Production Operations Management - Kopykitab

Production and Operations Management SECOND EDITION R.B. KHANNA Formerly Professor Indian Institute of Planning and Management (IIPM) Jaipur Delhi-110092 2015

PRODUCTION AND OPERATIONS MANAGEMENT, Second Edition R.B. Khanna 2015 by PHI Learning Private Limited, Delhi. All rights reserved. No part of this book may be reproduced in any form, by mimeograph or any other means, without permission in writing from the publisher. ISBN-978-81-203-5121-9 The export rights of this book are vested solely with the publisher. Fifth Printing (Second Edition) May, 2015 Published by Asoke K. Ghosh, PHI Learning Private Limited, Rimjhim House, 111, Patparganj Industrial Estate, Delhi-110092 and Printed by Rajkamal Electric Press, B-35/9, G.T. Karnal Road Industrial Area, Delhi-110033.

To my dear wife SAROJ who stood by patiently when the demands of this book took priority over her demands for my time

Contents Preface Preface to the First Edition Part I: xiii xv The Why of Production and Operations Management 1. Operations Management—An Introduction 3–14 Learning Objectives  3 1.1 Introduction  3 1.2 Difference between Products and Services  5 1.3 What is Operations Management?  6 1.4 Brief History of Operations Management  7 1.5 Impact of Information Technology and Globalisation  10 1.6 Organisation of This Book  11 Concept Quiz  11 Questions  14 2. Operations Strategy and Competitiveness 15–27 Learning Objectives  15 2.1 Introduction  15 2.2 Business Strategy  16 2.3 Competitive Priorities  16 2.4 Order Qualifiers and Order Winners  19 2.5 Developing an Operations Strategy  20 2.6 Productivity and Competitiveness  21 2.7 Latest Trends  23 2.8 Summary  24 Concept Quiz  25 Questions  27 Part II: The What of Production and Operations Management 3. Product and Service Design Learning Objectives  31 3.1 Introduction  31 31–43 v

vi Contents 3.2 Traditional Approach  32 3.3 Concurrent Design  33 3.4 Steps in The Design Process  33 3.5 Design for Manufacture and Assembly (DFMA)  37 3.6 Design of Services  37 3.7 Classification of Services  39 3.8 Technology and Design  40 3.9 Summary  40 Concept Quiz  41 Questions  43 4. Reliability, Maintainability, Availability and Value Analysis 44–57 Learning Objectives  44 4.1 Introduction  44 4.2 Failures  45 4.3 Reliability  46 4.4 Maintainability  47 4.5 Availability  48 4.6 Maintenance  49 4.7 Value Analysis  51 4.8 Summary  53 Concept Quiz  54 Questions  56 Supplement 1: Dynamic Programming 58–67 Replacement Models 68–76 Introduction  58 Definitions  58 Summary  65 Questions  65 Supplement 2: Introduction  68 Replacement of an Equipment which Deteriorates Over Time  68 Replacement of Items that Fail Completely  71 Summary  73 Questions  73 5. Product Quality Learning Objectives  77 5.1 Introduction  77 5.2 Quality of Design  78 5.3 Quality of Conformance to Design  79 5.4 Costs of Quality  80 5.5 Total Quality Management  82 5.6 Quality Improvement and Employees  85 5.7 Tools for Identifying Quality Problems and Causes  86 5.8 ISO 9000:2000  89 5.9 Summary  92 Concept Quiz  92 Questions  95 77–95

Contents  vii Part III: The How of Production and Operations Management 6. Process Design and Selection 99–118 Learning Objectives  99 6.1 Introduction  99 6.2 Factors Affecting Process Design  100 6.3 Processes Flow Structures  101 6.4 Process Selection  105 6.5 Group Approach  107 6.6 Other Manufacturing Technologies  108 6.7 Process Design and Selection for Services  109 6.8 Summary  113 Concept Quiz  114 Questions  116 7. Work Study 119–147 Learning Objectives  119 7.1 Introduction  119 7.2 Behavioural Impact of Work Study  120 7.3 Method Study  120 7.4 Select  121 7.5 Record  121 7.6 Critical Examination  124 7.7 Develop  125 7.8 Install  125 7.9 Maintain  125 7.10 Ergonomics  127 7.11 Methods Improvement and Materials Handling  132 7.12 Work Measurement  132 7.13 Time Study  133 7.14 Activity Sampling  137 7.15 Predetermined Motion Time Systems  139 7.16 Synthetic Timings  140 7.17 Analytical Estimating  141 7.18 Summary  141 Concept Quiz  143 Questions  145 8. Process Quality—Statistical Quality Control Learning Objectives  148 8.1 Introduction  148 8.2 Process Capability  150 8.3 Six Sigma Quality  151 8.4 Process Control  151 8.5 Process Control for Attributes—p Charts  152 8.6 Process Control for Attributes—c Charts  154 8.7 Process Control for Variables —X and R Charts  155 8.8 Using Control Charts  160 8.9 Acceptance Sampling  162 8.10 Operating Characteristics Curve  163 148–182

