The National Institute

The National Institute of Engineering of Engineering (NIE),

one of the oldest private
[ (A Govt. Aided Autonomous Institution), Affiliation: Visvesvaraya Technological University] engineering colleges of the
Founded: 1946
1 country, was started in the
year 1946. 
Vision Mission Eminent founders, three
To impart state-of-the-art engineering education engineers Sri
NIE will be a globally acknowledged S.Ramaswamy, Retd.
through strong theoretical foundations and Superintending Engineer,
institution providing value based
practical training to students in their choice of Mysore PWD, Sri
technological & educational services through D.V.Narasimha Rao, Retd.
specialization Chief Engineer, Mysore
best-in-class people and infrastructure
To create new knowledge through innovation State Railways and Sri
T.Rama Rao, Retd.
and cutting-edge research in science and Executive Engineer of
engineering Mysore PWD, took lead in
establishing NIE,
To provide a platform for inclusiveness and Managing Committee
collaboration by following ethical and responsible NIE is being managed by a
Managing Committee of
engineering practices for long-term interaction President, Vice-President,
with academia and industry Hon. Secretary and Hon.
Treasurer and six
To encourage entrepreneurship and to develop distinguished Directors.
sustainable technologies for the benefit of global Presently, 9 out of 10
elected Managing
society Committee members are
NIE alumni. NIE Group
of Institutions
Programmes: NIE offers 7 Bachelor, 11 Master’s and 5 Post-graduate Diploma programmes and has 13 Centres of Excellence. Started as a single institute,
NIE today has a group of
The student strength is about 3500. Many funded research projects of Central and State Governments, VTU, ISRO and institutions; under its
McMaster University amounting to about Rs. 700 lakh are presently carrying out at NIE. Society and Trust.
 Address: Mananthavadi Rd, Vidayaranya Puram, Mysore-570 008 Karnataka State, INDIA, •The National Institute of Engg.
• NIE Institute of Technology, about
(O), Telefax: 0821-2485802 Phone:0821- 248 0475 2 kms from Infosys, Mysuru
• NIE Industrial Training Institute
Principal:  Dr. N. V. Raghavendra,Professor, Mech. Dept. • NIE First Grade College
 Dr.Aravinda Rao M Yadwad
Department of Mechanical Engineering Ph. D Professor

Dr. N. V. Raghavendra Ph. D

Professor
2 Dr.M.V.Achutha Ph. D

Vision Mission Professor & Head

The Department of Mechanical Engineering The Department of Mechanical Engineering is Dr.B.Suresha Ph.D Professor

will mould globally competent engineers by committed to: S.Shamsundar M Sc(Engg)

Associate Professor
 Provide a strong foundation in mechanical
imparting value based technological Tajmul Pasha M.Tech
engineering to make our engineers globally
education through contemporary Associate Professor
competitive.
infrastructure & best in class people Ravikumar Beeranur M.Tech
Inculcate creativity in developing solutions to Asst. Professor

mechanical engineering problems by adopting B.Hulugappa M.Tech Asst.

ethical and responsible engineering practices. Professor
K.K.Yogesh M.Tech Asst.
 Creating centres of Excellence to provide Professor
J.Dharanish M.Tech Asst.
students with opportunities to strengthen their Professor
Beemaraj M.Tech Asst.
leadership & entrepreneurial skills and research Professor
proficiency. Sunil S R Gaekwad M.Tech
Asst. Professor
Building relationships with globally Sharath Chandra N M.Tech
Asst. Professor
acknowledged academic institutions and Srikanth N.S M.Tech
industries. Asst. Professor
Srinag.P M.Tech Lecturer
HOD:  Dr.B.Suresha, Professor Vikram Athreya V M.Tech Asst.
The Department of Mechanical Engineering was established in the year 1958 and the first batch of B.E. graduates moved out of the portals of NIE in the year 1963.  Professor
Undergraduate course: [Bachelor of Engineering] B.E. degree(Mechanical Engineering): – 4 years duration Intake- 60*3=180
Post Graduate courses for M.Tech* Product Design and Manufacturing: 2 years duration (run by VTU) Aruna Mokhamatam M.Tech
Industrial Automation and Robotics : 2 years duration Asst. Professor
Nano Technology : 2 years duration
Machine Design : 2 years duration
M.Sc. (Engineering):by Research, Doctoral Program [Ph.D],
Short term courses: in CNC, CAD-CAM, Robotics and Finite Elements Method, UniGraphics.Etc. for employed Degree and Diploma Holders and
Engineering students.
 OPERATIONS MANAGEMENT (3-0-0)

