NAME-AMAN AGARWAL

SEC-C
REG NO-201800119
INDUSTRIAL ENGINEERING AND
MANAGEMENT ASSIGNMENT
Assignment 1: Pioneers in Management (Contribution of
Henry Fayol, Gilberth and Mayo School of Management
Thought: Human Behavior, Social System, System
Approach, management process school)

Pioneer #1. F.W. Taylor (1856-1915):

F. W. Taylor was a pioneer in propounding scientific principles of management as a result of his research in various

areas of industrial activity.

He stimulated interest in time study of operations. He has also contributed in the direction of management and

therefore, called as “Father of Scientific Management”. He changed the philosophy of management as a whole as he

gave the scientific approach to the management.

Definition of Scientific Management:

Scientific Management implies application of scientific methods and principles to the difficulties and questions that

arise during the management of a business.

In other words scientific management means use of scientific tools, such as definition, analysis, measurement,

experimentation and proof in dealing with the problems of Management. Thus scientific Management may be

defined as the “Art of knowing exactly what is to be done and the best way of doing it”.

Taylor tried to work out some system whereby the interests of management and the workers could be same. His

focus was on maximization of worker’s productivity.

The various contributions made by Taylor are as follows:

(i) Development of Science for each Element of an Individual Work:

Analyze the work scientifically thus replacing rule-of-thumb method. It was required to find out a what is to be done

by a particular worker how he is to work and what equipment would be necessary to do it. This information was

provided to the worker so as to reduce the wastage of material and time etc. and improve the quality of output/work.

(ii) Division of Labor or Functional Management:

Taylor introduced the concept of functional organization. Under functional management every production worker

would have eight bosses; each of them would give orders in his function speciality. This is the principle of

specialization. It is essential for efficiency in all spheres of activities as well as in work supervision.

(iii) Use of Time, Motion and Fatigue Study:

Efficiency implies finding out the best way of doing a job. The best way of doing a task is that which involves the

minimum efforts, time, fatigue and cost.

Taylor undertook studies on fatigue incurred by the workers and the time essential to complete the job. He suggested

that for improving production rate, the work of each person should be planned in advance and the worker should use

predetermined method and given time for a definite work.

(iv) Standardization of Methods, Machines, Tools and Procedures:

Shoveling work and shovel loads revealed the importance of standardization of methods and tasks. Standardization

helps hi reducing, time, labor and cost of production. The success of scientific management is related with

standardization of system i.e. techniques of production, machines and tools utilized.

(v) Scientific Selection and Training of Workers:

For maintaining production efficiency, it is essential that the workers should be physically and technically sound for

the task they are required to perform.

Taylor suggested that proper care should be taken while selecting work force and due consideration should be given

to their education aptitude and work experience etc. Thus scientific procedures need to be devised to select workers

best suited to perform specific tasks and then to train them within the industry in order to meet the objectives of the

enterprise.

(vi) Differential Piece Rate System:

Taylor advocated Differential Piece Rate System of payment which provides an incentive for a worker to achieve

high level of optimum output. It distinguishes the more efficient workers from the less efficient workers and

motivates to produce more.

(vii) Economy and Profit:

Scientific management lays more stress on the economic aspect of production. Maximum output can be achieved

only by optimum utilization of resources and elimination of wastage in all forms in order to minimize cost. Cost

control and economy will result in higher wages for workers.

(viii) Cooperation between Labor and Management:

Mental revolution is the most important feature of scientific management as it would create a congenial and

favorable atmosphere/environment leading to harmony and cooperation. The objective of maximum prosperity of

employees and employers can be achieved only if there is perfect mutual cooperation between the management and

the work force.

Criticism to Scientific Management:

(i) It fails to appreciate the social context of workers and higher requirements of workers.

(ii) Managers feel it unwarranted interference in managerial prerogatives.

(iii) Taylor’s concept that unions are really not needed was resisted by workers.

(iv) Fails to recognize the suggestions and ideas of work force.

Pioneer #2. Henry L. Gantt:

Gantt is recognized as one of the-great contributors of the scientific management era. H. L. Gantt was a close

associate of Taylor and worked with him. He emphasized the importance of leadership and paid more attention to

the human factor involved in production planning and control in business operations.

He is mainly remembered for his contributions as mentioned below:

(a) Gantt developed a daily “Balance Sheet Chart” i.e. production control charts known as Gantt charts or Bar charts.

These are used to deal with complex activities. In these charts the job or the activities being performed are

represented on vertical axis whereas the time elapsed is shown on horizontal axis. This proved to be revolutionary in

the area of production planning and control. Gantt charts graphically presented the process of work, by showing the

machine operation, quantities completed, man hour performance, deliveries and the work in arrears to facilitate day

to day planning of the work.

(b) He tried to eliminate the hardships of Taylor’s differential piece-rate system and brought out his “task and bonus

plan”. Differential piece-rate system was an incentive plan whereby the worker was paid on the basis of his daily

output. Gantt’s task and bonus plan was so structured that the worker was paid a guaranteed daily wage whether or

not he completed the standard work. But if he completed four hours working in three hours or less, he was paid for

four hours. Thus the workers received bonus as a result of the introduction of this system.

