Master of Business Administration - MBA Semester II MB0044 Production & Operations Management - 4 Credits (Book ID: B1133) Assignment

Set- 1 (60 Marks) Note: Each Question carries 10 marks. Answer all the questions. Q1. Explain in brief the origins of Just In Time. Explain how JIT is implemented.
Just-In-Time (JIT) manufacturing is a process by which companies dont keep lots of excess inventory; instead, they manufacture a product as an order comes in. It is a management philosophy of continuous and forced problem solving. The objective of JIT manufacturing system is to: Eliminate waste that is, minimise the amount of equipment, materials, parts, space, and workers time, which adds a great value to the product Increase productivity JIT means making what the market demands when it is in need. It is the most popular systems that incorporate the generic elements of lean systems. Lean production supplies customers with exactly what the customer wants, when the customer wants, without waste, through continuous improvement. Deploying JIT results in decrease of inventories and increases the overall efficiencies. Decreasing inventory allows reducing wastes which in turn results in saving lots of money. There are many advantages of JIT. JIT: Increases the work productivity Reduces operating costs Improves performance and throughput Improves quality Improves deliveries Increases flexibility and innovativeness For industrial organisations to remain competitive, cost efficiencies have become compulsory. JIT helps in this process. It is extended to the shop floor and also the inventory systems of the vendors. JIT has been extended to mean continuous improvement. These principles are being applied to the fields of Engineering, Purchasing, Accounting, and Data processing. However, for organisations to completely implement JIT manufacturing system, they need to have a proper commitment along with the following basic facilities - proper material, quality, equipment, and people involvement. Characteristics of JIT

In this section, we will study different methods by which inefficiency is reduced and unproductive time is minimised. The consequent savings are to be utilised for reducing cost and rendering better service to the customer. Shigeo Shingo an authority on JIT at Toyota classifies the wastes to be eliminated as follows. The seven wastes to be eliminated according to JIT are: 1. Over production 2. Inventory 3. Waiting time 4. Movement 5. Effort 6. Defective products 7. Over processing

Seven wastes

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1. Over production: Over production is to manufacture products before it is actually needed. If the demand for that product decreases, the extra parts or products produced may not be useful or needed. Also over production results in high storage costs and is also difficult to detect defects. So, over production is considered a waste. 2. Inventory: Excess procurement or production builds up stock of materials which are not immediately used, thus locking space and funds carrying heavy costs. The figure 13.2, illustrates the inventories at different levels of an organisation Supplier distribution, Production, and Customer distribution.

Inventories in an organisation 3. Waiting time: Waste of time happen when goods are not moving or being processed. The operator, the machine or the part will either be not working or be worked upon. The duration of waiting is can be said to be unproductive and may create more serious consequences. 4. Movement: Any unnecessary movement is a waste of energy; it causes blockages, disrupting movements and delaying the flow of other items creating delays. 5. Effort: The people, who work, do not make a study as to how the products on which they are making are utilised and do not realise the purpose for which they are made. This lack of education will lead to waste of resources. Finally, they end up in shortage of resources when needed. 6. Defective products: The defective products lead to a tremendous loss to the company. This is because they use up the same equipments, workmen and the time that would be used to make good products. Thus defective products use up resources and result in losses.

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7. Over Processing: Some steps like unnecessary processing or production do not add value to the final output. As a result, it is waste of all the inputs that go into the process. Since these wastes have to be eliminated, a thorough study of how they occur and what steps would result in their elimination is of paramount importance. The next section focuses on some of them. 13.3 Key Processes to Eliminate Waste The key processes to eliminate the wastes are listed below:

13.3.1 Kanban for material flow 13.3.2 High quality production 13.3.3 Small and uniform workloads 13.3.4 Suppliers as partners 13.3.5 Flexible workforce and training 13.3.6 Total productive maintenance

Q2. Bring out the historical background of Value Engineering. Elucidate three companies which have incorporated VE with brief explanation. Q3 . Explain the key elements of Quantitative modelling. What is work study and motion study. Q4. What is Rapid Prototyping? Explain the difference between Automated flow line and Automated assembly line with examples. Q5. List different methods for selecting a suitable plant location and explain any two. Q6. Explain Jurans Quality Trilogy and Crosbys absolutes of quality. List out Demings 14 points.

Master of Business Administration - MBA Semester II MB0044 Production & Operations Management - 4 Credits (Book ID: B1133) Assignment Set- 2 (60 Marks)

Note: Each Question carries 10 marks. Answer all the questions. Q1. Sketch the business process model and define the terms. Differentiate between Explain Logical Process Modelling and Physical Process Modelling.

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Q2. Explain project management life cycle and its phases. With an example explain Work Breakdown Structure.

Q3. Define industries best practices? Explain any one popular industry best practise followed by all companies. Q4. Explain PMIS. What is Key Success Factor (KSF), Explain with example. Q5. Explain the seven principles of supply chain management. Take an example of any product in the market and explain Bullwhip effect. Q6. Time taken by three machines on five jobs in a factory is tabulated below in table below. Find out the optimal sequence to be followed to minimise the idle time taken by the jobs on the machines.

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