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OPERATIONS MANAGEMENT– OPM16101

UNIT  CONTENTS

1 Operations  Management:  An  Introduction:  Meaning;  Importance;  Historical

Contributions,   Scientific  Management  –  Time  and  Motion  Studies,  World  War  II  to  the 1960?s  –  Operations Research, The 1970s and 1980s –  Japanese Challenge, The 1990s and After; Systems View of Operations Management; Transformation Approach, Value Driven Approach,  Operations  Management  Basics;  Functions  of  Operations  Manager,  Interface with  Other  Functions,  Operations  Management?s  Future  Challenges;  Efficiency  and Effectiveness.

2 Facility  Location:  Need  for  a  Facility  Location  Planning;  Nature  of  Location  Decisions,Types of Facilities; Factors Affecting Location Decisions, Factors Affecting Manufactured Products,  Factors  Affecting  Service  Products;  Selection  of  Site  for  the  Plant,  Country, State/District,  Plant  Location;  Procedures  for  Location  Decisions,  Facility  Master  Plan, Impact Planning, Site Evaluation.

3Types  of  Manufacturing  Systems  :  Production  Systems,  What  is  Effective  Production Management?; Types of Production Systems, Project, Job Shop,   Batch  Production (Disconnected  Line),  Assembly  Line,  Continuous  Flow,  Cell  Manufacturing  (Group Technology),  Flexible  Manufacturing  Systems  (FMS);  Production  System  and  its Environment.

4Plant  Layout:  Facility  Layout;  Types  of  Layout;  Process  Layout,  Process  Layout  and Material  Handling  Costs,  Process  Layout  in  Nokia,  Advantages  and  Disadvantages  of Process  Layout;  Product  or  Line  Layout,  Assembly  Line,  Defining  The  Layout  Problem, Assembly Line Balancing, Graphic and Schematic Analysis, Limitations of Product Layout; Fixed  Layout;  Cellular  or  Group  Layout,  The  U-shaped  Assembly  Line,  Advantages  and Disadvantages,  Comparison  of  Layouts;  New  Approaches  to  Layout  Design,  Flexibility, Mixed-model Line; Material Handling, Objectives of Materials Handling, Types of Material Handling  Equipment,  New  Developments,  Guidelines  and  Principles  for  Materials Handling; Operations Decisions .

5 Production  Planning  and  Control:  Meaning  of  Production  Planning;  Functions  of Production  Planning  and  Control;  Master  Production  Schedule;  Material  Requirement Planning  (MRP),  Assumptions and  Pre-requisites,  Material  Planning,  MRP  Process,  MRP System,  Benefits  of  MRP  System,  Outputs  –  The  Materials  Requirement  Plan,  Priority Planning;  Capacity  Requirement  Planning;  Process  Planning;  Maintenance  Management Concepts, Operations and Maintenance Contracts.

6 Material Management: Material Management, Procurement, Make or Buy, Receiving and Dispatch; Material Planning, Factors Affecting Material Planning, Techniques of Planning Materials;  Inventory  Control,  Reasons  for  Maintaining  Inventory,  The  Eyeball  System, Reserve  Stock  (or  Brown  Bag)  System,  Perpetual  Inventory  Systems,  Stock  Control, Inventory  Control  Records;  Controlling  Inventory,  Step  1:  Inventory  Planning,  Step  2: Establish Order Cycles, Step 3: Balance Inventory Levels, Step 4: Review Stocks, Step 5: Follow-up  and  Control;  Budgeting  and  Material  Requirement  Planning;  Purchase Management, Purchasing Interfaces, Purchasing Cycle; Store Management.

7 Inventory  Control  and  Management:  Importance  of  Inventory,  Manufacturing  of

Inventory,  Functions  of  Inventory;  Inventory  Costs, Holding  (or  Carrying)  Costs,  Cost  of  Ordering,  Setup  (or  production  change)  Costs,  Shortage  or  Stock-out  Costs;  Inventory Classification,  ABC  Classification,  Other  Models;  Fundamental  Approaches  to  Manage  Inventory,  Key  Differences  among  Approaches  to  Managing  Inventory;  Fixed -order  Quantity  Approach,  Fixed-order  Quantity  Modeling,  Inventory  Model  with  Uncertainty, Fixed-order Interval Approach.

8 Quality Control: What is Quality? Definition of Quality; Quality Control; Quality Purpose; Quality  Assurance;  Acceptance  Sampling;  Statistical  Quality  Control,  Collection  and Presentation  of  Data,  Major  Statistical  Measures  for  “Central  Tendency”,  Chance  and Assignable  Causes  of  Variations,  Process  Capability  Defined,  Control  Charts  in  Process Control,  Techniques  of  Statistical  Quality  Control  (SQC);  Control  Charts  for  Variables; Control Charts for Attributes; Quality Circles.

9 Quality Management:  Total Quality Management; Quality Management Function, Where to  Inspect?  How  much  to  Inspect?  Control  of  Inspection  Costs,  TQM  Approach;  Service Quality Measurement; Eight Building Blocks of TQM; Different Pillars of TQM, Pillar 1: Synergistic Relationships, Pillar 2: Continuous Improvement and Self Evaluation, Pillar 3: A  System  of  Ongoing  Process,  Pillar  4:  Leadership;  International  Standards;  Essence  of International  Standards;  Overview  of  ISO  Standards;  ISO  9000  Quality  Standard, Conformance  and  Guidance  Standards,  ISO  Standard  Series  and  Some  Other  Standards, Elements of the ISO Standards,  ISO  9000  Quality  System  Certification;  Six  Sigma, Meaning and Definitions, Historical background and Development of Six Sigma, Statistical Framework  for  Six  Sigma,  DPU  and  DPMO  concepts,  DMAIC  Model,  Training  for  Six Sigma, Benefits of Six Sigma.

10 Work  Study:  Work  Study;  Why  Work  Study  Valuable?; Techniques  of Work  Study  and Relationship;  Basic  Procedure  of  Work  Study;  Work  Study  and  Production  Management; Advantages of Work Study; Applications of Work Study; Method Study; Need for Method Study;  Procedure  for  Method  Study;  Charts  used  in  Method  Study,  Types  of  Charts; Diagrams  used  in  Method  Study;  Symbols  used  in  Method  Study;  Objectives  of  Method Study; Scope of Method Study; Time Study; Principles of Motion Study, Use of the Human Body,   Arrangement of the Workplace,   Design of Tools and Equipment.

11Work  Measurement:  Work  Measurement,  Work  Sampling  Method,  Elemental  Standard Data Approach; Components of Work Measurement; Work Measurement Methods; What is the  Need  of  Work  Measurement?;  Work  Measurement  Techniques,  Time  Study,  Work Sampling,  Work  Sampling  Compared  to  Time  Study;  Standard  Time;  Computation  of Standard Time; Industrial Safety.