(c) Gantt pleaded for a policy of preaching and teaching of workers and thus stressed the need of training of workers

for improving their productivity, it was because of him that management during his period considered training as

one of the responsibilities of the management.

(d) He thought of extending the principles of scientific management to the solution of the problems of an industrial

society as a whole. It appealed for harmonious relationship between employees and employers and discouraged the

use of power in a arbitrary fashion. He considered that non-financial rewards and good physical environment were

essential for achieving higher productivity.

(e) Gantt emphasized the importance of the concept of service over profit. He developed the concept of industrial

responsibility.

We thus observe that Gantt’s contributions were more in the nature of refinements rather than fundamental concepts

and have been more useful than that of Taylor to the development of scientific management.

Pioneer #3. H. Emerson Philosophy of Efficiency

(1856-1915):

He concerned himself with the management of the enterprise as a totality and not only with shop management as

was done by F.W. Taylor. He popularized scientific management and interpreted the concepts of standard time,

standard cost and prevention of wastes of all kinds.

In 1912 he advocated 12 principles of improving the efficiency which are (1) Ideas (2) Common Sense (3)

Competent Counsel (4) Discipline (5) Fair deal (6) Adequate reliable, Immediate and Permanent record (7)

Dispatching (8) Standards and schedules (9) Standardized working conditions (10) Standardized Operations (11)

Standard working instructions and (12) Reward for efficiency.

According to him, efficiency and hence productivity does not exist in extreme effort but in elimination of

undesirable effort and preventing wastes of all kinds, the elimination of women and child labour in competitive

employment; Efficiency of a system means that the right work is done in right manner by right men at right place

and in right time.

He advocated the “Line and staff organization” instead of functional foremanship. As to rewards for efficiency, he

suggested the different rates of efficiency besides a guaranteed minimum wage. He was mainly concerned with

improving the efficiency of the workers. That is why he is often called the “high priest of efficiency”.
Pioneer #4. Frank B. Gilberth (1868-1924) and Lillian
M. Gilbert:

Frank Gilberth and his wife Lillian Gilberth were contemporary of Taylor, but they worked independently on time

and motion study. They made memorable contribution to improvement or working methods and thus to discover one

best way of accomplishing a task, with marked efficiency and least expertization.

He developed a unique technique of last work. Faster speed work however, did not refer to hurrying with the work

but economizing the time sequence by eliminating unnecessary movements and exhausting motions and methods of

accomplishing a task. Lillian concerned herself with the human aspect of management.

They considered that the root cause of worker’s dissatisfaction was the lack of management interest in them. They

stressed that management should understand their requirements and personality. He and his wife Lillian M. Gilberth

maintained that the human aspect must be considered as a major area of consideration and study in the field of

management.

According to L. M. Gilberth, the philosophy of motion study says, “Man is considered as the centre of activity and

as expressing himself in motions, aided by tools and machines using materials as medium of expression”.

Thus for orderly organization of complex industrial activities following sequences of operations should be

followed:

(a) Identification of the problem and its objectives.

(b) Defining the problem objectives.

(c) Collection of relevant data on the problem.

(d) Interpretation and analysis of data.

(e) Consideration of available alternatives.

(f) Formulation of tentative conclusions about tackling the problem.

(g) Initiating or starting selected action on the basis of conclusions and verifying the results. (h) Reviewing and

evaluating the results and incorporating any corrective action if essential and needed.

(i) Framing rules to serve as guide to planning and execution.

Some important contributions of Gilbert are:

(i) Development of Motion Study:

He defined motion study, “as the science of eliminating wastage in all forms resulting from unnecessary, ill directed

and inefficient motion”. According to Gilbert the purpose of motion study was to improve work methods so as to

discover or develop one best way of accomplishing a task.

He identified seventeen (17) on the job motions and called them THERBLIGS (Therbligs) is Gilberth spelt back

words with the transposition of one letter. He maintained that a therblig analysis could be applied to any job.

Further, he developed the system to any job. Further, he developed the system of “Flow Process Chart” which makes

the study of various processes of activity easier. He also developed micro motion study and SIMO charts.

(ii) Development of Chronocyclographs:

He used microchrometer of speed clock and took photographs by cine cameras of the workers and the clock. Thus

three observations were taken i.e. what movements occurred, how much time they took and what was the direction

of movements. This process was termed as Chronocyclograph.

(iii) Study of Fatigue:

Gilberth carried out studies on fatigue and its elimination. They concluded that fatigue could be considerably

reduced by allowing rest periods, spacing the work and lightening the load.
Pioneer #5. Mary Parker Follet (1868-1933):

Mary Parker Follet was a philosopher and political scientist, gave “Law of the situation” in 1919 and made

important contributions in the field of functional authority, leadership, coordination, control and concept to the

nature of management and of human relationship within industrial groups.

She analyzed the nature of consent on which and democratic group is based through an examination of

Psychological factors underlying it.

According to her, this consent was not static but was a continuous phenomenon. She also proved that conflict can be

constructive and could be harnessed to the service of the group.

The most fruitful way of resolving conflict according to Follet was not through domination and compromise on the

plea that domination gives the feeling of loss and surrender to both the sides. She was in favor of integration

whereby the parties themselves examined together the new ways of achieving their conflicting desires since, this

gives a more stable solution to problem of conflicts.

