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MB0044: Production & Operations Management Assignment Set I
Note: Each question carries 10 Marks. Answer all the questions.
1. What are the components of systems productivity? Explain how CAD and CIM help in improving
productivity.
Answer:
System Productivity
Enhancement of productivity is achieved by either reducing the inputs for the same output or
increasing the output by using the same input. Productivity can be calculated for a: Single operation
Functional unit Department or division Plant Productivity is a measure of the efficiency of the
system and looks at the economies achieved during the processes. Every process will have a number of
contributors which help in achieving maximum productivity. The processes are: People, Machines,
Facilitating goods, Ancillary equipments, and Technology. Each of these elements attempts to enhance
the contribution of other elements. Opportunities exist at all stages of the workflow in the entire
system to introduce measures for increasing productivity. However in actual manufacturing situations,
the inefficiencies will have cascading effect in hampering productivity. Communication, effective review
processes and innovative methods will ensure optimisation of resources. Building up reliability into the
equipments, managing the supply chain to economise on the cost factors improves productivity. Quality
circles are very efficient in incorporating low cost and non-intrusive methods of improving productivity
and quality throughout the organisation. Quality circles:
Involve all persons who are actually involved in the production system and the information they elicit
and bring about improvements that are highly cost effective
Unveil creativity and encourage team work and bring about improvements almost on a day to day basis
Bring continuous incremental changes in a harmonious way instead of dramatic changes
Encourage identification of possible failures and seek methods of preventing things going wrong
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Computers in Design CAD
MB0044: Production & Operations Management Roll No. 510929890
MB0044: Production & Operations Management Assignment Set I
Note: Each question carries 10 Marks. Answer all the questions.
1. What are the components of systems productivity? Explain how CAD and CIM help in improving
productivity.
Answer:
System Productivity
Enhancement of productivity is achieved by either reducing the inputs for the same output or
increasing the output by using the same input. Productivity can be calculated for a: Single operation
Functional unit Department or division Plant Productivity is a measure of the efficiency of the
system and looks at the economies achieved during the processes. Every process will have a number of
contributors which help in achieving maximum productivity. The processes are: People, Machines,
Facilitating goods, Ancillary equipments, and Technology. Each of these elements attempts to enhance
the contribution of other elements. Opportunities exist at all stages of the workflow in the entire
system to introduce measures for increasing productivity. However in actual manufacturing situations,
the inefficiencies will have cascading effect in hampering productivity. Communication, effective review
processes and innovative methods will ensure optimisation of resources. Building up reliability into the
equipments, managing the supply chain to economise on the cost factors improves productivity. Quality
circles are very efficient in incorporating low cost and non-intrusive methods of improving productivity
and quality throughout the organisation. Quality circles:
Involve all persons who are actually involved in the production system and the information they elicitand bring about improvements that are highly cost effective
Unveil creativity and encourage team work and bring about improvements almost on a day to day basis
-
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Bring continuous incremental changes in a harmonious way instead of dramatic changes
Encourage identification of possible failures and seek methods of preventing things going wrong
Computers in Design CAD
MB0044: Production & Operations Management Roll No. 510929890
Designs of products are increasingly depending on Computer Aided Design (CAD). It is an electronic
system for designing new parts or products or altering existing ones, replacing drafting traditionally
done by hand. The designs are made using powerful desktop computers and graphics software. Designer
can create drawings and view them from any angle on a display monitor. Images of different
components can be seen as assembled; sections taken and relative positions can be checked to great
accuracies. Views can be made from different angles and positions, so that the visualisation process of
the designed component/product helps the designer to suggest alternatives to the customer and the
production department.
The drawings can be sent via intranet or internet to the concerned persons and their opinions taken.
Corrections and incorporations can be made very quickly. The computer can also simulate the reaction
of a part to strength and stress tests. Using the design data stored in the computers memory,
manufacturing engineers and other users can quickly obtain printouts of plans and specifications for a
part or product. The software can generate the volume, weights of components as also other
engineering parameters like centre of gravity, deflections under estimated loads, and various other
design parameters on complicate forms, either for single components or assemblies. Laborious
mechanical drawings or complicated calculations need not be drawn for people using this software. The
database can be prepared, updated continuously and their access to executive. Analysts use CAD to
store, retrieve, and classify data about various parts. CAD helps to increase the efficiency of a designers
work. This aids in reducing the time required for making a design or modifying a product and thus
concept market period gets drastically cut. This implementation also cuts the cost of product
development and sharply reduces the time to market new products. It saves time by enabling designers
to access and modify old designs quickly, rather than start from scratch.
Computer integrated manufacturing (CIM)
Integration occurs when a broad range of manufacturing and supporting activities are linked. CIM is the
complete automation of a manufacturing plant, with al l processes functioning under computer controland digital information tying them together. The three major functions in manufacturing are production,
design, and management function. Production function converts resources into products. The design
function transforms customer specifications into design. Finally the management functions plan and
control production activities. The three computer aids in CIM are:
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Computer aid to the production function (automated flow of materials)
Computer aid to the design function (automated flow of technological information)
Computer aid to the management function (automated flow of managerial information) When it
comes to production, CIMs are included in different areas of production process such as in engineering
design, production planning, shop control, order processing, material control, distribution and many
other areas. Information flow across all the functions takes place with the help of computers.
Transmission, processing, distribution, and feedback happen almost in real time so that intended
MB0044: Production & Operations Management Roll No. 510929890
activities are conducted rapidly.
CIM process helps in rapid production and also reduces indirect costs. CIM uses computers to control
the entire production process. This integration allows the processes to exchange information with each
other and thus they become capable of initiating actions. As response times decrease, customer
satisfaction increases resulting in better business. CIM helps in avoiding accumulation of materials
resulting in better throughput and better utilisation of space. Bar coded labels that accompany materials
contain instructions for processing them which are read by sensing devices and display the status on
monitors. This information is available to all concerned personnel responsible in planning, marketing
and other activities so that they will be aware of the status of any order. If expediting is needed to meet
deadlines, they will be able to seek intervention. Identifying shortages and ensuring faster deliveries
become easy with CIM.
2. What do you understand by industry best practice? Briefly explain different types of Benchmarking.
Answer: Industry Best Practices :
Each industry would have developed over years or decades. During this development materials would
have changed and processes would have changed. As all products or services are meant to serve needs
of the customers, they undergo continuous changes both in shapes and features. Materials and
methods go on improving incessantly because of the research that is conducted. The companies that
were at the front innovate to stay in business as new entrants would be adopting the latest techniquesthat the pioneers had taken decades to establish. So, the various firms in any industry would end up
adopting almost similar methods of getting an output required. Such practices would get refined to a
great extent giving rise to what we call industry best practices. These tend to get stabilised or changed
owing to the development of new equipments which are designed. A manufacturer, with an eye on
growing markets, demands for higher quality and reduced prices. Competition benefits those who can
-
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use all these to their advantage. Industry best practices open up the field for benchmarking by
companies which need to improve their performance.
The following are the types of benchmarking considered by various firms.
Process Benchmarking Business Process Financial Benchmarking Performance Benchmarking
Product Benchmarking Strategic Benchmarking Functional Benchmarking Tools like Pareto Analysis
(an example is shown in figure) are used to make the choice or choices from among many aspects in any
one of the above categories. MB0044: Production & Operations Management Roll No.
510929890
MB0044: Production & Operations Management Assignment Set I
Note: Each question carries 10 Marks. Answer all the questions.
