and assignment of jobs.
8. Organizational Productivity: Human resource management focuses on achieving higher
production and most effective utilization of available resources. This leads to an enhancement
in organizational goals and objectives.
Limitations /Criticism on HRM
1. Recent Origin: So it lacks universally approved academic base. Different people try to define
the term differently. Some thinkers consider it as a new name to personnel management. Such
superficial actions may not bear much fruit which equired is change in attitudes, approaches.
2. Lack of Support of Top Management: The change in attitude at the top can bring good
results. Owing to passive attitude at the top, this work is handled by personnel management
people. Unless there is a change in approach and attitude of top management nothing
remarkable will happen.
3. Improper Actualization: HRM implemented partially training and development requirements
of employees. The aspirations and needs of people should be taken into account while making
human resource policies on improper actuated..
4. Inadequate Development Programs: There are many programs such as career planning, on
the job training, development programs, MBO, counseling etc. In reality HRM programs are
confined to class room lectures and expected results are not coming out of this approach.
5. Inadequate Information: Some enterprises do not have requisite information about their
employees. In the absence of adequate information and data base, this system cannot be
properly implemented. So collection, store and retrieval information is not HRM programs.
……………………………………….
Q.51.Explain Functions of HRM/HR Manager:

Functions of HRM/HR Manager:

………………………….

54
 Q. 52. What is Human Resource Development? Explain objectives and Limitations?

Human Resources Development (HRD):It is a learning experience, which is a series of

organized activities, conducted within a specialized time and designed to produce behavioral
changes for across of increasing knowledge, capabilities and positive work attitudes of all
people working at all levels in a business undertaking. HRD is Updating of skill and knowledge
to meet the present and future organizational challenges.

Components/Objectives/steps/Merits of HRD
1. Employee career development: which includes all the activities in the lifelong process of
developing an employee’s career?
2. Tuition assistance:, providing tuition or helping to pay for it.
3. Succession planning: which involves identifying and developing new leaders to replace old
leaders when they leave
4. Adaptability: Continues training that develops the professional skills of employees can help
the to them adapt themselves to organizational change that takes place on a continuous basis..
5. Mentoring: Mentoring occurs when an experienced person assists another in developing
specific skills and knowledge..The mentor enhances the mentored professional and personal
growth.
6. Coaching: A form of development in which a coach supports a learner. The coach tries to get
the learner to achieve a specific goal. That goal may be professional, personal, or both.
7. Performance management, which is an ongoing process between a supervisor and an
employee. It occurs throughout the year. The supervisor clarifies expectations, sets objectives,
and identifies goals. The supervisor also provides feedback and reviews results.
8. Performance development, which usually goes hand-in-hand with performance
management. Performance development providing opportunities for the employee to grow .
9. Employability: Employability means the ability, skills, and competencies of an individual to
seek gainful employment anywhere. So, HRD should aim at improving the skills of
employees in order to motivate them to work with effectiveness.
10. Equity: Recognizing employee irrespective of caste, creed, religion and language, can create
a very good environment in an organization with provides equal opportunities to all
employees in career planning, promotion, quality of work life, training and development.
----------------------------

Q. 53. Difference the HRM.HRD, PM, and industrial relations?

Personnel management(PM): Personnel management can also be defined as, that field of
management which is concerned with the planning, organizing, directing and controlling various
operative functions of procurement, development, maintenance and utilization of a labor force in
such a way that objectives of company, those of personnel at all levels and those of community
are achieved by consideration of the well-being of the individual, enables all those engaged to
make their maximum personal contribution in the effective working .

Industrial Relations (IR): The relation of Individual or group of employee and employer for
engaging themselves in a way to maximize the productive activities. In the words of Lester,
“Industrial relations involve attempts at arriving at solutions between the conflicting objectives
55
and values; between the profit motive and social gain; between discipline and freedom, between
authority and industrial democracy; between bargaining and co-operation; and between
conflicting interests of the individual, the group and the community.

