GOOD MORNING

WELCOME TO THE NEW ACADEMIC

YEAR
All the best for a very happy and productive
semester.

COURSE OBJECTIVES
i) realize the basic problems in industry-related to
manufacturing / operational aspects,
ii) understand various approaches available to treat and
analyze these problems
iii) learn various solution procedures for these problems .
iv ) handle real life situations and
v) know more about the changes that have taken place in
manufacturing systems.

TARGET AUDIENCE:
M.Tech / PhD / DD / BTech students interested in the area
of OPERATIONS MANAGEMENT

ME 711 MANUFACTURING
PLANNING AND CONTROL
AUTUMN 2015-16
Instructor: Prof. A. Subash Babu
Room 309 A / MED Second Floor
Slot 1
Monday: 8.30
Tuesday: 9.30
Thursday 10.35
Room Number LT003

HOW MANY OF YOU ARE INTERESTED IN

Manufacturing Industry (Auto,

FMCG,

Appliances, Machine building, etc)

Consulting (Technology/ Management)

Academic Institutions
Research & Development(GM, GE, RR etc.,)
Public Sector ( oil, Power, ISRO, DRDO)
Civil Services ( IAS, IFS, IRS, IPS)
Any job that pays well
SO ???

COURSE METHODOLOGY
MANAGING OPERATIONS - COMMON

ME 711 covers many dimensions of

operations

Class room discussions - PPT/ Board

Problem solving
Team assignments / projects related to
a) Real life Manufacturing Systems,
b) R & D efforts in manufacturing management
c)Case discussions
d)Seminars and Presentations

Industry visits / Guest Lectures

WHAT IS EXPECTED OF THE STUDENTS

TARGET : About 40 students
Attendance Minimum 80 % as per IITB rules (there
are about 40 lectures of about 55 minutes this
semester)
Active class participation in cases and problem
solving
Must actively participate in course projects and
assignments
Students must come to the class with calculator

COURSE PLAN
Overview of traditional and advanced manufacturing systems
Preplanning: Forecasting, Capacity planning, Aggregate planning,
and Inventory planning; Location and Layout planning
Operations planning : MRP, MRP II, Assembly Lines, CMS (GT),
FMS and JIT Systems
Operation and control: Lot sizing decisions, Production scheduling,
Line of balance and Concepts and applications of Theory of
Constraints.
Road map to World Class Manufacturing Systems: Lean
manufacturing , Agile manufacturing , Quick response manufacturing
systems and Intelligent Manufacturing; Management of Technology
Applications of recent developments in IT including ERP, CIM,
eManufacturing, Enterprise Application Integration (EAI), Multi
Agent based systems : Concepts and applications.
Case studies
Guest lectures/industry visits will be arranged if students evince
interest.

TEXT/REFERENCES
(Additional references will be given in the class.) One of 1/3/9 can be purchased.
1.D.D. Bedworth and J.E. Bailey, Integrated Production Control System -Management,
Analysis and Design, John Wiley, 1983.
2.S.Nahmias, Production and Operations Analysis, McGraw Hill ( 4 th Ed.), 2012
3.D Sipper and R.L Buffin Jr, Production, Planning , Control and Integration, McGraw Hill
Intl., 1998
4.L.A. Johnson and D.C. Montgomery, O.R. in Production Planning, Scheduling and Inventory
Control, John Wiley and Sons, 1974.
5.A.C. Hax and D. Candea, Production and Inventory Management, Prentice Hall, 1984.
6.R.G Askin and JF Goldberg, Design and Analysis of Lean Production Systems, John Wiley &
Sons(Asia)Pvt Ltd. , 2003
7.M.T Flaherty, Global Operations Management, McGraw Hill Intl., 1996
8.R Stein, Reengineering manufacturing system Applying TOC, Mercel Dekker,Inc 1996
9.N Slack, S Chambers and R Johnston, Operations Management, Prentice Hall / Pearson
Education, Sixth Ed: 2010
10.J Heizer and B Render ; Operations Management , Prentice Hall, Tenth Ed. 2010
11.M.L Pinedo, Scheduling : Theory , Algorithms , and Systems , Springer, 2008
12.J.W.Davis, Lean manufacturing strategies that work; Industrial Press, New York; 2009

ASSESSMENT PLAN
End Semester 50 Marks
In-semester 70 Marks
Test 1 : 15 Marks
Quizzes 20 Marks ( including surprise)
Group / Individual Assignments 25 Marks

Bonus on overall performance 10 Marks

We will follow AP, AA to CD ; XR , XX and FR grading
System (GRADES WILL BE BASED ON 120 MARKS).