1. What are the components of systems productivity? Explain how CAD and CIM help in improving
productivity.
Answer:
System Productivity
Enhancement of productivity is achieved by either reducing the inputs for the same output or
increasing the output by using the same input. Productivity can be calculated for a: Single operation
Functional unit Department or division Plant Productivity is a measure of the efficiency of the
system and looks at the economies achieved during the processes. Every process will have a number of
contributors which help in achieving maximum productivity. The processes are: People, Machines,
Facilitating goods, Ancillary equipments, and Technology. Each of these elements attempts to enhance
the contribution of other elements. Opportunities exist at all stages of the workflow in the entire
system to introduce measures for increasing productivity. However in actual manufacturing situations,
the inefficiencies will have cascading effect in hampering productivity. Communication, effective review
processes and innovative methods will ensure optimisation of resources. Building up reliability into the
equipments, managing the supply chain to economise on the cost factors improves productivity. Quality
circles are very efficient in incorporating low cost and non-intrusive methods of improving productivity
and quality throughout the organisation. Quality circles:
-
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Involve all persons who are actually involved in the production system and the information they elicit
and bring about improvements that are highly cost effective
Unveil creativity and encourage team work and bring about improvements almost on a day to day basis
Bring continuous incremental changes in a harmonious way instead of dramatic changes
Encourage identification of possible failures and seek methods of preventing things going wrong
Computers in Design CAD
MB0044: Production & Operations Management Roll No. 510929890
Designs of products are increasingly depending on Computer Aided Design (CAD). It is an electronic
system for designing new parts or products or altering existing ones, replacing drafting traditionally
done by hand. The designs are made using powerful desktop computers and graphics software. Designer
can create drawings and view them from any angle on a display monitor. Images of different
components can be seen as assembled; sections taken and relative positions can be checked to great
accuracies. Views can be made from different angles and positions, so that the visualisation process of
the designed component/product helps the designer to suggest alternatives to the customer and the
production department.
The drawings can be sent via intranet or internet to the concerned persons and their opinions taken.Corrections and incorporations can be made very quickly. The computer can also simulate the reaction
of a part to strength and stress tests. Using the design data stored in the computers memory,
manufacturing engineers and other users can quickly obtain printouts of plans and specifications for a
part or product. The software can generate the volume, weights of components as also other
engineering parameters like centre of gravity, deflections under estimated loads, and various other
design parameters on complicate forms, either for single components or assemblies. Laborious
mechanical drawings or complicated calculations need not be drawn for people using this software. The
database can be prepared, updated continuously and their access to executive. Analysts use CAD to
store, retrieve, and classify data about various parts. CAD helps to increase the efficiency of a designers
work. This aids in reducing the time required for making a design or modifying a product and thusconcept market period gets drastically cut. This implementation also cuts the cost of product
development and sharply reduces the time to market new products. It saves time by enabling designers
to access and modify old designs quickly, rather than start from scratch.
Computer integrated manufacturing (CIM)
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Integration occurs when a broad range of manufacturing and supporting activities are linked. CIM is the
complete automation of a manufacturing plant, with al l processes functioning under computer control
and digital information tying them together. The three major functions in manufacturing are production,
design, and management function. Production function converts resources into products. The design
function transforms customer specifications into design. Finally the management functions plan and
control production activities. The three computer aids in CIM are:
Computer aid to the production function (automated flow of materials)
Computer aid to the design function (automated flow of technological information)
Computer aid to the management function (automated flow of managerial information) When it
comes to production, CIMs are included in different areas of production process such as in engineering
design, production planning, shop control, order processing, material control, distribution and many
other areas. Information flow across all the functions takes place with the help of computers.
Transmission, processing, distribution, and feedback happen almost in real time so that intended
MB0044: Production & Operations Management Roll No. 510929890
activities are conducted rapidly.
CIM process helps in rapid production and also reduces indirect costs. CIM uses computers to control
the entire production process. This integration allows the processes to exchange information with each
other and thus they become capable of initiating actions. As response times decrease, customer
satisfaction increases resulting in better business. CIM helps in avoiding accumulation of materials
resulting in better throughput and better utilisation of space. Bar coded labels that accompany materials
contain instructions for processing them which are read by sensing devices and display the status on
monitors. This information is available to all concerned personnel responsible in planning, marketing
and other activities so that they will be aware of the status of any order. If expediting is needed to meet
deadlines, they will be able to seek intervention. Identifying shortages and ensuring faster deliveries
become easy with CIM.
2. What do you understand by industry best practice? Briefly explain different types of Benchmarking.
Answer: Industry Best Practices :
Each industry would have developed over years or decades. During this development materials would
have changed and processes would have changed. As all products or services are meant to serve needs
of the customers, they undergo continuous changes both in shapes and features. Materials and
-
8/3/2019 SMU Assignment paper-MB0044
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methods go on improving incessantly because of the research that is conducted. The companies that
were at the front innovate to stay in business as new entrants would be adopting the latest techniques
that the pioneers had taken decades to establish. So, the various firms in any industry would end up
adopting almost similar methods of getting an output required. Such practices would get refined to a
great extent giving rise to what we call industry best practices. These tend to get stabilised or changed
owing to the development of new equipments which are designed. A manufacturer, with an eye on
growing markets, demands for higher quality and reduced prices. Competition benefits those who can
use all these to their advantage. Industry best practices open up the field for benchmarking by
companies which need to improve their performance.
The following are the types of benchmarking considered by various firms.
Process Benchmarking Business Process Financial Benchmarking Performance Benchmarking
Product Benchmarking Strategic Benchmarking Functional Benchmarking Tools like Pareto Analysis
(an example is shown in figure) are used to make the choice or choices from among many aspects in any
one of the above categories. MB0044: Production & Operations Management Roll No.
510929890
MB0044: Production & Operations Management Roll No. 510929890
Example of Pareto Analysis
1.
Planning:
Planning determines the process, service or the product to be benchmarked on which metrics are
assigned for collection of data. 2.
Analysis:
Analysed data gives inputs for comparison with the target companys performance on the parameter
benchmark on which data was collected. Measuring gaps helps in identifying the process which should
be improved for reaching the benchmark. 3.
Integration:
Resources are required across all functions to achieve the target needs. Integration involves putting
together resources like people, equipments, and communication, so that, progress is unhindered and all
activities reach their logical conclusions without loss of initiative or time. 4.
Action:
When changes are needed, actions have to be planned according to the steps earlier stated. Teams are
provided with necessary leadership, authority, and supporting facilities to enable them to complete all
-
8/3/2019 SMU Assignment paper-MB0044
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activities within the time frame set for the purpose. Since benchmarking is done in specific areas, it is
necessary to maintain the focus, and implement actions without losing initiative, so that, results become
demonstrable.
MB0044: Production & Operations Management Assignment Set I
Note: Each question carries 10 Marks. Answer all the questions.
1. What are the components of systems productivity? Explain how CAD and CIM help in improving
productivity.
