Production and Operations Management

Cover:

Contents:

1 INTRODUCTION TO PRODUCTION AND OPERATION MANAGEMENT

1.1 Introduction
1.2 Historical Evolution of Production and Operations Management
1.3 Concept of Production
1.4 Production System
1.4.1 Classification of Production System
1.5 Production Management
1.5.1 Objectives of Production Management
1.6 Operating System
1.6.1 Concept of Operations
1.6.2 Distinction between Manufacturing Operations and Service Operations
1.7 Operations Management
1.7.1 A Framework for Managing Operations
1.7.2 Objectives of Operations Management
1.8 Managing Global Operations
1.9 Scope of Production and Operations Management

2 PLANT LOCATION AND LAYOUT

2.1 Introduction and Meaning
2.2 Need for Selecting a Suitable Location
2.3 Factors Influencing Plant Location/Facility Location
2.3.1 General Locational Factors
2.3.2 Specific Locational Factors for Manufacturing Organisation
2.3.3 Specific Locational Factors for Service Organisation
2.4 Location Theories
2.5 Location Models
2.5.1 Factor Rating Method
2.5.2 Weighted Factor Rating Method
2.5.3 Load-distance Method
2.5.4 Centre of Gravity
2.5.5 Break Even Analysis
2.6 Locational Economics
2.7 Plant Layout
2.7.1 Objectives of Plant Layout
2.7.2 Principles of Plant Layout
2.8 Classification of Layout
2.8.1 Process Layout
2.8.2 Product Layout
2.8.3 Combination Layout
2.8.4 Fixed Position Layout
2.8.5 Group Layout (or Cellular Layout)
2.9 Design of Product Layout
2.10 Design of Process Layout
2.11 Service Layout
2.12 Organisation of Physical Facilities

3 MATERIAL HANDLING

3.1 Introduction and Meaning
3.2 Objectives of Material Handling
3.3 Principles of Material Handling
3.4 Selection of Material Handling Equipments
3.5 Evaluation of Material Handling System
3.6 Material Handing Equipments
3.7 Guidelines for Effective Utilisation of Material Handling Equipments
3.8 Relationship Between Plant Layout and Material Handling

4 MATERIALS MANAGEMENT

4.1 Introduction and Meaning
4.2 Scope or Functions of Materials Management
4.3 Material Planning and Control
4.3.1 Techniques of Material Planning
4.4 Purchasing
4.4.1 Objectives of Purchasing
4.4.2 Parameters of Purchasing
4.4.3 Purchasing Procedure
4.4.4 Selection of Suppliers
4.4.5 Special Purchasing Systems
4.5 Stores Management
4.5.1 Codification
4.6 Inventory Control or Management
4.6.1 Meaning of Inventory
4.6.2 Reasons for Keeping Inventories
4.6.3 Meaning of Inventory Control
4.6.4 Objectives of Inventory Control
4.6.5 Benefits of Inventory Control
4.6.6 Techniques of Inventory Control
4.6.7 Inventory Model
4.7 Standardization
4.7.1 Advantages of Standardization
4.7.2 Disadvantages of Standardization
4.8 Simplification
4.8.1 Advantages of Simplification
4.9 Value Analysis
4.9.1 Value Analysis Framework
4.9.2 Steps in Value Analysis
4.10 Ergonomics (Human Engineering)
4.10.1 Objectives of Human Engineering
4.11 Just-In-Time (JIT) Manufacturing
4.11.1 Seven Wastes
4.11.2 Benefits of JIT

5 PRODUCTION PLANNING AND CONTROL

5.1 Introduction and Meaning
5.2 Need for Production Planning and Control
5.3 Objectives of Production Planning and Control
5.4 Phases of Production Planning and Control
5.4.1 Planning Phase
5.4.2 Action Phase
5.4.3 Control Phase
5.5 Functions of Production Planning and Control
5.5.1 Parameters for PPC
5.6 Operations Planning and Scheduling Systems
5.7 Aggregate Planning
5.8 Master Production Schedule (MPS)
5.9 Material Requirement Planning (MRP)
5.9.1 Objectives of MRP
5.9.2 MRP System
5.10 Capacity Planning
5.10.1 Measurement of Capacity Planning
5.10.2 Process of Capacity Planning
5.11 Routing
5.11.1 Techniques of Routing
5.12 Scheduling
5.12.1 Principles of Scheduling
5.12.2 Inputs to Scheduling
5.12.3 Scheduling Strategies
5.12.4 Types of Scheduling
5.13 Scheduling Methodology

