Subject: IMT-15: Production and Operation Management-MT1
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PART-A

Q1. What are production/operation systems? Discuss its components, giving examples from both service and non-service organizations.

Q2. What do you understand by product design?

Q3. What are the competitive priorities of a firm?

Q4. Why is layout planning necessary?

Q5. Explain any three of the following terms:

(a) Aggregate production planning

(b) Master production plan

(c) Rough cut capacity

(d) Scheduling

PART-B

Q1. Write short notes on following:

a. Acceptance sampling.

b. OC Curve.

Q2. What do you mean by PERT?

Q3. Draw a diagram of MRP II.

Q4. What is the need for a maintenance management system?

Q5. What do you mean by linear programming?

PART-C

Q1. The table below shows a job consisting of 3 sub-jobs a, b and c, along with their time estimates

Job

1-2

1-6

2-3

2-4

3-5

4-5

6-7

5-8

7-8

a(days)

1

2

2

2

7

5

5

3

8

b(days)

7

5

14

5

10

5

8

3

17

c(days)

13

14

26

8

19

17

29

9

32

Draw the project network diagram for each of the jobs. Find the critical path and minimum time taken for each sub-job. Can the total project be completed in 40 days?

Q2. Perform ABC analysis on the following sample of items in an inventory.

Item AnnualConsumption Price/Unit
A 400 20
B 2900 30
C 40 20
D 1200 10
E 40 10
F 320 02
G 250 10
H 900 10
I 700 30
J 90 20

Q3. Jaycee potteries manufactures ceramic bowls and mugs. Two main resources used by the company are skilled labour and clay. The resources required and the profit per unit of each product is tabulated below:

Product

Resource Requirement

Profit/ Unit

Labour (hrs / unit)

Clay (kg / unit)

Bowl

1

4

40

Clay

2

3

50

There are 40 hours of skilled labour and 120 kg of clay available each day. Formulate the problem for maximization of profit as a linear programming problem and find the solution graphically using iso-profit lines.

Q4. The processing time (in hours) of seven jobs to be processed on three machine M1, M2, M3 in the order M1, M2 and M3 are tabulated below:

Job

M1

M2

M3

A

1

7

8

B

3

3

10

C

7

8

9

D

9

2

11

E

4

8

9

F

5

6

14

G

2

1

12

Q5. Sequence these jobs using Johnson's method and find the overall processing time. Find also the waiting time of the jobs and idle times of the three machines.


CASE STUDY - 1

The table below gives details about the various tasks in assembly operation.

Task Requirement (s) Precedence (min) Task Time
A - 10
B C 20
C A 30
D A,C 15
E A 10
F B 20
G D 10
H G 15
I G,H 15

Questions

     (a) Explain the heuristic steps involved.

     (b) Find the theoretical minimum cycle time.

     (c) Find the theoretical number of work stations.

     (d) Assign tasks to the work stations using the LOT rule.

     (e) Calculate the efficiency of the assembly line.

     (f) Determine the balance delay.


CASE STUDY - 2

A company is setting up an assembly line to produce 192 units per 8 hours shift. The following table identifies the work elements, times and immediate predecessors.

Work Element Time (seconds) Immediate Predecessor(s)
A 40
B 80 A
C 30 D,E,F
D 25 B
E 20 B
F 15 B
G 120 A
H 145 G
I 130 H
J 115 C,I
Total = 720 seconds

Questions:

1. What is the cycle time?

2. What is the theoretical minimum number of work stations?

3. Draw the precedence diagram.

4. Determine the idle time, efficiency, and balance delay.