According to her, different situations require different types of leadership meaning thereby that leaders are products

of their times and the leadership features are a function of the particular or specific situation. The success of a leader

does not merely depend on the training he possesses but on the specific situation at a time in which he utilizes his

leadership.

She was of the opinion that for achieving good results various limbs of the organizing body should be well

coordinated and closely act together so that they work as a single entity.

She also advocated for integration of interests of investors, consumers and workers. Mary parker Follet pleaded for

the application of scientific methods to the solution of personnel problems.

Pioneer #6. Henri Fayol (1841-1925):

A French industrialist during his long and successful carrier as an Industrial manager Mr. Fayol tried to probe into

the bottom of the principles of administration and management Fayal analyzed the process of management as he had

observed it first-hand.

He said that managerial activities at the upper levels are more significant than other activities. He was the first to

state principles of management and functions of a manager. Many of the talents which are recognized today as

principles of management were originally specified by Fayol.

His conclusion was that all industrial activities could be subdivided in following six groups:

1. Technical Activities:

Technical activities involve technical knowhow, production, manufacture and adaptation etc.

2. Commercial Activities:

Buy, sell and exchange.

3. Financial Activities:

These activities involve search for and optimum use of capital.

4. Accounting Activities:

Stock taking balance sheets, and cost sheets to determine financial position of the enterprise.

5. Security:

It is related with protection of assets and man power.

6. Managerial or Administrative Activities:

Means to follow management functions like planning, organizing, commanding, coordination and controlling (of all

the above activities).

ELTON MAYO AND THE HAWTHORNE STUDIES

Elton Mayo (1880–1949) joined the Harvard faculty in 1926 as associate professor of industrial
research, and two years later was asked to work with Western Electric, as part of the Harvard
research group, to continue the Hawthorne studies.

Mayo was intrigued by the initial results of the early illumination studies that showed output had
increased upon changes in illumination—either brighter or darker—but no one knew why. Mayo
believed the increased output came from a change in mental attitude in the group as the workers
developed into a social unit.

Other experiments included the piecework experiment, the interviewing program, and the bank
wiring room experiments. From these experiments the Mayoists concluded that employees have
social needs as well as physical needs, and managers need a mix of managerial skills that include
human relations skills.
Assignment 2: Production Management: Types of
Production, Types of Planning, Manufacturing Planning,
Production Planning

What is Production?
Production is a process of value addition, which is developed to transform a set of input elements like man, raw
material, capital, energy, information into finished products and services in proper quality and quantity.
In other words, Production is a process of combining various inputs (man, machine, and material, money) in order to
make something for consumption (product or services).
Significance of value addition in production can be transform row material into goods, assemble many small parts,
or design a service. Production can be seen every day in factories, offices, hospitals, etc. Production can be
agricultural, manufacturing, or service.

Factors of production:-

Nature:-

Nature is a very important factor for any production. It is impossible to carry out production without land, water, and
other resources. Suitable land and the availability of water make production easier.

Natural resources, such as oil and coal, can be extracted from the land and refined for production purpose
consumption. Cultivation of crops on land by farmers increases its value and utility. Area, the shape of the
production site, cost, drainage, and other facilities, the probability of floods, chance of earthquakes, etc. influence
the selection of plant location.
Water is used for processing, drinking and sanitary purpose within a production site. Depending upon the nature of
the plant water should be available in adequate quantity and proper quality.

In the production of leather, textile, etc. climate is an influencing factor. For such industries extreme humid or dry
conditions are not suitable for production.

Labor
Human effort is a necessary factor for production. Skilled labor can make a significant difference in any production.
Another important factor that influences plant location decisions is the availability of labor near the factory. The
combination of an adequate number of labors with suitable skills and reasonable labor wages can highly benefit
the production firm.
Labor by an uneducated and untrained worker is generally paid at low wages. Skilled and trained workers are
referred to as human capital and they get paid at higher wages because they bring more than their physical capacity
to the workplace. Hire skilled labor for their specific work increase the productivity of a production unit.
 Capital

Capital generally refers to money. But money is not a factor of production, because money is not directly involved
with the production of product or services. Money used as a resource to buy capital goods like machine, equipment,
raw materials etc.

It is important to distinguish between private capital and personal capital. Buying a car for personal use and family
transport is not considers capital. But buying a vehicle for commercial uses considers as capital.
During a financial crisis or when they suffer losses, companies cut back on the capital expenditure to ensure profits.
And, during periods of economic expansion, they invest in capital to purchase machinery and equipment to bring
new products to market.

Enterprise
Enterprise is the activity that combines all the other factors of production into a product or service for the consumer
market. Enterprise as a function involves in organizes other factors like applying government rules and regulation,
working discipline within the production site, etc. into an operating unit. A good management team is greatly
benefited in every business enterprise

Types of Production
There are four main types of production that are generally employed. Which type is suitable is decided by the nature
of the product being produced, demand of the product on the market and supply of raw materials.

