I am grateful to the following people for their help and motivation in completing this book. I am grateful to my wife Prerna Sinha and sons Harshit Anand and Arpit Anand for their patience and loving participation in carrying out this work.
IntroductIon
- pre-industrial revolution era
- Industrial revolution
- scientific management
- operations research and Quantitative phase
- automation and computer-integrated manufacturing phase
- factory of the future
After the industrial revolution, Taylor and Gilbreth (Frank B. Gilbreth and his wife, Lillian Gilbreth) contributed a lot to the field of industrial engineering and later these contributions were known as the basis of Scientific Management. Second major contributions in the field of scientific management are from Gilbreth family (Frank B. Gilbreth and his wife, Lillian Gilbreth).
- Job-shop production
- Batch production
- mass production
- continuous production
Manufacturing time and production costs are lower compared to workshop production due to higher volume. Since the final product is standard compared to workshop production and produced in batches, economies of scale can be achieved to some extent.
The product may therefore require to be produced for stock according to the principles of batch production/mass production. Therefore, depending on the demand, the product variety must be taken into account and the process that provides the best efficiency in terms of machine and labor utilization must be chosen.
- partial productivity
- total factor productivity
- efficiency
- effectiveness and productivity Index
- productivity cycle
- factors Influencing the productivity
- reasons for lower productivity
- Ways to Improve productivity
- the technology used to Improve productivity
- guidelines for productivity measurement systems
The time consumed in different processes such as inspection, maintenance, production affects the productivity of the system. The productivity of any system can be improved either by proper use of resources or by effective utilization of the system or its processes.
Which of the following is NOT a factor affecting productivity. a) design of the work space (b) use of the Internet (c) standardization of processes (d) Bicycle. Which of these factors affects productivity. a) methods and technology (b) workers (c) management (d) all of the above.
Which of the following formulas is the correct formula for total factor productivity? a) Total factor productivity Total output Total input. Which of the following is the most flexible production system? a) Production in a workshop (b) Serial production (c) Mass production (d) Continuous production 15. Which of the following products has the highest productivity. a) Production in a workshop (b) Series production (c) Mass production (d) None of the above.
What is productivity measured in units of output per rupee of input over a two-year period. Management has an option of Rs 12,000 for equipment with a five-year lifespan.
IntroductIon
Plant location and layout is pre-production planning in which various factors are considered to determine the location of the new facility and design the layout of the facilities in that location. In operational management, the word facility location and layout is often used in place of plant location and layout.
FacIlIty locatIon
- Factor-rating Method
In the facility location and layout, many other facilities besides the production facility are considered such as warehouse, distribution center, retail or service center, etc. In this method, all the important factors of facility location are considered and they are assigned some weights based on their importance.
First find the weighted scores of factory locations and then calculate the sum of the weighted scores for each location, as shown in Table 2.2.
- cost–Volume–profit ratio/Break-Even analysis
Annual fixed costs (land, property taxes, insurance, equipment, and buildings) and variable costs (labor, materials, transportation, and overhead) are shown in Table 2.5: Variable costs per unit (Rs). a) Graphs of total costs for all locations are presented in Figure 2.3.
FacIlIty/plant layout
- product layout
- process layout
- difference between product layout and process layout
- Group layout
- Fixed position layout
A schematic diagram of the process layout is shown in Figure 2.5, where the material flow is zigzag. This layout is used for bulky and fragile products such as aircraft, ships, railcars, etc.
Block dIaGraM
Find the area needed for the departments as shown in Table 2.7
Start with an initial layout as shown in Figure 2.9
Find the amount of movements between the departments as shown in Table 2.8
Show initial traffic as shown in Figure 2.10
Rearrange the blocks; the blocks with high interaction should be close to each other as shown in Figure 2.11
Finalize the layout of blocks as shown in Figure 2.12
- aSSEMBly lInE BalancInG
- Group tEchnoloGy
- part Family
- types of classification and coding Systems
- opitz classification System
- problems in Implementation of Gt
- advantages of Gt
- cEllular ManuFacturInG
- Machine cell design
- Best Machine arrangement
Volume of work to be done in the cell: It includes the number of parts per year and the amount of work required per part. The number of machines in the cell, the total cost of operating the cell and the amount of investment required are required.
