Production And Operations Management

SECTION 1 STRATEGY TO MANAGE BUSINESS DYNAMICS
	1 Understanding Production and Operations Management
		Introduction
		Production
		Increasing the ‘Value’ of Business through Operations
		Production System and Other Functions
		Evolution of Production and Operations Management
		Production Management
		Organization of Production Function
		Operations Management
		Significance of Production and Operations Management in Business
		Manufacturing Vs Service Operations
		Manufacturing Operations
		Service Operations
		Differences between Production and Operations Management
		Kinds of Production Systems
		Nature and Types of Decision-Making in Production and Operations Management
		Functions of Production and Operations Management
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		References
		Hints and Answers
	2 Operations: Policy and Strategy
		Introduction
		Strategic Management Process for Production and Operations
		Setting the Operations Strategy
		Implications for Operations Strategy
		Components of Operations Strategy
		Productivity
		Factors Improving Productivity
		Business Productivity
		Productivity: The Two Aspects
		Production Function
		Wastivity
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		Numerical Problems
		References
		Hints and Answers
	3 International Production and Operations Management
		Introduction
		International Production and Operations Management
		Evolution of Industrialization in Global Scenario
		Nature of IPOM
		Objectives of IPOM
		Importance of IPOM
		Comparison between Domestic and International POM
		Strategic Aspects in IPOM
		Business Process Outsourcing
		Knowledge Process Outsourcing
		Supply Chain Management
		Transfer of World Class Technology
		Recapitulation
		Key Terms
		Objective Type Questions
		Questions for Discussion
		References
		Hints and Answers
	4 Managing Technology in Operations Management
		Introduction
		Technology and Operations Management (TOM)
		Integrating Technology with Production System
		Technology in Manufacturing
		Managerial Issues
		Use of Technology in Design
		Major Categories of Software Systems in Manufacturing
		Functional Areas as Independent Operations
		Automation in Production and Operations
		Automation Tools
		Management of Technology
		Technology Management Process Assessment
		Technology as a Strategy to Gain Competitive Advantage
		Categories of E-Services
		Challenges for Technology and Operations Management
		Operations Management Software
		Key Issues and Challenges
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		References
		Hints and Answers
	5 Value Analysis: An Applied Concept for Manufacturing and Service Industry
		Introduction
		Basic Features of Value Analysis
		Objectives of Value Analysis
		Importance of Value Analysis
		Benefits of Value Analysis
		Value Analysis as a Multidisciplinary Approach
		Activities for Value Analysis
		VA Team Selection
		Value Analysis Job Plan
		Function Analysis System Technique (FAST)
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		References
		Hints and Answers
SECTION 2 PRODUCT AND PROCESS DESIGN AND DEVELOPMENT
	6 Effective Product Design
		Introduction
		What is Good Design?