HRM HRD PM IR
1.Nature :It refers to 1.Continuous develop- 1.Concerned with the 1.Interrelations
the application and ment and improve the planning, organizing, among managers,
manage the people in performance of directing , controlling workers, agencies
the organization to people in the and utilization of and employees in
obtain the objective organization. man power the e organization
2. Mgt function. It is 2.It is Proactive Mgt 2.Maintenance and 2.Negotiate,collecti-
Reactive function function utilization of labor ve bargaining
3. Objective improve 3Develop the skills, 3.Properacquring and 3. Healthy labor mgt
the wok culture of the knowledge,competen- use of human factors relations,coordina-
employees. cy of employees. within the org Tions.
4. Process : Routine 4. Ongoing 4.Old process 4. Moderate process
5. Dependency : 5. It is a subsystem of 5. It is a basic System 5. It is a subsystem of
Independent HRM of manpower Mgt. Industrial Mgt .
6.Organizing:organi- 6. organizing by HRD 6.organizeing by 6.organizeing by
zeing by HR manager manager personal manager relation manager
………………………..
Q.54.What is Job evaluation? Explain Advantages and disadvantages of Job Evaluation?

Meaning of Job evaluation: It is the process of establishing the value or worth of jobs in a job
hierarchy. It attempts to compare the relative intrinsic value or worth of jobs within an
organization. Job evaluation is a comparative process. In other words process of determining the
relative worth of different categories of jobs by analyzing their responsibilities. It is ranking of
job, not job holder.

Advantages/need /merits of Job Evaluation

1. Determination of compensation to jobs: Job evaluation is the cornerstone of the

compensation policy. It provides a rational basis for establishing base compensation for the
whole hierarchy of jobs in an organization by ascertaining their relative worth.
2. Maintaining consistency in the compensation structure: it can maintain internal and
external pay structure consistency. Internal is connected with maintenance of relative
remuneration rates within the organization, while external establishes a desired relativity of
an organizations wage structure with that of the industry.
3. Systematic analyses of HR functions – Job evaluation invariably involves a systematic
analysis of organizational jobs and generates a lot of data about the nature and duties of jobs
and the knowledge, skills, and abilities needed to perform jobs effectively.

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4. Improves industrial relations – By establishing wages rates for jobs in a scientific and
rational manner, job evaluation tends to eliminate wage inequalities. This helps in reducing
employee grievances arising out of wages and makes employer-employee relations
harmonious.
5. Determining the wage differentials: Job evaluation standardizes the process of determining
the wage differentials for various jobs. It means uniform standards will be applied to all jobs
in the organization to know their relative worth..
6. Reduce the rate of labor turnover: It also assists in retaining the workers or, in other
words, keeping down the rate of labor turnover because workers’ wages are determined
systematically by the process of job evaluation.
7. Removing inequalities in existing wage system: Job evaluation is a logical and, to some
extent, an objective method of ranking jobs relative to one another. It may help
8. Removing grievances: It improves labor management relations and workers morale. The
workers complaints or claims can be judged, it simplifies discussion of wages to remove the
grievance.
9. Establishing clear negotiations: Job evaluation replaces the many accidental factors,
occurring in less systematic procedures of wage bargaining by more impersonal and
objective standard thus establishing a clear basis for negotiations.
10. Easy to employment execution: The information collected in the process of job description
and analysis may also be used for the improvement of selection, transfer, and promotion
procedures on the basis of comparative job requirements.