SuMMary
Which of the following layout has the highest productivity. a) Product layout (b) Process layout (c) Group layout (d) Fixed position layout. Which of the following tools is used to visualize the amount of movement that occurs between departments in a plant.
ExErcISES
IntroductIon
- characteristics of Forecasts
- Forecasting Horizons
- Steps of Forecasting
- Qualitative Forecasting
- Quantitative Forecasting
Selection of items for forecast: A forecast for one item cannot be applied to another item. Here, α tries to smooth out the variation of actual and forecasted demand values in the previous period.
- Seasonal adjustment
Find an equation of the regression line and estimate the demand for week 14. Seasonal factors are then multiplied by the annual demand forecast to give a forecast for each season/quarter.
The basic difference between seasonality and cycles is. a) the duration of repeated patterns in seasonality is longer than cycles. Which of the following forecasting techniques is based on a previous forecast and a fixed proportion of forecast error.
Moving average forecasting techniques are used to (a) instantly reflect changing patterns in data (b) manage changes in data. In the exponential smoothing method (a), all past data have equal weights. b) recent data is given less weight than past data (c) recent data is given more weight than past data (d) none of these.
Based on the data in Table 3.15, forecast the demand for periods with three-period weighting. Based on the data in Table 3.15, forecast demand for the periods using the adjusted exponential smoothing method (α = 0.5 and b = 0.3).
IntroductIon
Aggregate planning identifies the best way to use a firm's limited resources to meet fluctuating demand. The aggregate planning problem can be clarified by a discussion of the various available decision options.
MIxed StrAtegy
- linear Programming for Aggregate Planning
- the linear decision rule
Total cost=c II t(ie inventory cost)+c PR t(ie RRegular production cost ie overtime product . ) +c Oo t( iion cost)+c UU t(ie idle production cost) the purpose of linear programming is to minimize the total production costs, i.e. Total cost=c II t(ie inventory cost)+c PR t(ie RRegular production cost ie idle production. ) +c UU t( ccost) +c Ss t(ie subcontractor production cost) The goal of linear programming is to minimize the total production costs, i.e.
SuMMAry
MultIPle-choIce QueStIonS
Hiring and firing as a strategy to meet fluctuating demand is used under (a) a level production strategy (b) a hunting demand strategy. Which of the following strategies is used to manipulate the demand for the product. a) hiring and firing strategy (b) constant workforce strategy (c) overtime production strategy (d) pricing strategy.
Answers
Which of the following strategies is known to lower employee morale. a) hiring and firing strategy (b) constant workforce strategy (c) overtime production strategy (d) subcontracting strategy. Find the production costs under the following strategies. a) Constant workforce level and inventory (b) Subcontracting as a strategy to meet fluctuating demand (c) Overtime as a strategy to meet fluctuating demand (d) Hiring and firing as a strategy to meet fluctuating demand.
IntroductIon
- MrP Inputs
- MrP Processing and outputs
- Benefits and limitations of MrP
Use MRP to determine the schedules for the orders to be released to manufacture and assemble the components so that the 500 staplers can be delivered on time. Utilization of the same parts at different levels, indicating the need to restructure the BOM.
MrP II
- characteristics of MrP II
- advantages of using MrP II
- Features of erP
- Benefits of erP
Minty says that “MRP II does not replace MRP, nor is it an improved version of MRP. Typical basic modules in an MRP II system are master production planning (MPS), item master data, bill of materials (BOM), input data, stocks and orders, purchasing management, MRP, shop floor control (SFC), capacity planning or CRP, standard cost calculation, cost reporting/- management, distribution resource planning (DRP).
Strategic benefits: Business growth support, business alliance support, building business innovations, building cost leadership, generating product differentiation, building external linkages, enabling e-government, maintaining competitiveness, etc. Benefits of IT infrastructure: Building business flexibility for now and future changes, reducing IT cost, increasing IT infrastructure capability, etc.
