Presentation

for
Viva

OMKAR SAKPAL
WE TUBE
Analysis Of Process Capacities

PROF . R. D. NADKARNI
In Production planning and control technique there are two types of layout namely
1. Product Layout
2. Process Layout

Product Layout
• The entire layout of machine is only for particular product. In these layout product flows through
particular sets of machine only.
• Production done by various machines in given order or sequence.
• Machine Capacity can be determine by the Single machine or Group of machine
• Overall Capacity of product is determine by slowest machine or slowest process for particular line in
these layout
• Some Examples – Cylinder Head ,Cylinder Head , Connecting Rod.

Process Layout
• Here Group of Products flows through group of Machines. We can do group production by using
groups of machine which are necessary for production of product.
• Some Examples –Gears.
Biggest Challenge in front of Production team is to maximise the profit by maximising the capacity & output of
various components produce in production process layout.
Process Capacity Analysis and Profit maximising can be done by Linear Programming Technique.

Linear Programming Technique

• In these technique first we need to plot graphical expression of two products for each stage use in production.
• After Plotting all stages in linear diagram we will get some intersects points for each stage.
• Intersected Points will give us combination which will give us profit idea from which we can select the point
which will give us the maximum profit as shown in following graph example.
• Each intersect point will give us mathematical equation by solving
those we can get combination of products.
• Shaded portion that will determine the maximum quantity both
products that can be produce.
• By Increasing the Capacity of any stage/process by certain
percentages we can maximise more profit from process. To execute
this we need to put addition investment in process. We have to minus
this extra investment cost so we can get exact idea about profit which
will can get by increasing capacity of certain stage.
Problems Solving Tools for

Manager -1

PROF. MRUNAL LAMGE

FMEA (Failure Modes And Effect Analysis)
• FMEA is very systematic process. It one of the problem solving technique developed by Aerospace industry in
1960s. After that it is used in automotive industry and now a days it is used across in all industry.
 FMEA is tool allows you to-
 Prevent system from problems before it occur.
 Reduce cost by identifying system, product & process improvements early in the development cycle.
 Create more robust processes. It improves the process.
 It prioritize the actions which helps to avoid or decrease risk of failure.
 It evaluate the system, design and processes from new vantage point.

 FMEA provides a systematic process to-

 Identify and Evaluate:
 Potential Failure Modes.
 Potential Causes of Failure Mode.
 Identify and Quantify the impact of potential failure.
 Identify and Prioritize action to reduce or eliminate the potential failure.
 Implement the action plan based on assigned responsibilities and completion date.
 Why FMEA use ?
• FMEA is use to identify the biggest contributor to failures and helps to eliminate them.
• To reduce probability of failure result in reducing the cost of production.
• To build the quality in product & Process.

When FMEA is use?

• FMEA is most beneficial as a “Before-the-event” action.
• Design FMEA should be done during initial design of product
• Process FMEA should be done during design of manufacturing process.

Potential Applications of FMEA

• Component proving process.
• Outsourcing and resourcing process.
• Develop suppliers to achieve Quality Renaissance/Scorecard target.
• Major Process /Equipment/ Technology changes.
• Cost Reduction.
• Justification of Fast Track RESA. (Research evaluation & Safety Analysis)
• New Product / Design Analysis.
• Assist in analysis of a flat parcto chart.
Guide to do Process FMEA-
Following ten steps are to be follow to implement FMEA

1. SCOPE PROJECT
2. BRAINSTORM ALL POTENTIAL FAILURE MODES.
3. IDENTIFY POTENTIAL EFFECTS OF FAILURE.
4. DETERMINE SEVERITY RANKING.
5. IDENTIFY ALL PTENTIAL CAUSES OF FAILURE.
6. DETERMINE OCCURRENCE RANKING.
7. DEFINE CURRENT CONTROL METHODS.
8. DETERMINE DETECTION RANKING.
9. CALCULATE RISK PRIORITY NUMBERS (Rpn= Risk Priority Number=Severity*Occurrence*Detection
Ranking).
10. PRIORITIZE CORRECTIVE ACTION.
Managing Negativity In The
Team:
Tools For Young Manager

PROF. MRUNAL LAMGE

Negativity- A serious business issue.
• Depending on personality characteristics, individuals express negativity in many ways. Although staff members
may have good reason for being negative at work. It must be confronted.
• Negativity resulting in Increased absenteeism, Higher staff turnover, Lower morale & Decreased
productivity.
• Managers have various tools. They have numerous coping strategies to temporarily subdue the negativity.
• When mangers understands the causes of employee negativity & put in place measure to prevent employee
negativity then negativity fails to gain foothold in the work environment.

Reasons of Employee Negativity study conducted by Towers Perrins & Researchers Gang & Gang as follows-
• The Excessive Workload.
• Concerns about the management's ability to lead the company.
• Anxiety of Future (Long term job, Income & Retirement Security).
• Lack of challenge in the work.
• Insufficient Recognition.

Learning/Finding about the Workplace negativity and Preventing it-

• Receiving Complaints from employee, Doing exit interviews of leaving employees.
• Watching Discussion on employee intranet, managing the appraisal and 360-degree feedback process.
• Collecting Information about work.
Other Important Factors of Negativity &Possible Solution
• Change not Implemented Well.
Individuals normally hesitate for change. If we do not reduce resistance negativity will increase. To avoid it one
can follow below steps
• Communicate throughout the change process the reason for change and explain how it beneficial for
production target achievement.
• Train Individuals about change before or as it is being implemented.
• Communicate time table for change step by step.
• Give individuals positive feedback for adapting new change and celebrate milestones.
• History of Punishing excellent performers and rewarding the poorer once.
• The Absence of learning environment
• A Challenge to security or stability.
• One-size-fits-all approaches of individual motivation.