Disadvantages/limits /demerits of Job Evaluation

1. No standard list of factors: There is no standard list of factors to be considered for job
evaluation. Moreover, all job factors can’t be measured accurately. Thus, job evaluation
lacks scientific precision.
2. Might not retain workers: The wages fixed for a job on the basis of job evaluation might
not retain workers who can make much money elsewhere because of law of demand and
supply.
3. Oppose the Trade unions: Trade unions oppose and suspicion the job evaluation because
some of the methods are not scientific and are difficult to understand. They fear that the job
evaluation will do away with collective bargaining for settlement of wages..
4. Time consuming process: requiring specialized technical personnel to undertake it and thus
too costly.
5. Financial burden: Job evaluation leads to frequent and substantial changes in wage and
salary structure, which in turn creates financial burden on the organization.
…………………………………

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 Q.55.What is Job evaluation? Explain various methods to measure the Job evaluation?

Methods /Techniques of Job Evaluation

Fig: Techniques /Methods of Job Evaluation

1. Points Rating:. Under this method, jobs are broke down based on various identifiable factors
such as skill, effort, training, knowledge, hazards, responsibility, etc. Thereafter, points are
allocated to each of these factors.
2. Factor Comparison Method: This method is a combination of both ranking and point
methods in the sense that it rates jobs by comparing them and makes analysis by breaking jobs
into compensable factors. key jobs are selected and compared in terms of common factors.
3. Ranking/job Comparison Method: Job as a whole is compared with other until all the jobs
have been evaluated and ranked. All jobs are ranked in the order of their importance from the
simplest to the hardest or from the highest to the lowest.
4. Grading/Job Classification Method:. Job grades are determined on the basis of information
derived from job analysis. The grades or classes are created by identifying some common
denominator such as skills, knowledge and responsibilities.
5. Competitive Market Analysis Method: This approach looks at external data. Job evaluation
forms the basis for market pricing. You utilize job descriptions to compare jobs to like
positions within the external marketplace.
-------------------RSR------------------------

Q. 56. Define the Merit Rating? Explain methods of Merit Rating/ Performance appraisal?

Definition of Merit rating/Performance appraisal:

According to Dale Yodder Merit-rating is the ``process of evaluating the employee’s

performance on the job in terms of the requirements of the job towards assessing the worth or
excellence or potentiality of an employee, for the purpose of how employee effectively assigned
or carrying the work``

Purpose /Role of Merit rating for promote the employee on performance

1. Documentation: It provides a document of employee performance over a specific period of

time. It’s a piece of paper that can be placed in an employee file.
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2. Clarify Expectations: Employees need to understand what is expected of them and the PA
process allows for a manager to clarify expectations and discuss issues with their employee.
3. Annual Planning: It provides a structure for thinking through and planning the upcoming
year and developing employee goals.
4. Motivation: The process should motivate employees by rewarding them with a merit
increase and as part of a comprehensive compensation strategy.
5. Structure: This process creates a structure where a manager can meet and discuss
performance with an employee. It forces the uncomfortable conversations that often need.
6. Feedback: Employees crave feedback and this process allows a manager the opportunity to
provide the employee with feedback about their performance and discuss how well
the employee goals were accomplished. It is opportunity to discuss employee development.

Methods of Merit rating/preference appraisal:

1. Ranking Method: Under this method, a man is compared with all others without considering
any specific factors. A rank is prepared by placing the best at the top and the poorest in
performance at the bottom. This method is suitable in case of small scale concerns.
2. Grading Method: Under this method, the performance of the employees is evaluated against
certain grades such as poor, good, very good, excellent or outstanding, satisfactory or
unsatisfactory. The grade which describes his performance can be allocated to him.
3. Graphic Scales Method: Under this method, performance of an employee is evaluated
against certain specific factors. Five degrees or scales are established for each factor and each
degree is defined. This method is most widely used in merit rating and is also the oldest.
4. Man-To-Man Comparison method: This method resembles with the factor-comparison
method of job- evaluation. Under this method certain Key personnel are selected for each
factor (which may include initiative, leadership, dependability, safety etc.) Other employees
will be compared with these key personnel by considering one factor at a time.
5. Check List method: In order to reduce bias or prejudice of the rater, the merit rating under
this method is actually done by the HR Department. The supervisor simply reports the.
Performance of the employee by putting ‘Yes’ or ‘No’ against a series of descriptive phrases.
6. Forced Choice Description Method: Usually the raters try to rate the employees in the
‘average’ category because it does not require further explanation. Under this method, the rate
is forced to select a statement from a pair of statements though both may be applicable or un
applicable to him.
7. Selection of Critical Incidents Method: The act or conduct of an employee during crucial or
critical circumstances is recorded by the rater. These critical incidents are carefully analyzed
and the behavior or qualities of the employees are carefully rated.
8. Free essay method: The supervisor writes a report about the worker which is based on his
assessment about performance of workers. The supervisor continuously watches the behavior
with employees, job knowledge, employee traits, development requirements for future, etc

