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PART – A ANSWERS
1. Define Production System. (Nov 2010)& (Nov 2013)
"The methods, procedure or arrangement which includes all functions required to
accumulate (gather) the inputs, process or reprocess the inputs, and deliver the marketable
output (goods)."
PART – B ANSWERS
1. Write the main functions of Production Management? (Nov 2010/13 / Apr 2013)
The components or functions of production management are as follows:
Selection of Product and Design,
Selection of Production Process,
Selecting Right Production Capacity,
Production Planning,
Production Control,
Quality and Cost Control,
Inventory Control, and
Maintenance and Replacement of Machines
Production Planning:
Production management includes production planning. Here, the production manager
decides about the routing and scheduling.
Routing means deciding the path of work and the sequence of operations.
The main objective of routing is to find out the best and most economical sequence of
operations to be followed in the manufacturing process.
Routing ensures a smooth flow of work.Scheduling means to decide when to start and
when to complete a particular production activity.
Production Control
Production management also includes production control. The manager has to monitor
and control the production.
He has to find out whether the actual production is done as per plans or not.
He has to compare actual production with the plans and finds out the deviations. He
then takes necessary steps to correct these deviations.
Production management also includes quality and cost control. Quality and Cost
Control are given a lot of importance in today's competitive world.
Customers all over the world want good-quality products at cheapest prices.
To satisfy this demand of consumers, the production manager must continuously
improve the quality of his products. Along with this, he must also take essential
steps to reduce the cost of his products.
Inventory Control
Production management also includes inventory control. The production manager must
monitor the level of inventories.
There must be neither over stocking nor under stocking of inventories.
If there is an overstocking, then the working capital will be blocked, and the materials
may be spoiled, wasted or misused.
If there is an under stocking, then production will not take place as per schedule, and
deliveries will be affected.
2. What are the objectives of Production Function? (Nov 2011)& (Nov 2013)(April/May
2015)
Objectives of Production Function
To produce goods and services as per the estimated manufacturing cost and minimum
inputs of resources.
To produce right quality goods and services as per the established standards and
specifications.
To produce goods and services as per the decided time schedule.
Minimize the use of resources to the optimum level. These are 4 M's :- like Machinery,
Materials, Manpower and Money. These inputs are to be used to full extent to result
minimum cost, quality and time.
Maximize the utilization of manpower.
Minimizing the total cost of production with continuous elimination of non-value
added activities and improving labour productivity on the production shop floor.
Around the same time, Frank Gilberth and his leaned wife Lillian Gilbert examined the
motions of the limbs of the workers (such as the hands, legs, eyes etc.) in performing
the jobs and tried to standardize these motions into certain categories and utilize the
classification to arrive at standards for time required to perform a given job.
This was the precursor to the present day ‘motion study’. Although to this day
Gilberth’s classification of movements is used extensively, there have been various
modifications and newer classifications.
collective Efficiency:
So far focus was on controlling the work output of the manual laborer or the machine
operator.
The aspects of collective efficiency came into being later, expressed through the efforts
of scientists such as Gantt who shifted the attention to scheduling of the operations.
Even now, we use the Gantt charts in operations scheduling. The considerations of
efficiency in the use of materials followed later. It was almost 1930, before a basic
inventory model was presented by F W Harris.
Quality:
After the progress of applications of scientific principles to the manufacturing aspects,
thought progressed to control over the quality of the finished material itself.
Till then, the focus was on the quantitative aspects; later on it shifted to the quality
aspects.Quality which is an important customer service objective came to be
recognized for scientific analysis.
The analysis of productive system, therefore, now also included the effectiveness
criterion in addition to efficiency. In 1931, Walter Shewart came up with theory
regarding Control Charts for quality or what is known as ‘process control’.
This field, which has developed over the years is now known as; acceptance sampling.
These experiments showed that worker efficiency went up when the intensity of
illumination was gradually increased, and even when it was gradually decreased, the
worker efficiency still kept rising.
This puzzle could be explained only through the angle of human psychology; the very
fact that somebody cared, mattered much to the workers who gave increased output.
Till now, it was Taylor’s theory of elementalisation of task and thus the specialization
in one task which found much use in Henry Ford’s Assembly Line.
During this war, the Allied Force took the help of statisticians, scientists, engineers
etc. to analyze and answers questions such as: What is the optimum way of mining the
harbors of the areas occupied by the Japanese
After World War II, this field was further investigated and developed by academic
institutions. Various techniques such as linear programming game theory, queuing theory
and the like developed by people such as George Dantzig A Charnes
5. Explain the relationship of production with other functions? (Nov 2012)& (Apr 2013)
An organization is considered as a system having several sub-systems. Marketingsub-
system has to make available the products to the consumers for their consumption. It
receives sales orders, which are communicated to the production sub-system.
Production utilizes raw materials, which are processed on plant and machinery to turn
out a value-added finished product. In other words, an organization utilizes the
available facilities to satisfy the market.
The finance function makes available finance necessary to carry out their functions to
all other departments.
Personnel function is a support function which plans and provides manpower to all
other sub-systems. It formulates suitable personnel policies.
All business sub-systems are inter-linked and inter-dependent. Marketing may fail, if
the production does not fulfill the expectations of customers by providing suitably
manufactured products.
Production may fail in the absence of the working capital necessary to buy raw
material for turning out the product.
If skilled manpower is not available all other plans will come to a naught. The co-
ordination amongst the various sub-systems is necessary for effective functioning of
any organization.
Cash flow statements and current asset management has to be examined in the light of
production decisions. Make-or-buy or plant expansion has financial implications.
They should understand ho-w products can be customized. Production has a great role
to play in new product development. In service industries, Marketing and operation
overlap each other.
MIS has to install suitable control systems for production control which takes inputs
from marketing information system and provides output to purchasing information
system.