		Objectives of Product Design
		Guiding Principles in Designing the Product
		Importance of Product Design
		Factors Affecting Product Design
		Key Issues in Product Design
		Product Selection
		Product Development Process
		An Effective Product Design Process
		Essential Features of Product Development Process
		Industrial Design Involvement
		Managing Industrial Design
		Various Design Considerations
		Concurrent Engineering
		Service Design
		Challenges in Product and Service Design
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		References
		Hints and Answers
	7 Process Design and Analysis
		Introduction
		The Process
		Kudos Process Development Model
		Process Planning
		Criteria for Classification of Conversion Process
		Types of Non-Manufacturing (Services) Operations
		Manufacturing Process for Tangible Products
		Process Design
		Flexible Manufacturing System (FMS)
		Process Flow Chart: An Overview
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		References
		Hints and Answers
	8 Integrated Product and Process Development
		Introduction
		Integrated Product Design Process
		Elements of IPPD Process
		Factors Influencing IPPD Decisions
		Tools of the IPPD Process
		Inter-relationship of Product Design and Process Design
		Principles of IPPD
		Integrated Product Teams (IPTs)
		Characteristics of Implementation
		IPPD to Other Practices
		Optimizing Product and Process Design
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		References
		Hints and Answers
	9 Project Management
		Introduction
		Concept of a Project
		Nature of Projects
		Characteristics of a Project
		Categories of Projects
		Examples of Projects
		Project Life Cycle
		Project Management
		Project Management Activities
		Importance of Project Management
		Project Organization
		Project Management Techniques
		Activity Cost-Time Trade-offs (Crashing)
		Scheduling of Service Projects
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		References
		Hints and Answers
	10 Facility Location
		Introduction
		Location Viewpoints
		Definition of Facility Location
		Possible Mistakes in Selecting the Site
		Strategic Importance of Facility Location
		Competitive Excellence in Facility Location
		Trends in Location Strategy
		Factors Influencing the Facility Location
		Important Criteria for Location
		Determining the Size and Capacity of the Facility
		Facility Location Procedure
		Location Selection Methods
		Services
		Evaluation Techniques of various Locations
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		References
		Hints and Answers
	11 Demand Forecasting
		Introduction
		Forecasting
		Utility of a Forecast
		Time Frame of Forecasts
		Major Characteristics Applicable to Various Forecasts
		Objectives of Demand Forecasting
		Forecasting Procedure
		Measuring Forecast Errors
		Criteria for Selecting a Forecasting Method
		Focus Forecasting
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		For Discussion
		References
		Hints and Answers
	12 Capacity Planning
		Introduction
		Strategic Capacity Planning
		Importance of Capacity Decisions
		Setting up Production Capacity in an Organization
		Measuring Capacity
		Goal of Capacity Planning
		Determinants of Effective Capacity
		Need for Capacity Planning
		Forecasting Demand for Capacity Planning
		Sources of Capacity
		Make or Buy Decisions to Enhance Capacity
		Economics of Scale in Capacity Planning
		Constraints in Capacity Planning
		Production Scheduling
		Input/Output Control
		Finite Material and Capacity Planning
		Capacity Control
		Capacity Planning Terminology
		Capacity Strategy
		Capacity Utilization
		Sizing Capacity Cushion
		Capacity Focus
		Capacity Flexibility
		Planning Service Capacity
		Key Decisions of Capacity Planning
		New Models of Capacity Planning with Dynamic Environment
		CP Tools and Limitations
		Centralized Vs Hybrid Capacity Planning
		Global and Indian Trends
		Future of Capacity Planning
		Capacity Alternatives
		Approaches to Finding Out Optimum Capacity
		Failure of Capacity Planning
		Capacity Planning Problem
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		References
		Hints and Answers
	13 Facility Layout
		Introduction
		Facility Layout
		Techniques of Design Layout
		Facility Layout Planning
		Facility Layout and Its Design
		The Procedure
		Types of Facility Layout
		Assembly Lines
		Assembly Line Balancing
		Process-Oriented Facility Layout (Job Shop/Functional Layout)
		Comparison of Product Layout and Process Layout
		Fixed Position Layout
		Cellular/Group Technology Layout
		Combined or Hybrid Layout
		Strategic Layout Decision-Making Aspects