We can avoid negativity by applying many methods/tips at work place. Below few tips to avoid negativity-
• Listen, Listen, Listen technique like arranging group discission, lunch with manager and many more.
• Share everything you know about situation to build the trust with the work force.
• Encourage people.
• Make opportunities available for people to express their opinion about workplace policies and procedures.
• Provide timely, proactive response to questions and concerns.
PERT-Program Evaluation &
Review Techniques

PROF. GAURANG CHANDARANA

Every Project have start time and end times implies deadline. Various tools for project management to successful implement.
Three Famous tools are as follows-
• Gyan chart.
• Critical path method (CPM).
• PERT (Program Evaluation & Review Techniques).

What Is PERT?
• PERT was developed for the U.S. Navy Special Projects Office in 1957 to support U.S. Navy’s Polarise Nuclear
Submarine Project.
• PERT is model design to analyse & represent the tasks involved in completing project.
• It also gives minimum time require and total time require to complete the project.
• It is commonly used in conjunction with CPM (Critical Path Method).
• PERT was developed to simply the planning and scheduling of large and complex project.
• It is and event oriented technique. It is used in project where time is major factor than cost.
• It is applied to very large scale, one time, complex, non-routine project. (eg.-1968 Winter Olympics in Grenoble).

Rules to use or apply PERT Chart

• It is tool that facilitates the decision making. Chart must be number sequence of 10s (10,20) so we can put extra sub activity
in between.
• Two consecutive events in PERT Chart are link by activities which are conventionally represent as Arrows.
• The events are presented in logical sequence. One can not skip event in between.
• The Planner Decides which are milestone should be in PERT event, Chart may have multiple pages.
• It is useful in a line the Parallel Activities which are important in between sequence events.
There are some terminology used for PERT Chart
Terminology 1
• PERT Event- Point that marks the Strat Or Complition of Evnts
• Predecessor Event and Successor Event
Terminology 2
• PERT Activity- The actual performance of Task which consumes time and requires resources.
• Optimistic Time(O)- Minimum Require time to accomplish the task.
Terminology 3
• Pessimistic time- The maximum require time to accomplish the task is everything goes wrong.
• Most Likely Time- The best estimated time to accomplish the task if everything proceeds normally.
• Expected Time- The best estimated time to accomplish the task; accounting for thr fact that things don’t always proceed as
normally.
Terminology 4
• Float/Slack- It is amount of time delay in sub-activity without causing actually delay in entire project.
• Critical Path- It is the longest sequential path to complete the project. CP= Start Time/End Time. It will give us the
Pessimistic time.
• Lead Time
Terminology 5
• Lag Time- Earliest time by which successor event can follow as specific PERT Event.
• Slack- It is how much we are ahead of time or behind the time
• Fast Tracking- Performing critical activity parallel.
• Crashing Critical Path- Shortening the duration of entire project time.
Implementation of PERT Chart
• For Each task show earliest start date.
• Show estimated length of time required to complete the activity.
• Show whether activities are parallel or sequential
• If activities are sequential then show which stages they depend on.
• Prepare a Gantt Chart.
• Prepare a network diagram.
• Map Critical path in network diagram.
• Take crash action. Which means how we can reduce the time to complete process.

Advantages Of PERT
• It will helps you to show which activities are dependent of which one means give us visible dependence of elements.
• Helps us to identify the Critical Path & Makes this visible.
• Facilitates the identification of Early start time, Late start and slack for every activity.

Some Limitation of PERT

• Network Charts can be large as it involves multiple tasks ,sub-task and parallel activity. It lead to limitation of printing
chart on normal paper for that one may need special paper or equipment.
• Lack of timeframe in PERT/CPM Chart harder to show status even though we have different colour codes.
Transaction Analysis
The success requires the analyse of transaction to understand how successful we are on each of occasion in this
transaction.
Whenever we do it then main focus of transaction is on the way we communicate with people.
TA Communications express as follows for successful transaction
• C Quality of Self Commitment
• O Quality of Self Ownership
• M Quality of Mutual Trust
• M Quality of Me
• U Quality of You
• N Quality of Our Networking
• I Quality of Our Integrity
• C Quality of Our Capabilities
• A Quality of Our Attitude
• T Quality & Ability to Transform/In time
• I Quality of Inputs
• O Quality of Outputs
• N Never Say No
• S Quality of Our Success
One by appropriately adjusting his style as above mention can get Successful Transaction
We are all Egoistic People we all have some egos small, little more, big; measure is not available as one can not measure
it.
This Ego can be problematic for Transaction.
There are three Egos in mind
• Parent
It represents Experience, excellence. This gentlemen can guide and mentor people
• Adult
Nothing like superiority scenario all equality
• Child
It represents Unexperienced

Transaction can be smoothly done by adjusting your ego according to person with whom we are doing transaction.
Cross Transaction leads in breakdown of Transaction.
Successful Transaction done in parallel state as Parent- Child , Adult-Adult , Child-Parent.
Welcome Transaction done between Parent and Child transaction like parallel forms.
The Key Word for best transaction is always look in Eyes and Face. Is he is absorbing it taking interest in transaction so
we can change way of transaction according to his absorption capacity; so transaction can not break in way.