6. Explain the input and output relationship in Production System? (Nov 2013)
There exists some relationship between inputs and output of a firm.
In Economics, such a relationship is known as production function.
Production function is an expression of the technological relation between physical
inputs and output of a good.
Symbolically: Ox = f i1, i2, i3………………………. in)
{Where: Ox = Output of commodity x; f = Functional relationship; i1, i2, …. in = Inputs
needed for Ox}
2. Production function establishes a relation between inputs and output, which is technical
in nature.Production function is not economical in nature as we do not consider the value
of inputs and output.
4. The production function includes only the technically efficient methods of production as
no rational entrepreneur will use inefficient methods.
7. What are the functions of Production Management? (Apr 2013)
Selection of Product and Design,
Selection of Production Process,
Selecting Right Production Capacity,
Production Planning,
Production Control,
Quality and Cost Control,
Inventory Control, and
Maintenance and Replacement of Machines
Here the output refers to the quantity of and services produced by the company, and inputs
refers to the quantities of resources such as labor, material, physical facilities, and energy
consumed for producing the same.
Productivity is concerned with the inputs used in the process. Thus productivity
represents only the numerator in the above equation for productivity.
Productivity is used to assess the extent to which certain outputs can be extracted
from a given input.
We can measure productivity for a single input resource such as manpower used, or
for multiple resources.
Here the term ‘land’ is used to denote all natural resources rather than just land.
Managers also need to pay attention to the total production to make sure that a
company is meeting the requirements of products and services required by the
customers.
Managers also need to pay attention to production for production planning and
scheduling.
Similarly, long term planning of sales volumes and production capacities also
requires focusing on production.
PART – C ANSWERS
Product design
Designing the product and conceive the idea about its production.
Process design
Determination of the production process which is most relevant and efficient in the
givenstate of affairs
Quality control - Controlling the production and ensuring the quality by setting the
check points and taking the periodic measurements of the current performance.
Materials management
Managing the inventories of raw material, semi-finished and finished goods in a way
that neither excessive money may block in this non-productive operation nor the
required material.
Maintenance management
Analysis the deviations and formulating the corrective measures to stay in track with
planned quality, time-schedule and predetermined cost schedules.
Fortune 500 companies aren't just successful because of luck or market factors. Rather,
they are the beneficiaries of well-planned strategies that make the best use of their
resource.
In other words, of strong production management teams. Production management
departments help keep Fortune 500 companies on top by efficiently utilizing resources
and satisfying customers.
Raw Materials
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Production Process
Managing the production process is the most important function of a production
management department.
The department must decide how many workers are necessary, which equipment
should be used, and what process will provide the best product to meet customer
needs.
A strong production management department will streamline the production process so
that it costs the least amount of money while still maintaining the necessary level of
quality.
Customer Satisfaction
By ensuring a quality product, keeping costs low and delivering products in a timely
manner, a successful production management team helps a company attract and retain
customers.
Adding to a company's customer base brings in profits and is the primary benefit of
effective management of the production process.
Investor Confidence
The optimal materials for a company are not necessarily the highest quality or
lowest price available but are instead the materials best suited for a company's production
model.
Production Process
Managing the production process is the most important function of a production
management department.
The department must decide how many workers are necessary, which equipment should be
used, and what process will provide the best product to meet customer needs.
Customer Satisfaction
By ensuring a quality product, keeping costs low and delivering products in a timely
manner, a successful production management team helps a company attract and retain
customers.
Adding to a company's customer base brings in profits and is the primary benefit of
effective management of the production process.
Investor Confidence
Because effective production management contributes to the profitability of a company, it
lends that company an image of success and contributes to investor confidence.
Fortune 500 companies understand this principle better than most businesses. By attracting
investors, a well-managed company can attain more capital, allowing it to further improve
or expand its business.
In the final analysis, strong production management makes a business successful because
it attracts money through both profits and investment.
With batch production and flow production it is one of the three main production
methods.
Job production can be classical craft production by small firms (making railings for
a specific house, building/repairing a computer for a specific customer, making flower
arrangements for a specific wedding etc.), but large firms use job production, too, and the
products of job production are often interchangeable, such as machined parts made by a
job shop.
Examples include:
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Fabrication shops and machine shops whose work is primarily of the job
production type are often called job shops.
The associated people or corporations are sometimes called jobbers.
Job production is, in essence, manufacturing on a contract basis, and thus it forms a
subset of the larger field of contract manufacturing.
But the latter field also includes, in addition to jobbing, a higher level of
outsourcing in which a product-line-owning company entrusts its entire production
to a contractor, rather than just outsourcing parts of it.
Benefits
Key benefits of job production include:
Can provide emergency parts or services, such as quickly making a machine part
that would take a long time to acquire otherwise
Can provide parts or services for machinery or systems that are otherwise not
available, as when the original supplier no longer supports the product or goes out
of business (orphaned)
Workers can be easily motivated due to the skilled nature of the work they are
performing
4. What are the different types of Production? Explain. (Apr 2014)
A production manager will have to choose most appropriate method for his enterprise.
The final decision regarding any particular method of production is very much affected by
the nature of the products and the quantity to be produced.
Production methods may be broadly classified as Job Production, Batch production and
Mass or Flow Production.
It is that form of production where identical products are produced in batches on the basis
of demand of customers’ or of expected demand for products.
This method is generally similar to job production except the quantity of production.
Instead of making one single product as in case of job production, a batch or group of
products are produced at one time.
It should be remembered here that one batch of products may not resemble with the next
batch.
Under batch system of production the work is divided into operations and one operation is
done at a time.
After completing the work on one operation it is passed on to the second operation and so
on till the product is completed.
PART – A ANSWERS
11. List out any two objectives of Production Planning and Control?
(iii) The resources are used in the best possible manner in such a way that the cost of
production is minimized and delivery date is maintained.