Four types of production are-

1. Unit or Job type Production,

2. Batch Production,
3. Mass Production,
4. Continuous Production or process production.

1. Unit or Job type Production:-

Unit or Job type Production is most commonly observed when you need to produce one single unit of a product at
a time. A typical example of Job production is tailored outfits that are made just for you according to your size or a
cake that is made just like you want it.
This type of production depends a lot on the skill of the worker. Dependency is more on manual work than
mechanical work because every product is different from others. Customer service plays an important role in Unit or
Job production.

2. Batch Production:-

Batch production most commonly used in consumer durables, FMCG or other such industries where there are a
large variety of products being manufactured with variable demands. Batch production takes place in batches. The
manufacturer needs to know the number of units he has to manufacture, and they are manufactured in one batch.
Examples of batch production are FMCG like Biscuits, confectionaries, packaged food items etc. It is also used in
Medicines, Hardware, Consumer durables and many such industries.
 Batch Production is done in batches, so once a batch production starts; stopping the process midway may cost a
huge amount to the company. Demand and supply play a major role in batch production. For example – the
production of the seasonality of products heavily depends on the demand.

3. Mass Production:-

Mass production is also known as flow production or assembly line production. This is one of the most common
types of production system used in the automobile industry and is also used in industries where continuous
production is required. For example- the manufacturing process was adopted by Ford Company.
An Assembly line or mass-production plant typically made for specialized product manufacturing. There are
multiple workstations installed and the assembly line goes through all the workstations one by one. The work is
done in such a manner each workstation is responsible for one single type of work. As a result, these workstations
are very efficient and production due to which the whole assembly line becomes productive and efficient.

Market demand does not play a major role in Mass production. However, the production capacity of the company
determines the success of mass production. Mass production requires huge initial investment and working capital.

4. Continuous Production or process production:-

There is a lot of similarity between mass production and continuous production. It can be differentiated by the
amount of mechanical work involved. In Mass production, both machines and humans work together. But, in
continuous production, most of the work is done by machines rather than humans. In continuous production, the
production is continuous, 24×7 hours, in a year.

An example of Continuous production is brewing. In brewing, the production goes on 24 hours a day and 365 days
a year. This is because brewing takes a lot of time and attention as well.
Once production started you cannot stop, otherwise, it will lead to a huge loss. so, a controlled environment is
required for continuous production.

Production Function:-
 The production function is the expression of the number of variables like raw materials, their quantity, number of
machinery, the number of finished products, etc.
 A production function thus involves a wide range of activities from the plant location to the packing of products to
be distributed by the marketing division of the organization. More experienced marketing division demand will
more, thus production will be increased.
 The modern evolution of the production function started with the industrial revolution in western countries and
North America. New machinery was developed which helps in starting new and big industries. 
 Various factors like labor charges, lack of skilled labor, etc led to automation. The first stage of evolution of
automation is Detroit Automation, the second stage is feedback control, and the third stage is Computer technology.
 The selection of plant location and plant layout is always difficult. The location of the plant should be in such a
place where resources are easily available and low distribution costs. A good plant layout permits the material to
move little and at minimum cost.
 Production, planning, and control consider the determination and regulation of the production processes and
functions like routing, scheduling, dispatching, etc.
 Another important function is Research and Development. Research means a critical investigation to acquire new
knowledge and applied it to explore facts and information for the practical problem. The development comes after
applied research. Development involves the design and fabrication of new or modification of products and then
testing them.
What is Production process?
The business plant is basically a product making unit. In other words, it is a technical unit in which inputs are
converted into output for sale to consumers, other firms and various government departments.

Production is a process in which resources or inputs (composed of natural resources like land, labor and capital
equipment) are combined by entrepreneurs to create goods and services (also referred to as outputs or products).
Inputs are the beginning of the production process and outputs are the end of the process.

The production system can be visible as consisting of 3 factors – inputs, manufacturing process and outputs. In fact,
the outputs are the starting factor of the operation inasmuch as they must be considered in the mild of the market
possibilities.

What is Product Planning?

Product Planning is the procedure of identifying and articulating market requirements that define a product’s
benefits or features. Product planning works as the basis for decision-making about price, distribution and
promotion. Product planning is the process of creating a product idea and following the idea until the product is
introduced to the market.

Definition of product Planning:-

Product planning is the evaluation of the range, specification, and pricing of new and existing products
according to the present and future market requirements and competition.

Planning of product is to satisfy the company objectives and to specify the required research, design, and
development support. Product planning mean managing the product throughout its life using various marketing
strategies, including product extensions or improvements, increased distribution, price changes and promotions.

Concept of Product Planning

Process design is done according to product planning.
 In the planning activity, both existing and new products must be included and it follows the activity itself should
deal with the proper balance between old and new products.

Product planning usually represents the activity that links the company with its market which is directly concerned
with the development of the company.

Product planning can be done by top management or by line management but successful product planning can only
occur within a clear framework of goals and objectives laid down by the board of directors.