Answer:
System Productivity
Enhancement of productivity is achieved by either reducing the inputs for the same output or
increasing the output by using the same input. Productivity can be calculated for a: Single operation
Functional unit Department or division Plant Productivity is a measure of the efficiency of the
system and looks at the economies achieved during the processes. Every process will have a number of
contributors which help in achieving maximum productivity. The processes are: People, Machines,
Facilitating goods, Ancillary equipments, and Technology. Each of these elements attempts to enhance
the contribution of other elements. Opportunities exist at all stages of the workflow in the entire
system to introduce measures for increasing productivity. However in actual manufacturing situations,
the inefficiencies will have cascading effect in hampering productivity. Communication, effective review
processes and innovative methods will ensure optimisation of resources. Building up reliability into the
equipments, managing the supply chain to economise on the cost factors improves productivity. Quality
circles are very efficient in incorporating low cost and non-intrusive methods of improving productivity
and quality throughout the organisation. Quality circles:
Involve all persons who are actually involved in the production system and the information they elicit
and bring about improvements that are highly cost effective
Unveil creativity and encourage team work and bring about improvements almost on a day to day basis
Bring continuous incremental changes in a harmonious way instead of dramatic changes
-
8/3/2019 SMU Assignment paper-MB0044
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Encourage identification of possible failures and seek methods of preventing things going wrong
Computers in Design CAD
MB0044: Production & Operations Management Roll No. 510929890
Designs of products are increasingly depending on Computer Aided Design (CAD). It is an electronic
system for designing new parts or products or altering existing ones, replacing drafting traditionally
done by hand. The designs are made using powerful desktop computers and graphics software. Designer
can create drawings and view them from any angle on a display monitor. Images of different
components can be seen as assembled; sections taken and relative positions can be checked to great
accuracies. Views can be made from different angles and positions, so that the visualisation process of
the designed component/product helps the designer to suggest alternatives to the customer and the
production department.
The drawings can be sent via intranet or internet to the concerned persons and their opinions taken.
Corrections and incorporations can be made very quickly. The computer can also simulate the reaction
of a part to strength and stress tests. Using the design data stored in the computers memory,
manufacturing engineers and other users can quickly obtain printouts of plans and specifications for a
part or product. The software can generate the volume, weights of components as also other
engineering parameters like centre of gravity, deflections under estimated loads, and various other
design parameters on complicate forms, either for single components or assemblies. Laborious
mechanical drawings or complicated calculations need not be drawn for people using this software. The
database can be prepared, updated continuously and their access to executive. Analysts use CAD to
store, retrieve, and classify data about various parts. CAD helps to increase the efficiency of a designerswork. This aids in reducing the time required for making a design or modifying a product and thus
concept market period gets drastically cut. This implementation also cuts the cost of product
development and sharply reduces the time to market new products. It saves time by enabling designers
to access and modify old designs quickly, rather than start from scratch.
Computer integrated manufacturing (CIM)
Integration occurs when a broad range of manufacturing and supporting activities are linked. CIM is the
complete automation of a manufacturing plant, with al l processes functioning under computer control
and digital information tying them together. The three major functions in manufacturing are production,
design, and management function. Production function converts resources into products. The designfunction transforms customer specifications into design. Finally the management functions plan and
control production activities. The three computer aids in CIM are:
Computer aid to the production function (automated flow of materials)
-
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Computer aid to the design function (automated flow of technological information)
Computer aid to the management function (automated flow of managerial information) When it
comes to production, CIMs are included in different areas of production process such as in engineering
design, production planning, shop control, order processing, material control, distribution and many
other areas. Information flow across all the functions takes place with the help of computers.
Transmission, processing, distribution, and feedback happen almost in real time so that intended
MB0044: Production & Operations Management Roll No. 510929890
activities are conducted rapidly.
CIM process helps in rapid production and also reduces indirect costs. CIM uses computers to control
the entire production process. This integration allows the processes to exchange information with each
other and thus they become capable of initiating actions. As response times decrease, customer
satisfaction increases resulting in better business. CIM helps in avoiding accumulation of materials
resulting in better throughput and better utilisation of space. Bar coded labels that accompany materials
contain instructions for processing them which are read by sensing devices and display the status on
monitors. This information is available to all concerned personnel responsible in planning, marketing
and other activities so that they will be aware of the status of any order. If expediting is needed to meet
deadlines, they will be able to seek intervention. Identifying shortages and ensuring faster deliveries
become easy with CIM.
2. What do you understand by industry best practice? Briefly explain different types of Benchmarking.
Answer: Industry Best Practices :
Each industry would have developed over years or decades. During this development materials would
have changed and processes would have changed. As all products or services are meant to serve needs
of the customers, they undergo continuous changes both in shapes and features. Materials and
methods go on improving incessantly because of the research that is conducted. The companies that
were at the front innovate to stay in business as new entrants would be adopting the latest techniques
that the pioneers had taken decades to establish. So, the various firms in any industry would end up
adopting almost similar methods of getting an output required. Such practices would get refined to a
great extent giving rise to what we call industry best practices. These tend to get stabilised or changed
owing to the development of new equipments which are designed. A manufacturer, with an eye on
growing markets, demands for higher quality and reduced prices. Competition benefits those who can
use all these to their advantage. Industry best practices open up the field for benchmarking by
companies which need to improve their performance.
-
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The following are the types of benchmarking considered by various firms.
Process Benchmarking Business Process Financial Benchmarking Performance Benchmarking
Product Benchmarking Strategic Benchmarking Functional Benchmarking Tools like Pareto Analysis
(an example is shown in figure) are used to make the choice or choices from among many aspects in any
one of the above categories. MB0044: Production & Operations Management Roll No.510929890
MB0044: Production & Operations Management Roll No. 510929890
Example of Pareto Analysis
1.
Planning:
Planning determines the process, service or the product to be benchmarked on which metrics are
assigned for collection of data. 2.
Analysis:
Analysed data gives inputs for comparison with the target companys performance on the parameter
benchmark on which data was collected. Measuring gaps helps in identifying the process which should
be improved for reaching the benchmark. 3.
Integration:
Resources are required across all functions to achieve the target needs. Integration involves putting
together resources like people, equipments, and communication, so that, progress is unhindered and all
activities reach their logical conclusions without loss of initiative or time. 4.
Action:
When changes are needed, actions have to be planned according to the steps earlier stated. Teams are
provided with necessary leadership, authority, and supporting facilities to enable them to complete all
activities within the time frame set for the purpose. Since benchmarking is done in specific areas, it is
necessary to maintain the focus, and implement actions without losing initiative, so that, results become
demonstrable.
MB0044: Production & Operations Management Roll No. 510929890
3. List out the various automated systems for transfer of materials in the production plant. What do you
understand by Line Balancing? Explain with an example.
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Answer: Automated Flow Lines
When several automated machines are linked by a transfer system which moves the parts by using
handling machines which are also automated, we have an automated flow line. After completing an
operation on a machine, the semi-finished parts are moved to the next machine in the sequence
determined by the process requirements and a flow line is established. The parts at various stages fromraw material to ready for fitment or assembly are processed continuously to attain the required shapes
or acquire special properties to enable them to perform desired functions. The materials need to be
moved, held, rotated, lifted, and positioned for completing different operations. Sometimes, a few of
the operations can be done on a single machine with a number of attachments. They are moved further
to other machines for performing further operations. Human intervention may be 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.
The main consideration is to balance times that different machines take to complete the operations
assigned to them. It is necessary to design the machines in such a way that, the operation times are the
same throughout the sequence in the flow of the martial. In fixed automation or hard automation,
where one component is manufactured using several operations and machines, it is possible to achieve
this condition. We assume that product life cycles are sufficiently stable to invest heavily on the
automated flow lines to achieve reduced cost per unit.
Automated Assembly Lines
MB0044: Production & Operations Management Assignment Set I
Note: Each question carries 10 Marks. Answer all the questions.
1. What are the components of systems productivity? Explain how CAD and CIM help in improving
productivity.