(iv) Determination of economic production runs with a view to reduce setup costs.
PART – B ANSWERS
All other phases that are related with the manufacturing are a production system
environment. And this definition system normally called system discrimination.
Stratum formulation:
A production system normally consistswith hierarchy of the organization.
And those are related with the size of the organization and the function of the
organization.
And stratum normally related with the size, hierarchy, and the function of the
organization.
Specialization of function:
If the production system expands its area of production and large number of
hierarchy and start each performing specialized function.
Then the interrogation function of the specialization will give you the maximum
output or benefit.
Increase of entropy:
We know that everything is changing in our life day by day. We need to cope with
those changes.
We will change our old employee by the new ones, we will replace our machine by
new machine and we will change our technology by new technology for stability of
our production.
2. What are the main functions of Production Planning and Control? (Dec
2011)(April/May 2015)
Production planning and Control department is one of the important department for
the apparel manufacturing company.
Each functions has been explained briefly just overview about the task. To know
details about the task read related articles.
Preparation of time and action calendar for each order from order receiving to
shipment.
The job schedule contains list of tasks to be processed for the styles.Against each
tasks planner mentions when to start a task and what is dead line for that task.
Name of responsible person (department) for the job is being listed. For example,
scheduling planned cut date (PCD), line loading date etc.
Loading production:
Planner defines which style to be loaded to the production line and how much quantity to
be loaded.
Where a company has multiple factories (facilities) for production and factories are
set for specific product, planner need to identify which facility will be most
suitable for new orders.
Sometimes there may be a capacity shortage in a factory, in that case planner need
to decide which facility will selected for that orders.
Capacity planning:
PPC department plays a major role during order booking. They decide (suggest)
how much order they should accept according to their production capacity.
Allocating of total capacity or deciding how much capacity to be used for an order
out of total factory capacity.
Line planning:
Preparing detailed line planning with daily production target for the production line. Most
cases line planning is made after discussing with production team and Industrial engineers.
Read - What is Line Planning?
• In which sequence the job (from raw material stage to finished goods stage)
Therefore, the main objective of routing is the selection of best and cheapest way to
perform a job. It depends upon:
• Efficiency of employees
(iii) The resources are used in the best possible manner in such a way that the cost of
production is minimized and delivery date is maintained.
(iv) Determination of economic production runs with a view to reduce setup costs.
(vi)To ensure regular and timely supply of raw material at the desired place and of
prescribed quality and quantity to avoid delays in production.
(vii) To perform inspection of semi-finished and finished goods and use quality control
techniques to ascertain that the produced items are of required specifications.
Uses of Scheduling
Importance
If the maintenance manager schedules four employees when only one is needed,
the company will lose money.
If materials such as chemicals are not stored and disposed of properly, the
company could have compliance issues.
Scheduling
For instance, in a paper supply warehouse the forklift and delivery truck could be
in need of maintenance at the same time. Without the forklift, employees cannot
move boxes of paper around the warehouse.
Without the delivery truck, they can't deliver paper orders to customers. The
maintenance manager needs to know which task has the higher priority and which
once can afford to wait a little while.
Cost Control
Controlling costs is an important objective, but is not entirely under the control of
the maintenance manager.
The budget of the maintenance department is usually set by the company, and the
maintenance manager has to work with whatever is provided. For instance, a part
needed to maintain a certain piece of equipment might be available from more than
one supplier.
The maintenance manager might have to decide between a less-expensive part that
may wear out more quickly,
Compliance
Maintenance managers must ensure that all maintenance tasks are conducted in
compliance with local, state and federal laws and regulations.
It might be easier and more affordable to schedule just one employee to work on a
piece of equipment, but if there is a safety regulation requiring two employees to
perform the task then the maintenance manager could incur a fine for the company
by failing to heed the regulation.
Part of the job of the maintenance manager is to stay familiar with all relevant
regulations and make sure they are followed.
You'll see many benefits from routine maintenance, and it's very easy to keep your
car up to date – you can find the maintenance recommendations in your owner's
manual
Maintenance doesn't have to be expensive. Read our tips on auto parts to save
money, and if you have the inclination, do some of the maintenance yourself
Proper maintenance makes your car more reliable. Do you want your car to start
every time, and never leave you stuck on the side of the highway? Then keep up-
to-date on your maintenance, and check over the basics (like engine oil and
coolant) as often as time permits
You can increase your fuel economy. Spending just a little money on maintenance
will save you money at the gas station. Learn more about fuel economy
and machinery resources, plan human resources, plan production processes and purchase
materials.
Forward scheduling is planning the tasks from the date resources become available
to determine the shipping date or the due date.
Backward scheduling is planning the tasks from the due date or required-by date to
determine the start date and/or any changes in capacity required.
Once the entrepreneur has taken the decisions regarding the product design and
production processes and system, his next task is to take steps for production
planning and control, as this function is essentially required for efficient and
economical production.
One of the major problems of small scale enterprises is that of low productivity
small scale industries can utilise natural resources, which are otherwise lying.
Small scale sector can play an important role, similar to the one played by small
scale industries in other developed countries.
The small entrepreneur possessing the ability to look ahead, organize and
coordinate and having plenty of driving force and capacity to lead and ability to
supervise and coordinate work and simulates his associates by means of a
programme of human relation and organization of employees, he would be able to
get the best out of his small industrial unit.
Gorden and Carson observe production; planning and control involve generally the
organization and planning of manufacturing process.
The ultimate objective is the organization of the supply and movement of materials
and labour, machines utilization and related activities, in order to bring about the
desired manufacturing results in terms of quality, quantity, time and place.
Production control regulates and stimulates the orderly how of materials in the
manufacturing process from the beginning to the end
10. What are the advantages of Production and Control? (Apr 2014)
Production is well planned and its time aspects are well controlled. Therefore, production
control reduces the number of risk-orders and overtime works on plant.
