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Answer.1) An operation may be defined “as the process of changing inputs into
outputs thereby adding value to some entity”. Right quality, right quantity, right
time and right price are the four basic requirements of the customers and as such
they determine the extent of customer satisfaction. And if these can be provided at
a minimum cost, then the value of goods produced or services rendered increases.
Thus the objectives of production management are “to produce goods and services
of the right quality, in the right quantities, according to the time schedule and a
minimum cost”. Objectives of production management may be amplified as under:
• Producing the right kind of goods and services that satisfy customers’ needs
(effectiveness objective). • Maximizing output of goods and services with
minimum resource inputs (efficiency objective). • Ensuring that goods and services
produced conform to pre-set quality specifications (quality objective). •
Minimizing throughput-time- the time that elapses in the conversion process- by
reducing delays, waiting time and idle time (lead time objective). • Maximizing
utilization of manpower, machines, etc. (Capacity utilization objective). •
Minimizing cost of producing goods or rendering a service (Cost objective). Key
elements of Operations Management
The right kind of products and good designs of the products are crucial for the
success of an organizing. A wrong selection of the product and/or poor design of
the products can render the company’s operation ineffective and non-competitive.
Products/services, therefore, must be chosen after detailed evaluation of the
product/services alternatives in conformity with the organization’s objectives.
Techniques like value engineering may be employed in creating alternate designs,
which are free from unnecessary features and meet the intended functions at the
lowest cost. 2. Process selection and planning
POM3 Selection of the optimal “conversion system” is as important as choice of
products/services and their design. Process selection decisions include decisions
concerning choice of technology, Equipment, machines, material handling systems,
mechanization and automation. Process planning involves detailing of processes if
resource conversion required and their sequence.
Plant location decisions are strategic decisions and once plant is set up at a
location, it is comparatively immobile and can be shifted later only at a
considerable cost and interruption of production. Although problem of location
choice does not fall within preview the production function and it occurs
infrequently, yet it is of crucial importance because of its major effect on the
performance of every department including production. Therefore, it is important
to choose the right location, which will minimize total “delivered customer” cost
(Production and distribution cost). Locational decisions involve evaluation of
locational alternatives against multiplicity of relevant factors considering their
relative importance to the organization and selecting those, which are operationally
advantageous to the organization. 4. Facilities (Plant) layout and materials handling
Plant layout is concerned with relative location of one department (Work centre)
with another in order to facilitate material flow and processing of a product in the
most efficient manner through the shortest possible time. A good layout reduces
material handling cost, eliminates delays and congestion, improves co-ordination,
provide good housekeeping etc. while a poor layout results in congestion, waste,
frustration, inefficiency and loss of profit. 5. Capacity Planning
POM3 manufacturing takes place in the manner stated in the plan. 7. Inventory
control
Work-study, also called time and motion study, is concerned with improvement of
productivity in the existing jobs and the maximization of productivity in the design
of new jobs. Two principal component of work-study are: (i) (ii) Method study
Work measurement
Method study has been defined (BS 3138) as the systematic recording and critical
examination of the existing and proposed ways of doing work, as a means of
developing and applying easier and more effective methods and reducing costs.
Method study when applied to production methods yields one or more of the
following benefits: • • • • • • • • 10. Improved work environment Improved facility
layout Better utilization of facilities Greater safety Lesser materials handling
Smooth production flow Lower work-in-process Higher earnings for the workmen
Maintenance and replacement
Short production runs and frequent changes of set also characterize batch
production up. The equipment and the assembly set up is used for a limited number
of parts or assemblies and is then changed to make a different product. The
production is generally made to stock. (b) Skilled labour in specific trades: The
labour force is expected to posses skill in one specific manufacturing process,
Turning, milling, drilling, welding, grinding, hobbing, fitting etc. The operator may
perform simpler machine set-ups but the separate machine tool setter performs
those involving complex operations. (c) Supervision to possess knowledge of a
specific process The supervision has considerable knowledge of a specific process.