Answer:
System Productivity
Enhancement of productivity is achieved by either reducing the inputs for the same output or
increasing the output by using the same input. Productivity can be calculated for a: Single operation
Functional unit Department or division Plant Productivity is a measure of the efficiency of the
-
8/3/2019 SMU Assignment paper-MB0044
14/58
system and looks at the economies achieved during the processes. Every process will have a number of
contributors which help in achieving maximum productivity. The processes are: People, Machines,
Facilitating goods, Ancillary equipments, and Technology. Each of these elements attempts to enhance
the contribution of other elements. Opportunities exist at all stages of the workflow in the entire
system to introduce measures for increasing productivity. However in actual manufacturing situations,
the inefficiencies will have cascading effect in hampering productivity. Communication, effective review
processes and innovative methods will ensure optimisation of resources. Building up reliability into the
equipments, managing the supply chain to economise on the cost factors improves productivity. Quality
circles are very efficient in incorporating low cost and non-intrusive methods of improving productivity
and quality throughout the organisation. Quality circles:
Involve all persons who are actually involved in the production system and the information they elicit
and bring about improvements that are highly cost effective
Unveil creativity and encourage team work and bring about improvements almost on a day to day basis
Bring continuous incremental changes in a harmonious way instead of dramatic changes
Encourage identification of possible failures and seek methods of preventing things going wrong
Computers in Design CAD
MB0044: Production & Operations Management Roll No. 510929890
Designs of products are increasingly depending on Computer Aided Design (CAD). It is an electronic
system for designing new parts or products or altering existing ones, replacing drafting traditionally
done by hand. The designs are made using powerful desktop computers and graphics software. Designer
can create drawings and view them from any angle on a display monitor. Images of different
components can be seen as assembled; sections taken and relative positions can be checked to great
accuracies. Views can be made from different angles and positions, so that the visualisation process of
the designed component/product helps the designer to suggest alternatives to the customer and theproduction department.
The drawings can be sent via intranet or internet to the concerned persons and their opinions taken.
Corrections and incorporations can be made very quickly. The computer can also simulate the reaction
of a part to strength and stress tests. Using the design data stored in the computers memory,
manufacturing engineers and other users can quickly obtain printouts of plans and specifications for a
part or product. The software can generate the volume, weights of components as also other
-
8/3/2019 SMU Assignment paper-MB0044
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engineering parameters like centre of gravity, deflections under estimated loads, and various other
design parameters on complicate forms, either for single components or assemblies. Laborious
mechanical drawings or complicated calculations need not be drawn for people using this software. The
database can be prepared, updated continuously and their access to executive. Analysts use CAD to
store, retrieve, and classify data about various parts. CAD helps to increase the efficiency of a designers
work. This aids in reducing the time required for making a design or modifying a product and thus
concept market period gets drastically cut. This implementation also cuts the cost of product
development and sharply reduces the time to market new products. It saves time by enabling designers
to access and modify old designs quickly, rather than start from scratch.
Computer integrated manufacturing (CIM)
Integration occurs when a broad range of manufacturing and supporting activities are linked. CIM is the
complete automation of a manufacturing plant, with al l processes functioning under computer control
and digital information tying them together. The three major functions in manufacturing are production,
design, and management function. Production function converts resources into products. The design
function transforms customer specifications into design. Finally the management functions plan and
control production activities. The three computer aids in CIM are:
Computer aid to the production function (automated flow of materials)
Computer aid to the design function (automated flow of technological information)
Computer aid to the management function (automated flow of managerial information) When it
comes to production, CIMs are included in different areas of production process such as in engineering
design, production planning, shop control, order processing, material control, distribution and many
other areas. Information flow across all the functions takes place with the help of computers.
Transmission, processing, distribution, and feedback happen almost in real time so that intended
MB0044: Production & Operations Management Roll No. 510929890
activities are conducted rapidly.
CIM process helps in rapid production and also reduces indirect costs. CIM uses computers to controlthe entire production process. This integration allows the processes to exchange information with each
other and thus they become capable of initiating actions. As response times decrease, customer
satisfaction increases resulting in better business. CIM helps in avoiding accumulation of materials
resulting in better throughput and better utilisation of space. Bar coded labels that accompany materials
contain instructions for processing them which are read by sensing devices and display the status on
monitors. This information is available to all concerned personnel responsible in planning, marketing
-
8/3/2019 SMU Assignment paper-MB0044
16/58
and other activities so that they will be aware of the status of any order. If expediting is needed to meet
deadlines, they will be able to seek intervention. Identifying shortages and ensuring faster deliveries
become easy with CIM.
2. What do you understand by industry best practice? Briefly explain different types of Benchmarking.
Answer: Industry Best Practices :
Each industry would have developed over years or decades. During this development materials would
have changed and processes would have changed. As all products or services are meant to serve needs
of the customers, they undergo continuous changes both in shapes and features. Materials and
methods go on improving incessantly because of the research that is conducted. The companies that
were at the front innovate to stay in business as new entrants would be adopting the latest techniques
that the pioneers had taken decades to establish. So, the various firms in any industry would end up
adopting almost similar methods of getting an output required. Such practices would get refined to agreat extent giving rise to what we call industry best practices. These tend to get stabilised or changed
owing to the development of new equipments which are designed. A manufacturer, with an eye on
growing markets, demands for higher quality and reduced prices. Competition benefits those who can
use all these to their advantage. Industry best practices open up the field for benchmarking by
companies which need to improve their performance.
The following are the types of benchmarking considered by various firms.
Process Benchmarking Business Process Financial Benchmarking Performance Benchmarking
Product Benchmarking Strategic Benchmarking Functional Benchmarking Tools like Pareto Analysis
(an example is shown in figure) are used to make the choice or choices from among many aspects in any
one of the above categories. MB0044: Production & Operations Management Roll No.
510929890
MB0044: Production & Operations Management Roll No. 510929890
Example of Pareto Analysis
1.
Planning:
Planning determines the process, service or the product to be benchmarked on which metrics are
assigned for collection of data. 2.
Analysis:
-
8/3/2019 SMU Assignment paper-MB0044
17/58
Analysed data gives inputs for comparison with the target companys performance on the parameter
benchmark on which data was collected. Measuring gaps helps in identifying the process which should
be improved for reaching the benchmark. 3.
Integration:
Resources are required across all functions to achieve the target needs. Integration involves putting
together resources like people, equipments, and communication, so that, progress is unhindered and all
activities reach their logical conclusions without loss of initiative or time. 4.
Action:
When changes are needed, actions have to be planned according to the steps earlier stated. Teams are
provided with necessary leadership, authority, and supporting facilities to enable them to complete all
activities within the time frame set for the purpose. Since benchmarking is done in specific areas, it is
necessary to maintain the focus, and implement actions without losing initiative, so that, results become
demonstrable.
MB0044: Production & Operations Management Roll No. 510929890
3. List out the various automated systems for transfer of materials in the production plant. What do you
understand by Line Balancing? Explain with an example.
Answer: Automated Flow Lines
When several automated machines are linked by a transfer system which moves the parts by using
handling machines which are also automated, we have an automated flow line. After completing an
operation on a machine, the semi-finished parts are moved to the next machine in the sequence
determined by the process requirements and a flow line is established. The parts at various stages from
raw material to ready for fitment or assembly are processed continuously to attain the required shapes
or acquire special properties to enable them to perform desired functions. The materials need to be
moved, held, rotated, lifted, and positioned for completing different operations. Sometimes, a few of
the operations can be done on a single machine with a number of attachments. They are moved further
to other machines for performing further operations. Human intervention may be 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.
