INDIAN INSTITUTE OF MANAGEMENT, LUCKNOW

POST GRADUATE PROGRAMME

COURSE OUTLINE
COURSE: MANUFACTURING SYSTEMS DESIGN Term IV, 2010-
2011
FACULTY: Prof. Rajiv K. Srivastava 2nd Year Elective

1.0 INTRODUCTION AND OBJECTIVES

In today's world of ever-increasing domestic and global competition, it has become apparent
that for significantly improving productivity and quality, it is no longer sufficient to exercise greater
control over existing manufacturing systems: the improvements must begin from system design. The
success achieved by world class manufacturers, notably those in Germany and Japan, has shown that
well conceived and executed manufacturing can be used as a strategic weapon for achieving corporate
and national prosperity. The managers of tomorrow must be aware of the changes that are taking place
in the nature of the manufacturing function worldwide.

This course provides a focus on the design aspects of manufacturing systems as distinct from
the planning and control issues normally addressed in most Operations Management courses. It seeks
to present together the concepts, techniques and solutions relating to manufacturing systems design
based on the choice of competitive priorities. The objectives of the course are:

1. To introduce and familiarize students with contemporary manufacturing systems.

2. To acquaint students with the tools and techniques used in the analysis, design and evaluation
of different types of manufacturing systems.

3. To provide an understanding of the issues involved in the integration of different aspects of

manufacturing, with special reference to the changing competitive priorities.

Literature and computer based assignments will be used from time to time to supplement and
reinforce the concepts and techniques discussed in class.

2.0 SOURCE BOOKS

2.1 Course Book

1. Goldratt, E., and Cox, J., "The Goal: A Process of Ongoing Improvement",
3rd Revised Edition, Productivity & Quality Press Pvt. Ltd. Madras, 2005.

2.2 Main Reference Books

1. Askin, R.G., & Standridge, C., "Modeling and Analysis of Manufacturing Systems", John
Wiley, 1993.

2. Cohen, M.A., & Apte, U.M., "Manufacturing Automation", Irwin, 1997.

3. Hopp, W.J., & Spearman, M.L., "Factory Physics: Foundations of Manufacturing

Management", 2nd Edition, Irwin, 2000.

4. Monden, Y., "The Toyota Production System: A Practical Approach to Production

Management", 2nd Edition, Industrial Engineering & Management Press, 1993.
2.3 Supplementary Reference Books

1. Blackburn, J.D. (Ed.), "Time-Based Competition: The Next Battle Ground in American
Manufacturing", Irwin, 1991.

2. Hall, R.W. & Nakane,J., "Flexibility: Manufacturing Battlefield of the 1990's", Association
for Manufacturing Excellence, 1990.

3. Harmon, R.L., & Peterson, L.D., "Reinventing the Factory", Free Press, 1990.

4. Heragu, S., "Facilities Design", PWS Publishing, 1997.

5. Hirano, H., "JIT Factory Revolution", Productivity Press, 1988.

6. Hitomi, K., "Manufacturing Systems Engineering", 2nd Edition, Taylor & Francis, 1996.

7. Miltenburg, J., "Manufacturing Strategy: How To Formulate and Implement a Winning Plan",
Productivity Press, 1995.

8. Moody, P.E., "Strategic Manufacturing: Dynamic New Directions for the 1990's", Irwin,
1990.

9. Nyman, L.R. (Ed.), "Making Manufacturing Cells Work", Society of Manufacturing

Engineers, 1992.

10. Pine, B.J., "Mass Customization", Harvard Business School Press, 1993.

11. Rembold, U., Nnaji, B., & Storr, A. "Computer Integrated Manufacturing and Engineering",
Addison Wesley, 1993.

12. Sekine, K., "One Piece Flow", Productivity Press, 1990.

13. Suri, R., "Quick Response Manufacturing: A Companywide Approach to Reducing Lead
Times", Productivity Press, 1998.

14. Tompkins, J.A., & White, J.A., "Facilities Planning", 2nd Edition, John Wiley, 1996.

15. Upton, D.M., "Designing, Managing, and Improving Operations", Prentice Hall, 1998.

3.0 EVALUATION

Assignments, Quizzes, Class Participation/ Viva 35%

Mid-Term Examination 30%
Term-End Examination 35%
4.0 SESSION DETAILS
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Session No. Topic
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1 Course Overview and Contemporary Manufacturing Concepts

2 Principles and Types of Manufacturing Systems:

Relationship to Manufacturing Strategy;
Taxonomies;
Features and Applicability of Different Systems;

3-6 Flow Line & Assembly Systems:

Design Issues in Flow/Assembly Lines;
Choice of Cycle Time;
Mixed Model Line Balancing/Sequencing;
Coping With Variability;
Layout, Handling & Work In Process Management

7-10 Group Technology and Cellular Manufacturing Systems:

Grouping Methods;
Cell Design;
Cell Implementation and Operation
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MID-TERM EXAMINATION
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11-12 Factory Physics Concepts in Manufacturing Systems Analysis

13-14 Time Based Manufacturing:

Lead Time Constituents & Reduction;
Improving Speed & Dependability

15-16 Flexibility & Customization in Manufacturing:

Flexibility Concepts;
Flexible Manufacturing Systems (FMS);
Customization & Mass Customization

17-18 Designing Material Flow & Information Systems

One Piece Flow and Facilities Design;
Material Handling;
Information & Decision Technologies in Manufacturing,
Computer Integrated Manufacturing (CIM);

19-20 Evaluation, Selection & Implementation of Manufacturing Systems

(with Manufacturing Systems "classic" cases)
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TERM-END EXAMINATION
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Session duration: 90 minutes

 MSD Topic-Wise References/ Readings Mapping 2010-11

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Topic References Readings

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Manufacturing Concepts C1; M2, 3

Manufacturing Strategy S7, 8, 15

Manufacturing Systems Overview M1, 2; S3, 6

Flow Line & Assembly Systems C1; M1, 3, 4 1-3

Group Technology and Cellular Manufacturing Systems M1, 2, 4; S3-5, 9, 13 4-5

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Factory Physics Concepts M3 6

Time Based Manufacturing C1; S1, 13 7

Flexible Manufacturing & Mass Customization S2, 10 8-9

Material Flow Systems C1; M1, 4; S4, 12, 14 10

Manufacturing & Support Technologies M2; S11, 14 11

Evaluation, Selection & Implementation of Manufacturing Systems S5, 15 12-13

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Notes:
• The References column lists books with one or more chapters containing material related to
the topic coverage.
• C in the column means titles listed as Course Books
• M in the column means titles listed as Main Reference Books in the Course Outline.
• S in the column means titles listed as Supplementary Reference Books.
• The number in the References column refers to the serial number of the book within the
category
(Main or Supplementary).
• The Readings column lists the supporting material included in the polycopy.
• The number in the Readings column refers to the serial number on the Contents page
(the Course Outline is un-numbered)