MultIPle-choIce questIons
One unit of A requires 3 units of B and 5 units of C. The net requirement of C is. a) the amount of materials required to produce the products (b) quantities and times of planned order to be released (c) capacity requirements to produce the product. a) severely limited by MRP computer systems (b) not related to MRP. Dependent and independent demand of a commodity differs in that. a) for all goods, the demand from all components is dependent demand (b) the amount of independent demand must be predicted.
Use MRP to determine the schedules for the orders to be released for the production and assembly of the components so that the 200 units of product A can be delivered on time. Add an additional 10 percent scrap surcharge to any planned order of D. The minimum order size for E is 200 units.
- IntroductIon
- objectives of Inventory control
- Functions of Inventory
- understocking and overstocking
- classIFIcatIons oF Inventory
- Inventory costs
- contInuous and PerIodIc Inventory revIew systems
- economIc order QuantIty
- Basic eoQ model
- eoQ model without Instantaneous receipt
- demand occurs at a constant rate of D Items Per year
- eoQ model with shortages
- eoQ model with Quantity discount
- reorder PoInt
- reorder Point for variable demand
- reorder Point for variable lead time
- reorder Point for variable demand and variable lead time
As evident from the above heading, “ABC” denotes “Always Better Control.” The basis for analyzing the annual cost of consumption of the inventory items is the “Vital Few – Trivial Many” principle, and the criterion used here is the money spent. , not the amount consumed. The service level is the probability that the available inventory will be sufficient to meet demand during the lead time (that is, the probability of an inventory shortage will not occur).
The function of inventory is. a) to meet the fluctuating demand of the market (b) to make smooth production systems. Which of the following EOQ model assumes that material cost is the variable cost. a) Basic EOQ model with immediate receipt.
- Engineering design Process
- Feasible design and optimal design
- type of design at Evolution stage
- Product specification
- Product concEPt and concEPt sElEctIon .1 Product concept
- concept selection
- types of Product development
- Brainstorming
- Product lIFE cyclE
- standardization
- simplification
- differentiation
- diversification
- Modular design
- sequential versus cE
- Factors Influencing the need of cE
- Benefits of cE
Optimization through evolution: Most of the design is optimized at the time of technological evolution. Any delay in launching the product on time causes losses to the profits of the organization.
MultIPlE-choIcE QuEstIons
In this chapter, the step-by-step product design process has been discussed in detail. Standardization in product design means. a) Reduction of variations in the specifications of product components (b) Improvement of the use of parts in a product family.
IntroductIon
- FMS components
- FMS layout configurations
- Functions of computer in FMS
- FMS data Files
- FMS Planning
- FMS benefits
But in the second type of arrangement, parts can flow in both directions, as shown in Figure 8.2. Pallet reference file: Consists of a work record that requires pallet clamping.
- computer-aided design
- computer-aided Manufacturing
- computer-aided Process Planning
- numerical control
- computer numerical control
- comparison of nc and cnc Machines
- direct numerical control
Tool life file: It keeps track of the tool life of the various cutting tools. This method searches the part family file to determine if a default route sheet exists for the given part code.
- the 3 M’s of lean (Muda, Mura and Muri)
- toyota Production Systems
- evolution of toyota Motor and concept of lean Manufacturing
- the concept of the JIt System
- objective of JIt
- advantages of JIt System
- Kanban control in lean Manufacturing
Human involvement: The human resource management plays an important role in the implementation of the JIT manufacturing system. Concept of immediate customer: A JIT uses the concept of 'immediate customer' where each worker in the firm considers the next worker who continues the production process to be the customer.
- Variables of aMS
Using a high level of parts commonality in the early stages of the manufacturing process can delay product differentiation. The agile manufacturing is focused on the quick response to the changes required according to the requirements of the market.
IntroductIon
One of the main objectives of work study and plant layout is to minimize material handling time and cost. Provide training to persons operating material handling equipment for their efficient handling and safe operation.
- transport equipments
- positioning equipments
Some storage equipment may include the transportation of materials (eg, the storage/retrieval machines in an automated storage/retrieval system). Parts feeders can be used to provide inspection capabilities regarding the shape and weight of the parts (eg the coin feeder on a vending machine).