Objectives of Product planning:-

1. To meet the customer needs, It is product planning that identifies the customer needs, requirements, aspirations,
likes and preferences and guides the firm’s resources and efforts towards the accomplishment
2.  To spot-light firm’s strengths and weaknesses, so that firm can work on the weakness and improve the product.
3.  To fortify better resource utilization, product planning helps to develop new product and modify existing ones in a
way better utilization of resources can be achieved, it reduces the cost of the product.
4. To guarantee a firm’s survival, product planning predicts what likely to changes in products, technologies, product
ideas, inputs so that the latest can be given to the consumers.
Product planning needs for current deficiencies, which are stimulated as a result of some deficiency occurring in
the product today and the solution achieved through the development, production, and use of new processes. 
Through the prediction of societal, political, ecological, technological and economic trends anticipated needs can be
determined. For example- we suspect that economic restrain in future will likely prohibit the use of a certain
system that is currently using. As a result replacement of that system exhibit, a lower overall life cycle cost is
needed to accomplish the designated function.

 
Step by step Process of Product Planning:-
Below are the key steps of product planning that you should go through when planning a new product:

1. Define the product concept

Define the concept is the most important step in your planning process that pivots and defines the product you are
trying to build. Write this stage and ensure your idea for the product is effective and realistic. Another part of the
product concept is making sure you have unshakable knowledge of the upcoming problems based on your strong
understanding of the solutions needed.

2. Market research
A small company should consider doing marketing research before planning a new product. Market researchers
use quantitative and qualitative research to gain a better and more complete perspective about a market potential or
possibility.
 Qualitative researchers target to collect an in-depth understanding of human behavior and the reasons that
govern such behavior. The methods of qualitative research can be departed into observation and focus groups. The
focus groups allowed companies to ask their consumers about their likes and dislike about a product in a small
group.
 Qualitative research involves thinking and analysis that are non-numerical in nature, which includes questions of
“how” and “what”. Qualitative research is suited to solve the problem areas of basic market exploratory studies,
product development and diagnostic studies.

Quantitative research refers to the systematic experiential investigation of social phenomena via statistical,
mathematical or numerical data or computational techniques. The objective of quantitative research is to develop
and employ mathematical models, theories and hypotheses concern with fact.
Quantitative research is about understanding aspects of a market or what kinds of customers making up the market.
And it can be split into soft and hard parts. The soft part means phenomena like customer behavior and the hard part
is market size, brand shares, etc.

3. Plan your product testing process

If the results of the surveys prove favorable, the company may decide to launch the new product on a small scale or
regional basis. During this time, the company will distribute the products in one or more cities. The company will
run advertisements and sales promotions to spread awareness of the product, tracking sales results to determine the
products potential success.
4. Product life cycle
Product planning must also include managing the product through several stages of its product life cycle. These
stages include the introduction stage, growth stage, maturity stage and decline stage.  The product life cycle can be
viewed as an important source of investment choice for the company. If a company wants to make sure that its
products are going to successful, it needs to study the product life cycle to analyze market attractiveness and
supplement the conclusion before launch a new product or enters into a new market.
The first stage is Introduction which means it is time for a company or brand to launch and promote its new
products. Sales are usually strong during the growth phase, while competition is low. In the introduction stage
company want to attract customer’s attention as much as possible and confirm the product’s initial distribution, the
company does not need to worry about the competition generally as the products are new.
In the Growth stage, the new products have been accepted in the market and their sales and profits have just begun
to increase, the competition has happened so that the company will promote their quality to stay competitive. There
will have second communication as the manufacturer can start to receive consumer’s feedback and then make
improvements.
The third is the maturity stage where the sales and profit have grown slowly and will reach their peak. The firm
will face tremendous competition in terms of creating high-quality products.
The last is the Decline stage where the product is going to end and will be discontinued. The sales of the product
will reduce until it is no longer in demand as it has become saturated, customers who want to buy this product has
already got that. Then the company or brand will stop making the old products and pays attention to designing and
developing the new products to gain back the customer base, stay in the markets.
Elements of product planning
Product planning include-

1. Marketing and Market analysis.

2. The performance of feasibility studies.
3. Advanced product planning.
1. Marketing and Market analysis
 

The prospect of marketing depends upon the nature of the product. If the product doesn’t have technical
specifications, the product is simple; marketing function may not be required direct engineering involvement.

If the product is complex the marketing effort involves a team approach, constituting the nontechnical sales with
engineers in a role to support salespeople and answering customer’s questions about characteristics, features,
maintenance required, etc.

 
 After the completion of product planning, it is necessary to determine whatever the technology currently exists will
satisfy the need or not.

In this case, technology refers to techniques required for achieving a practical goal. And this is basically
accomplished through technology review and technological forecasting, which means, what is the market trend and
what will likely available in the future, etc. 

Producer of the prospective system will complete a preliminary analysis of the market potential and market share. 

2. Performance of feasibility studies

The performance of the feasibility study is to extend the preliminary market analysis with the intent of arriving at a
preferred system configuration that the producer is willing to propose in a response to an identified need.

The feasibility study includes-

 A detailed requirement analysis.

 Identification of alternative configurations.
 Screening and evaluation of available alternatives. And,
 Selection of preferred approach.
The output of the study constitutes a proposal covering the technical characteristics of the preferred system
configuration. This information, combined with advanced planning data is reviewed to determine whether the
manufacturer proceeds further or not.

The feasibility study comprises another important step in the decision- making process, thus influencing further
product activities, especially in the case of large scale systems.

