ASSIGNMENTS

Subject Code: MB0044

(4 credits)
Set 1
Marks 60
SUBJECT: PRODUCTION & OPERATIONS MANAGEMENT
Note: Each Question carries 10 marks
1. Explain the various automated systems for transfer of materials in the production plant? Illustrate your
answer by considering an example of an automobile showroom.

Ans. 1: Automated Flow Lines

When several automated machines are linked by a transfer system which moves the parts by using handling machines
which are also automated, we have an automated flow line. After completing an operation on a machine, the semi-
finished parts are moved to the next machine in the sequence determined by the process requirements – a flow line is
established. The parts at various stages – raw material to ready for fitment or assembly – are processed continuously to
attain the required shapes or acquire special properties to enable them to perform desired functions. The materials need
to be moved, held, rotated, lifted, positioned etc. for completing different operations. Sometimes, a few of the
operations can be done on a single machine with a number of attachments. They are moved further to other machines
for performing further operations. Human intervention may be needed to verify that the operations are taking place
according to standards. When these can be achieved with the help of automation and the processes are conducted with
self regulation, we will have automated flow lines established. One important consideration is to balance times that
different machines take to complete the operations assigned to them. It is necessary to design the machines in such a
way that the operation times are the same throughout the sequence in the flow of the martial.

In fixed automation or hard automation, where one component is manufactured using several operations and machines
it is possible to achieve this condition – or very nearly. We assume that product life cycles are sufficiently stable to
invest heavily on the automated flow lines to achieve reduced cost per unit. The global trends are favoring flexibility
in the manufacturing systems. The costs involved in changing the set up of automated flow lines are high. So,
automated flow lines are considered only when the product is required to be made in high volumes over a relatively
long period. Provision for extra pallets or tool holders or conveyors is made in the original design to accommodate
anticipated changes. The logic to be followed is to find out whether the reduction in cost per piece justifies the costs of
designing, manufacturing and setting up automated flow lines. Group Technology, Cellular Manufacturing along with
conventional Product and Process Layouts are still resorted to as they allow flexibility for the production system.
Production managers see every bottleneck as an opportunity to hasten the flow and reduce inventories. However, it is
important to note that setting up automated flow lines will not be suitable for many industries

Automated Assembly Lines

All equipments needed to make a finished product are laid out in such a way as to follow the sequence in which the
parts or sub-assemblies are put together and fitted. Usually, a frame, body, base will be the starting point of an
assembly. The frame itself consists of a construction made up of several components and would have been
‘assembled’ or ‘fabricated’ in a separate bay or plant and brought to the assembly line. All parts or sub-assemblies are
fitted to enable the product to be in readiness to perform the function it was designed to. This process is called
assembly. Methodologies of achieving the final result may vary, but the basic principle is to fit all parts together and
ensure linkages – mechanical, electrical or electronic – so that their functions are integrated and give out the desired
output.

Product Layouts are designed so that the assembly tasks are performed in the sequence they are designed. You will
note that the same task gets repeated at each station continuously. The finished item comes out at the end of the line
The material goes from station 1 to 5 sequentially. Operation 2 takes longer time, say twice as long. To see that the
flow is kept at the same pace we provide two locations 2a and 2b so that operations 3, 4 an 5 need not wait. At 5, we
may provide more personnel to complete operations. The time taken at any of the locations should be the same.
Otherwise the flow is interrupted. In automated assembly lines the moving pallets move the materials from station to
station and moving arms pick up parts, place them at specified places and fasten them by pressing, riveting, screwing
or even welding. Sensors will keep track of these activities and move the assemblies to the next stage. An operator will
oversee that the assemblies are happening and there are no stoppages. The main consideration for using automated
assembly lines is that the volumes justify the huge expenses involved in setting up the system.

Flexible Manufacturing Systems

These consist of a production machines; material handling and transferring machines, and a computer system.

The machines are arranged in a sequence to perform operations according to the technical requirements. After each
operation the material is picked up and transferred to the next machine where it is held and next operation performed.
During this process the machines have to stop, release the material that has been worked upon and receives the
component from the previous operation and clamped the cycle is programmed and the various actions of the machines
are performed by the controls that are executed by the computer system. The tools are loaded, movements are effected,
speeds controlled automatically without the need for worker’s involvement. One system as described above is
designed to produce components that belong to a ‘group’. A group of components will have similar shapes, though
varying in sizes, requiring a series of operations which are almost identical, so that same machines can be programmed
to produce them in batches by changing the programme in the computers. Since reprogrammed operations are capable
of producing different components, we have flexibility in the manufacturing process. This flexibility leads to better
utilization of the equipments. It reduces the numbers of systems and aids in reduction of investment as well as space
needed to install them. One of the major concerns of modern manufacturing systems is to be able to respond to market
demands which have uncertainties. Continuous development of products necessitates changes in parts. Flexibility is
important so that manufacturing systems are capable of accommodating these changes. Automated systems help in
reducing costs but they demand huge investments. Cellular layouts of arranging machines help in flexibility, because
when machines that have similar processes are grouped together to make similar components skills, materials and
machine times can be shared. Scheduling and sequencing become more efficient because volumes required can be
distributed or delayed or clubbed together to meet variation in demands. The machines receive instructions from the
computer regarding settings, loading and unloading of the machines.

2. State the important considerations for locating an automobile plant? Collect information on layout planning
of an automobile plant from various sources and furnish the same.

Ans. 2
3. Who are the players in a project management? What are the various roles and responsibilities of the players
in a project management?

4. What are the various steps in project monitoring and controlling a project?

5. Explain the necessity and objectives of SCM.

6. What are the steps involved in SCM implementation?

 ASSIGNMENTS
Subject Code: MB0044
(4 credits)
Set 2
Marks 60
SUBJECT: PRODUCTION & OPERATIONS MANAGEMENT
Note: Each Question carries 10 marks

1. Explain how material flow information helps in work centre decision. Consider the example of a shopping
center to illustrate your answer.

Ans. 1:

2. What are the reasons for failure of a project? Give suitable examples.

3. Explain the various phases in project management life cycle?

4. What are the seven principles of SCM?

5. Explain Bullwhip effect and how it could be prevented.

6. What do you understand by Line Balancing? What is the importance of order picking in material handling? Give
suitable examples.