Production & Operations Management -

ADL-14-Ver1
Assignment - A
Question 1 (a) Define Production Management and discuss its scope and functions.

Answer: Production Management: It is the conversion of inputs into outputs, using physical
resources, so as to provide the desired utility / utilities of form, place, possession of state or a
combination thereof to the customer while meeting the organizational objectives of

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Question 1 (b) Production Management deals with decision-making related to co-

production process so that the resulting goods or services are produced
according to the specifications, in the amounts and by the schedules demanded
and a t a minimum cost.” Discuss.

Question 2 (a) Compare and Contrast the Continuous and Intermittent Production
systems.

Question 2 (b) What do you understand by the term Flexible Manufacturing System?
Do you think it necessary for our country; discuss highlighting the examples
from our industries?

Question 3 (a) What is Production Planning and Control?

Question 3 (b) State main elements or functions of PPC.
Question 3 (c) Define Aggregate Planning and State its importance.

Question 4. For different types of manufacturing systems, we definitely have different

Production Planning & Control (PPC).” Do you agree with the statement?
Explain your viewpoint. Also explain the PPC for Intermittent & Continuous
manufacturing systems.

Question 5 (a) Plant layout is the physical arrangement whether existing or in plans, of
industrial facilities”. In the light of above statements discuss various types of
layouts commonly found in different industries.

Question 5 (b) What are the benefits that accrue due to a good plant layout?

Question 5 (c) Mention the guiding principles in designing a layout of production

facilities.

Assignment - B
Question 1 (a) Explain how Work Study (Work Measurement & Method Study) leads to
higher productivity?
Question 1 (b) How Standard Time per unit is calculated? Calculate the Standard Time
per piece in the following case.
The worker working on the machine has been given average performance
rating as 110%.
The total allowance for the job under given conditions of working is 15%.

Question 2 (a) Solve the following Transportation Problem and Find the Minimum
Transportation Cost.

Question 2 (b) A company makes two kinds of leather belts. Belt A is a high quality belt,
and B is of lower quality. The respective profits are Rs. 40 and Rs 30 per belt.
Each belt of type A requires twice as much time as a belt of type B, and, if all
belts were of type B, the company could make 1000 per day. The supply of
leather is sufficient for only 800 belts per day (both A and B combined). Belt A
requires a fancy buckle, and only 400 per day a re available. There are only
700buckles a day available for belt B. Set up the linear programming equations
for the problem and use Graphical Method for solving the same

Question 2 (c) The workmen in an Engineering company are expected to work for 400
minutes in a shift of 8 hrs. The remaining time is meant for rest and personal
needs.
I. Determine the Standard Time per piece of a job whose normal time is 2
minutes.
II. Calculate the no. of pieces to be produced per day. III. If the workmen
engaged on the above job produce 180 pieces in the shift, what is their
efficiency?

Question 3 (a) What is material Requirement Planning? Describe briefly the MRP
Process (preferably diagrammatically).

Question 3 (b) The product structure of an item (A) is as given below:

(1) Show by a diagram, when production of each component or assembly
must be carried out in order to complete the final assembly by week 15?
(2) Work out the number of components or subassemblies required to
produce 1250 Nos. of the product “A” required in 15 week, assume that all
scheduled receipts are zero.

Case Study
An Electric Company produces MCBs. The demand forecast for MCBs for the next 12
months is as follows:

The cost of holding the inventory of MCBs, each costing Rs.40 are 2 % per month. If
there are shortage of MCBs, the enterprise has a loss of customer goodwill and the loss
of opportunity costs is estimated at Rs. 60 per MCB.

a) Estimate the relevant costs of producing 2,50,000 MCBs every month.

Take initial inventory as 30,000 MCBs.

b) If the production is carried our @2,00,000 MCBs per month for Jan, Feb., March,
April; @2,00,000 MCBs per month for Ma y, June, July & Aug ; and @ 3,00,000 MCBs
per month for Sept, Oct, Nov, Dec. Calculate the total costs for this alternative plan.

Assume cost of producing in over-time costs @Rs. 6 per MCB, costs if under-
time(production below full capacity)@Rs. 3 per MCB and Rs 5 per MCB being the set-
up cost(cost of changing production rate).

Compare the two plans and find the better one.

Hint:

Alternate-1: Calculation sheet for Average Inventory and Lost Sale (units)

Assignment - C
1. The transportation cost and labour cost are the two most important factors in
determining the site location.
a) True (b) False

2. Location breakœeven analysis can be employed for determining the site location
decision.
a) True (b) False

3. Brown and Gibson's Model for location measure has nothing to do with annual
turnover.
a) True (b) False

4. The continuous Production system is that where facilities are standardized as to

routing and flow.
a) True (b) False

5. The mass production is one in which large variety of products are produced.
a) True (b) False

6. The intermittent process is based on functional type of layout.

a) True (b) False

7. The fixed type of layout is one where all facilities like manpower, equipment and
materials are brought to the place of working.
a) True (b) False

8. FMS stands for Flexible Manufacturing System.

a) True (b) False

9. Batch Production is an example of Continuous Production System.

a) True (b) False
10. The Continuous Production System employs General Purpose Machines and
intermittent
Production System purpose Machines.
a) True (b) False

11. Fredrick Taylor is called the Father of Motion Studies and B. Gilbreth is called the
Father of scientific management.
a) True (b) False

12. Wilson gave formula for determining the Economic Order Quantity.
a) True (b) False

13. Incase of components in series, the reliability is higher than the highest of any
component in the system and in case of components in parallel; the reliability is less
than the least in the system.
a) True (b) False

14. If F (t1) and F (t2) are the probability of failures of two components in the parallel
system,
then the reliability of the system is given by 1-[1-F (t1)] x [1-F (t2)]
a) True (b) False

15. In ABC analysis, -A” items are those which consume 70% by value and are hardly
10% of the total items whereas -C” items are those which consume 10% by value and
are more than 70% of total items.
a) True (b) False

16. A quality circle is a small group of employees in a company who discuss and try to
improve the quality of the output and other work related matters.
a) True (b) False

17. P system of inventory control is basically Fixed Order Quantity System and Q
system of inventory control is Fixed Periodical Review System.
a) True (b) False

18. In P type of inventory control system the average inventory is more than Q type of
inventory control system.
a) True (b) False

19. Integrated approach towards material management is not necessary for inventory
control.
a) True (b) False

20. A good management is one which starts on Incentive Scheme right from the start of
the factory.
a) True (b) False

21. A forklift can be used for horizontal as well as vertical movements.

a) True (b) False
22. Mobile cranes cannot move from one place to another.
a) True (b) False

23. Hand trolleys are used for handling larger loads over small distances.
a) True (b) False

24. Line Layouts generally involve low investments by way of equipment and
machinery.
a) True (b) False

25. Plant layout and material handling are closely inter-related.

a) True (b) False

26. Material handling cost is directly proportion to the size of unit load.
a) True (b) False

27. EOQ strikes a balance between inventory carrying cost and ordering costs.
a) True (b) False

28. Measure of Central tendency is a data set refers to the extent to which the
observations are scattered.
a) True (b) False

29. The value of all observations in the data set is taken into account when we calculate
its mean.
a) True (b) False

30. If the curve of a certain distribution tails off towards the right end of the measuring
scale on the horizontal axis, the distribution is said to be positively skewed.
a) True (b) False

31. Extreme values in a data have a strong effect upon the Mode.
a) True (b) False

32. If the value of mean=35.4 and value of median=35 the shape of the curve skewed is
-right”.
a) True (b) False

33. It gives equal weightage to all previous months.

a) Exponential Smoothing (b) Moving Average