Sub Code : ME7E204 CIE : 50 %

Hrs / Week : 03 SEE : 50
SEE Hrs : 3 Hrs %
Max.
Course Instructor:
Marks: 100

Dr. Aravindrao M.Yadwad

B.E, M.Tech, Ph.D, PGDHRM., MBA, MASME, MISTE, MCI, C.Engg.,FIE.
Professor & Dean [Student Affairs]
Department of Mechanical Engineering
The National Institute of Engineering
MYSORE - 570008, KARNATAKA Cell:09964470900
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 Time Table

Days ‘A’ section

/Timings [405]

Mon --------------

Tue -------------

Wed 12.40-1.30
Thu 11.00 – 11.50

Fri 12.40-1.30

Sat -----------

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 Course Content
Module - 1
Operations Management Concepts: Introduction, Historical Development, Operations Management
Definition, and Framework for managing operation, The trending operation management Products v/s
Services, Productivity, Factors affecting Productivity, International Dimensions of Productivity, Scope of
operations management.
Operations Decision Making: Introduction, Characteristics of decisions, framework for Decision
Making, Decision methodology, Decision support system. Concept and Numerical problems on
economic model (BEA), Decision tree analysis.
SLE: Trending in manufacturing industries 8 hrs

Module - 2
System Design and Capacity Planning: Introduction, System configuration, Manufacturing and
Service system, Design capacity, System capacity, capacity planning, investment decisions and
Numerical problems
Facility Location and Layout: Introduction, Need of selecting a suitable location, factors influencing
plant location, Location Planning for Goods and Services, Foreign locations, Objectives of the good
plant layout. Facility layout, Classification of layouts, Analysis and selection of layouts, Minimizing cost
in job shop layout.
SLE: Assembly Line balancing 7hrs 5
 Course Content
Module -3
Demand Forecasting: Nature and use of forecast , Forecasting time horizon, short and long range forecasting, sources of
data, demand patterns, forecasting models: qualitative forecasting techniques, quantitative forecasting models- linear
regression, moving average, exponential smoothing, Numerical problems.

SLE: Forecasting as a planning tool 8hrs

Module – 4
Aggregate Planning and Master Scheduling: Introduction to Planning and Scheduling, Objectives of Aggregate
Planning, Aggregate Planning strategies and Methods, transportation model for aggregate planning. Objective and
concept of the Master Scheduling, Master Scheduling Methods, Numerical problems
Material and Capacity Requirements Planning: Inputs and outputs of MRP system, BOM, MRP logics, introduction to
CRP and ERP.
Modern production management tools: Just in time manufacturing: overview of JIT, basic elements of JIT, Benefits of
JIT, universal problem solving sequence, Push/Pull production. Japanese manufacturing Techniques: In brief Kanban,
Poka yoke and kaizen. 8hrs

SLE: Capacity Management.

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 Course Content

Module– 5
Scheduling and Controlling Production Activities: Introduction ,scheduling strategy & guidelines,
Scheduling methodology, concept of single machine scheduling, measure of performance, SPT, WSPT
rule, EDD rule, minimizing nos. of tardy jobs. Flow shop scheduling: Johnson algorithm’s’ jobs on ‘2’
and ’3’ machines, Gantt chart, CDS heuristics. Job shop scheduling: Scheduling ‘2’ jobs on ‘M’
machines.Numerical problems. 8hrs
SLE: Gantt Chart

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Text Book:
1. Operations Management by B. Mahadevan, Theory and practice, Pearson education, second
edition-
2007.