2. Avoidance of Bottlenecks
The incomplete work does not get accumulated because production control maintains an
even flow of work.
3. Cost Reduction
Production control programmes minimizes the idleness of men and machines, keeps in
process inventories at a satisfactory level, leads to a better control of raw materials
inventory, reduces costs of storage and materials handling, helps in maintaining quality
and containing rejection and thus reduces unit cost of production.
It reduces the loss of time by the workers waiting for materials and makes most effective
use of equipment.
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5. Co-Ordination
It serves to co-ordinate the activities of plant and results in a concerted effort by workmen.
6. Benefits to Workers
PART – C ANSWERS
1. What do you understand by Production Planning? and explain the steps involved in
Production Plannnig. (Dec 2011)& (Apr 2014)&(Nov 2012)
Routing can be defined as the process of deciding the path (route) of work and the
sequence of operations.
The type, number and sequence of manufacturing operations, and the place
of production.
Routing may be either very simple or complex. This depends upon the nature of
production. In a continuous production, it is automatic, that it is very simple.
The main objective of routing is to determine (fix) the best and cheapest sequence
of operations and to ensure that this sequence is followed in the factory.
Scheduling
Scheduling is the second step in production planning and control. It comes after
routing.
Fix the starting and completing, date and time, for each operation.Scheduling is
also done for materials, parts, machines, etc. So, it is like a time-table of
production. It is similar to the time-table, prepared by the railways.
Time element is given special importance in scheduling. There are different types
of schedules; namely, Master schedule, Operation schedule and Daily
schedule.Scheduling helps to make optimum use of time.
It sees that each piece of work is started and completed at a certain predetermined
time. It helps to complete the job systematically and in time. It brings time
coordination in production planning.
All this helps to deliver the goods to the customers in time. It also eliminates the
idle capacity. It keeps labor continuously employed.
Dispatching
It provides the necessary authority to start the work. It is based on route-sheets and
schedule sheets.
Issue of materials, tools, fixtures, etc., which are necessary for actual production.
Issue of orders, instructions, drawings, etc. for starting the work.
Maintaining proper records of the starting and completing each job on time.
Moving the work from one process to another as per the schedule.
Starting the control procedure.
Recording the idle time of machines.
Dispatching may be either centralized or decentralized:
Under centralized dispatching, orders are issued directly by a centralized authority.
Under decentralized dispatching, orders are issued by the concerned department.
Follow-up
Follow-up finds out and removes the defects, delays, limitations, bottlenecks,
loopholes, etc. in the production process.
Types of maintenance
Traditionally, 5 types of maintenance have been distinguished, which are differentiated by the
nature of the tasks that they include:
Corrective maintenance:
The set of tasks is destined to correct the defects to be found in the different equipment
and that are communicated to the maintenance department by users of the same equipment.
Preventive Maintenance:
It is used to be a systematic character, that is, the equipment is inspected even if it has not
given any symptoms of having a problem.
Predictive Maintenance:
It pursues constantly know and report the status and operational capacity of the
installations by knowing the values of certain variables.
This maintenance it is the most technical, since it requires advanced technical resources,
and at times of strong mathematical, physical and / or technical knowledge.
The set of tasks whose goal is to review the equipment at scheduled intervals before
appearing any failure, either when the reliability of the equipment has decreased
considerably so it is risky to make forecasts of production capacity .
This review is based on leaving the equipment to zero hours of operation, that is, as if
the equipment were new. These reviews will replace or repair all items subject to wear.
The aim is to ensure, with high probability, a good working time fixed in advance.
The basic maintenance of equipment made by the users of it. It consists of a series of
elementary tasks (data collections, visual inspections, cleaning, lubrication, retightening
screws…) for which no extensive training is necessary, but perhaps only a brief training. This
type of maintenance is the based on TPM (Total Productive Maintenance).
Manages Control:
Reduces Overtime
It ensures all loose ends are tied and enough contingency planning is done to
manage operations in case of undesirable circumstances and situations.
Management defines tasks and allocates resources effectively, ensuring that all
objectives are met in a timely and orderly fashion.
Improves Quality
It gives a small amount of leeway to tolerances but within well established control
limits.
End users can benefit from a better level of support provided by maintenance
management. It allows for reliable, on time, and quality service.
Since maintenance management details the goals and objectives of departments and
employees, it make it easier for managers to spot errors and deviations from established
and desired outcomes.
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Maintenance management ensures that labor, materials and equipment are well utilized,
which reduces waste of allocated resources. Utility costs are lowered and the production of
hazardous waste material is decreased with managed effort.
Improves Safety
Before implementing it with your company, it's important to understand the drawbacks.
Complexity
Production scheduling can be complex. When you get involved with production
scheduling, you must keep track of which production crew will be working, which
materials will be used and which products will be produced.
In large manufacturing firms, this can lead to a lot of work for the person in charge of
production scheduling. The production scheduler often has to learn product numbers, part
numbers and other specific information to make it work.
Cost
Another potential problem with using production scheduling is the cost of implementation.
When you implement a production scheduling system, you may need to buy software and
other resources to help facilitate the process.
Can be skewed:
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UBA31-PRODUCTON MANAGEMENT
UNIT-3 PLANT LOCATION –PLANT LOCATION
PROBLEMS-TYPES OF LOCATIONS-PLANT LAYOUT-
OBJECTIVES-TYPES-PRINCIPLES
Plant location is paramount importance, both for a new enterprise as well as for the
existing ones. The fundamental objective of an organization is to maximize its profits.
Profits can be increased sales or by decreasing cost of production.
5. What are the employee welfare & public needs in plant location?
The economic objective of enhancing employee welfare and catering to public needs
should also be served by plant location. If a place is selected, where educational, recreational,
medical, religious of the employees are maintained.
