SUB: OPERATIONS MANAGEMENT

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MARKS: 100

SUB: OPERATIONS MANAGEMENT

Note: Section A has 12 questions with 10 marks each. Attempt any eight questions from

Section A. (Total Marks 8 X 10 =80)

Section B has 2 questions with 20 marks each. Please attempt any 1. (1 X 20)

Please note that if a question has 2 parts like A & B – You need to attempt both.

SECTION A

1. (a) Explain what you understand by the term "Total Quality Management", paying particular attention to the following terms : quality, supplier-customer interfaces, and process.

(b) Define Productivity. List some factors that can affect productivity and some ways in which productivity can be improved.

Answer:

2. (a) Give two examples (with supporting details) of the impact of technology in product and service design, in the context of service and manufacturing firms.

(b) A firm uses simple exponential smoothing with α = 0.1 to forecast demand. The forecast for the first week of February was 500 units, whereas actual demand turned out to be 450 units.

(i) Forecast the demand for the second week of February.

(ii) Assume that the actual demand during the second week of February turned out to be 505 units. Forecast the demand for the third week of February.

Answer:

3. (a) Bloomsday Outfitters produces T-shirts for road races. They need to acquire some new stamping machines to produce 30,000 good T-shirts per month. Their plant operates 200 hours per month, but the new machines will be used for T-shirts only 60 percent of the time and the output usually includes 5 percent that are "seconds" and unusable. The stamping operation takes 1 minute per T-shirt, and the stamping machines are expected to have 90 percent efficiency considering adjustments, changeover of patterns, and unavoidable downtime. How many stamping machines are required?

(b) Give an example of a business that would use a push and one that would use a pull operations control system. Explain your choice and briefly describe how the system works.

Answer: Target stamping-30000nos

Limiting Factor-machine availability time-200*60%=120hrs per month.

Practical stamping Capacity-120*60mins *90%(efficiency)*95(Good units)=6156

Machines Required-30000/6156=Approx 5machines

4. (a) What factors should be taken into account when taking make-or-buy decisions ? Illustrate your answer with examples from both a manufacturing and service organization.

(b) What are the two major uncertainties encountered in managing inventories and what is usually done to compensate for those uncertainties?

Answer:

5. (a) What are the various methods of judgmental forecasting ? Comment on possible errors that are associated with judgmental forecasting.

Answer: Judgmental forecasts rely on subjective inputs from various sources. Time-Series forecasts projects patterns identified in recent time-series observations. A time-series is a time-ordered sequence of observations taken at regular time intervals. Associative models are based on the development of an equation that summarizes the effects of predictor variables. Predictor variables are used to predict values of the variable of our interest.

It is important to know how to calculate a forecast error: Error = Actual - Forecast. There are three ways of measuring the accuracy of forecasts:

(b) A time study of a restaurant activity yielded a cycle time of 2.00 minutes, and the waitress was rated at PR = 96 percent. The restaurant chain has a 20 percent allowance factor, find the standard time.

Answer:

6. Discuss the nature and scope of operations management in terms of production decisions.

Answer: E.S.Buffa defines production management as follows: ‘Production management deals with decision-making related to production processes so that the resulting goods or services are produced according to specifications, in the amount and by the schedule demanded and out of minimum cost’.

Joseph G .Monks defines Operations Management

7. Explain the product selection and stages involved therein.

Answer: Product Selection and Development Process are very complex process, which begins with idea generation and continues till commercialization. The process requires coordination between various departments. The process can be broken up into the following stages:

1. Exploration: New ideas are sought from the sales force, since that is the department which is in constant direct contact with customers.

8. Explain the process for capacity planning.

Answer: Capacity planning has seen an increased emphasis due to the financial benefits of the efficient use of capacity plans within material requirements planning systems and other information systems. Insufficient capacity can quickly lead to deteriorating delivery performance, unnecessarily increase work-in-process, and frustrate sales personnel and those in manufacturing. However, excess capacity can be costly and unnecessary. The inability to properly manage capacity can be a barrier to the achievement of maximum firm performance. In addition, capacity is an important factor in the organization's choice of technology.

9. What are the various kinds of production systems? Discuss the nature of Mass Production.

Answer: The types of production system are depicted in the following image.

The types of production system are grouped under two categories viz.,

·       Intermittent production system, and

·      Continuous production

·       

10. Discuss in brief how do you organize value engineering function in an electronic industry?

Answer: The term "Value Engineering" is not so familiar these days, since ostensibly it was developed by General Electric back in the World War II era. Per Wikipedia, "Value engineering (VE) is a systematic method to improve the "value" of goods or products and services by using an examination of function. Value, as defined, is the ratio of function to cost. Value can therefore be increased by either improving the function or reducing the cost. It is a

11. Define. Purchase Systems.. What are the common objectives of the purchasing function?

Answer: It is a formal request. Shareholders can issue a requisition notice to a company requiring it to put resolutions to a vote. In business, one department of a company might submit a requisition to the purchasing department for supplies it wants to order. In healthcare, a doctor might issue a requisition for a laboratory test to be performed on a patient to

SECTION B (ANSWER ANY ONE)

1. (a) What are the advantages of having a company-wide data-bank ? Show how different functions e.g. cost accounting, sales, inventory, manufacturing can be integrated with a data-bank.

(b) A contractor has to supply 10,000 bearings per day to an automobile manufacturer. He finds that, when he starts a production run, he can produce 25,000 bearings per day.

The cost of holding a bearing in stock for one year is Rs. 2 and the set-up cost of a production run is Rs. 1,800. How frequently should production runs be made? (Assume 300 working days in a gear)

Answer: From the data of the problem in usual notations, we have

2. Write short notes on any five of the following:

(a) Cellular manufacturing

Answer:

(b) ISO 9000

Answer:

(c) Fish-bone Diagram

Answer:

(d) AGVS

Answer:

(e) Cross Impact Matrix

Answer:

(f) Benchmarking

Answer:

(g) CIM

Answer:

(h) Job Enlargement

Answer:

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