Supervisor in the grinding section for example, may not expert in turning and
drilling work but s expected to possess a find of knowledge of different types of
grinding operations. Page 4
POM3 Similarly a supervisor in the gear shop is expected to have sound
knowledge in working of different types of gear cutting machines. (d) Limited span
of control: The amount of supervision required in batch production is lower than
that of jobbing production. The ration of direct workmen to supervisors is more or
less a function of batch size. The smaller the batches, the lower are the ratio of
direct workers to supervisors, and vice versa. This is because smaller lots require
each supervisor to spend a great deal of his time in allocating new work, giving
instructions, follow up on the shop floor for proper movement of materials from
and to the machines, identifying delays and interruptions, and arranging, in
consultation with planning, work load in his section to keep his men busy. (e)
General purpose machines and process type of layout Plant and equipment is
procured and arranged to obtain maximum flexibility. General purpose machines
and handling equipment capable of performing variety of operations with
minimum set –up times are installed in lieu of variety of products. The machines
are arranged to give process layout-layout by function. Similar machines capable
of doing similar types of operations are grouped together and kept at one place.
Presses for example, are put together and kept at one place milling machines are
placed together at another place, drilling machines are kept at the third place, gear
cutting machines are located at the fourth place and so on. Each Group of machines
is usually designated as a work centre or a section or a shop. (f) Manual materials
handling: Materials handling in batch production as compared to jobbing
production are small. Individual components and parts are placed in trolleys and
trays and are transported as unit loads. Materials handling may be mechanized by
deploying power driven trucks. (g) Manufacturing cycle time affected due to
queues: The manufacture cycle time is comparatively smaller than jobbing
production but is much more than mass and flow production. The batches of work
tend to queue up at different machines due to differing cycles times, batch sizes
and sequence of operations. (h) Large work-in-progress: Work in progress is
comparatively large due to varying work content of different components,
imbalance in manufacturing times, formation of queues between the machines. (i)
Flexibility of production schedules: Disruptions due to machine breakdown or
absenteeism do not seriously affect production as job can be shifted to another
machine or another operator from another machine can be shifted. (j) Need to have
production planning and control: Functions of production planning and control in a
batch production unit are more complex than those in jobbing production or mass
and flow production: Page 5
POM3 • Materials control and tools control functions are important. kind of
replenishment system needs to be used to ensure routine replenishment Some
• Detailed operational layout and route sheets are prepared for each part of the
product. • Loading and scheduling needs to be more detailed and more
sophisticated since every machine requires to be individually scheduled. •
Progressing function is very important to collect information on progress of work.
A separate progress card needs to be maintained to record progress of each
component. • Expediting is generally necessary since quite often jobs, due to
imbalances in work content, tend to lag behind
Q.3) (a) Why are locational decisions important? What factors should be
taken into account while deciding location of a unit to manufacture washing
machines?
Answer.3a) Locational decisions generally arise when:
• A new manufacturing (or servicing) unit is to be set up.
• Existing plant operations are difficult to expand due to poor selection of site
earlier.
• The growth of the business makes it advisable to establish additional facilities in
new territories.
• There is emergence of new social (chronic labour problems) political (political
instability or economic conditions that suggest a change in the location of the
existing plant.
• The product development has over weighted the advantages of the existing plant.
• The changes in the industrial Policy of the Government, favoring decentralizing
and dispersal of industries to achieve overall development of the country, do not
permit expansion of the existing plant
Bread, soap factories, etc. require the market to be nearby. If factory cannot be
started in Bombay, it may be started in Thane, Kalyan or Poona. If the product is
exported, location near ports is desirable. This is particularly important for
producers who sell bulky commodities, which incur high transportation costs
Nearness to market not only lowers transportation costs but also gives many other
benefits namely: • A good many administrative problems, which cause perpetual
headaches and add to costs, are avoided. • Liaison with dealers or whole sellers can
be maintained economically and easily • Other costs such as commission to
middlemen, which at times run as high as 20 to 50 percent can be reduced
significantly. • Customer’s accounts do not remain outstanding for settlement. This
recovery is easy and less time saving which itself reduces selling costs. 2.
