ASSIGNMENT ON PRODUCTION AND OPERATIONS

MANAGEMENT

Q.1: Explain the various automated systems for transfer of

materials in the production plant? Illustrate your answer by
considering an example of an automobile showroom.

Answer:

• Basically, automation system comes to reduce labor power and time in the
production. Here we can see the evolution systems with some examples.

• The goods requited by society were produces in small quantities by craftsman

who would know the need of the community and produced them by their own
hands with simple tools.

• The apprentices or by another craftsman, who would make them to meet the
requests made. The parts and components used to make these machines had to be
replaced when they wore making parts so that interchangeability was achieved
made setting up standards and specifications important for meeting.

• The craftsmen gave way to engineers, workers, superiors and inspectors.

Division of labor became necessary to achieve efficiencies and the jabs that
became specialized. Competition has necessitated improved quality, reduced
sates and better services to the customer.

• Automation systems cost huge sums of money and therefore a deep analysis of
the various factors has to be done. For services, automation usually means labor
saving devices in education, long distance learning technology helps in
supplementing class room instruction. The facilitating goods that are used are
web site and videos.

• Automation in the banking sector has resulted in ATMs which same the banks a
huge amount customer satisfaction. Automation is ideas when the service
provided or the product manufactured is highly standardized.

• Some extent of automation can be designed even with customization i. e. product

or service a meant to produce or deliver low volume specific to a requirement.
The advantages of automation are it has low variability and will be more
consistent on a repetitive basis.

• The machines have sensing and control devices that enable them to operate
automobile. The simplest of them called machine attachments replace human
effort. They guide, locate, move and achieve revise position by means of came,
optical sensing. Load sensing mechanisms and activate the controls to remove
human intention.

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• Robots are higher in the order of automation as they perform a variety of tasks.
They are designed to move movements according to programmers written into
the computer that inside them.
• With the help of automation, inspection of component can be done 100% ensures
highest quality identification and movement of materials are helped by bar codes
which are read and fed into the system far monitoring quantity, location,
movement etc.

• They help the automated systems to start information and provide information
for effecting any changes necessary. To make effective use of automated
machines, we need to have the movement of materials from and to different time
as stores, automated, Automated storage and Retrieval systems- ASRS- receive
orders for materials from anywhere in the production area, collect materials in
the works times.

• Computers and information systems are used for placing orders for matters, give
commands adjust inventory records which show the location and quantity of
materials needed.

• Automated guided vehicle systems- AGVS – are pallet trucks and unit load
carriers follow embedded guide wires or paint strips to destinations as
programmed.

• In an automobile showroom we can see all the work automatically with latest
machine.

KUKA Industrial Robots being used at a bakery for food

production

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Q.2: State the important considerations for locating an

automobile plant? Collect information on layout planning of
an automobile plant from various sources and furnish the
same?

Answer:
1. To locate an automobile company or plant many thing should be consider. For an
automobile plant automated flaw lines, automated assembly lines, flexible
manufacturing systems, global transition rapid prototyping. Building
manufacturing flexibility things are necessity.

2. About the automated flow lines we can say it is a machine which is linked by a
transfer system which moves the parts by using handling machines which are
also automated, we have an automated flow line.

3. Human intervention ma is needed to verify that the operations are taking place
according to standards. When these can be achieved with the help of automation
and the processes are conducted with self regulation, we will have automated
flow lines established.

4. In fixed automation or hard automation, where one component is manufactured

using services operations and machines it is possible to achieve this condition.
We assume that product life cycles are sufficiently stable to interest heavily on
the automate flow lines to achieve reduces cast per unit.

5. Product layouts ate designed so that the assembly tasks are performed in the
sequence they are designed at each station continuously. The finished item came
out at the end of the line.

6. In automated assembly lines the moving pallets move the materials from station
to station and moving arms pick up parts, place them at specified place and
system them by perusing, riveting, & crewing or even welding.

7. Sensors will keep track of their activities and move the assembles to the next
stage.

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8. The machines are arranged in a sequence to perform operations according to the

technical requirements.

9. The tools are loaded, movements are effected, speeds controlled automatically
without the need for worker’s involvement.

10. The flexibility leads to better utilization of the equipments.

11. It reduces the numbers of systems and rids in reduction of investment as well as
a space needed to install them.

12. One of the major cancers of modern manufacturing systems is to be able to

respond to market demands which have uncertainties.

13. Prototyping is a process by which a new product is developed in small number

so as to determine the suitability of the materials, study the various methods of
manufactured, type of machinery required and develop techniques to overcome
problems that may be encountered when full scale manufacture is undertaken.

14. Prototypes do meet the specification of the component that enters a product and
performance can be measured on these.