The main consideration is to balance times that different machines take to complete the operations
assigned to them. It is necessary to design the machines in such a way that, the operation times are the
same throughout the sequence in the flow of the martial. In fixed automation or hard automation,
where one component is manufactured using several operations and machines, it is possible to achieve
-
8/3/2019 SMU Assignment paper-MB0044
18/58
this condition. We assume that product life cycles are sufficiently stable to invest heavily on the
automated flow lines to achieve reduced cost per unit.
Automated Assembly Lines
All equipments needed to make a finished product are laid out in such a way as to follow the sequence
in which the parts or sub-assemblies are put together and fitted. Usually, a frame, body, base will be the
starting point of an assembly. The frame itself consists of a construction made up of several components
and would have been assembled
or fabricated
in a separate bay or plant and brought to the assembly line. All parts or subassemblies are fitted to
enable the product to be in readiness to perform the function it was designed to. This process is called
assembly. Methodologies of achieving the final result may vary, but the basic principle is to fit all parts
together and ensure linkages so that their functions are integrated and give out the desired output.
MB0044: Production & Operations Management Roll No. 510929890
MB0044: Production & Operations Management Assignment Set I
Note: Each question carries 10 Marks. Answer all the questions.
1. What are the components of systems productivity? Explain how CAD and CIM help in improving
productivity.
Answer:
System Productivity
Enhancement of productivity is achieved by either reducing the inputs for the same output or
increasing the output by using the same input. Productivity can be calculated for a: Single operation
Functional unit Department or division Plant Productivity is a measure of the efficiency of the
system and looks at the economies achieved during the processes. Every process will have a number of
-
8/3/2019 SMU Assignment paper-MB0044
19/58
contributors which help in achieving maximum productivity. The processes are: People, Machines,
Facilitating goods, Ancillary equipments, and Technology. Each of these elements attempts to enhance
the contribution of other elements. Opportunities exist at all stages of the workflow in the entire
system to introduce measures for increasing productivity. However in actual manufacturing situations,
the inefficiencies will have cascading effect in hampering productivity. Communication, effective review
processes and innovative methods will ensure optimisation of resources. Building up reliability into the
equipments, managing the supply chain to economise on the cost factors improves productivity. Quality
circles are very efficient in incorporating low cost and non-intrusive methods of improving productivity
and quality throughout the organisation. Quality circles:
Involve all persons who are actually involved in the production system and the information they elicit
and bring about improvements that are highly cost effective
Unveil creativity and encourage team work and bring about improvements almost on a day to day basis
Bring continuous incremental changes in a harmonious way instead of dramatic changes
Encourage identification of possible failures and seek methods of preventing things going wrong
Computers in Design CAD
MB0044: Production & Operations Management Roll No. 510929890
Designs of products are increasingly depending on Computer Aided Design (CAD). It is an electronic
system for designing new parts or products or altering existing ones, replacing drafting traditionally
done by hand. The designs are made using powerful desktop computers and graphics software. Designer
can create drawings and view them from any angle on a display monitor. Images of different
components can be seen as assembled; sections taken and relative positions can be checked to great
accuracies. Views can be made from different angles and positions, so that the visualisation process of
the designed component/product helps the designer to suggest alternatives to the customer and the
production department.
The drawings can be sent via intranet or internet to the concerned persons and their opinions taken.
Corrections and incorporations can be made very quickly. The computer can also simulate the reaction
of a part to strength and stress tests. Using the design data stored in the computers memory,
manufacturing engineers and other users can quickly obtain printouts of plans and specifications for a
part or product. The software can generate the volume, weights of components as also other
engineering parameters like centre of gravity, deflections under estimated loads, and various other
-
8/3/2019 SMU Assignment paper-MB0044
20/58
design parameters on complicate forms, either for single components or assemblies. Laborious
mechanical drawings or complicated calculations need not be drawn for people using this software. The
database can be prepared, updated continuously and their access to executive. Analysts use CAD to
store, retrieve, and classify data about various parts. CAD helps to increase the efficiency of a designers
work. This aids in reducing the time required for making a design or modifying a product and thus
concept market period gets drastically cut. This implementation also cuts the cost of product
development and sharply reduces the time to market new products. It saves time by enabling designers
to access and modify old designs quickly, rather than start from scratch.
Computer integrated manufacturing (CIM)
Integration occurs when a broad range of manufacturing and supporting activities are linked. CIM is the
complete automation of a manufacturing plant, with al l processes functioning under computer control
and digital information tying them together. The three major functions in manufacturing are production,
design, and management function. Production function converts resources into products. The design
function transforms customer specifications into design. Finally the management functions plan and
control production activities. The three computer aids in CIM are:
Computer aid to the production function (automated flow of materials)
Computer aid to the design function (automated flow of technological information)
Computer aid to the management function (automated flow of managerial information) When it
comes to production, CIMs are included in different areas of production process such as in engineering
design, production planning, shop control, order processing, material control, distribution and many
other areas. Information flow across all the functions takes place with the help of computers.
Transmission, processing, distribution, and feedback happen almost in real time so that intended
MB0044: Production & Operations Management Roll No. 510929890
activities are conducted rapidly.
CIM process helps in rapid production and also reduces indirect costs. CIM uses computers to control
the entire production process. This integration allows the processes to exchange information with eachother and thus they become capable of initiating actions. As response times decrease, customer
satisfaction increases resulting in better business. CIM helps in avoiding accumulation of materials
resulting in better throughput and better utilisation of space. Bar coded labels that accompany materials
contain instructions for processing them which are read by sensing devices and display the status on
monitors. This information is available to all concerned personnel responsible in planning, marketing
and other activities so that they will be aware of the status of any order. If expediting is needed to meet
-
8/3/2019 SMU Assignment paper-MB0044
21/58
deadlines, they will be able to seek intervention. Identifying shortages and ensuring faster deliveries
become easy with CIM.
2. What do you understand by industry best practice? Briefly explain different types of Benchmarking.
Answer: Industry Best Practices :
Each industry would have developed over years or decades. During this development materials would
have changed and processes would have changed. As all products or services are meant to serve needs
of the customers, they undergo continuous changes both in shapes and features. Materials and
methods go on improving incessantly because of the research that is conducted. The companies that
were at the front innovate to stay in business as new entrants would be adopting the latest techniques
that the pioneers had taken decades to establish. So, the various firms in any industry would end up
adopting almost similar methods of getting an output required. Such practices would get refined to a
great extent giving rise to what we call industry best practices. These tend to get stabilised or changedowing to the development of new equipments which are designed. A manufacturer, with an eye on
growing markets, demands for higher quality and reduced prices. Competition benefits those who can
use all these to their advantage. Industry best practices open up the field for benchmarking by
companies which need to improve their performance.
The following are the types of benchmarking considered by various firms.
Process Benchmarking Business Process Financial Benchmarking Performance Benchmarking
Product Benchmarking Strategic Benchmarking Functional Benchmarking Tools like Pareto Analysis
(an example is shown in figure) are used to make the choice or choices from among many aspects in any
one of the above categories. MB0044: Production & Operations Management Roll No.
510929890
MB0044: Production & Operations Management Roll No. 510929890
Example of Pareto Analysis
1.
Planning:
Planning determines the process, service or the product to be benchmarked on which metrics are
assigned for collection of data. 2.
Analysis:
-
8/3/2019 SMU Assignment paper-MB0044
22/58
Analysed data gives inputs for comparison with the target companys performance on the parameter
benchmark on which data was collected. Measuring gaps helps in identifying the process which should
be improved for reaching the benchmark. 3.