viii Contents 8.11 Average Outgoing Quality Limit (AOQL)  166 8.12 Sampling Plans  167 8.13 Solution by Computer Package  168 8.14 Summary  175 Concept Quiz  177 Questions  179 Part IV: The Where of Production and Operations Management 9. Facility Location 185–209 Learning Objectives  185 9.1 Introduction  185 9.2 The Why of Location Decision Problems  186 9.3 Factors Affecting Facility Location  186 9.4 Factor Rating Analysis and Forced Decision Matrix  189 9.5 Economic Analysis  192 9.6 Load Distance Methods  199 9.7 Locating Service Facilities  203 9.8 Summary  203 Concept Quiz  204 Questions  206 10. Facility Layout 210–238 Learning Objectives  210 10.1 Introduction  210 10.2 Factors Affecting Layout  211 10.3 Basic Production Layout Formats  212 10.4 Process Layout  213 10.5 Systematic Layout Planning  217 10.6 Product Layout  219 10.7 Line Balancing  219 10.8 Machine Balancing in Group Technology  226 10.9 Service Layout  229 10.10 Summary  230 Concept Quiz  232 Questions  234 11. Capacity and Equipment Selection Learning Objectives  239 11.1 Introduction  239 11.2 Capacity  240 11.3 Decision Tree Analysis  240 11.4 Allocation of Capacities Through Linear Programming  244 11.5 Simulation  247 11.6 Economic Analysis for Equipment Selection  247 11.7 Equipment Balancing  248 11.8 Summary  250 Concept Quiz  252 Questions  253 239–256

Contents  ix Supplement 3: Simulation 257–283 Introduction  257 Steps Involved in Monte Carlo Simulation  258 Summary  278 Questions  278 Part V: The When of Production and Operations Management 12. Forecasting 287–314 Learning Objectives  287 12.1 Introduction  287 12.2 Types of Forecasts  288 12.3 Qualitative Methods of Forecasting  288 12.4 Time Series Analysis  289 12.5 Simple Moving Average  290 12.6 Weighted Moving Average  291 12.7 Exponential Smoothing  292 12.8 Causal Methods  295 12.9 Linear Regression  295 12.10 Multiple Regression  298 12.11 Decomposition of Time Series  301 12.12 Measures of Forecasting Accuracy  304 12.13 Selecting A Forecasting Method  306 12.14 Summary  309 Concept Quiz  310 Questions  312 13. Aggregate Production Planning 315–337 Learning Objectives  315 13.1 Introduction  315 13.2 Production Planning System  315 13.3 Aggregate Production Planning  317 13.4 Production Planning Strategies  318 13.5 Aggregate Planning Techniques  319 13.6 Linear Programming Approach  324 13.7 Transportation Model Approach  327 13.8 Other Methods  330 13.9 Aggregate Planning for Services  330 13.10 Yield Management  331 13.11 Summary  333 Concept Quiz  333 Questions  335 14. Material Management and Inventory Control Learning Objectives  338 14.1 Introduction  338 14.2 Material Management  339 14.3 Objectives of Materials Management Department  339 14.4 Centralisation Versus Decentralisation  341 14.5 Inventory Management  341 14.6 Costs Associated with Inventory  342 338–366

Production And Operations Management 25% OFF Publisher : PHI Learning ISBN : 9788120351219 Author : R B Khanna Type the URL : http://www.kopykitab.com/product/6777 Get this eBook

2. Operations Strategy and Competitiveness 15-27 Learning Objectives 15 2.1 Introduction 15 2.2 Business Strategy 16 2.3 Competitive Priorities 16 2.4 Order Qualifiers and Order Winners 19 2.5 Developing an Operations Strategy 20 2.6 Productivity and Competitiveness 21 2.7 Latest Trends 23 2.8 Summary 24 Concept Quiz 25 Questions 27 Part II .