Reference Books:

1.Operations Management by I. Monks, J.G., McGraw-Hill International Editions, 1987.

2.Modern Production/Operations Management by Buffa, Wiley Eastern Ltd, Year 2007
3.Production and Operations Management by Pannerselvam. R.,PHI, Year 2012
4.Productions & Operations Management by Adam & Ebert, Year 2002
5.Production and Operations Management by Chary, S. N., Tata-McGraw Hill, Year 2000
6.JIT manufacturing by M.G. Korgoonkar First Edition, McMillan India Ltd, Year 2003

Assessment Methods:
1. Written Tests (Test 1,2 & 3) are Evaluated for 25 Marks each out of which sum of
best two for 50 marks are taken.

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 Course Outcomes

Upon successful completion of this course, the student will be able to:
1.Understand role of operation management, the factors affecting productivity
and develop decision support system.
2.Understand the different capacities, facility location and layouts.
3.Analyze different qualitative and quantitative forecasting models.
4.Evaluate different material and capacity requirement planning methods.
5.Understand and solve different job scheduling strategies.
6.Understand the Optimization of time in material logistic process.

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 Program Outcomes
1. Demonstrate engineering knowledge in the four streams of mechanical engineering, namely, thermal
engineering, design engineering, manufacturing engineering and industrial management.
2. Solve real life problems through the application of engineering knowledge.
3. Design a component, system or process to meet desired needs with realistic constraints.
4. Formulate mathematical models and conduct experiments to analyze the complexities of mechanical
systems.
5. Provide solutions to varied engineering problems using computational tools.
6. Overcome engineering challenges to cater to the needs of the society.
7. Design and manufacture products which are economically and environmentally sustainable.
8. Discharge professional and ethical responsibility considering societal health and safety.
9. Function competently as an individual and as a part of multi-disciplinary teams.
10. Communicate effectively and express ideas with clarity
11. Exhibit professionalism by employing modern project management and financial tools.
12. Possess the knowledge of contemporary issues and ability to engage in life-long learning
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Mapping of course outcomes with program outcomes

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 Unit 4
Aggregate Planning and Master Scheduling: Introduction to Planning and
Scheduling, Objectives of Aggregate Planning, Aggregate Planning strategies and
Methods, transportation model for aggregate planning. Objective and concept of
the Master Scheduling, Master Scheduling Methods, Numerical problems

Material and Capacity Requirements Planning: Inputs and outputs of MRP

system, BOM, MRP logics, introduction to CRP and ERP.

Modern production management tools: Just in time manufacturing: overview of

JIT, basic elements of JIT, Benefits of JIT, universal problem solving sequence,
Push/Pull production. Japanese manufacturing Techniques: In brief Kanban,
Poka yoke and kaizen. 8hrs

SLE: Capacity Management.

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Planning Sequence

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Master Scheduling

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Material and Capacity Requirements Planning:

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Materials requirements planning;
Computerized Inventory Control
Production Planning System
Management Information System
 Manufacturing Control System

*This is the most comprehensive approach to manufacturing inventory and

other dependents which demand an efficient inventory management system.

The MRP system determines item-by-item, what is to be processed and

when, as well as what is to be manufactured when.

*This is based on order priorities and available capacities.

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An MRP system is intended to simultaneously meet three objectives:

Ensure materials and products are available for production and delivery to
customers.
 Maintain the lowest possible level of inventory.
 Plan manufacturing activities, delivery schedules and purchasing activities

MRP Functions;
Forecasting
Order, Planning and Control
 Priority Planning and Control
 Planning Capacity Requirement and Development of
Broad Business Plans

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The Scope of MRP in Manufacturing organizations;

Manufacturing organizations, whatever their products, face the same daily practical problem - that
customers want products to be available in a shorter time than it takes to make them.
This means that some level of planning is required.