Proximity to source of raw materials:
Since raw materials usually constitute 50 to 60 percent of the total product cost, it
is important that the firm gets its requirements of raw materials at the right time
and at the reasonable price for which the plant must be located in the neighborhood
of some source which can meet the raw materials requirement of the unit
“Proximity to supply of raw materials” factor assumes still greater importance if
raw materials are of perishable nature or if they are expensive to transport, or if
their weight is substantially reduced by processing. Proximity to sources of raw
materials is equally important for small units. This is because usually small units
are not considered important customers. Page 7
POM3 They get least priority and in the event of scarcity are the one to be struck
off first from the list. The availability of materials to small units to a large extent
thus depends on their follow up and personal visits to the supplier’s plant which is
possible only if the buyer’s plant is close by. 3. Infrastructural facilities:
Transportation cost to the value added is a key determinant of the plant location.
The structure of the transportation cost depends on (i) Characteristics of the
commodity (ii) average distance of shipment (iii) medium of shipment: rail, road,
and air sea. The need for transport arises because raw materials and fuel are to be
moved to factory site and finished goods are to be transported from factory to
markets. Other things being equal since transport cost has a major effect on product
cost, the regions well served by transport facilities are most suitable for industrial
locations. 5. Labour and wages:
Plant location should be such that required labour is easily available in the
neighbourhood. Importing labour from outside is usually costly and it causes lot of
administrative problems. Availability of required labour locally is better since
problem of arranging accommodation and other related problems do not arise.
Since normally workers with specific skills are required, some sort of training
facility should also be available in the neighborhood. Skilled employees are easily
available if ITI’s, or Engineering colleges are there in the neighbourhood. 6.
Legislation and taxation:
POM3 The policies of the state Government and Local Bodies relating to issue of
licenses, building codes, labour laws, etc. are the factors in selecting/rejecting a
particular community/site. In order to disperse industries and ensure balanced
economic growth, both Central and State government offer a package of incentives
for setting up industries in particular locations. Exemption from excise duty, sales
tax and octroi, soft loans from financial institutions, subsidy in electricity charges,
etc. are some of the incentives offered. Since taxes and duties levied by the State
Government and Local bodies substantially influence product cost, the incidence of
such taxes/levies must be taken into account while selecting a community/site. 7.
Climatic conditions:
Climatic factors may not have a major influence these days because of modern air
conditioning facilities available today. However, it may be important factor for
certain industries like textile mills, which require high humidity. 8. Industrial and
labour attitudes:
Safety factor may be important for certain industries such as: Nuclear power plants
Explosive factories Location of such industries close to border areas is undesirable.
10.Community facilities (or social infrastructure):
Community attitudes towards work (i.e. whether the people in the location are hard
working or otherwise) as well as their attitudes towards the incoming entrepreneurs
(helpful and cooperative or otherwise) can make or mar an industry. Locational
decisions, therefore, must take such factors also into account particularly while
setting up labour intensive units.
12.Supporting industries and services:
Locational factors should also include proximity of services needed by the firm. A
firm desirous of getting some or all parts made from outside or some of the
operations done from outside must see that such sub-contractors are located in the
neighbourhood. Getting a job done from units located at far off places will mean
not only additional transportation cost but also time consuming and costly. Also if
units are too far off, the control on quality of work done by them cannot be
exercised. 13. Suitability of the land:
Site selection should also take into account topography and soil structure of the
land. The soil structure must be capable of bearing loads of foundations. Though
modern building techniques can overcome the limitations of the soil, but if
considerable improvement is required then selection of a low cost and may
ultimately turn out to be expensive.
Site size (Plot size) must be large enough to accommodate the present production
facilities, parking and access facilities but also leave sufficient room for future
expansion. As a general rule, a site five times the actual plant size is considered
minimum for all these things including future expansion.
Page 16
POM3 • Activity time in CPM technique are related to costs while it is not so in
PERT since it is event oriented Significance of critical path Critical path analysis
offers several advantages. It
(i) Forces through pre-planning. Each and every activity compromising the project
is identified and recorded. Nothing is left to memory or chance which prevents
crises in scheduling (ii) Increases coordination of tasks as technological
relationship between the activities suggests which activities can run simultaneously
and which should succeed others. (iii) Helps computations of different project
duration’s for different level of resources and thereby select a plan that minimizes
total project cost. (iv) Indicates optimal start and finish times of each activity of the
project. (v) Defines areas of responsibility of different departmental heads for
timely execution of the project. (vi) Facilitates progress reporting and limits
unnecessary discussion at the progress meetings. (vii) Identifies troubles spot often
in advance and apply remedial measures. (viii) Enables the plan to be revised in
accordance with changes/changing circumstances. (ix) Helps to exercise “control
by exception” and prevents cost overruns. A Project comprises a series of activities
and the identification of the individual activities requires knowledge and
experience of the men responsible for the planning of the project. Even the
preliminaries-mere listing of the activities-make the operating personnel: • Think
of details about the project well in advance.