		Facility Layout in Manufacturing
		Layout for a Service Business
		Layout for an Office
		Layout for Commercial Outlets
		Layout for a Warehouse
		Systematic Layout Planning
		Determinants for Selection and Design of Layout
		Designing Facilities
		Factory Layout—Focus of Facility Design
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		References
		Hints and Answers
SECTION 4 MEDIUM AND SHORT RANGE PLANNING ISSUES
	14 Aggregate Planning
		Introduction
		Aggregate Planning
		Aggregation
		Equation of Aggregate Planning Problem
		Need for Aggregate Planning
		Involvement of Various Business Functions in Formulating Aggregate Plan
		Aggregate Planning Strategies
		Hybrid Strategy
		Developing Aggregate Plan
		Aggregate Planning Costs
		Techniques for Aggregate Planning
		Approaches to Aggregate Planning
		Objective Techniques to Formulate Aggregate Plan
		Functional Objective Search (FOS) System
		Aggregate Planning in Services
		New Trends in Aggregate Planning
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		Numerical Problems
		References
		Hints and Answers
	15 Materials and Resource Requirement Planning
		Introduction
		Terms Used in MRP
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		Numerical Problems
		References
		Hints and Answers
		Introduction
	16 Production Planning and Control
		Production/Operations Planning and Control (PPC)
		Objectives of Production Planning and Control
		Benefits of Production Planning and Control
		Production Planning
		Production Control
		Production Control System (PCS)
		Importance of Production Planning and Control
		Procedure of Production Planning and Control
		Difference between Production Planning and Production Control
		Classification of Production Planning and Control Functions
		Stages in Production Planning and Control Function
		Production Planning and Control in Different Production Systems
		Elements of Effective Production Planning and Control
		Utility and Benefits of PPC Functions
		Constraints of PPC
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		References
		Hints and Answers
	17 Operations Scheduling and Workplace Planning
		Introduction
		Operations Scheduling
		Workplace Planning and Control
		Production and Operations Scheduling
		Production Planning and Production Scheduling Interface
		Scheduling Process-Focused Manufacturing
		Approaches to Scheduling
		Loading
		Sequencing
		Gantt Charts
		Scheduling Decisions
		Scheduling Product-Focused Manufacturing
		Production Scheduling and Control for Delivery Schedules
		Production Scheduling for High Volume and Continuous Production
		Scheduling Service Operations
		Problems in Service Scheduling
		Kinds of Service Operations
		Master Production Schedule (MPS)
		Workplace Planning and Control
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		Numerical Problems
		References
		Hints and Answers
	18 Waiting Line (Queue) Management
		Introduction
		Waiting Line Problem Economics
		Service Configuration
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		Numerical Problems
		References
		Hints and Answers
	19 Inventory Management and Just-in-Time
		Introduction
		Objectives of Inventory
		Inventory Decisions
		Inventory Models
		Inventory Costs
		Balancing Inventory Carrying Costs against Ordering Costs
		Inventory Management and Control (IMC)
		Inventory Models
		Inventory Control Techniques
		Inventory Management—Evaluating its Efficiency
		Just-in-Time (JIT)
		JIT Manufacturing and JIT Purchasing
		Designing Focused Factories through JIT Production
		Demand Pull System
		Kanban System
		Push System
		Manufacturing Cycle Time (Throughput Time)
		Comparison of JIT and Traditional Systems of Operations
		The JIT Attitude
		Continuous Improvement (Kaizen)
		JIT and Lean Management
		Wastages in Operations
		Tactical Tools of JIT
		JIT Implementation
		JIT in Services
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		Numerical Problems
		References
		Hints and Answers
	20 Supply Chain Management
		Introduction
		Evolution of Supply Chain Management
		Need for Supply Chain Management
		Objectives of Supply Chain Management
		Supply Chain Management and Structure
		Supply Chain Decisions
		Handling the Customer and Supplier Interface for SCM
		Opportunities Created by Supply Chain Management
		Importance of Supply Chain Management
		Elements of Supply Chain Management
		Functions of Supply Chain Management
		Key Issues in Supply Chain Management
		Traditional versus Integrated SCM Approaches
		Supply Chain Management Problems
		Strategies of SCM
		Integrating and Coordinating the Supply Chain