59
 Fig: Methods of Merit rating/preference appraisal.
………………………………
Q.57. Explain various types of Wage incentive plans?
Wage payment System: It is the way of giving financial compensation to the workers for the
time and effort invested by them in converting materials into finished products. It indicates the
basis of making payment to the workers, which may be either on time basis or output basis. The
selection of the system depends on the type and nature of the concern and its products.

Types/Methods of Wage payment systems/ Plans

1. Time rate system: Under this system, the amount of remuneration or the total wages payable
to the workers depends on the time for which he is employed. Wage payment to be calculated
as follows:
Total wages = Total hours worked x wages rate per hour.
2. Piece rate system:. Under it, a worker is paid on the basis of output. In this system, the wage
rate is expressed in terms of per unit of output, per job or per work-order. Wage to be
calculated as follows:
Total wages = total output x wages rate per unit of output
3. Incentive wages payment plans: Under these plans, the advantages of time and piece-wages
system are combined, and incentives are provides to workers to work hard. Incentives by way
of bonus and other are given to efficient works for time saved.
Types of Incentive Wage Payment plans
a) Halsey Plan: This plan was first designed by Halsey in 1890. Standard time is fixed for
completing a work in advance. A person taking standard or more time is paid for the time
taken by him. A worker completing his task in less than the standard time is paid for
some of the time saved. The payments for time saved generally wages for one half of
time saved are paid. Formula as follows
W = T x R + (S – T/2) Where S= Standard time or allowed time to complete the job.
T = Time taken

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b) Rowan Plan: A worker is guaranteed minimum wages for time spent on the job. He gets
bonus for completing the job in less than the standard time. Bonus will be calculated on
the proportion of wages of the time taken which he saved bears to the standard time
allowed. Wages are calculated by the following relations: W = T x R + (S-T/S) x T x R

Fig General Incentive wage plans

c) Emerson Plan: Emerson developed this efficiency plan in 1910. A standard output is
fixed for determining the efficiency of workers. A worker reaching up to 66⅔% of
efficiency is paid only minimum wages and bonus is paid only when his efficiency
crosses this limit. The rate or bonus increases with the increase in efficiency.
d) Bedeaux Plan: This plan was devised by Charles E. Bedeaux in 1911. The benefit of
time saved goes both to the worker and his supervisor in the ratio of 3/4 and 1/4th
respectively. The standard time in terms of minutes which are called Bedeaux points or
B’s. Each B represents one minute through time and motion study
e) Taylor’s Differential Piece-. The standard time was fixed for completing a task with the
help of time and motion study. If a worker completes the task in the standard time he is
paid at higher rate and lower rate is paid if more than the standard time is taken.
f) Gantt’s Task and Bonus Plan: H. L. Gantt tried to improve Taylor’s method of wage
payment. The workers are guaranteed minimum wages for taking standard time or more.
A person taking less than the standard time gets time wages plus bonus.
g) Group Incentive Plan: A number of persons may be associated in completing a task.
The work of one person may be influenced by the work of the other. Under such
conditions, incentives may be offered for raising group performance.
i. Scalon Plan: This method is named after Joseph Scalon. There is a payment of one
percent participating bonus for every one percent increase in productivity under this
plan. The bonus is available to all workers except top management.
ii. Co-Partnership: The employees are offered shares of the enterprise at reduced rates in
this plan. The payment is also collected in installments. The employees share profits of
the enterprise as its members.