S Selection of a region
Selection of a locality
S Selection of site
The first concern should be the stability of the country and its attitude towards
external investment.
Some regions such as western Europe and Asia have welcomed foreign
investment.
Sourcing requires that firms producing a given product must also produce a
specified percentage of components.
Selection of site is the important step requiring the assistance of experts. There are
instances where even government officials were influenced to demographic data to the
process.
The city area as a location of industrial unit has got many negative aspects. The other
extreme is the rural area, which again is not free from many limitations.
Plant layout,” Identically involves the allocation of space and the arrangement
of equipment in such a manner that overall operating costs are minimized”.
Nature of product
Volume of production
Basic managerial policies and decisions
Nature of plant location
Type of industry process
12. What is the responsibility for the plant location decision? (NOV/DEC-2011)
The responsibility for making this decision ultimately rests upon the chief executive,
subject to approval by the board of directors. They prepare cost analysis with the proper
supporting data.
PART-B ANSWERS
1. Explain the objectives of plant location? (NOV/DEC-2011, APRIL/MAY-2013)
Security:
It is one of the important objectives. The plant should be free from
foreign attack ,anti-social elements and earthquakes.
Existence of
Availability of power complementa
ry
Finance and
Transport facilities resarch
Availability of
water and
Suitablity of climate resource
E Regional factors
Site factors: They are determined by two factors; Prize of land, Disposal of waste.
In labour costs:
1. Reduction in number of workers
2. Increase in production per man-hour
3. Reduction in the length of haul
In other manufacturing costs:
1. Maintenance and tool replacement
2. Spoilage and scrap minimized
3. Saving motive power
In production control:
1. Provision adequate made
2. Increase pace of production
3. Achievement of production targets
4. Reduction in the number of stock
In supervision:
1. Helps in easing the burden of supervision
2. Reduces the level of inspection and costs
inspection
PART-C ANSWERS
1. Explain the trends in location of industries?
Decentralization of industries
Under the conscious industrial policy of the Government, concentration of industrial units is
prevented through licensing policy. New units are not permitted to be started in certain
industrially congested areas. Similarly, existing units either establish their additional plants in a
less developed area or sometimes relocate the whole unit in such areas.
(i) The first thing is planning a layout is to study the objectives, production plan and the
nature of machines, equipment and manufacturing operations involved in the production
process.
(ii) Accumulate layout data machine data cards, machine load charts and templets of
equipment.
(iii) On the basis of information collected in step develop process charts which are vital in the
development of a sound layout. These charts summaries the production activities that are
required to achieve the manufacturing objectives.
(iv) Develop an over-all flow plan of operations for efficient processing and materials
handling. The best flow of work both horizontal an vertical and the integration of
operations form the receipt of the raw materials to storage of finished goods are the
objectives to be attained. Process charts. Machine load data, production rate desired etc.
should be considered in drafting the plan.
(v) The sequence of mechanical operations is studied to fix the position of respective
machines performing desired operations.
(vi) Select best suited type of building and develop a tentative plot plan for the site. The
exact specifications of the building are designated only after the layout is developed in
considerable detail.
(vii) Layout templates or models of individual production machines and space for service
activities: materials handling, receiving and shipping, inspection, storage, maintenance,
offices etc. according to flow plan operations.
(viii) Decision about the location of services facilities like cafeteria, toilets etc. Inside the
plant building is taken, keeping into consideration the requirements of the produciton
process and comforts of the workers
Process Layout
Advantages:
1. In process layout machines are better utilized and fewer machines are required.
3. Lower investment on account of comparatively less number of machines and lower cost of
general purpose machines.
4. The diversity of tasks and variety of job makes the job challenging and interesting.
5. Supervisors will become highly knowledgeable about the functions under their department.
• Product layouts are used to achieve a smooth and rapid flow of large volumes of products or
customers through a system.
• A job is divided into a series of standardized tasks, permitting specialization of both labor and
equipment.
• The large volumes handled by these systems usually make it economical to invest huge amount
of money in equipment and job design.
• Operations are arranged in the sequence required to make the product. For instance, if a portion
of a manufacturing operation.
Product Layouts
Advantages
Fixed-Position Layouts
In fixed-position layouts, the materials or major components remain in a fixed position, and
workers, materials, and equipment are moved as needed.
Some of the major factors which affect plant layout are: (1) Policies of management (2) Plant
location (3) Nature of the product (4) Volume of production (5) Availability of floor space (6)
Nature of manufacturing process and (7) Repairs and maintenance of equipment and machines.
type of layout best suited. For example, in case of industries manufacturing cycles, typewriters,
sewing machines and refrigerators etc., process layout method is best suited.
PART – A Answers
The Gilbreths made use of scientific insights to develop a study method based upon the analysis of work
motions', consisting in part of filming the details of a worker’s 'activities and their body posture while
recording the time.
Work measurement is the application of techniques designed to establish the time for an average worker to
carry out a specified manufacturing task at a defined level of performance. It is concerned with the length of
time it takes to complete a work task assigned to a specific job.
Work sampling is the statistical technique for determining the proportion of time spent by workers in various
defined categories of activity (e.g. setting up a machine, assembling two parts, idle…etc.).
Time study is a direct and continuous observation of a task, using a timekeeping device (e.g., decimal minute
stopwatch, computer-assisted electronic stopwatch, and videotape camera) to record the time taken to
accomplish a task and it is often used when there are repetitive work cycles of short to long duration
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The standard time is the time required by an average skilled operator, working at a normal pace, to perform a
specified task using a prescribed method. It includes appropriate allowances to allow the person to recover
from fatigue and, where necessary, an additional allowance to cover contingent elements which may occur
but have not been observed.
Method study is the process of subjecting work to systematic, critical scrutiny to make it more effective
and/or more efficient. It is one of the keys to achieving productivity improvement.