• Observe critically the way in which the various activities interact or compete for
scarce resources • Improve upon the original plans even before network is formally
drawn and analyzed. A project, therefore, must be torn into a set of identifiable
activities. are no set rules but general guidelines are as under: There
• An activity should represent the smallest unit of the operation or set of operations
over which management desires control. • An activity should represent an
operation or set of operations, which can be performed using a particular kind of
equipment or a special skill. For example in construction project, plumbing is
considered as one activity while wiring can be considered as another activity since
the first activity requires plumbers and the second activity needs electricians.
Page 17
POM3
Q.12) (b) Activity 1-2 1-3 1-4 2-5 3-5 4-5 4-6 5-6 Optimistic 02 03 02 04 02 06 01
01 04 05 02 03 02 05 03 05 Most Likely 10 06 10 01 12 04 08 13 Pessimistic
Answer:
Page 18
POM3 (a) Expected time of an activity can be obtained from the three time
estimates using the formula: te = a + 4m +b 6 where a m b a m b te = = = = = = =
Optimistic time most likely time pessimistic time 2 3 10
2 + 4 x 3 + 10 6 24 6 = 4
te
Expected times of all activities of the network, calculated on above lines, are
tabulated below. Activity 1-2 1-3 1-4 2-5 3-5 4-5 4-6 5-6 Three time estimates 02-
03-10 4 02-04-06 4 02-06-10 6 01-01-01 1 04-05-12 6 02-03-04 3 02-05-08 5 03-
05-13 6 Expected time
66
44
61
Page 19
POM3 Critical path is 1-3,3-5,5-6 and the duration for the project is 16 weeks
(4+6+6) Variance is
Vi
(b –a) X (b – a) 6 6 4 9 16 9 25 9
V1-3
V3-5
V5-6
VV
==
= 2.236 = 1.34
Q.10) (a) What are X-R Charts? How are they made and used in controlling a
process? Answer.10) X-R chart is a pair of chart consisting of a average (called X
chart) and a range Chart (called R chart) placed one below another on a piece of
graph paper. The X chart is used to control the mean value of the characteristic an
R-chart is used to restrict the range of variations in the values. X-R charts are
drawn when the characteristics are measurable. Each chart consists of three values:
a central line, upper control limit and lower control limit. The central line
represents the arithmetic average of the sample means which equals the mean of
the population, u. The upper and lower control limits are located at three standard
deviation on either side of the central line. Samples of fixed size are drawn at
regular intervals and measurements are taken. The samples wise values of the
mean and range are plotted in their respective X and R charts. The spread of
sample points in the charts is studied to decide the remedial action (if any) to be
taken. The X chart analyses whether or not the mean of the quality Characteristics
is within control while R-chart analyses whether or not the variability is within
control. STEPS TO PREPARE X-R CHART A pre-requisite to the preparation of
the chart is the decision on the following aspects: • Quality Characteristics refer to
the property of the product, which is to be assessed. The quality characteristics
must be capable of being measured. In case of more than quality characteristics,
separate chart is made for each quality characteristic. • Sample size refers to
number of pieces comprising each sample. Sample size is an important decision. It
is a common practice to use sample of n = 4 or 5 to have low appraisal cost. Large
samples such as n = 15 or 20 are used if the process standard deviation is large. •
Sample Population refers to the number of samples to be collected to construct a
control chart. The number of samples must be sufficient. Usually, 20 samples each
of size 4 or 5 are enough to have good estimates of the process average (X) and
dispersion (R). • Time Interval measures the time gap between consecutive
samples. Time interval, as a genera rule, should be proportional to the average
frequency of out-of-control conditions. It is a fairly complex decision since a
number of factors such as cost economy, susceptibility of the process to Page 21
POM3 disturbances; convenience of the inspector etc. requires to be considered.