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 iii. Profit Sharing: The workers are an integral part of any organization and their
contribution to its prosperity should also be rewarded by making them the recipients of
profits.
------------------------
Q.58 .What is value Engineering? Explain the implementing process?

Value Engineering: It is also called as value analysis Systematic examination of factors

affecting the cost of a product or a service in order to achieving the specified purpose at the
required standard of quality and reliability. Organized approach to providing the necessary
functions in a project at the lowest cost. Value engineering promotes the substitution of
materials and methods with less expensive alternatives, without sacrificing functionality. It is
focused solely on the functions of various components and materials, rather than their physical
attributes.
Process/Steps/procedure/construction of Value Engineering.

1. Orientation: This phase identifies specific problems to address and serves to determine
the scope of the project. Problems are broken down into constituent elements that represent
issues to be addressed. Potential gains can be estimated for each problem solved.
2. Information: In this phase, data is collected and analyzed. It serves to refine the scope of the
project. Priorities are finalized and targets for improvement are set, as well as methods used
to evaluate progress.
3. Function Analysis: During this phase, a function is defined each function is then analyzed to
see what improvements can be made, if it is unnecessary, if it is of primary or secondary
importance, or if a new function is required. Costs are assigned to each function.
4. Creative: This phase explores different ways to perform the functions defined in the previous
phase. It should employ methods that break down cultural, perceptual and emotional blocks
that inhibit inventive thinking. This phase is not intended to result in final solutions.
5. Evaluation: During this phase, ideas resulting from the creative phase are grouped and
ranked, and the best ones selected for further investigation.
6. Development: In-depth examination of each idea. Each idea is given a detailed technical
analysis to determine how it can be implemented and how much it will cost. identifies
functions that will be targeted for improvement and helps determine the best way to proceed.
7. Presentation: This phase includes meetings with stakeholders and decision makers, and
involves the production of reports, flowcharts, and other materials that can be used to aid the
decision making process.
8. Implementation: Finalize the implementation plan, sometimes by making minor changes
requested by stakeholders. Adequate monitoring should be provided to demonstrate and track
progress until the project is complete.
………………………………….
Q.59.What is value Engineering? Explain Importance /advantages of Value Engineering?

Importance /Merits/advantages /Role of Value Engineering

1. Improved product design and quality: Product design is a means of adding value to a
product by ensuring that its layout is attractive to the customer. Product design is all about
trying to link customer needs to product, therefore providing the customer with value.

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 2. Eliminating the unnecessary functions: value engineering is concerned with improving
profits by attempting to reduce costs, eliminating the unnecessary functions and by improving
products by adding new features in a cost effective way that are so attractive to the market.
3. Substitution of materials and methods: value engineering promotes the substitution of
materials and methods with less expensive alternatives, without sacrificing functionality. It is
focused solely on the functions of various components and materials, rather than their
physical attributes.
4. Alternatives for achieving the function: Alternatives in Engineering is established value
engineering with extensive experience in new and remodelled retail, grocery, restaurant,
commercial, and light industrial facilities. Choose alternative courses of actions available.
5. Provides competitive advantages: The competitive advantage is useful to generate more
sales with compared to their rivals through concentrating various factors such as cost
structure, branding, the quality of product offerings, the distribution network, intellectual
property etc are monitoring by value engineering .
6. Standardization of the parts and components: value engineering identifying the possibility
of using the engineering components or function in different products of the firms, this brings
economy in the manufacturing cost of the parts and components.
7. Techno-economic excellence: Techno-economic excellence is a potentiality agenda that
examine technology development and research project in terms of costs, benefits, risks,
uncertainties, and timeframes to evaluate economic consequences of new technology.
8. Higher productivity: Value engineering promotes higher productivity benefits to workers of
the company, the firm and customers. Productivity growth leads to lower costs which in turn
enable. Higher wages, larger bonuses and better benefits for workers.
9. Encourages joint decision making: strength of Joint decision making is that it gives
managers the opportunity to share knowledge about a decision that needs to be made,
generate more ideas and facilitate greater creativity in problem-solving by collectively.
10. Atmosphere of creativity: The Importance of creativity in the Value management field for
Problem solving. Rapidly changing business environments produce problems
which managers have not previously encountered. Tried and trusted methods of approaching
new problems can meet the failure. Individuals prove their skill, ingenuity and creativity.
………………..
Q.60.Explain the process of Enterprise resource planning (ERP)?