In this method it is fixed by the observer by comparing the operators movement with his own concept of
normal pace.
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Performance rating is the step in the work measurement in which the analyst observes the
worker's performance and records a value representing that performance relative to the analyst's concept of
standard performance.
In this method the operators speed is rated against a single standard pace which is independent of job
difficulty. The observer merely rates the speed of movement of activity, paying no attention to job itself.
(1) Target time for each job can be scientifically estimated, with this estimate realistic schedules and
manpower requirements can be prepared.
(2) Sound comparison of alternative methods is possible by comparing their basic times.
(3) Useful wage incentive schemes can be formulated on the basis of target times.
(4) It can lead to proper balancing of the work distribution.
Synthetic data are "any production data applicable to a given situation that are not obtained by direct
measurement"
PART – B Answers
Work measurement may be defined as “the art of observing and recording the time required to do each
detailed element of an Industrial activity/operation.”
Target time for each job can be scientifically estimated, with this estimate realistic schedules and
manpower requirements can be prepared.
Sound comparison of alternative methods is possible by comparing their basic times.
Useful wage incentive schemes can be formulated on the basis of target times.
In can lead to proper balancing of the work distribution.
It can help to analyse the activities for performing a job with the view to eliminate or reduce
unnecessary or repetitive operations so that human effort can be minimized.
To standardise the efficient method of performing operations.
To standardise conditions for efficient performance.
To determine man and machines ratio for effective and efficient utilisation of both.
To provide information’s and basis for production planning and scheduling activities.
The standard time is the time required by an average skilled operator, working at a normal pace, to perform
a specified task using a prescribed method .It includes appropriate allowances to allow the person to recover
from fatigue and, where necessary, an additional allowance to cover contingent elements which may occur
but have not been observed.
The standard time can be determined using the following techniques:
a. Time study
b. Predetermined motion time system
c. Standard data system
d. Work sampling.
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In competitive business environment , it is necessary that the employees work harder, be more productive so
that, production costs be kept low to meet global competition. Operations managers have to continuously
strive for low production costs , high product quality and improve every facet of manufacturing .In this
direction ,improving labor productivity and reducing costs by improving work methods and simplifying the
work, needs special attention by operations managers. To facilitate this, the work study technique (now
known as industrial engineering) has been developed over a period of time.
Following are the main differences between piece rate system and time rate system.
1. Meaning
Piece rate system is a method of wage payment to workers based on the quantity of output they have
produced. Time rate system is a method of wage payment to workers based on time spent by them for the
production of output.
2. Nature Of Payment
Piece rate system pays the workers according to the units of output produced. Time rate system pays the
workers according to the time spent in the factory.
3. Emphasis
Piece rate system gives emphasis on larger quantity of output. Time rate system emphasis on better quality of
output.
4. Discrimination
Piece rate system discriminates the workers and pays more wages to efficient and skilled workers. Time rate
system does not discriminate the workers and pays the same wages to efficient and inefficient workers.
5. Supervision
Piece rate system requires strict supervision to get the required quality output. Time rate system requires
strict supervision to get required quantity of output.
7. Flow Of Production
Piece rate system does not bring uniformity in the flow of production and causes an excessive wastage of
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inputs. Time rate system helps maintain a uniform flow of production and ensures an efficient use of
materials, tools and equipments.
Manpower planning
Work measurement data is used for manpower planning. This is because it gives information about the total
hours required to perform the job. This helps to estimate the number and type of employees who are required
to do the job. It ensures that there will not be any excess staff.
Work measurement data also helps to estimate the number of machines and equipment that will be required
in the future. This helps to find out the number of employees who will be required to handle these machines
and equipment.
Performance appraisal
Performance appraisals are done to find out whether the employees are efficient or not. It is done to find
strengths & weaknesses of employees.
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Work measurement helps to do performance appraisals. This is because it fixes the standard-output and
standard-time for each employee. The employees who produce the standard-output within the standard-time
are efficient and vice versa. Thus, it also helps to find out the strengths and weaknesses of the employees.
Training of employees
Work measurement helps to train the employees, especially the new employees. It divides the full job into
small elements (parts). It gives complete details about each element of the job. It gives details about; how to
do each element, the time taken for each element, the machines and tools involved in each element, etc.
These details are used for training the employees.
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that instant and the percentage of observations recorded for a particular activity or delay is a measure of the
percentage of time during which the activity or delay occurs.
Synthesis
Synthesis is a work measurement technique for building up the time for a job at a defined level of
performance by totaling element times obtained previously from time studies on other jobs containing the
elements concerned, or from synthetic data.
Estimating
The technique of estimating is the least refined of all those available to the work measurement practitioner. It
consists of an estimate of total job duration (or in common practice, the job price or cost). This estimate is
made by a craftsman or person familiar with the craft. It normally embraces the total components of the job,
including work content, preparation and disposal time, any contingencies etc., all estimated in one gross
amount.
Analytical estimating
This technique introduces work measurement concepts into estimating. In analytical estimating the estimator
is trained in elemental breakdown, and in the concept of standard performance. The estimate is prepared by
first breaking the work content of the job into elements, and then utilising the experience of the estimator
(normally a craftsman) the time for each element of work is estimated - at standard performance. These
estimated basic minutes are totalled to give a total job time, in basic minutes. An allowance for relaxation
and any necessary contingency is then made, as in conventional time study, to give the standard time.
Comparative estimating
This technique has been developed to permit speedy and reliable assessment of the duration of variable and
infrequent jobs, by estimating them within chosen time bands. Limits are set within which the job under
consideration will fall, rather than in terms of precise capital standard or capital allowed minute values. It is
applied by comparing the job to be estimated with jobs of similar work content, and using these similar jobs
as "bench marks" to locate the new job in its relevant time band - known as Work Group.