The making of X-R Charts involves the following Steps: Step 1: Collect Data
(a) Collect sufficient samples spread over a reasonable period. Each sample must
be of equal size. (b) Measure each component comprising the sample for the given
quality characteristic (c) Record individual measurements on a work data sheet.
Step 2: Calculate mean (X) and Range (R) of each sample
Step 3: Calculate grand Average (X) and mean Range (R) A The grand average,
which is written as, X (X double bar) is the average of the sample averages and is
obtained by dividing the total of the averages of all the samples by the total number
of samples. B The mean range, which is written as, R (R bar) is the average of the
ranges and is obtained by dividing the total of the ranges of the samples by the
total number of samples.
Step 4:
A Set up a control chart with the central line drawn at X (X double bar), upper
control limit located X + A2R (R bar) and the lower control limit set up at X-A2R.
B Plot the averages to see whether the process was under control when samples
were drawn. C If all points fall within the control limits, the process is said to be
under control D If process is not under control (indicated by some points falling
outside the control limits), eliminate points outside the control limits and compute
new trial control limits for the remaining points. E Repeat step 4 (d) until all points
fall within the control limits F Control limits in a particular situation should be
revised from time to time as additional data is accumulated. Step 5: Calculate
control limits of the range chart Page 22
POM3 A The control chart for range chart is set up with central line as R, upper
control limit (UCLR) located at D4R above the central line and lower control limit
(LCL) at D3R below the central line B Plot the value of the range of each sample.
C If all points fall within the control limits no modification is necessary unless it is
desired to reduce the process dispersion D if range chart exhibits lack of control
indicated by some points falling outside the control limits, eliminate those points
out of control and compute new trial control limits E Repeat step 5 (d) until all
points fall within the control limits. F Control limits in a practical situation should
be revised time to time as additional data is accumulated.
Step 6: Use control chart A Collect samples of fixed size at specified intervals of
time. B Measure each unit of the sample for the quality characteristics, calculate
mean and the range of each sample. C charts D action Plot the values of X and R of
each sample in their respective Study the trend of the points to interpret and
suggest remedial
Q10 (b) ABC company produces a solvent, which must contain 3 percent of
alcohol. It tries to maintain the actual percentage at 3 + 0.3 percent. It tests hourly
in samples of five. The following table shows the results of last five samples. Set
up a control chart for mean and examine whether the process is under control. A)
Solution: (i) Collect data (ii) Calculate mean (X bar) and range(R bar)
Page 23
Sample No. 1 2 3 4 5 (iii) X(X bar) 2.92 2.98 3.06 3 3
Calculate grand average and the mean range = 2.92 + 2.98 + 3.06 + 3 + 3 5 = 2.992
(iv)
Set Up control chart for the average = = 2.992 UCLx = X (X bar) + A2.R(R bar)
Central Line = CLx = X(X bar) Upper Control Limit = = 2.992 + 0.5768 x 0.14
3.476
(v)
Set up a range chart = R(R bar) = LCLR = = 0.14 D3.R (R
0 x 0.14
==
POM3 One of the most commonly used approaches consists of following steps:
Step 1: Prepare a list of all relevant factors.
Step 2: Estimate expenses on materials, transport, wages, power etc for each
location on each of the above factors. Step 3: Collect data on intangible factors like
community facilities, community attitudes etc. Step 4: Analyse the tangible data
for each location and calculate rate of return on investment. Step 5: Select
provisionally a locational based on financial data.
Step 6: Compare the intangible data for the different locations and select the
optimal location considering intangible data. Q.3) (b) What are objectives of a
good layout? Discuss any six principles of a good layout? Answer.3)(b)
OBJECTIVE OF A GOOD PLANT LAYOUT Only through an efficient layout, the
organization can attain the following objectives: (i) (ii) (iii) (iv) (v) Economy in
handling of materials, work-in-process and finished goods. Minimization of
product delays. Lesser work-in-progress and minimum manufacturing cycle time.
Efficient utilization of available space. Easy supervision and better production
control.
(vi) Greater flexibility for changes in product design and for future expansion. (vii)
Better working conditions by eliminating causes of excessive noise, objectionable
odor smoke etc.
(iii) Uni-direction flow: A good layout is one that makes the materials move only
in the forward direction, towards stage of completion, with any backtracking. ?