Enterprise resource planning (ERP): ERP is a management information system integrates many
areas such as planning, purchasing, inventory, sales, marketing, finance, and human resources. ERP
is most frequently used in the context of software, with many applications. i.e. An enterprise
planning system is an integrated computer-based application used to manage internal and
external resources, including tangible assets, financial resources, material and human resources”.

Need/Objectives/purpose of Enterprise resource planning (ERP)

1. Business Integration and Improved Data Accuracy: ERP composed with various
modules/ sub-modules where a module represents a particular business component. If data is
entered in one module it automatically updates other related.

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2. Planning and MIS: The various decision support tools like planning engines and
simulations functions, form an integral part of an ERP system that helps in proper utilization
of resources like materials, human resources, and tools.
3. Improved Efficiency and Productivity: ERP provides a tremendous boost to the efficiency
of day to day and routine transactions such as order fulfillment, on time shipment, vendor
performance, quality management, sales realization, and cash management.
4. Establishment of Standardized Procedures: ERP is based on international best practices,.
Department silos are purged, and maverick practices are done away with. Because of top-
down view available to management, chances of theft, fraud and obsolescence are
minimized.
5. Flexibility and technology: ERP vendors are also quick to adopt latest technologies, from
mainframe to client server to the internet. Upgrading to latest technology for a running ERP
system is uncomplicated, involving mostly adoption of service packs and patches.
6. Drastically increase efficiency and productivity: ERP streamline your entire organization
and put your data all in one place, enabling more accurate reporting and a more efficient,
collaboration-based and data-driven work environment.
7. Save on unnecessary costs. ERP system creates efficiencies that make your business leaner
as it grows. Many businesses report that they are able to expand without adding additional
staff or IT costs.
8. Improve security and accessibility: ERP applications to the cloud allow you to scale,
extend and upgrade quickly. It also increases visibility and accessibility even further, taking
full advantage of an ERP system’s capabilities.\
9. Gain a professional partner. When you upgrade to an ERP system, you also gain the
partnership of your ERP implementation provider and all the support – from implementation
and training to software support to community membership.
10. Grow your business. An ERP system can eliminate inefficiencies, wasted time and wasted
resources, empowering your business to thrive and flourish. If you’ve been burdened by an
inability to keep up with demand because you’re limited by conventional.

Fig: Features /principles of ERP.

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 ………………………………………….
Q, 61.what is Supply Chain Management? Explain the Features of Supply chain Management?

Meaning of Supply chain management (SCM):

It the management Process of flow of goods and services, involves the movement and storage
of raw materials, of work-in-process inventory, and of finished goods from point of origin to
point of consumption. In other words it is the oversight of materials, information, and finances
as they move in a process from supplier to manufacturer to wholesaler to retailer to consumer.