System operational concept consists of the following information-

 Identification of the ultimate mission of the system.
 Determination of the size, weight, accuracy, capacity, rate of output, etc characteristics of the system.
 Identification of quantity of equipment, employees, facilities etc.
 Determine the time needed to complete the process or how many hours per day, operation cycle per month, etc.
 Anticipate how efficiently the production system will perform, the effectiveness of the logistics support, the time
between two consecutive maintenance, maintenance downtime, failure rate, etc.
 Details of the environmental condition at which the system expected to operate. (e.g.: temperature, humidity,
mountain or flat terrain, etc). 
System maintenance concept –
 The system maintenance concepts determine how the maintenance support will be there throughout the product life
cycle, repair policy, maintenance manpower required, time and cost needed, etc.
  It provides the basis to establish the requirement for total logistic support. Give an assumed design configuration of
the main functional equipment, it is then necessary to consider how it should be supported. The maintenance concept
is completed by logistic analysis, which leads to the identification of maintenance tasks, frequency of the tasks, skill
level of the maintenance worker, facilities and data, etc.
 The level of maintenance includes- organizational maintenance, intermediate maintenance and depot
maintenance.
 Organizational maintenance is performed at the operational site. Maintenance at this level limited to a periodic
check of the equipment’s performance, cleaning of equipment, visual inspection, repair if needed, replace some old
components with new ones, etc.
 Intermediate maintenance is performed in mobile or semi-mobile organizations at the customer’s locations.  At
this level item, is removed or replaced. Intermediate maintenance workers are more skilled and better than those at
the organizational maintenance, and they are responsible for performing more effective and detailed maintenance.
 Depot maintenance is the highest type of maintenance and supports the accomplishment of tasks above and beyond
the capabilities of the Intermediate maintenance level. Deport maintenance is a specialized system, used for
maintenance of complex and bulky equipment, large spares, environmental control provision, etc.
Results of the feasibility study will be presented to the management and information should include- Details about
functional features and physical characteristics of the system and a description of support and maintenance
requirements.

3. Advanced Product planning

 

1. Product system evaluation, selection and justification is the composed result of market analysis and feasibility
study help in justifying products in terms of need and technical approach. The selected product must be evaluated in
terms of life-cycle cost which associated with the cost of planning, R&D, investment, operation and support and
system phase-out.

These costs are estimated by year and pricing should be accordingly, with of objective of gaining maximum profit
on investment.

2. Product specification and plans– specification covers the technical requirements for the product and planning
documentation consider all management related activity. The combination of specification and plan along with the
associated cost data comprise the proposal for all subsequent research, design, production, testing, logistic support
activity.

3. Product acquisition plan refers to a process of acquiring a product or system commencing with the identification
of the need and extending through the delivery of the product to customers. It may involve research, design,
production, and evaluation activities. Materials under the product acquisition plan must include-
 Details of tusks which covers all acquisition functions,
 Scheduling tasks using a bar chart, PERT, Gantt chart, line of balancing, etc.
 The organization of tasks. Identified work packages classified by the standpoint of task type, the complexity of the
task, and completion schedule.
 Cost, schedule, performance, effectiveness measurement and control. This may take in the form of a range of values
with both upper and lower limit, or a set of maximum and minimum criteria.
 Point out the problem area and those potential areas where the problem likely to occur and take corrective action.

4. Product evaluation plan indicates requirements of the product in terms of range, accuracy, capacity, power,
availability, reliability, maintainability, etc must be evaluated to ensure completion.
The product evaluation plan should include-

 Test and evaluation requirements.

 Categories of test and evaluation.
 Test preparation phase.
 Test and evaluation procedure.
 Data collection, analysis and corrective action methods.
 System network, modification and retest procedure.
 Test and evaluation reporting.
5. Product use and logistic support: It is a detailed maintenance plan which proposed the level of maintenance and
recommended function to be performed. Product use and logistic support includes-

 Plan technical data to include system maintenance procedure.

 Supply a support plan to cover the acquisition of spares and repair parts.
 Transportation and handling plan to cover the packing, use of containers and shipment of material.
 The training includes system operator training, maintenance training and equipment training.
 

6. Product proposal will recommend a course of action best on the result of the feasibility study and advanced
product planning. 

The proposal may be classified as-

 Internal Proposal is generated within the factory and directed for approval to the management of the company to
generate a scope of work.
 External proposal generated within the company and directed to an outside agency.
Advantages of product planning
1. Improved the system of the organization for regular and timely delivery,
2. Better supplier communication for raw materials procurement,
3. Product planning reduced investment in inventory,
4. Reduced production cost by increasing efficiency,
5. Smooth flow of all production processes,
6. Proper production planning reduced waste of resources,
7. Production cost savings that improve the bottom line.
 What is product design?
Before starting to manufacture a new product or improve a product, it is essential to design the product first. 
When a new idea has been conceived and developed to the point at which it shows itself to be both technically
and commercially stable, it considers how the product should be made, Factors affecting product design, etc.
 
 New and improved product design idea comes from consumer’s feedback, Research and development, and
other competitor’s products.
 Product design deals with both form and function. Form design takes care of the shape of the product and functional
deals with its working.
A design department consists of designers, engineers, and draughtsman. Making a new or modified product will
require the service of the following department of the company.
       Marketing.
       Research and development.
       Design.
       Manufacture.
       Account and personnel. 
Product Design Requirements:
The essential requirements of a good product design are it should earn profit with consideration of customer
satisfaction. Let’s discuss product design requirements from both the customer and companies’ point of view.