1) Obtaining and recording all information of job, operator, and surrounding conditions likely to affect the
carrying of the work.
2) Recording the complete description of the method and breaking down the operation into elements.
3) Measuring with timing device and recording the time taken by the operator to perform each element of
operation.
4) At the same time assessing the effective speed of operator to predetermined normal speed.
5) Converting the observed times, to normal times.
6) Determining the allowances to be made over and above the normal time for the operation.
7) Determining the allowed time for the operation.
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PART C-ANSWERS
Definitions:
Allowances in time study can be defined as the extra time figures which are to be added to the basic time of
an operation to account for personnel desires, delays, fatigue of operators, any special situation and the
policies of the firm or organization. Standard time of a job is obtained by adding various allowances to the
basic or normal time of the job.
Type of Allowances:
1. Relaxation Allowance:
Relaxation allowance is the most essential part of the time added to the basic time. Other allowances like
contingency allowances, policy allowances or other special allowances are applied under certain conditions
only. Relaxation allowances are added so as to allow the worker or operator to recover from fatigue.
Relaxation allowances itself can be sub-divided into two categories:
o Fixed Allowances:
Fixed allowances consist of the allowances given for personnel needs or desire. These personnel needs
includes going for watching getting a drink etc. It is also agreed that women need more personnel time than
man. The usual percentage of the personnel allowances is 5% for male workers and 7% for women.
Fixed allowance also includes the allowances for the basic fatigue. This allowances is given to take account
of the energy expanded during work and to remove the monotony. Usually, it is taken as 4% a worker who
carried out the job while seated, who is engaged in a light work under good working conditions and makes
only the normal use of hands, legs and his senses.
o Variable Allowances:
In calculating the relaxation allowance, variable allowances are added to the fixed allowances which are
made, depending upon the circumstances of the job. Variable addition is given be improved.
Following factors are to be taken into account:
1. Standing
2. Weightlifting applications.
3. Light conditions.
4. Abnormal posture or position.
5. Visual strains.
6. Air conditions or availability.
7. Aural strenes.
8. Mental stress.
9. Mental monotony.
10. Physical monotony.
2. Contingency Allowances:
It is also known as delay allowance. It accounts for some other contingencies such as unexpected work as
well. “A contingency allowance is an allowances of time that is to be added in normal time or to be included
in standard time to meet the legitimate and unexpected items of work or delays, the precise measurement of
which is not economical due to their irregular and infrequent nature of occurrences.”
Other and Special Allowances:
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There are some other and special allowances which are to be added for certain conditions. These allowances
are provided for certain reasons and for come specific period of time. Some of their allowances are:
1. Special Allowances:
As the name suggests, these allowances are added for some special conditions. Most of these allowances are
temporary and are taken out as soon as conditions normalise.
These include the following:
(a) Start up, shut down, and tooling:
These allowances are given per work period. These allowances compensate for the time loss during cleaning
and tooling periods and the shut down at the end of the work period.
(b) Setup and change over:
These types of allowances are provided when a new type of product is started. There include the time taken
in set up of machine. Dismantling the previous work piece or tool for new set up is also included in it as the
worker is forced to be idle when the new set up is mounted or the previous one is being withdrawn. These
allowances are withdrawn as soon as the production starts completely.
(c) Rejection reworks and excess work:
A rejection allowance is provided to compensate for rejection of work. This product rejection is inherent in
much process because of come uncontrollable factors. Reworks also present this similar picture. So, these
allowances are added for certain conditions when the work is not being done under standard conditions and
some excess work results.
(d) Learning, training and implementation:
And the name suggests, these allowances are given to the trainees before they acquire full ability to perform
a task within the actual standard time. Some of the workers are engaged in implant training of new
operatives and thus some of their production time is lost in this process. Thus, at this stage, training
allowances are added.
2. Policy Allowances:
Policy allowance is not a part of time study. It can be permanent or temporary in nature. It is applied
according to the policy of the firm in which the time standard is to be applied. Policy allowance is given to
honour the wage agreements that are made by the employers with the trade unions.
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One of them is the sufficient time available to perform the study. A work sampling study usually
requires a substantial period of time to complete. There must be enough time available (several weeks or
more) to conduct the study.
Another characteristic is multiple workers. Work sampling is commonly used to study the activities of
multiple workers rather than one worker.
The third characteristic is long cycle time. The job covered in the study has relatively a long cycle time.
The last condition is the non-repetitive work cycles. The work is not highly repetitive. The jobs consist
of various tasks rather than a single repetitive task. However, it must be possible to classify the work
activities into a distinct number of categories.
Work measurement helps to uncover non-standardization that exist in the workplace and non-value
adding activities and waste. A work has to be measured for the following reasons:
a) To discover and eliminate lost or ineffective time.
b) To establish standard times for performance measurement.
c) To measure performance against realistic expectations.
d) To set operating goals and objectives.
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PART – A QUESTIONS
Pre-production inspection
The branch of philosophy that deals with the nature, expression, and perception of beauty, as in the fine ar
ts.The study of the psychological responses to beauty and artistic experiences.
Time study is a direct and continuous observation of a task, using a timekeeping device (e.g., decimal
minutes topwatch, computer-assisted electronic stopwatch, and videotape camera) to record the time
taken to accomplish a task[3] and it is often used when:[4]
Depending on the type of variation chart used, the average sample range or the average sample
standard deviation is used to derive the X-bar chart's control limits. Categories: Statistical charts and
diagrams. Quality control tools.
To establish the desired quality standards which are acceptable to the customers
To discover flaws or variations in the raw materials and the manufacturing processes in
order to ensure smooth and uninterrupted production.
An Xbar-R chart plots the process mean (Xbar chart) and process range (R chart) over time for
variables data in subgroups.