15. It helps in con be reforming the design and any shortcomings can be rectified at
low cost.

16. Flexibility has three dimensions in the manufacturing field. They are variety,
volume and time. Their demands will have to be satisfied.

17. In that sense they become constraints which restrict the maximization of
productivity. Every business will have to meet the market demands of its various
products in variety volumes of different time.

18. Flexibility is also needed to be able to develop new products or make

improvements in the products fast enough to cater to shifting marker needs.

19. Manufacturing systems have flexibility built into them to enable organization
meet global demand.

20. You have understood how the latest trends in manufacturing when implemented
help firms to stay a head in business.

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Q.3: Who are the players in a project management? What are

the various roles and responsibilities of the players in a
project management?

Answer:

Introduction:
At first we will discuss about project management then we will discuss about players
in project management. Project management is the practice of controlling the use of
resources, such as cost, time manpower, hardware and software involved in a project.
That starts with a problem statement and end with delivery of a complete product.

Here we will see the participants of project management. In the project management
player’s individual and organizations both are involved- That is actively involved in the
project whose interests may be affected by the outcome of the project.

Exert influence over the project and its results players or also called “stake holders’’
of the project.

• Project manager –

The individual who is responsible for managing the project.

• Customer –

The individual or organization that will use the product- the end result of the
project.

• Performing organization –

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The enterprise whose employees are mast directly involved in doing the work of
the project.

• Sponsors –

The individual or group within or external to the performing organization that

funds the project.

 Role and Responsibilities of Project

Management:
There are number of projects which an organization works on. It is not possible
for one individual to manage all the projects. There is a team of managers who manage
the projects. There may be different teams working on different projects. An
experienced project manager and this team may manage more than one project at a time.
The project team is responsible for ensuring that the project upon completion shall
deliver the gain in the business for which it is intended for.

• The project team has to properly co-ordinate with each other working on
different aspects of the project.

• The team members are responsible for the completion of the project as per
the plans of the project.

 Characteristics of project mindset:

• Time:

It is possible to improve the pace of the project by reducing the time frame of the
process. The mindset is normally to work in a comfort made by stretching the time
limits.

• Responsiveness:

It refers to quickness of response of an individual. The vibrancy and livens of an

individual or an organization are proportional to its capability of evolving process
and structure for superior responsiveness time constant.

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• Information sharing:

Information is owner information is the matter key to today’s business.

Information sharing is the characteristic of the project mindset today.

• Process:

Project mindset lays emphasis on flexible process. The major difference in a

process and a system is in its capabilities of providing flexibility to different
situational encounters. Flexible process possesses greater capabilities of adaptability.

• Structured planning:

Structure planning based a project management life cycle enables one to easily
and conveniently work according to the plan.

Q.4: What are the various steps in project monitoring and

controlling a project?

Answer:
Any project aimed at delivering a product or service has to go through phases in
a planned manner in order to meet the requirements. It’s only by careful monitoring of
the project progress. It required establishing control factors to keep the project on the
track of progress.

The results of any stage in a project, depends on the inputs to that stage. It is
therefore necessary to control all the inputs and the corresponding outputs from a stage.
A project management may use certain standard trolls to keep the project on track.

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The project manager and the team members should be fully aware of the
techniques and methods to rectify the factors influencing delay of the project and its
product. The methodology of PERT (programmer Evolution Review Technique) and
CPM (critical path method) may be used to analyze the project.

In the PERT method one car find out the variance and use the variance to
analyze the various probabilistic estimates pertaining to the project. Using the CPM one
can estimate the start time and the finish time for every event of the project in its WBS
(work Breakdown Structure). The analysis charts can be used to monitor, control, track
and execute a project.

 Monitoring and Controlling a Project:

a. Preliminary work:
The team members understand the project plans, project stage schedule, progress
controls, tracking the schedules. Summary of the members have to understand the
tolerances in any change and maintain a change control log. They must realize the need
and importance of quality for which they have to follow strictly quality agendas. They
must understand the stage status reposes, stage and reports, stage end approval reports.

b. Project progress:
The members must keep a track of the project progress and communication the same
to other related members of the project. They must monitor and control project progress,
through the use of regular check points, quality charts. Statistical tables, control the

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quality factors which are likely to deviate from expected values as any deviation may
result in change to the stage schedule.

c. Stage control:
The manager must establish a project check paint cycle. For this suitable stage
version control procedure may be followed.

d. Resources:
Plan the resources required for various stage of the project. Brief both the project
team and the key resources about the objectives of every stage, planned activities,
products, organization. Metrics and project controls.

e. Quality control:
This is very important in any project: Quality control is possible if the project
member’s follow- Schedule quality review, Agenda for quality review, conduct quality
review and follow up.

f. Progress control:
It is the main part at assessment- Progress control assesses- monitor performance,
update schedule, update casts, Re-plan stage schedule, conduct team status review etc.
Along with we create status report, create flash reports, project status reports etc.

g. Approvals:
Lastly, project sage reviews and the decisions taken and actions planned need to be
approved by the top management. The goals of such review are to improve quality by
finding defects and to improve productivity by finding defects in a cost effective
manner. The group review progress includes several stage like planning, preparation and
overview, a group review meeting and rework recommendation and follow-up.