Features /characteristics/scope of Supply chain Management

1. Inventory Management: In warehouses, managers can use SCMS to effectively manage the
quantity of stocked goods. The software can also help support inventory concerns such as
asset management, replenishment lead time, and future inventory and price forecasting.
2. Purchase Order Management: The purchase order processes are usually automated. It
reduces time and effort needed to generate purchase orders. Pre-defined parameters can be set
up to replenish inventories, generate serial numbers for product shipments.
3. Procurement: All activities and tasks associated with sourcing, purchasing, and payables can
be fully automated as a result, and businesses can build stronger relationships with vendors,
better access and manage their performance, and improve negotiations to get bulk discounts.
4. Logistics: With supply chain management, businesses can improve on-time delivery
performance and boost customer satisfaction by achieving complete visibility into how
finished goods are stored and distributed.
5. Forecasting and Planning: With supply chain management, organizations can more
accurately anticipate customer demand and plan their procurement and production processes
accordingly. As a result, they can avoid unnecessary purchases of raw-materials, eliminate
manufacturing over-runs, and prevent the need to store excess finished goods
6. Return Management: Supply chain software can accelerate the inspection and handling of
defective or broken goods – on both the buy and sell side of the business – and automate the
processing of claims with suppliers and distributors, as well as insurance companies.
7. Processing Customer Requirements: SCMS can help enhance the speed of customer
requirement processing. This includes checking for raw material availability, product
manufacturing, and passing the product to the logistics team.
8. Supplier Relationship Management: The strategic planning and managing of all supplier
interactions can be accomplished with SCMS. The software can be used to assess the
supplier’s assets and capabilities and compare them with the organization’s business strategy.
9. Warehouse Management: SCMS can effectively support a warehouse management system
in the movement and storage of products. SCMS can quickly process transactions such a
picking, placing, receiving, and shipping.
10. Customization: Prebuilt components in the application and customized configuration of
business rules introduce flexibility that helps businesses adapt to changes quickly and go to
market faster, with customized solutions for consumers with programming languages.

……………………………………………………………

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Q, 62.what is Supply Chain Management? Explain Advantages of SCM?
Advantages /benefits of supply chain management
1. Better Flow of Materials, Products and Information: supply chains are always shorter
times between manufacturing a product and getting it out to the customer that ordered it.
Achieving this Material, Products and Information maximized to get delivery times down.
2. Enhanced Financial Practices and Cost Cutting: Having an uncomplicated and efficient
flow of information and goods is important, but financials make the world go around.
Improving cash flow is a common sticking point for many supply chains.
3. Vendor Relationships: Many supply chain management systems contain features that allow
users to compare supplier costs and support structures. It allows the supply chain managers to
make meaningful choices on which suppliers to form partnerships with.
4. Improving collaboration with your suppliers. Dialogue and cooperation to improve CSR
performance will strengthen relations with suppliers and can contribute to increasing
productivity and reducing costs.
5. Ensuring customers' expectations and requirements. Responsible supply chain
management can document that your products are produced in conditions that comply with
internationally recognized standards and guidelines.
6. Attracting and retaining employees: A sound reputation is important to your company's
ability to attract and retain the most qualified employees. When you outsource tasks to
suppliers, it is very important to signal to employees that high priority is given to their issues.
7. Creating new market opportunities: Responsible supply chain management can be used
proactively to brand your company and create new market opportunities with applying global
information network to attracting new customers.
8. Raise Output: Supply (SCM) software is designed in a way to improve communication,
collaboration and coordination with vendors, transportation and shipping companies,
Suppliers and raise bi-directional information flow.
9. Raised Your Business Profit Level: Welcoming behavior towards new innovative
technologies flourishes new ways of success for your organization. Higher visibility and
improved collaboration feature ultimately raising your organizational’ output.
10. Boost Cooperation Level: Higher cooperation level within the organizational task. Supply
chain management software gives you access to track what your supplier and distributors are
doing all the times and vice versa.
11. Improved Responsiveness: Manufacturers are too caring with changing market demands.
This has led to the emergence of tools which enable better visibility, communication, and
collaboration, and empower manufacturers by more responsive, flexible and versatile.
12. Improved Data Visibility: SCM software systems contain features that drill down into the
daily processes of a supply chain to give decision-makers information on underperforming
areas and what to expect in the near future in regards to demand.
……………………………………..

