Q1 :Discuss the functions of operations management.

Ans :-

1. Planning
Operations management is involved throughout in the development and production cycles to a stage where products are ready to be dispatched to the marketing and sales department to provide them to final consumers. Product design and development: This deals with the issues of converting market feedback on the requirements pertaining to the type of product to be produced into specifications and drawings that help in production. Production process selection: This helps in evaluating different process options possible to produce the type of product in terms of volume and variety and other factors to select the best-suited process. Production planning: This helps effectively plan the production to meet the required quantities of products within the scheduled time. Capacity planning: This deals with the issues pertaining to planning the capacity for the plant that enables cost-competitive production event with certain degree of fluctuations in the required volumes.

2. Organizing
Work study: Also known as time and motion study, it aims at improving the cycle time required for producing a product. Materials management: This aims at establishing sources for the required materials in terms of input materials or consumables at the right time so that no delays in production occur. Purchasing management: This is responsible for making the input material available in time, at the right price and in the right quantity and quality.

3. Controlling
Stores management: This refers to managing the stores for input materials, consumables and finished stocks while avoiding overstocking of materials. Stores are also accountable for recording the stock and consumption of these materials. Value analysis: The process of obtaining the best possible combination between cost and required functional specifications of a product by assigning a value to every operation of the production process and identifying the function of the product. Quality control: This is responsible for monitoring the quality requirements of the product so that no defective parts are passed on to the consumers.

Inventory management: This is responsible for maintaining minimum inventory of all critical materials and ensuring that there is no overstocking or stock-out.

Q2 :- Discuss the any five main functions of production planning and control.
Ans:1. Order preparation: The work of PPC begins once an order is received from the sales department. This order is then converted into a work order or shop order and sent to various departments concerned, action planning. 2. Materials planning: On receiving the order PPC decides the raw materials required for manufacturing, considering the capacity of various production shops, the bill of materials, inventory on hand, and lead time for procurement. 3.

Estimating: This involves establishing the operation time for every process; this also leads to
fixation of performance standards for both men and machines. Loading: This involves allocating jobs to machines as per the capacity of Preparation of machine loads Fixing of actual dates of various operations/sequence of operations to be performed on the jobs Coordination with the sales department to confirm delivery dates and keeping them informed about the status of the schedules

4. Dispatching: Dispatching means preparation and distribution of work orders and manufacturing instructions to the concerned departments in accordance with the details worked out under routing and scheduling functions. The work order received by the various departments is an authority for them to start the work according to that schedule. 5.

Expediting and follow-up: Follow-up means to see whether the work is being carried
out according to the plan and orders and instructions issued. It ascertains that the materials, tools and equipment are supplied at the job at the right time and to the right person or job. Follow-up is the means by which the progress and execution of the plan is evaluated from time to time and divergence from the plan is noted. The reasons for such divergence are then found out and efforts are made to eliminate them from the plan.

Q 3 :- What are the various types and functions of stores?

Ans:- Types of stores :-

Receiving Store :They perform activities that control the quality and quantity of purchased materials before it is accepted for production. This type of stores is also called goods inward store. Inward: It is used to store the incoming materials until they are accepted and taken into stock. Quarantine: It is used to store the stock materials temporarily that are under dispute or need certification from the supplier. Rejection: This is used to store materials that are defective and rejected by a company until the materials are sent back to the respective suppliers.

Main store
Main stores perform activities that are concerned with storage and issuance of accepted materials and deal with the maintenance of records of materials. It can be maintained either in the company as a godown or a warehouse located near the company from where goods can be easily transferred. It is further divided into the following types: Crib: It is used to store stocks such as cutting and hand tools, gauges, etc., that are to be issued to the workmen at the beginning of their shift and to be received at the end of their shift. Finished Part: This store is used to store stock components and parts that are produced in economic sizes in the plant itself. Sub: This is used to store bar stocks, casting and forgings that require a lot of space and need to be stored in open spaces and is also called the raw material stores. Plant Store: It is used to store spare parts of tools and machineries that are used in a plant for production.

Warehouse Store
Warehouse performs activities that are concerned with receipt, packing and dispatch of finished goods to various destinations. It involves handling of papers and documents related to goods. This type of store is also called finished product store.

Special Store :They perform activities that are related to receipt, storage and issuance of special materials such as bank papers, petroleum products, etc. They are further divided into the following types: Bonded: These stores are used to store materials that are related to banks and stocks that are excisable. Statutory: It is used to store petroleum products such as kerosene and diesel that require safety precautions.

 Temperature-controlled: This store is used to store materials such as meat, fish and vegetables or goods such as rubber or active ingredients such as vitamins and calcium that require temperature-controlled storerooms. The various function of stores are : Requesting the purchasing department for adequate quantity of materials so that the deliveries can be made in the appropriate time. Protecting the materials from conditions such as bad weather, damage and stealing. Issuing materials only to authorized people or requisitions. Maintaining proper records of stores so that they can be provided at right time.