Since straight line is the shortest distance between any two, points, materials as far
as possible should be made to move on the principle of straight line flow. And
when straight line flow is not possible, other flows like U-shaped flow, circular
flow or zig zag flow may be adopted, but the layout may ensure that materials
move in the forward direction (Fig 4.1) ? To ensure forward flow, equipment if
necessary may be duplicated.
(iv) Effective use of available space: A good layout is one that makes effective use
of available space both horizontal and vertical • Backtracking and duplicated
movements consume more time, involve un-necessary materials handling, add to
cost and lead to inefficiency. • Raw materials, work-in-progress and finished goods
should be piled vertically one above another rather than being strewn on the floor. •
Pallets or equivalents should be made use of to pile up several layers one above
another • Area below the work tables or in the cupboards built into the wall are
welcome since they reduce requirement of space
(v) Maximum visibility: A good layout is one that makes men, machines and
materials ready observable
Q.4) How does production planning differ from production control? What are
the key functions of production planning and control?
Answer.4) Production planning versus production control. Planning (Planning the
work) Control (Working the Plan) Planning involves collection and maintenance of
data regarding time standards, materials and their specifications, machines and
their quantities, tools and their process capabilities, drawings and operational
layouts etc. Planning is seeing that requirements tool, machines, men, instructions,
authorization and the like-will be available at the right time and in the right
quantities and are of proper quality. Planning involves preparations of load charts
and fitting various work orders into uncommitted time available on the company’s
facilities (men or machines). Planning involves preparation of all necessary forms
and paper work. Planning involves designing suitable feed back as to what may
happen.
Control involves actual seeing that the jobs are started and completed as per
schedule prepared by the scheduling cell of the PPC. Control involves actual issue
of forms and paper work. Control involves keeping track of what is happening and
collecting information as to what has happened. Control involves suggesting
remedial action when the job is falling behind schedule. Control is thus a diffused
activity (in the shops) and includes functions such as dispatching, progressing and
expediting.
Order Preparation includes activities like making of work orders, converting work
orders to shop orders, preparing auxiliary orders and releasing such orders to those
concerned to authorize their activities
Selection of the job Selections of the jobs to be studied for methods improvement
by the method study practioner is a managerial responsibility and it (selection) may
be based on economic technical or human consideration. Economic consideration
justifies selection based on the economic worth (i.e. money saving potential) of the
job. Technical consideration identifies jobs, which require studies to overcome
manufacturing difficulties (excessive rejection, relaxation in prefixed performance
standards, inability if the shops to stick to specified machining parameters such as
speeds, feeds, depth of cut etc., inconsistent quality etc.) Human consideration in
job selection is usually given weightage while introducing method study practices
for the first time. Recording of facts Systematic recording is the most crucial step
in method improvement. Since recording by long hand (or by descriptive method)
has its limitations, it is not recommended for use in method study. Instead, five
symbols and eight charting conventions are used to record facts relating to the job
under study.
POM3 Five typical symbols are O, ||, ?, D and V and eight charting conventions
concern composition of the chart, reject, rework, repletion, change of state,
introducing of new material, combined events and numbering of events. The
document on which details of the process are recorded by the above referred
symbols and conventions is called chart. There are four basic types of chart: (i)
operation process chart (ii) Flow process chart (iii) multiple activity charts and (iv)
two handed process chart. Besides charts, two types of diagrams-flow diagram and
string diagram are drawn when recording details of an existing layout. Travel chart
is another typical chart, which is used to record frequency of movements (weight x
distance) between work centres/departments.
Repetitive short cycle operation which involves quick hand/feel motions (i.e.
microscopic motions) may be studied with micro motion study. Glibreth, founder
father of micro motion study, also developed photographic techniques called
cyclograph and chronocylegraph to record path of the motions of the members of
the body. Critical examination Critical examination aims to analyze the facts
critically and thereby give rise to alternatives, which form the basis of selection
and development of easier, and effective methods. Critical examination is
conducted through a systematic and methodical questioning process. Each activity
recorded on the chart, whether it relates to processing or inspection, or material
handling, or to any other aspect, is picked up one at a time and is examined
minutely. The questioning process is considered under five major heads, namely
the purpose, the place, the sequence, the person and the means. These five aspects
in critical examination are referred to as five governing considerations.