WHAT DO I EXPECT
1) Minimum 80 % attendance there are about 40 lectures
2) Participation in the class and enthusiasm in sharing
experience
3) Must actively participate in problem solving, cases,
course projects and assignments
4) Come to the class with calculator
5) Strictly use of cell phone and other communication
devices not allowed in the class
6) No sleeping and chit chatting in the class
7) Do not enter the class after 10 minutes of the stipulated
time

INTRODUCTION
Lecture 1
July 23 (Thursday ), 2015

Advice:
Form a team of two for the assignments / projects / seminars

MANAGEMENT OF MANUFACTURING
SYSTEMS

MANUFACTURING AS A SYSTEM
Production System

Inputs

Conversion
Subsystem

Outputs

Control
Subsystem

MANUFACTURING SYSTEMS
Common components are
Input, Conversion capability ,Output
Output monitors, Feedback and Input regulators
Engines for achieving organizational
excellence.
Conversion systems.
Value adding systems.
Vehicle for achieving organizational goals

INPUTS
Primary Resources (need to organize)
Machines, Materials, Personnel, Capital,
Utilities

Market( need to ascertain)

Competition, Customer Desires, Product Info.

External( need to appreciate)

Legal, Economic, Social, Technological

WHAT ARE THE PERSPECTIVES OF MANAGEMENT ?

CONVERSION SUBSYSTEM

Physical (Manufacturing)
Locational Services (Transportation)
Exchange Services (Retailing)
Storage Services (Warehousing)
Other Private Services (Insurance)
Government Services ( Deal with Federal,

OUTPUTS
Direct
Products
Services

Indirect
Revenue / Profit
Technological Advances / Knowledge
Waste
Pollution

State, Local)

ALL NEED TO BE FACILITATED

THE TASKS

Manage inputs
Build capability
Monitor output
Apply feed back / feed forward concepts to
a) regulate input and
b) have appropriate capability
Challenging ?

ALL NEED TO BE TARGETTED AND

MANAGED ( Minimise / Maximise)

WHAT ARE THE SITUATIONS ?

Just be one of the ordinary and try to
survive
Just target average performance
Achieve excellence , be a leader and make
your own rules

MANUFACTURING EXCELLENCE

Manufacturing organisations are always

in pursuit of innovative concepts to meet
various customer, business and societal
needs.

WHAT ARE THE RESULTS ?

DIFFERENT TYPES OF MANUFACTURING SYSTEMS ??

MANUFACTURING SYSTEMS EVOLVED

KEEPING IN MIND

1. Productivity
2. Material Flow
3. Information
integration
4. Quality
5. Lead time
6. Inventory
7. Cost

8. People , participation,
empowerment and
knowledge
9. Flexibility
10. Agility
11. Customer Responsiveness
12.Technology
13. Value
14. Sustainability

POPULAR MANUFACTURING SYSTEMS

Assembly Lines
Group technology / cellular manufacturing systems
(GT /CMS)
MRP 1 / MRP 2 supported systems
Flexible manufacturing system (FMS)
Computer integrated manufacturing (CIM)
Just in time production systems (JIT)
ERP supported manufacturing systems
Agile manufacturing systems (AMS)
Quick response manufacturing systems (QRMS)
Reconfigurable Manufacturing Systems (RMS)
Lean production systems (LEAN)
WHICH IS WORLD CLASS MANUFACTURING ?

WCM COMPANIES IN GENERAL

Always in pursuit of excellence How ?
Add value to the product
Serve the customer better and better
Practice a flexible approach to meeting customer
requirements
Improve cycle time
Improve product quality
Eliminate wastes of all forms
Change the way people are managed.
Use technology for competitive advantage
Rely on long-term strategic thinking and suitable
actions