PART – B QUESTIONS
Centralised Inspection
The inspection takes place at a centre that is close to one or more of the manufacturing centres.
The quality check-ups are improved
There is closed supervision
There is no pressure put on the workers
The inspection costs are low
To establish the desired quality standards which are acceptable to the customers?
To discover flaws or variations in the raw materials and the manufacturing processes in order to
ensure smooth and uninterrupted production.
To evaluate the methods and processes of production and suggest further improvements in their
functioning.
To study and determine the extent of quality deviation in a product during the manufacturing
process.
To analyse in detail the causes responsible for such deviation.
To undertake such steps which are helpful in achieving the desired quality of the product.
1. To collect information regarding the performance of the product with established standards for
the use of engineering production, purchasing and quality control etc.
2. To sort out poor quality of manufactured product and thus to maintain standards.
3. To establish and increase the reputation by protecting customers from receiving poor quality
products.
4. Detect source of weakness and failure in the finished products and thus check the work of
designer.
It suggests the checking of materials in process at the machine or in the production time by patrolling
inspectors. These inspectors moves from machine to machine and from one to the other work centres.
Inspectors have to be highly skilled. This method of inspection minimise the material handling, does not
disrupt the line layout of machinery and quickly locate the defect and readily offers field and correction.
Inspection is the most common method of attaining standardisation, uniformity and quality of
workmanship. It is the cost art of controlling the product quality after comparison with the established
standards and specifications. It is the function of quality control. If the said item does not fall within the
zone of acceptability it will be rejected and corrective measure will be applied to see that the items in
future conform to specified standards. Inspection is an indispensable tool of modern manufacturing
process. It helps to control quality, reduces manufacturing costs, eliminate scrap losses and assignable
causes of defective work.
Quality control can be defined as that Industrial Management technique by means of which
product of uniform acceptable quality is manufactured.
(2) Inspection of production process. The work of inspection is done while the
production process is simultaneously going on. Inspection is done at various work centres of men
and machines and at the critical production points. This had the advantage of preventing wastage
of time and money on defective units and preventing delays in assembly.
(3) Inspection of finished goods. This is the last stage when finished goods are inspected
and carried out before marketing to see that poor quality product may be either rejected or sold at
reduced price.
To decide about the standard of Quality of a product that is easily acceptable to the customer.
To check the variation during manufacturing.
To prevent the poor quality products reaching to customer.
An overview of TQM quality management practices highlights the different approaches or practices
followed to ensure the highest level of customer satisfaction in a product or service. It involves all
stakeholders and stresses on the importance of work responsibility from every member.
Total Quality Management is
led by top management
involves all departments and members
a continuous process
It involves
Leadership
Customer satisfaction
Collective responsibility
According to an analysis of TQM quality concepts, the customer comes first and is of the highest priority.
It is the desire for utmost customer satisfaction that drives a company, organization or firm to work
towards quality. When TQM is integrated as part of the work ethics, it becomes a 'way of life' for the
organization as a whole irrespective of the work being part of an operation or a project.
PART – C QUESTIONS
Quality control (QC) is a procedure or set of procedures intended to ensure that a manufactured product
or performed service adheres to a defined set of quality criteria or meets the requirements of the client or
customer. QC is similar to, but not identical with, quality assurance (QA).
Include better products and services ultimately establishing a good reputation for a company.
Higher revenue from having more satisfied customers.
In statistical quality control, the p-chart is a type ofcontrol chart used to monitor the proportion of
non conforming units in a sample, where the sample proportion nonconforming is defined as the
ratio of the number of nonconforming units to the sample size.
The control limits for this chart type are where is the estimate of
the long-term process mean established during control-chart setup.
An x bar chart is used to monitor the average value, or mean, of a process over time. For each
subgroup, the x bar value is plotted. The upper and lower control limits define the range of
inherent variation in the subgroup means when the process is in control.
The Chart Construction Process In order to construct x bar and R charts, we must first
find our upper- and lower control limits. This is done by utilizing the following formulae:
UCL = µ+ 3σ √n
LCL = µ - 3σ √n
3. Briefly explain the TQM with its approaches and techniques? (Nov-2010)
As you consider your approaches of Total Quality Management (TQM), you have to evaluate which
methods best suit your company and your management style. The term came from the teachings of the
late statistician and industrial consultant, W. Edwards Deming, who promoted five basic principles:
Reduce errors that occur during the manufacture or presentation of a product or service.
Render efficiency among the components (staff or company departments) necessary to produce
the product or service.
Utilize the most modern equipment or procedures available.
Maintain constant levels of employee training and education.
Assess levels of customer satisfaction.
C chart. In this chart we plot the number of defectives (per batch, per day, per machine, per 100
feet of pipe, etc.). This chart assumes that defects of the quality attribute are rare, and the control
limits in this chart are computed based on the Poisson distribution (distribution of rare events).
U chart. In this chart we plot the rate of defectives, that is, the number of defectives divided by
the number of units inspected (the n; e.g., feet of pipe, number of batches). Unlike the C chart,
this chart does not require a constant number of units, and it can be used, for example, when the
batches (samples) are of different sizes.
Np chart. In this chart, we plot the number of defectives (per batch, per day, per machine) as in
the C chart. However, the control limits in this chart are not based on the distribution of rare
events, but rather on the binomial distribution. Therefore, this chart should be used if the
occurrence of defectives is not rare (e.g., they occur in more than 5% of the units inspected). For
example, we may use this chart to control the number of units produced with minor flaws.
P chart. In this chart, we plot the percent of defectives (per batch, per day, per machine, etc.) as
in the U chart. However, the control limits in this chart are not based on the distribution of rare
events but rather on the binomial distribution (of proportions). Therefore, this chart is most
applicable to situations where the occurrence of defectives is not rare (e.g., we expect the percent
of defectives to be more than 5% of the total number of units produced).