		Integration of Supply Chain Management Components
		Models for Integrated Supply Chain Management
		Creating Supply Chain
		Managing Supply Chain
		Major Process Parameters to Evaluate Supply Chain
		Supply Chain Features and their Dynamics
		Measurement and Evaluation of Supply Chain Efficiency
		Improving SCM through Structural Changes
		Virtual Supply Chain Organizations
		Analytical Hierarchy Process (AHP)
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		References
		Hints and Answers
	21 Warehouse and Materials Management
		Introduction
		Warehouse/Stores Management
		Functions/Scope of Warehouse
		Significance of Warehouse Management
		Warehouse Designing (Layout)
		Measuring Warehouse Efficiency
		Methods of Stock Verification
		Materials Management (MM)
		Materials Planning
		Materials Budgeting and Control
		Standardization
		Simplification
		Classification and Codification
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		References
		Hints and Answers
	22 Materials Handling–Principles, Operations and Equipment
		Introduction
		Materials Handling
		Developing and Organizing Materials Handling
		Classification of Materials Handling Systems
		Factors to be Considered in the Selection of Materials Handling Equipment
		Selection and Placement of Handling System
		Analysis and Evaluation of Materials Handling System and its Effectiveness
		Problem Areas and Safety Measures
		Materials Handling Equipment
		Safety Consideration in Materials Handling
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		References
		Hints and Answers
	23 Maintenance Policy and Repairs
		Introduction
		Maintenance
		Maintenance Management
		Planning and Scheduling of Maintenance
		Areas of Maintenance
		Types of Maintenance
		Other Terms used in Maintenance and epairs
		Maintenance Services
		Possible Deficiencies in Maintenance
		Control Process in Maintenance Management
		Prerequisites of Preventive Maintenance
		Essential Elements of Preventive Maintenance
		Merits and Demerits of Preventive Maintenance
		Total Productive Maintenance (TPM)
		Planned Maintenance Technique (PMT)
		MAPI Method
		Alternatives for Acquiring Machinery
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		References
		Hints and Answers
SECTION 6 QUALITY IMPERATIVES FOR PRODUCTION EXCELLENCE
	24 Quality—A Tool for Achieving Excellence
		Introduction
		Continuous Improvement (KAIZEN)
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		References
		Hints and Answers
	25 Quality Control Techniques
		Introduction
		Acceptance Sampling
		Attribute Sampling
		Sampling Errors
		Statistical Process Control
		Operating Characteristic (OC) Curve
		Six Sigma
		Process Capability
		Taguchi Methods
		ISO-Certification
		ISO-9000: 2000 Series
		ISO-14000 Standards
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		References
		Hints and Answers
	26 World-Class Manufacturing
		Introduction
		Philosophies and Techniques in World-Class Manufacturing
		World-Class Manufacturing
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		References
		Hints and Answers
Section 7 Work ImprovementTechniques
	27 Work Study and Industrial Engineering
		Introduction
		Work Study
		Method Study
		Choosing a Measurement Technique
		Time Study
		Motion Study
		Steps in Work Measurement
		Work Measurement Techniques
		Job Design
		Industrial Engineering (I.E.)
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		Numerical Problems
		References
		Hints and Answers
	28 Quantitative Techniques for Decision-Making
		Introduction
		Progressive Approach to Decision-Making Model
		Optimization-Modelling Process
		Linear Programming
		Integer Programming
		Facility Location
		Decision Trees
		Game Theory: Payoff Table or Matrix (Maximin and Minimax)
		Dealing with Uncertainties and Scenario Modelling
		Theory of Constraints (TOC)
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		Numerical Problems
		References
		Hints and Answers
	29 Learning Curves
		Introduction
		Learning Curve—A Concept
		Plotting Learning Curve
		Learning Curve from Single-Unit Data
		Assistance Score Learning Curve
		Predicted Learning Curve
		Opportunity Cut-off
		Experience Curve
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		Numerical Problems
		References
		Hints and Answers
	30 Reliability and Redundancy
		Introduction
		Types of Failures
		System Availability
		Recapitulation
		Key Terms
		Objective Type Questions
		Review Questions
		Numerical Problems
		References
		Hints and Answers
Appendix A: Learning Curve Tables
Appendix B: Areas of the CumulativeStandard Normal Distribution1
Appendix C
Index