Integration:
Resources are required across all functions to achieve the target needs. Integration involves putting
together resources like people, equipments, and communication, so that, progress is unhindered and all
activities reach their logical conclusions without loss of initiative or time. 4.
Action:
When changes are needed, actions have to be planned according to the steps earlier stated. Teams are
provided with necessary leadership, authority, and supporting facilities to enable them to complete all
activities within the time frame set for the purpose. Since benchmarking is done in specific areas, it is
necessary to maintain the focus, and implement actions without losing initiative, so that, results become
demonstrable.
MB0044: Production & Operations Management Roll No. 510929890
3. List out the various automated systems for transfer of materials in the production plant. What do you
understand by Line Balancing? Explain with an example.
Answer: Automated Flow Lines
When several automated machines are linked by a transfer system which moves the parts by using
handling machines which are also automated, we have an automated flow line. After completing an
operation on a machine, the semi-finished parts are moved to the next machine in the sequence
determined by the process requirements and a flow line is established. The parts at various stages from
raw material to ready for fitment or assembly are processed continuously to attain the required shapes
or acquire special properties to enable them to perform desired functions. The materials need to be
moved, held, rotated, lifted, and positioned for completing different operations. Sometimes, a few of
the operations can be done on a single machine with a number of attachments. They are moved further
to other machines for performing further operations. Human intervention may be 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.
The main consideration is to balance times that different machines take to complete the operations
assigned to them. It is necessary to design the machines in such a way that, the operation times are the
same throughout the sequence in the flow of the martial. In fixed automation or hard automation,
where one component is manufactured using several operations and machines, it is possible to achieve
-
8/3/2019 SMU Assignment paper-MB0044
23/58
this condition. We assume that product life cycles are sufficiently stable to invest heavily on the
automated flow lines to achieve reduced cost per unit.
Automated Assembly Lines
All equipments needed to make a finished product are laid out in such a way as to follow the sequence
in which the parts or sub-assemblies are put together and fitted. Usually, a frame, body, base will be the
starting point of an assembly. The frame itself consists of a construction made up of several components
and would have been assembled
or fabricated
in a separate bay or plant and brought to the assembly line. All parts or subassemblies are fitted to
enable the product to be in readiness to perform the function it was designed to. This process is called
assembly. Methodologies of achieving the final result may vary, but the basic principle is to fit all parts
together and ensure linkages so that their functions are integrated and give out the desired output.
MB0044: Production & Operations Management Roll No. 510929890
MB0044: Production & Operations Management Roll No. 510929890
MB0044: Production & Operations Management Roll No. 510929890
Line balancing
: Line and work cell balancing is an effective tool to improve the throughput of assembly lines and work
cells while reducing manpower requirements and costs. Assembly Line Balancing, or simply Line
Balancing (LB), is the problem of assigning operations to workstations along an assembly line, in such a
way that the assignment be optimal in some sense. Ever since Henry Fords introduction of assembly
lines, LB has been an optimization problem of significant industrial importance: the efficiency difference
between an optimal and a sub-optimal assignment can yield economies (or waste) reaching millions of
dollars per year. LB is a classic Operations Research (OR) optimization problem, having been tackled by
OR over several decades. Many algorithms have been proposed for the problem. Yet despite the
practical importance of the problem, and the OR efforts that have been made to tackle it, little
commercially available software is available to help industry in optimizing their lines. In fact, according
to a recent survey by Becker and Scholl (2004), there appear to be currently just two commercially
available packages featuring both a state of the art optimization algorithm and a user-friendly interface
for data management. Furthermore, one of those packages appears to handle only the clean
formulation of the problem (Simple Assembly Line Balancing Problem, or SALBP), which leaves only one
package available for industries such as automotive. This situation appears to be paradoxical, or at least
-
8/3/2019 SMU Assignment paper-MB0044
24/58
unexpected: given the huge economies LB can generate, one would expect several software packages
vying to grab a part of those economies. A typical example are operations that require the vehicle to be
elevated above the operators: such operations can only be assigned to workstations with enough space
to contain the elevated vehicle. Zoning constraints are typical in the automotive industry any
algorithm to be applied there must support them.
4. Explain the different types of Quality Control Tools with examples? How do Crosbys absolutes of
quality differ from Demings principles?
Answer: Quality Control Tools
Flow Chart, Check sheet, Histogram, Pareto Analysis, Scatter Diagram, Control Chart, and Cause and
Effect Diagram are the basic seven control tools considered for achieving quality.
MB0044: Production & Operations Management Assignment Set I
Note: Each question carries 10 Marks. Answer all the questions.
1. What are the components of systems productivity? Explain how CAD and CIM help in improving
productivity.
Answer:
System Productivity
Enhancement of productivity is achieved by either reducing the inputs for the same output or
increasing the output by using the same input. Productivity can be calculated for a: Single operation
Functional unit Department or division Plant Productivity is a measure of the efficiency of the
system and looks at the economies achieved during the processes. Every process will have a number of
contributors which help in achieving maximum productivity. The processes are: People, Machines,
Facilitating goods, Ancillary equipments, and Technology. Each of these elements attempts to enhance
the contribution of other elements. Opportunities exist at all stages of the workflow in the entiresystem to introduce measures for increasing productivity. However in actual manufacturing situations,
the inefficiencies will have cascading effect in hampering productivity. Communication, effective review
processes and innovative methods will ensure optimisation of resources. Building up reliability into the
equipments, managing the supply chain to economise on the cost factors improves productivity. Quality
circles are very efficient in incorporating low cost and non-intrusive methods of improving productivity
and quality throughout the organisation. Quality circles:
-
8/3/2019 SMU Assignment paper-MB0044
25/58
Involve all persons who are actually involved in the production system and the information they elicit
and bring about improvements that are highly cost effective
Unveil creativity and encourage team work and bring about improvements almost on a day to day basis
Bring continuous incremental changes in a harmonious way instead of dramatic changes
Encourage identification of possible failures and seek methods of preventing things going wrong
Computers in Design CAD
MB0044: Production & Operations Management Roll No. 510929890
Designs of products are increasingly depending on Computer Aided Design (CAD). It is an electronic
system for designing new parts or products or altering existing ones, replacing drafting traditionally
done by hand. The designs are made using powerful desktop computers and graphics software. Designer
can create drawings and view them from any angle on a display monitor. Images of different
components can be seen as assembled; sections taken and relative positions can be checked to great
accuracies. Views can be made from different angles and positions, so that the visualisation process of
the designed component/product helps the designer to suggest alternatives to the customer and the
production department.
The drawings can be sent via intranet or internet to the concerned persons and their opinions taken.
Corrections and incorporations can be made very quickly. The computer can also simulate the reaction
of a part to strength and stress tests. Using the design data stored in the computers memory,
manufacturing engineers and other users can quickly obtain printouts of plans and specifications for a
part or product. The software can generate the volume, weights of components as also other
engineering parameters like centre of gravity, deflections under estimated loads, and various other
design parameters on complicate forms, either for single components or assemblies. Laborious
mechanical drawings or complicated calculations need not be drawn for people using this software. The
database can be prepared, updated continuously and their access to executive. Analysts use CAD tostore, retrieve, and classify data about various parts. CAD helps to increase the efficiency of a designers
work. This aids in reducing the time required for making a design or modifying a product and thus
concept market period gets drastically cut. This implementation also cuts the cost of product
development and sharply reduces the time to market new products. It saves time by enabling designers
to access and modify old designs quickly, rather than start from scratch.