Q.5: Explain the necessity and objectives of SCM?

Answer:
 Introduction:
SCM is the abbreviation of supply chain Management. It is considered by many
express worldwide as the ultimate solution towards efficient enterprise management.
Supply chain management (SCM) is the management of a network of interconnected
businesses involved in the ultimate provision of product and service packages required
by end customers (Harland, 1996). Supply Chain Management spans all movement and
storage of raw materials, work-in-process inventory, and finished goods from point of
origin to point of consumption (supply chain). Another definition is provided by the

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APICS Dictionary when it defines SCM as the "design, planning, execution, control,
and monitoring of supply chain activities with the objective of creating net value,
building a competitive infrastructure, leveraging worldwide logistics, synchronizing
supply with demand, and measuring performance globally."

Idea:
Supply chain management encompasses the planning and management of all
activities involved in sourcing, procurement, conversion, and logistics management. It
also includes the crucial components of coordination and collaboration with channel
partners, which can be suppliers, intermediaries, third-party service providers, and
customers. In essence, supply chain management integrates supply and demand
management within and across companies. More recently, the loosely coupled, self-
organizing network of businesses that cooperate to provide product and service offerings
has been called the Extended Enterprise. Supply chain management can also refer to
supply chain management software which includes tools or modules used to execute
supply chain transactions, manage supplier relationships and control associated business
processes.

Supply chain event management (abbreviated as SCEM) is a consideration of all

possible events and factors that can disrupt a supply chain. With SCEM possible
scenarios can be created and solutions devised.

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 Necessity and Objectives:

• Reduction of inventory

• Enactment in functional effectiveness of existing systems like ERP, Accounting.

Software and Documentation like financial reports statements ISO 9000 Documents
etc.

• Enhancement of participation level and empowerment level

• Effective integration of multiple systems like ERP, communication systems,

documentation system and secure, Design R&D systems etc.

• Better utilization of resources- men, material, equipment and money.

• Optimization of money flow cycle within the organization as well as to and from
external agencies.

• Enhancement of value of products, operations and services and consequently,

enhancements of profitability.

• Enhancement of satisfaction level of customer and clients, supporting institutions,

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statutory control agencies, supporting institutions, statutory control agencies,

suppliers and vendors, employees and executives.

• Enhancement of flexibility in the organization to help in easy implementation of

schemes involving modernization, expansion and divestment, mergers and
acquisitions.

• Enhancement of coverage and accuracy of management information systems.

With the objectives of SCM, its implementation is required. Implementation is in the

form of various functional blocks of an organization interpenetrated through which a
smooth flow of the product development is possible.

Q.6: What are the steps involves in SCM implementation?

Answer:

 Introduction:

There are many steps which involved in SCM implementation are- Business
Process, sales and marketing. Logistics, costing, demand planning, trade- off analysis,
environmental requirement, process stability, integrated supply, supplier management,
product design, suppliers, customers, material specifications, etc.

 Important aspect of SCM:

• The level of competition existing in the market and the impact of competitive forces
on the product development.

• Designing and working on a strategic logic for better growth through value
invention.
• Working out new value curve in the product development along with necessary
break point.

• Using it to analyses markets and the economies in product design. Tine, customer,
quality of product and the concept of survival of fittest.

 Steps of SCM implementation:

• Group customer by need:

Effective SCM groups, customer by distinct service needs those particular

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segments.

• Customize the logistics networks:

In designing their logistics network, companies need to focus on the service

requirement and profit potential of the customer segments identified.

• Listen to signals of market demand and plan accordingly:

Sales and operations planners must monitor the entire supply chain to detect
early warning signals of changing customer demand and needs.

• Differentiate the product closer to the customer:

Companies today no longer can afford to stock pile inventory to compensate for
possible forecasting errors; instead, they need to postpone product differentiation in the
manufacturing. Processes closer to actual customer demand.

• Strategically manage the source of supply:

By working closely with their key suppliers to reduce the overall casts of owning
materials and services; SCM maximizes profit margins both for themselves, and their
supplies.

• Develop a supply chain wide technology strategy:

As one of the cornerstones of successful SCM information technology must be

able to support multiple levels of decision making.

• Adopt channel spanning performance measures:

Excellent supply performance measurement systems do more than just monitor

internal functions. They apply performance criteria that embrace both service and
financial metrics, including each account’s true profitability.

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