SMU Assignment paper-MB0044

8/3/2019 SMU Assignment paper-MB0044

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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




productivity.

Answer:

System Productivity














Involve all persons who are actually involved in the production system and the information they elicitand bring about improvements that are highly cost effective



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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


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




productivity.

Answer:

System Productivity















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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









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





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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,





























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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












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


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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.




productivity.

Answer:

System Productivity



















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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








design, and management function. Production function converts resources into products. The designfunction transforms customer specifications into design. Finally the management functions plan and




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one of the above categories. MB0044: Production & Operations Management Roll No.510929890



1.

Planning:



Analysis:




Integration:




Action:





demonstrable.


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




productivity.

Answer:

System Productivity





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the designed component/product helps the designer to suggest alternatives to the customer and theproduction department.







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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







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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










510929890



1.

Planning:



Analysis:


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Integration:




Action:





demonstrable.








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







established.






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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.





productivity.

Answer:

System Productivity






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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







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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









510929890



1.

Planning:



Analysis:


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Integration:




Action:





demonstrable.
















established.






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or fabricated








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


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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.




productivity.

Answer:

System Productivity







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,







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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







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510929890



1.

Planning:



Analysis:




Integration:




Action:




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demonstrable.
















established.












or fabricated


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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.


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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


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.




productivity.

Answer:

System Productivity





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the designed component/product helps the designer to suggest alternatives to the customer and theproduction department.







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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





monitors. This information is available to all concerned personnel

SMU Assignment paper-MB0044

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