Computer integrated manufacturing (CIM)
-
8/3/2019 SMU Assignment paper-MB0044
26/58
Integration occurs when a broad range of manufacturing and supporting activities are linked. CIM is the
complete automation of a manufacturing plant, with al l processes functioning under computer control
and digital information tying them together. The three major functions in manufacturing are production,
design, and management function. Production function converts resources into products. The design
function transforms customer specifications into design. Finally the management functions plan and
control production activities. The three computer aids in CIM are:
Computer aid to the production function (automated flow of materials)
Computer aid to the design function (automated flow of technological information)
Computer aid to the management function (automated flow of managerial information) When it
comes to production, CIMs are included in different areas of production process such as in engineering
design, production planning, shop control, order processing, material control, distribution and many
other areas. Information flow across all the functions takes place with the help of computers.
Transmission, processing, distribution, and feedback happen almost in real time so that intended
MB0044: Production & Operations Management Roll No. 510929890
activities are conducted rapidly.
CIM process helps in rapid production and also reduces indirect costs. CIM uses computers to control
the entire production process. This integration allows the processes to exchange information with each
other and thus they become capable of initiating actions. As response times decrease, customer
satisfaction increases resulting in better business. CIM helps in avoiding accumulation of materials
resulting in better throughput and better utilisation of space. Bar coded labels that accompany materials
contain instructions for processing them which are read by sensing devices and display the status on
monitors. This information is available to all concerned personnel responsible in planning, marketing
and other activities so that they will be aware of the status of any order. If expediting is needed to meet
deadlines, they will be able to seek intervention. Identifying shortages and ensuring faster deliveries
become easy with CIM.
2. What do you understand by industry best practice? Briefly explain different types of Benchmarking.
Answer: Industry Best Practices :
Each industry would have developed over years or decades. During this development materials would
have changed and processes would have changed. As all products or services are meant to serve needs
of the customers, they undergo continuous changes both in shapes and features. Materials and
-
8/3/2019 SMU Assignment paper-MB0044
27/58
methods go on improving incessantly because of the research that is conducted. The companies that
were at the front innovate to stay in business as new entrants would be adopting the latest techniques
that the pioneers had taken decades to establish. So, the various firms in any industry would end up
adopting almost similar methods of getting an output required. Such practices would get refined to a
great extent giving rise to what we call industry best practices. These tend to get stabilised or changed
owing to the development of new equipments which are designed. A manufacturer, with an eye on
growing markets, demands for higher quality and reduced prices. Competition benefits those who can
use all these to their advantage. Industry best practices open up the field for benchmarking by
companies which need to improve their performance.
The following are the types of benchmarking considered by various firms.
Process Benchmarking Business Process Financial Benchmarking Performance Benchmarking
Product Benchmarking Strategic Benchmarking Functional Benchmarking Tools like Pareto Analysis
(an example is shown in figure) are used to make the choice or choices from among many aspects in any
one of the above categories. MB0044: Production & Operations Management Roll No.
510929890
MB0044: Production & Operations Management Roll No. 510929890
Example of Pareto Analysis
1.
Planning:
Planning determines the process, service or the product to be benchmarked on which metrics are
assigned for collection of data. 2.
Analysis:
Analysed data gives inputs for comparison with the target companys performance on the parameter
benchmark on which data was collected. Measuring gaps helps in identifying the process which should
be improved for reaching the benchmark. 3.
Integration:
Resources are required across all functions to achieve the target needs. Integration involves putting
together resources like people, equipments, and communication, so that, progress is unhindered and all
activities reach their logical conclusions without loss of initiative or time. 4.
Action:
When changes are needed, actions have to be planned according to the steps earlier stated. Teams are
provided with necessary leadership, authority, and supporting facilities to enable them to complete all
-
8/3/2019 SMU Assignment paper-MB0044
28/58
activities within the time frame set for the purpose. Since benchmarking is done in specific areas, it is
necessary to maintain the focus, and implement actions without losing initiative, so that, results become
demonstrable.
MB0044: Production & Operations Management Roll No. 510929890
3. List out the various automated systems for transfer of materials in the production plant. What do you
understand by Line Balancing? Explain with an example.
Answer: Automated Flow Lines
When several automated machines are linked by a transfer system which moves the parts by using
handling machines which are also automated, we have an automated flow line. After completing an
operation on a machine, the semi-finished parts are moved to the next machine in the sequence
determined by the process requirements and a flow line is established. The parts at various stages from
raw material to ready for fitment or assembly are processed continuously to attain the required shapes
or acquire special properties to enable them to perform desired functions. The materials need to be
moved, held, rotated, lifted, and positioned for completing different operations. Sometimes, a few of
the operations can be done on a single machine with a number of attachments. They are moved further
to other machines for performing further operations. Human intervention may be 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.
The main consideration is to balance times that different machines take to complete the operations
assigned to them. It is necessary to design the machines in such a way that, the operation times are the
same throughout the sequence in the flow of the martial. In fixed automation or hard automation,
where one component is manufactured using several operations and machines, it is possible to achieve
this condition. We assume that product life cycles are sufficiently stable to invest heavily on the
automated flow lines to achieve reduced cost per unit.
Automated Assembly Lines
All equipments needed to make a finished product are laid out in such a way as to follow the sequence
in which the parts or sub-assemblies are put together and fitted. Usually, a frame, body, base will be the
starting point of an assembly. The frame itself consists of a construction made up of several components
and would have been assembled
or fabricated
-
8/3/2019 SMU Assignment paper-MB0044
29/58
in a separate bay or plant and brought to the assembly line. All parts or subassemblies are fitted to
enable the product to be in readiness to perform the function it was designed to. This process is called
assembly. Methodologies of achieving the final result may vary, but the basic principle is to fit all parts
together and ensure linkages so that their functions are integrated and give out the desired output.
MB0044: Production & Operations Management Roll No. 510929890
MB0044: Production & Operations Management Roll No. 510929890
MB0044: Production & Operations Management Roll No. 510929890
Line balancing
: Line and work cell balancing is an effective tool to improve the throughput of assembly lines and work
cells while reducing manpower requirements and costs. Assembly Line Balancing, or simply Line
Balancing (LB), is the problem of assigning operations to workstations along an assembly line, in such a
way that the assignment be optimal in some sense. Ever since Henry Fords introduction of assembly
lines, LB has been an optimization problem of significant industrial importance: the efficiency difference
between an optimal and a sub-optimal assignment can yield economies (or waste) reaching millions of
dollars per year. LB is a classic Operations Research (OR) optimization problem, having been tackled by
OR over several decades. Many algorithms have been proposed for the problem. Yet despite the
practical importance of the problem, and the OR efforts that have been made to tackle it, little
commercially available software is available to help industry in optimizing their lines. In fact, according
to a recent survey by Becker and Scholl (2004), there appear to be currently just two commercially
available packages featuring both a state of the art optimization algorithm and a user-friendly interface
for data management. Furthermore, one of those packages appears to handle only the clean
formulation of the problem (Simple Assembly Line Balancing Problem, or SALBP), which leaves only one
package available for industries such as automotive. This situation appears to be paradoxical, or at least
unexpected: given the huge economies LB can generate, one would expect several software packages
vying to grab a part of those economies. A typical example are operations that require the vehicle to be
elevated above the operators: such operations can only be assigned to workstations with enough space
to contain the elevated vehicle. Zoning constraints are typical in the automotive industry any
algorithm to be applied there must support them.