In order to achieve customer satisfaction

 The product should be function correctly and possess the desired degree of accuracy. 
 The product should be easy to operate.
 Product design should be such that it is easy to achieve accessibility for servicing.
 The product should compact and obtain good space utilization.
 The price of the product should be reasonable compare to other products in the market.
In order to make an adequate profit
 The product should easy to manufacture within available resources.
 A well-design product will consist of a minimum number of parts.
 Good product design will call for a minimum number of operations and needed fewer raw materials.
 A well-designed product should be easy to peak and distribute.
Effect of product design on cost
1. Product cost depends on product design; complicated design makes the cost higher and vice versa.
2. Production cost is made up of direct labor cost, direct material cost, direct expense, and indirect expense cost.
3. The product should be designed with a material that is cheaper, machinable, and long-lasting at the same time. The
product should be made from minimum material to reduce machining and material cost.
4. Alternative cheap material can be used. For example, Aluminum can be used for making casting instate of
magnesium alloy or non-metals can be used depending upon the requirement.
5. Product cost can be reduced if there is a better mutual understanding between the design and manufacturing
division. It may be possible to reduce the cost of products in order to compete in the market.  
6. Product cost may be reduced by applying value analysis.
7. A product should be designed with fewer parts. The lesser the number of components lesser the product cost.
8. Some component of the product which cannot be economically and easily produced, it should purchase from outside
suppliers.
9. Productivity should be higher so that products can sell at a lower cost.
Factors affecting Product Design:
Product design depends upon the following factors:

1. Technical factors.
2. Industrial design factors.
3. Designing for a production-economic factor.
1. Technical factors
 Kind of workers will be working (skilled or unskilled) and condition of noise, vibrations, heat, etc.
 Accuracy, speed, feed, types of materials used, etc should be considered in the time of product design.
 product design determines how often maintenance and repair will be required.
2. Industrial Design factors:
 The product should be function at minimum cost and the product should have a pleasing appearance.
 Ensure that the product is suitable for human use and it should not cause excessive fatigue to the workers.
3. Design for Production-economic factors:
 The material should be the cheapest and the minimum amount of material being used in making each component
part.
 Waste during production should be minimized.
 Product design should be such as it makes the best use of factory layout and the project needs to complete with the
available labor.
 Does the product design allow maximum possible tolerance?
 The design needs to be simple, keep the type, and varieties of parts to a minimum.
 Right finish being use consistent with cost, endurance, and appearance requirements.
 Types of product design
There are 3 main types of product design, 

 System Design
 Process Design
 Interface Design
Product design process
1. Research stage
Design and Research is the first stage of the product design, in this stage design engineer has to find out what will
satisfy the customer? What they are going to make? What are the resources they have, to make that? The research
stage mainly focuses on targeted people, environmental conditions at which it will operate machines, etc.
Targeted people mean potential customers age, gender, educational background, income level, social status,
condition, etc. The environmental condition refers to where the design object will be located. Machines and
electronics device will be such as product should be user friendly, and safe.
2. Analysis stage
 The analysis of design is based on design and research. This stage is more focused on the visual of the product,
design customization in a targeted manner by analyzing the targeted users, Analyze the market so that it can meet
the current trend, and needs of most users. Find out the market challenge and alternative ways to solve that.

3. Conceptual design stage

The conceptual design includes some organized targets based on previous market demand and customers’ needs.
The conceptual design stage develops the design in the direction of the future product. So that we can save our
resources Input, increase the profit, and estimate and guide the late recycling issues.

4. Detailed design stage

The analysis of design is based on design and research. This stage is more focused on the visual of the product,
design customization in a targeted manner by analyzing the targeted users, Analyze the market so that it can meet
the current trend, and needs of most users. Find out the market challenge and alternative ways to solve that.

5. Design output stage

The design output stage is referred to as an expression of the final design, which is selected for manufacturing. In
this stage, detailed dimensions, various parts, structures, etc are checked for the final time. These outputs provide the
basis for production and construction after the design phase.

Types of Tools or software Product Designers Use

Product design covers a broad range of disciplines; the role requires several different types of tools. Some of the
important tool or software is:

 Wire framing apps (Sketch, Adobe XD, Figma, etc),

 Graphic design apps (Adobe Photoshop CC, Affinity Designer, CorelDraw Graphics Suite 2019, etc),
 Prototyping tools (InVision,  Adobe Experience Design, Origami Studio, etc),
 Research and data analytics tools (e.g., spreadsheets, sophisticated A/B testing apps)
 CAD (computer-aided design) software,
 Project management apps (e.g., Trello, Basecamp, Casual, etc),
 Product roadmap apps (e.g., ProductPlan).
Product design examples
Most popular product designs are,
 Coca Cola Bottle design – Now it is one of the most popular and well-known shapes in the world, Coca-Cola’s
curvy glass bottle were fabricated in 1915. In an attempt to design a bottle so distinct that you would recognize it by
feels in the dark or lying broken on the ground.
Oreo Cookie – The Oreo cookie has been the number 1 best selling cookie in the America since 1912. It is an
innovation, by simply sandwiching crème filling between two chocolate cookies. The design has been duplicated
often in the past 100 years, but the Oreo is a classic.
 IPhone – Since 2007, we have kept iPhones in our pockets and the design has grown and evolved every year. But
the iphone, has kept the signature clean, minimal, and glossy feel that Apple perforate into all its’ products.
Automatic Transmission – One of the most essential, yet most appreciated engineering designs. The design of the
automatic transmission revolutionized fuel economy and implanted the foundation from which future automatic
transmissions vehicle would be designed and built.
Definition of Production planning and control:
Production is the transformation of raw material into finished goods. Planning looks ahead anticipates
possible problems and decides in advance as to how the production carried out in the best way. 