6 QUALITY CONTROL

6.1 Introduction
6.2 Quality
6.2.1 Fundamental Factors Affecting Quality
6.3 Control
6.3.1 Need for Controlling Quality
6.4 Inspection
6.4.1 Objectives of Inspection
6.4.2 Purpose of Inspection
6.4.3 Types of Inspection
6.4.4 Methods of Inspection
6.4.5 Drawbacks of Inspection
6.5 Quality Control
6.5.1 Types of Quality Control
6.5.2 Steps in Quality Control
6.5.3 Objectives of Quality Control
6.5.4 Benefits of Quality Control
6.5.5 Seven Tools for Quality Control
6.5.6 Causes of Variation in Quality
6.6 Statistical Process Control
6.6.1 Control Charts
6.6.2 Acceptance Sampling
6.7 Quality Circles
6.7.1 Benefits of QC
6.8 Total Quality Management
6.8.1 Benefits of TQM
6.9 ISO 9000 Series
6.9.1 Objectives of ISO 9000 Series
6.9.2 Benefits of ISO 9000 Series
6.9.3 Steps in ISO 9000 Registration
6.10 Application ISO 9000: ISO 14000 Series
6.10.1 The Benefits of ISO 14000 Certification
Annexure–I
Annexure–II

7 WORK STUDY (TIME AND MOTION STUDY)

7.1 Introduction
7.2 Productivity
7.2.1 Factors Influencing Productivity
7.2.2 Total Productivity Measure (TPM)
7.2.3 Partial Productivity Measures (PPM)
7.2.4 Productivity Improvement Techniques
7.3 Work Study
7.3.1 Advantages of Work Study
7.4 Method Study
7.4.1 Objectives of Method Study
7.4.2 Scope of Method Study
7.4.3 Steps or Procedure Involved in Methods Study
7.4.4 Selection of the Job for Method Study
7.4.5 Recording Techniques for Method Study
7.5 Motion Study
7.5.1 Principles of Motion Study
7.5.2 Recording Techniques of Motion Study
7.6 Work Measurement
7.6.1 Objectives of Work Measurement
7.6.2 Techniques of Work Measurement
7.7 Time Study
7.7.1 Steps in Making Time Study
7.7.2 Computation of Standard Time

8 MAINTENANCE MANAGEMENT

8.1 Introduction and Meaning
8.2 Objectives of Maintenance
8.3 Types of Maintenance
8.3.1 Breakdown (Reactive) Maintenance
8.3.2 Preventive Maintenance
8.3.3 Predictive Maintenance
8.4 Maintenance Planning
8.5 Maintenance Scheduling
8.6 Maintenance Schedule Techniques
8.6.1 Modern Scientific Maintenance Methods
8.6.2 Six Sigma Maintenance
8.6.3 Enterprise Asset Management (EAM)
8.6.4 Lean Maintenance
8.6.5 Computer Aided Maintenance
8.7 Total Productive Maintenance (TPM)
8.7.1 Similarities and Differences between TQM and TPM
8.7.2 Pillars of TPM

9 WASTE MANAGEMENT

9.1 Introduction and Meaning
9.2 Reasons for Generation and Accumulation of Obsolete, Surplus and Scrap Items
9.3 Identification and Control of Waste
9.4 Disposal of Scrap

10 AUTOMATION

10.1 Introduction
10.2 Types of Automation
10.3 Computer Integrated Manufacturing
10.4 Reasons for Automation
10.5 Advantages of Automation
10.6 Disadvantages of Automation
10.7 Automation Strategies
10.8 Automated Flow Lines
10.9 Automated Guided Vehicles Systems
10.9.1 Types of AGVS
10.9.2 Applications of Automated Guided Vehicle Systems
10.10 Automated Storage/Retrieval Systems
10.10.1 Types of AS/RS
10.10.2 Basic Components of an AS/RS
10.11 Carousel Storage Systems
10.12 Carousel Storage Applications

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