4. Explain the different types of Quality Control Tools with examples? How do Crosbys absolutes of
quality differ from Demings principles?
Answer: Quality Control Tools
Flow Chart, Check sheet, Histogram, Pareto Analysis, Scatter Diagram, Control Chart, and Cause and
Effect Diagram are the basic seven control tools considered for achieving quality.
-
8/3/2019 SMU Assignment paper-MB0044
30/58
MB0044: Production & Operations Management Roll No. 510929890
Quality Control Tools
a)
Flow Chart
: Flow chart is a visual representation of process showing the various steps. It helps in locating the points
at which a problem exists or an improvement is possible. Detailed data can be collected, analysed, and
methods for correction can be developed using flow charts. The various steps include: Listing out the
various steps or activities in a particular job Classifying them as a procedure or a decision Each
decision point generates alternatives. Criteria and consequences that go with decisions are amenable to
evaluation for purposes of assessing quality. The flow chart helps in pin-pointing the exact points at
which errors have crept in.
Sample flow chart
b)
Check Sheet
: Check sheets are used to record the number of defects, types of defects, locations at which they are
occurring, times at which they are occurring, and workmen by whom they are occurring. The sheet
keeps a record of the frequencies of occurrence with reference to possible defect causing parameters. Ithelps to implement a corrective procedure at the point where the frequencies are more.
The table shows that the number of defects 1 and 5 are not many as compared to defect no 2
which increased over the days and appears to be stabilising at the higher
MB0044: Production & Operations Management Roll No. 510929890
side and therefore needs to be attended immediately. The column which shows days can be changed to
observed by the hour, if need be. c)
Histogram
Histograms are graphical representations of distribution of data. They are generally used to record huge
volumes of data about a process. They reveal whether the pattern of distribution has a single peak, or
many peaks and also the extent of variation around the peak value. This helps in identifying whether the
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problem is serious. When used in conjunction with comparable parameters, the visual patterns help us
to identify the problem which should be attended to.
Sample histogram chart
The values shown are the number of observations made regarding a parameter. Sometimes, the
percentages are shown to demonstrate the relative contribution of each of the parameters. d)
Pareto Analysis
: Pareto analysis is a tool for classifying problem areas according to the degree of importance and
attending to the most important. Pareto principle, also called 8020 rule, states that 80 percent of the
problems that we encounter arise out of 20 percent of items. If we find that, in a day, we have 184
assemblies having problems and there are 11 possible causes, it is observed that 80 percent of them,
that is, 147 of them have been caused by just 2 or 3 of them. It will be easy to focus on these 2 or 3 and
reduce the number of defects to a great extent. When the cause of these defects has been attended, we
will observe that some other defect becomes predominantly observed and if the process is continued,we are marching toward zero defects. e)
Scatter Diagram
: Scatter diagram is used when we have two variables and want to know the degree of relationship
between them (See Figure 6.5 for Sample scatter diagram). We can determine if there is cause and
effect relationship between the variables and the degree of extent over a range of values of the
variables. Sometimes, we can observe that there is no relationship, in which we can change one
parameter being sure that it has no effect on the other parameter.
MB0044: Production & Operations Management Assignment Set I
Note: Each question carries 10 Marks. Answer all the questions.
1. What are the components of systems productivity? Explain how CAD and CIM help in improving
productivity.
Answer:
System Productivity
Enhancement of productivity is achieved by either reducing the inputs for the same output or
increasing the output by using the same input. Productivity can be calculated for a: Single operation
Functional unit Department or division Plant Productivity is a measure of the efficiency of the
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system and looks at the economies achieved during the processes. Every process will have a number of
contributors which help in achieving maximum productivity. The processes are: People, Machines,
Facilitating goods, Ancillary equipments, and Technology. Each of these elements attempts to enhance
the contribution of other elements. Opportunities exist at all stages of the workflow in the entire
system to introduce measures for increasing productivity. However in actual manufacturing situations,
the inefficiencies will have cascading effect in hampering productivity. Communication, effective review
processes and innovative methods will ensure optimisation of resources. Building up reliability into the
equipments, managing the supply chain to economise on the cost factors improves productivity. Quality
circles are very efficient in incorporating low cost and non-intrusive methods of improving productivity
and quality throughout the organisation. Quality circles:
Involve all persons who are actually involved in the production system and the information they elicit
and bring about improvements that are highly cost effective
Unveil creativity and encourage team work and bring about improvements almost on a day to day basis
Bring continuous incremental changes in a harmonious way instead of dramatic changes
Encourage identification of possible failures and seek methods of preventing things going wrong
Computers in Design CAD
MB0044: Production & Operations Management Roll No. 510929890
Designs of products are increasingly depending on Computer Aided Design (CAD). It is an electronic
system for designing new parts or products or altering existing ones, replacing drafting traditionally
done by hand. The designs are made using powerful desktop computers and graphics software. Designer
can create drawings and view them from any angle on a display monitor. Images of different
components can be seen as assembled; sections taken and relative positions can be checked to great
accuracies. Views can be made from different angles and positions, so that the visualisation process of
the designed component/product helps the designer to suggest alternatives to the customer and theproduction department.
The drawings can be sent via intranet or internet to the concerned persons and their opinions taken.
Corrections and incorporations can be made very quickly. The computer can also simulate the reaction
of a part to strength and stress tests. Using the design data stored in the computers memory,
manufacturing engineers and other users can quickly obtain printouts of plans and specifications for a
part or product. The software can generate the volume, weights of components as also other
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engineering parameters like centre of gravity, deflections under estimated loads, and various other
design parameters on complicate forms, either for single components or assemblies. Laborious
mechanical drawings or complicated calculations need not be drawn for people using this software. The
database can be prepared, updated continuously and their access to executive. Analysts use CAD to
store, retrieve, and classify data about various parts. CAD helps to increase the efficiency of a designers
work. This aids in reducing the time required for making a design or modifying a product and thus
concept market period gets drastically cut. This implementation also cuts the cost of product
development and sharply reduces the time to market new products. It saves time by enabling designers
to access and modify old designs quickly, rather than start from scratch.
Computer integrated manufacturing (CIM)
Integration occurs when a broad range of manufacturing and supporting activities are linked. CIM is the
complete automation of a manufacturing plant, with al l processes functioning under computer control
and digital information tying them together. The three major functions in manufacturing are production,
design, and management function. Production function converts resources into products. The design
function transforms customer specifications into design. Finally the management functions plan and
control production activities. The three computer aids in CIM are:
Computer aid to the production function (automated flow of materials)
Computer aid to the design function (automated flow of technological information)
Computer aid to the management function (automated flow of managerial information) When it
comes to production, CIMs are included in different areas of production process such as in engineering
design, production planning, shop control, order processing, material control, distribution and many
other areas. Information flow across all the functions takes place with the help of computers.
Transmission, processing, distribution, and feedback happen almost in real time so that intended
MB0044: Production & Operations Management Roll No. 510929890
activities are conducted rapidly.
CIM process helps in rapid production and also reduces indirect costs. CIM uses computers to controlthe entire production process. This integration allows the processes to exchange information with each
other and thus they become capable of initiating actions. As response times decrease, customer
satisfaction increases resulting in better business. CIM helps in avoiding accumulation of materials
resulting in better throughput and better utilisation of space. Bar coded labels that accompany materials
contain instructions for processing them which are read by sensing devices and display the status on
monitors. This information is available to all concerned personnel