Control makes sure that the programmed production is constantly maintained.

What is the importance of production planning and control?

 It is necessary to improve the process for better utilization of resources.
 It helps to achieve better supplier communication for raw material procurement.
 Reduce investment for inventory purposes.
 Reduce production costs by proper estimation and increase the profit margin.
 Smooth flow of product without any interruption.
 Make sure the proper quality and quantity of equipment, raw materials, etc are available during production times,
etc.
 To ensure capacity utilization is aligned with forecast demand.
Functions of Production planning and control:
A production planning and control system consists of many functions. Various functions are as follows:

1. Forecasting,
2. Product design,
3. Process planning,
4. Routing,
5. Material control,
6. Tool control,
7. Loading,
8. Scheduling, etc.
 
1. Forecasting:
Forecasting is the process of making predictions of future data (type, quantity, quality, sales, etc) based on
past data by analysis of trends.
Every manufacturing enterprise surviving on its ability to access, with reasonable accuracy, the market trends
survival year ahead.

Forecasters will be able to make use of sales trends, but these must be considered in the light of the expected
introduction of new materials, fashion changes, technological changes, policies of competitors, unseasonable
weather economics situations of countries and foreign markets. 

Forecasting decides how many units to produce during a specific time period to avoid the extra cost of storage and
reduces the chance of making outdated products. So, a sales forecast should be accurate, easy to understand, and
economical.

Forecasting plays an important role in product development.

2. Product Design:
Before starting to manufacture a new product or improve a product, it is essential to design the product first.
  

For new and improved product design idea comes from better product planning, which is done by R&D department.

Product design deals with both form and function. Form design takes care of the shape of the product and functional
deals with its working.

A design department consists of designers, engineers, and draughtsman. Making of a new modified product will
require the service of the following department of the company.  

       Research and development.

       Design.
       Manufacture.
       Account and personnel. 

3. Process planning:
  Process planning is the preparation of the detailed planning on how to manufacture a product, thus it is
necessary to plan the process.
   Process planning determines the most economical way to perform an operation or number of operations to
complete the manufacture.

  It takes drawing and other specifications as input, which shows what to be made and forecast or which indicates
product quantity to be manufactured. 

The steps involved in process planning are:

1. Selection of process which is most economical, and sequence that satisfies product specification.
2. Select the material which brings the right quality, and chemical composition as per the product specification.
3. Selection of jigs, Fixtures and other special attachments.
4. Selection of cutting tools and inspection gauges.
5. Making process layout which indicates every operation and the sequence in which the operation is to be carried out.
6. Find set-up time and standard time for each and every operation.

4. Routing:
Routing lays down the flow of work in the plant. It determines what work needs to be done, how to be done,
and when to be done.

 
From the raw material to the finished product, routing decides the path and sequence of operation to be performed.

In production, layout routing is not required because the equipment is laid according to the sequence of operation.
But where every time a new job is coming route sheet has to be revised and this involves a greater amount of work
and experience.

5. Material Control:
Material control is the managerial activities relating to giving instructions to ensure maintaining adequate
quality and quantity of materials for an uninterrupted production process with the objective of minimizing
material cost.

Material control includes inventory control, cost of production, planning of materials, purchase procedure,
transportation, etc.
Inventory control is restricted to the stock of desire level, whether they are raw materials, work in progress, or
finished goods with the object of minimizing the cost.

6. Tool control:
Tool control is the process of determining tool requirements, procuring new tools, and controlling tools once
they have produced.

Tool control to ensure that the right tool will be available at the time of production. Lost time resulting from
incomplete tool planning can be expensive as well as causing work to delay.

In order to implement tool control, it is important to standardized tools within an organization.

7. Loading:                                                  
Loading can be defined as the study of the relationship between load and capacity of the workplace.
  

Loading is the assignment of work given to the labor and machinery without specifying when the work needs to be
done.

The objective of the loading is to maintain an up-to-date picture of the available capacity of the plant. 

The information provided by loading is used to-

1. Ensure the efficient utilization of the plant and manpower.

2. It helps to set the delivery date.
3. To assist in future planning of the purchase of new assets.
 
8. Scheduling:
Scheduling means when and what sequence the job will be done.
 Scheduling

                          
Scheduling of a production system depends on external factors like customers demand, delivery date, stock of goods
already lying with retailers, etc.

Scheduling affected by internal factors like the availability of machines, equipment capacity, availability of
manpower, stock of finished goods within the plant, etc.