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 Syllabus

UNIT – I
INTRODUCTION: Definition of industrial engineering (I.E), development, applications, role
of an industrial engineer, differences between production management and industrial
engineering, quantitative tools of IE and productivity measurement. concepts of management,
importance, functions of management, scientific management, Taylor’s principles, theory X and
theory Y, Fayol’s principles of management.
UNIT – II
PLANT LAYOUT: Factors governing plant location, types of production layouts, advantages
and disadvantages of process layout and product layout, applications, quantitative techniques for
optimal design of layouts, plant maintenance, preventive and breakdown maintenance.
UNIT – III
WORK STUDY: Importance, types of production, applications, workstudy, method study and
time study, work sampling, PMTS, micro-motion study, rating techniques, MTM, work factor
system, principles of Ergonomics, flow process charts, string diagrams and Therbligs,
UNIT – IV
STATISTICAL QUALITY CONTROL: Quality control, Queing assurance and its
importance, SQC, attribute sampling inspection with single and double sampling, Control charts
– and R – charts and S charts and their applications, numerical examples
TOTAL QUALITY MANAGEMENT zero defect concept, quality circles, implementation,
applications, ISO quality systems. six sigma – definition, basic concepts
UNIT – V
RESOURCE MANAGEMENT: Concept of human resource management, personnel
management and industrial relations functions of personnel management, Job-evaluation, its
importance and types, merit rating, quantitative methods, wage incentive plans, types.
VALUE ANALYSIS: Value engineering, implementation procedure, enterprise resource
planning and supply chain management.

…………………………………………………….

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 Important Questions
MID -I
1. i) What is Industrial Engineering? Explain Role of Industrial Engineer?
ii). what is Management? Explain Nature of management
2. i) Define plant layout? Explain the objectives of plant layout?
ii).Define Preventive Maintenance? Explain the process of preventive maintenance?
3. i). what is production? Explain the importance of production
ii). Difference between work study and method study?
4, i). What is Scientific Management? Explain Taylor principles of scientific management?
ii) Explain the functions of Management?
5. i). Define plant layout? Explain the principles of plant layout?
ii) Explain the various types of Plant Layouts
6. i). Explain Various Types of production?
ii) What is Wok Sampling? Explain need and Procedure to conducting work Sampling?
7. i) What is Plant location ? Write down the factors governing Plant location?
ii) Explain the Theory x and Theory y?
8. i) write down the Quantitative techniques for optimal design of plant layouts?
ii) Explain differences between Product and plant layout?
9. i) Define Work measurement? Explain steps involved in work study?
ii) Discuss about methods of Time measurement?
10. i) Explain differences between preventive and break down maintenance ?
ii) Explain Quantitative tools of Productivity Management?
MID –II
1. i) What is predetermined motion time system? Explain Merits of PMTS?
ii).what is Work factor system? Explain Types of Work factor system?
2. i)What is Flow process chart ? Explain its benefits to the organization?
ii) Discuss the basic motion elements of Therbligs ?
3. i) What is Quality control? Describe the importance of Quality control?
ii) Describe the need and importance of Methods Time Measurement?
4 i).what is Sampling Inspection? Explain advantages of sampling inspections?
ii) Explain the Principles of Ergonomics?
5. i) Define Zero Defect concept ? Explain the principles of Zero Defect concept?
ii) Explain the Methods and techniques of TQM?
6. .i) Define Quality circles? Explain role of Quality circles?
ii) What is Human Resource Management? Explain scope and importance of HRM?
7. i)What is Job evaluation ? Explain methods to measure job evaluation?
ii) What is Merit Raing? How it can be measured?
8. i) Differentiate the HRM , HRD, PM and Industrial relations ?
ii) Explain various types of Wage incentive plans?
9. i) What is Value Engineering? Explain the process of Value Engineering?
ii) Discuss about methods of Time measurement?
10. i)What is Supply chain Management ? Explain Advantages of SCM?
ii) Explain the process of ERP?

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