Making a bad decision in any of these areas will make the company lose money.

A few examples are given below:

•If a company purchases insufficient quantities of an item used in manufacturing, or the wrong
item, they may be unable to meet contracts to supply products by the agreed date.

•* If a company purchases excessive quantities of an item, money is being wasted - the excess
quantity ties up cash while it remains as stock and may never even be used at all. This is a
particularly severe problem for food manufacturers and companies with very short product life
cycles. However, some purchased items will have a minimum quantity that must be met,
therefore, purchasing excess is necessary.

•* Beginning production of an order at the wrong time can cause customer deadlines to be
missed.
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MRP Logic & BOM (without lead time consideration)-
Problem-1.

• Product M is made of two units of N and three of P. N is made of two units of R

and four units of S. R is made of one unit of S and three units of T. P is made of
two units of T and four units of U.

a.Show the bill of materials (product structure tree).

b. If 100 M are required, how many units of each component are needed?

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 Introduction to CRP and ERP.
Capacity Requirements Planning is a computerized
technique for projecting resource requirements for critical
work stations.

Inputs:
Planned order releases
Routing file
Open orders file

Outputs:
Load Profile for each work center

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CRP is a tool for:
determining capacity that is available and required.
Alleviating bottleneck work centers.

Helping planners make the right decisions on scheduling

before problems develop.

Verifies that you have sufficient capacity available to

meet the capacity requirements for MRP plans.

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 What is Capacity?
The work that the system is capable of doing in a period of
time.
It must be determined at different levels:
plant
department
work center.
It is normally stated in standard hours of work.
Rated Capacity = (no. of machines or workers) x (no. shifts or Machine hours)
x (% utilization) x ( System efficiency)

Best operating level is the percent of capacity utilization that minimizes average
unit cost.
Usually 80% with a 20% cushion
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 Utilization and Efficiency
Utilization is the percent of available time spent working.

Efficiency is how well a machine or worker performs compared to a standard

output level.

Actual Hours Charged

Utilization =
Scheduled Available Hours

Standard Hours Earned

Efficiency =
Actual Hours Charged

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Modern production management tools

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A pull system initiates production as a reaction to present demand, while a
push system initiates production in anticipation of future demand. In a pull
system, production is triggered by actual demands for finished products, while in
a push system, production is initiated independently of demands.

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 ERROR PROOFING
Techniques
• Design for Manufacturability
• “Poka-Yoke” System Devices
 ERROR PROOFING TECHNIQUES

OBJECTIVE
To improve the PROCESS by helping
people prevent ERRORS and increase the
chances of DETECTION, so that FAILURE
MODE occurrences are
ELIMINATED.
Poka yoke
WHAT IS
ERROR
PROOFING?

HOW AND
WHERE DO WE
APPLY IT?
FIVE BEST POKA-YOKE

1. GUIDE PINS OF DIFFERENT SIZES

2. ERROR DETECTION AND ALARMS

3. LIMIT SWITCHES

4. COUNTERS

5. CHECKLIST(S)
TOOLS FOR ANALYSIS
Flow Chart Fishbone Diagram Pareto Chart

Problem

Histogram Problem
5 Why’s Run Chart
Why
Why
Why
Why
Why Root Cause

Scatter Plot Control Chart Pictograph

What is Kaizen?
• Kaizen (Ky’zen)
• “Kai” means “change”
• “zen” means “good (for the better)”
• Gradual, orderly, and continuous improvement
• Ongoing improvement involving everyone

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How to Kaizen
• Identify the customer
• Deming Cycle
• Plan – identify what to change and how to do it
• Current state
• Future state
• Implementation plan

• Do – execute the improvement

• Check – ensure the improvement works
• Act – future and ongoing improvements
• Repeat
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Deming Cycle

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Types of Waste
• Overproduction
• Excess inventory
• Defects
• Non-value added processing
• Waiting
• Underutilized people
• Excess motion
• Transportation

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SLE: Capacity Management.

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