Development and selection: Development and selection stage concerns short listing
of ideas generated at the critical examination stage, testing each short listed idea
for its technical and economic feasibility, and making selection among the
alternatives wherever choice exists. To develop ideas and to ascertain their
technical and economical feasibility, the method study practioner needs to solicit
the cooperation of personnel from different departments of the company. Various
techniques available for the development and selection purpose are: cost benefit
analysis, break even analysis, investment analysis and critical path analysis.
Installation ‘Installation’ (or implementation) of the proposed method involves
preparation of project report on recommendations making oral presentation to the
top
It
Further the incentive plan should be such that it provides an opportunity to all
average workers to earn reasonable earnings. • Consistency of the standards
Standards once fixed should not be changed unless there is a permanent change in
methods, or change in equipment, or change in material and plan should provide
for the provisions to modify the performance standards. • Inbuilt check on process
rejections A good incentive scheme should exercise a check on the operator against
achieving higher bonus by poor workmanship. Payment should be made only for
pieces declared acceptable by the inspection department and a workman constantly
producing substandard pieces should be liable for disciplinary action. • Payment of
partially completed jobs The problem of payment for the incomplete work arises
only in case of long cycle jobs. Situations do arise when the jobs are of very long
cycle duration and cannot be finished within the bonus period. Similarly, a semi-
finished job may require to be handed over by one operator to another at the end of
shift, or prior to having a holiday. The scheme should clearly spell out as how
assessment of work done by the workmen on the same job will be carried out and
how disputes arising out of such assessment would be resolved. • Payment of Idle
Time Adequate safeguards must be provided to compensate the operator for the
time lost due to reasons beyond his control. A good incentive scheme should
ensure that an operator does not suffer financial loss for reasons attributable to the
managerial weakness, e.g.: lack of material due to bad buying, breakdowns of the
machines due to poor maintenance practices, non-availability of work etc. Thus an
operator rendered idle because of factors attributable to the management should be
given a lieu bonus.
Page 28
POM3 • Safeguards The scheme should be fair not only to the employees but also
to the employer. Safeguarding clauses as under should be incorporated to protect.
a. Management’s right to change a standard when there are changes in methods.
Materials and machines b. Management’s right to withdraw or discontinue
temporarily a scheme during bad period. c. Management’s right to initiate
disciplinary action against operators who continually produce sub-standard articles.
d. Management’s right to initiate disciplinary action against employees who, time
and again, do not achieve minimum standard of production even in the presence of
fair and accurate standards. e. Management’s right to initiate disciplinary action
against employees who, time and again are found using speeds and feeds higher
than those recommended in the process sheet (or operational layouts) • Maximum
ceiling on the earnings The system should have built-in-control against higher
earnings beyond a certain limit. Firstly, the system should discourage workers to
work beyond a certain limit otherwise too attractive an incentive scheme may
induce the worker to work more and more and thereby adversely affect his health.
Secondly, the system should ensure that in case of loose standards the company
does not lose financially. • Consistency of Plan The plan should be consistent over
a period of time. Frequent changes in the plan make it’s functioning difficult. Faith
in plan is lost if there are frequent revisions. • Acceptance of Labour Body The
scheme should finally have acceptance of the labour body. The body of workers’
representatives to prevent any misunderstanding and ill-feeling later on must
accept the basic incentive plan and its provisions. • Continuous Use The scheme
should be in continuous use. The temporary use of the scheme in good times and
its discontinuation in bad times makes it’s functioning difficult. • Define End
Results The plan must result in reduction in per unit labor cost.
Page 29
POM3
Q 13) Answer 13) i) Average Cycle time = 0.22 + 0.24 + 0.28 + 0.26 + 0.25 5 =
Normal Time = 0.25
Similarly, average cycle time and normal time for all the elements are calculated
and tabulated as below Element A B C D E Avg. cycle time 0.25 80 0.15 100 0.35
120 0.102 90 0.12 100 Rating 0.2 0.15 0.42 0.0918 0.12 Normal time
= Page 30
ii)
Relaxation Allowance
15 100 =
0.9818
0.1473 x 0.9818
Contingency Allowance
5 100 0.0491
?Standard time
=
Normal time + Relaxation Allowance + Contingency Allowance = ?Standard time
0.9818 + 0.1473 + 0.0491 = 1.1782