Production & Operation Management

Unit1

1. Types of Manufacturing System

 Job Shop Manufacturing

 Batch Production
 Mass Production
 Cellular Manufacturing
 Lean Manufacturing
 Flexible Manufacturing Systems (FMS)
 Green Manufacturing

2. Designing the product

 Idea Generation
 Concept Development
 Feasibility Analysis
 Detailed Design
 Prototype Development
 Testing and Evaluation
 Iterative Refinement
 final Design Freeze
 Manufacturing Planning
 Production:
 Quality Control
 Launch and Post-launch Support

3. Standardization in production and operation management

Standardization plays a crucial role in production and operations management
(POM) by providing consistency, efficiency, and quality across various
processes. Here's how standardization is applied in POM.
1. Process Standardization: Standardizing processes involves documenting and
formalizing the steps, procedures, and methods used to carry out specific tasks or
activities within the production and operations environment. This ensures that
 everyone follows the same set of instructions, leading to consistent outputs and
reduced variability in performance.
2. Product Standardization: Product standardization involves designing products with
uniform features, specifications, and components. By standardizing products,
companies can streamline production processes, reduce complexity, and achieve
economies of scale in manufacturing.
3. Quality Standards: Implementing quality standards such as ISO 9001 ensures that
products and processes meet specified quality requirements. Adhering to quality
standards helps improve product reliability, customer satisfaction, and overall
competitiveness.
4. Performance Metrics: Standardizing performance metrics and key performance
indicators (KPIs) allows companies to measure and evaluate their performance
consistently. Common metrics include production efficiency, cycle time, defect rate,
on-time delivery, and inventory turnover.
5. Inventory Management: Standardizing inventory management practices helps
optimize inventory levels, reduce stockouts, and minimize carrying costs. This
includes establishing standard procedures for ordering, receiving, storing, and
tracking inventory.

4. Modularization
Modularization is a strategy in production and operations management (POM) that involves
designing products, processes, or systems as a combination of interchangeable modules or
components. This approach offers several benefits and is commonly applied in various
industries.

 Flexibility
 Scalability
 Reduced Time-to-Market
 Enhanced Quality
 Cost Savings

6.Reverse Engineering
Reverse engineering is a process through which a product, component, or system is
analyzed and dissected to understand its design, structure, functionality, or inner
workings. This can be done for various reasons, including:

 Understanding Competitor Products

 Legacy Systems or Products

 Product Improvement or Innovation

 Compatibility or Interoperability
  Repair and Maintenance

 Legal Purposes

Unit 2

1. Capacity planning in production and operation management

Capacity planning in production and operations management (POM) involves

determining the optimal level of production capacity needed to meet current and future demand
for products or services. Effective capacity planning ensures that organizations can utilize
resources efficiently, minimize production bottlenecks, and meet customer demand while
controlling costs.

 Forecasting Demand
 Assessing Current Capacity
 Cost-Benefit Analysis
 Risk Management
 Monitoring and Adjustment

2. Capacity planning

Capacity planning is crucial in production and operations management due to several key
reasons.

 Meeting Customer Demand

 Controlling Costs
 Improving Operational Efficiency
 Decision-Making
 Enhancing Supply Chain Management

3. Capacity planning Strategies

Capacity planning strategies involve various approaches and techniques to ensure that
production capacity aligns with demand while optimizing resource utilization and controlling
costs.

 Lead Time Reduction

 Demand Forecasting
 Leveling Production
  Flexible Capacity
 Continuous Improvement
 Strategic Inventory Management
 Outsourcing

4.Facility Planning
Facility planning involves strategically designing and managing physical spaces to support
organizational objectives efficiently and effectively. Key considerations include:
Strategic Alignment - Aligning facility plans with organizational goals and long-term
objectives.
Space Utilization - Optimizing space to accommodate various functions and activities.
Functionality and Flow - Creating adaptable spaces to accommodate changing needs and
technologies.
Sustainability - Implementing environmentally friendly practices for resource conservation.
Accessibility - Designing facilities to be inclusive and accessible to all individuals.
Lifecycle Management - Considering the entire lifecycle of facilities from construction to
decommissioning.

5. Locational flexibility
Locational flexibility in production and operations management refers to the ability of
organizations to adapt their manufacturing or operational activities to different geographic
locations as needed.

 Adaptability
 Market Access
 Supply Chain Optimization
 Labor Optimization
 Risk Mitigation
 Cost Efficiency
 Scalability
Unit3
1. Process planning

Process planning is a crucial aspect of manufacturing that involves determining the most
effective sequence of operations and methods required to produce a part or product.

 Product Design Analysis

 Material Selection:
 Process Selection
 Quality Control
 Documentation

2.Characterictics of Production process system

Production process systems exhibit various characteristics depending on factors like the
industry, technology, and product complexity. Here are some common characteristics:

 Standardization
 Flexibility
 Automation
 Integration
 Quality Control
 Efficiency

3. Study Method

Studying effectively involves utilizing various methods and strategies tailored to individual
learning styles and preferences. Here's a guide to effective study methods:

 Understand Key Concepts:

 Real-World Examples
 Visual Aids and Diagrams
 Problem-Solving Practice
 Simulation and Modeling

4.Evolution of Normal & Standard time

In production and operations management (POM), the evolution of normal and standard time
measurement has closely followed the broader developments in industrial engineering and
work measurement.
  Early Industrial Era
 Scientific Management
 Time and Motion Studies
 Development of Time Standards
 Integration with Operations Management

Unit 4

1. Importance of Layout

The layout plays a crucial role in production and operations management (POM) as it directly
impacts efficiency, productivity, safety, and overall performance in manufacturing and service
operations.
 Optimizing Flow of Materials and Information
 Maximizing Space Utilization
 Minimizing Work-In-Process Inventory
 Enhancing Safety and Ergonomics

2.Types of Layout

 Process Layout (Job Shop Layout):

 Product Layout (Line Layout)
 Fixed-Position Layout
 Cellular Layout
 Hybrid Layout