Q 4 :- What are the various types of Projects , list their advantages and Disadvantages?
Ans :1. On the basis of composition :Projects can be classified on the basis of composition mainly into three types: 1. Pure project 2. Functional Project 3. Matrix project

Advantages Team members need not worry about multi reporting with a functional area manager and they have a single reporting. Short communication lines lead to quick decisions. Pride, motivation, and commitment of the team are high. Disadvantages Project close-up is mostly delayed due to the anxiety of team members having no functional home area and life-after-project. Ignorance of organizational goals and policies happens due to removal of, team members both physically and psychologically from the head office. Resource duplication occurs due to non-sharing of equipment and people across projects.

2.Functional Project
Several projects could be running simultaneously for example, several research projects in the R&D department of an organization. Advantages : A team member can work on multiple projects. Even if individuals leave the project or firm, technical expertise is maintained within that functional area which is a home after the project completion.

 There is synergy within the department since the team members keep moving from one project to another. Disadvantages : Project aspects not directly related to the functional area are short-charged. Team members are less motivated. Client needs are not treated as primary and are responded to slowly.

3.Matrix Project
Functional and pure project structures together form a matrix project and utilize personnel from separate functional areas.

Advantages : Inter-departmental communication is better. Parent organization policies are followed which increase project support.

Disadvantages : There are two bosses. Often the functional manager will be listened to before the project manager. It is doomed to failure unless the project manager has strong negotiating skills.

Q 5:- Describe the activities involved in Lubrication Maintenance and Importance of lubrication maintenance.
Ans: Identifying the right part of machine for lubrication: As it requires studying the manual and then performing the activity, it should be done by trained professionals. Lubrication surveys are also conducted. The lubrication layout not only lists the parts to be lubricated but also lists the type of lubricants to be used, process of lubrication, frequency and quantity of lubrication. Cleaning of oil tanks and hydraulic systems: The oil tanks need to be cleaned at regular intervals to ensure that the oil used for lubricating the machines is free from dust and dirt. In this process, the polluted oil is taken out from the gearboxes and worm-gear tanks; the tank is cleaned and then refilled with good quality oil. Bearings lubrication: Bearings should be lubricated with grease once a year. This helps in proper functioning and maintenance of the bearings. Lubricating oil pipes: Due to frequent use of the oil gun at the time of lubrication or improper handling, the lubricating pipes get damaged. They should be replaced with new ones to ensure proper lubrication of the machine. Replacing wicks: Wicks lubricate the machines through capillary action. In order to keep wick lubricators functional, they should be replaced at regular intervals.

 Scheduling the frequency of lubrication: The frequency of lubricating a machine or its parts depends upon their functions and machine requirements. While some moving parts such as tool slides and guide ways are oiled two to three times a day, some other parts are lubricated once a month or once in six months. Deciding the amount of lubrication required: To ensure proper lubrication, care should be taken that the lubricating agent or oil is used in the right quantity. Using less than the recommended quantity of lubricating oil will make a machine abrasive and damage the moving parts. Over lubrication is also bad since it can cause overflowing especially in oil tanks, etc. Selecting the right lubricant: The right quality of lubricant is essential for good lubrication and the long life of a machine. The right quality of lubricant is often mentioned in the instruction manual provided by the manufacturer. Importance of Lubrication Maintenance is regular and proper lubrication of machines helps in reducing the rate of their wear and tear, maintains the temperature of the machines and decreases the power consumption by the machines.

Q 6:- Explain Costs of Quality and its various types.

Ans:- Quality costs are those incurred by a company to ensure that a product provides perfect quality. Each time work needs be redone, for example, re-manufacturing a defective item, the cost of quality increases.

Prevention costs
Costs that are incurred in preventing the manufacture of non-conforming products and stopping any such product from reaching the customers are called preventive costs. Preventive costs include: Process planning costs: include the development costs for establishing procedures, manufacturing controls and setting up instructions for testing and inspection, reliability studies, new equipment design, etc. Training costs: are associated with developing and operating formal training programmes or attending seminars on quality assurance. General management costs: include those for clerical staff, supplies, and communications related to quality efforts.

Appraisal costs
They are incurred while maintaining quality levels through measurement and analysis of data in order to detect and correct problems. Testing and inspection costs are incurred while testing and inspecting incoming materials, work in process and finished goods and include salaries for employees, cost of equipment, cost of maintaining instruments.

Internal failure costs

It results from unsatisfactory quality that is found prior to the delivery of a product to the customer. It includes scrap and rework costs, costs of corrective action arising from time spent determining the causes of failure and correcting production problems.

External failure costs

It occurs after poor quality products reach the customer. Costs of investigating complaints, product recall costs, warranty claim costs, which include the cost of repair or replacement of products during warranty periods, and product liability costs of legal action and settlements are a major source of external failure costs.