CONTENTS
1. The Production (Manufacturing) Function 1
1.1 Inttoduction
1.2 Operation Concept of Production
1.3 Production as the Conversion Process
1.4 Productivity of Conversion Process
1.5 Objectives of Production Management
1.6 Components of Production Management
1.7 Responsibilities of a Production Manager
1.8 Production as a Co-ordination Function
1.9 Summary
1.10 Keywords
1.11 Self-assessment Questions
2. Manufacturing Methods 15
2.1 Intioduction
2.2 Factors Influencing Choice of Manufacturing Method 2.3 Classification of Manufacturing Methods
2.4 Selection of Manufacturing Methods
2.5 Summary
2.6 Keywords
2.7 Self-assessment Questions
3. Facilities (Plant) Location 35
3.1 Introduction
3.2 Need for Location Decisions
3.3 Factors Governing Plant Location
3.4 Economic Survey for the S ite Selection
3.5 Summary
3.6 Keywords
3.7 Self-assessment Questions
4. Facilities (Plant) Layout 51
4.1 Introduction
4.2 Objectives of a Good Layout
4.3 Principles, of a Good Layout
4.4 Types of Layouts
4.5 Cost Analysis of basic forms of Layout
4.6 Tools and Techniques for Layout Analysis
4.7 Summary
4.8 Keywords
4.9 Self-assessment Questions
5. Production Planning and Control (PPC) 71
5.1 Production Planning and Control
5.2 Objectives of PPC
5.3 Functions of PPC
5.4 Organization of PPC Department
5.5 Production Planning Horizon
5.6 Summary
5.7 Self-assessment Questions
6. Aggregate Planning 83
6.1 Introduction
6.2 Aggregate Planning Strategies
6.3 Aggregate Planning in Services
6.4 Summary
6.5 Keywords
6.6 Self-assessment Questions
7. Master Production Schedule 93
7.1 Introduction
7.2 Objectives of MPS
7.3 MPS Process
7.4 Summary
7.5 Keywords
7.6 Self-assessment Questions
8. Operations Scheduling 105
8.1 Introduction
8.2 Functions of Scheduling
8.3 Gantt Chart
8.4 Scheduling Methods
8.5 Priority Sequence Rules
8.6 Scheduling in Services
8.7 Summary
8.8 Keywords
8.9 Self-assessment Questions
9. Production Activity Control 115
9.1 Introduction
9.2 Functions of Production Activity Control
9.3 Functions of Dispatching
9.4 Concept of Progressing
9.5 Functions of Progressing
9.6 Summary
9.7 Keywords
9.8 Self -assessment Questions
10. JIT and Kanban 127
10.1 Intioduction
10.2 JIT Manufacturing
10.3 KANBAN-An Integrated JIT System
10.4 Summary
10.5 Self-assessment Questions
11. Project Planning & Control: Critical Path Analysis (PERT/CPM) 137
11.1 Introduction
11.2 Critical Path Analysis
11.3 Advantages of CPA
11.4 Network Logic
11.5 Steps for CPA
11.6 Summary
1.1.7 Self-assessment Questions
12. Maintenance of the Plant 171
12.1 Introduction
12.2 Typical Causes of Plant Breakdown
12.3 Costs Associated with an Eventual Breakdown 12.4 Objectives of a Good Maintenance System
12.5 Types of Maintenance
12.6 Preventive Maintenance
12.7 Corrective Maintenance
12.8 Summary
12.9 Self-assessment Questions
13. Quality Management 193
13.1 Introduction
13.2 Historic Development
13.3 Achievement of Quality
13.4 Quality Control
13.5 Types of Inspection
13.6 The Operating Characteristics Curve
13.7 Sampling Plans
13.8 Total Quality Management
13.9 Summary
13.10 Key Words
13.11 Self-assessment Questions
14. Quality Management - II (Statistical Process Control) 219
14.1 Introduction
14.2 Principles underlying Process Control
14.3 Control Charts as a Tool for Process Control
14.4 Types of Control Charts
14.5 Control Charts for Variables (X-R Charts)
14.6 Control Charts for Attributes
14.7 Summary
14.8 Self-assessment Questions
15. Six Sigma 249
15.1 Introduction to Six Sigma
15.2 Theory Six Sigma
15.3 How to Calculate Process Sigma
15.4 Process Variation
15.5 Six Sigma Methodology
15.6 Becoming a Six Sigma Organization
15.7 Six Sigma Organizational Architecture
15.8 Summary
15.9 Keywords
15.10 Self-assessment Questions
16. Work Study I (Method Study) 269
16.1 Ihtroduction
16.2 Method Study
16.3 Basic Procedure of Method Study
16.4 Selection of the Job
16.5 Recording of Facts
16.6 Critical Examination
16.7 Development and Selection
16.8 Installation of the Proposed Method
16.9 Maintenance of the Proposed Method
16.10 Summary
16.11 Keywords
16.12 Self-assessment questions
17. Work Study - II (Work Measurement) 305
17.1 Introduction
17.2 Techniques of Work Measurement
17.3 Time Study
17.4 Work Sampling
17.5 Incentive Schemes
17.6 Classification of Incentive Plans
17.7 Summary
17.8 Keywords
17.9 Self-assessment questions
18. Operations Management in Service Sector 339
18.1 Operations Management and its Relevance in
Service Industry
18.2 Service Concept of Operations
18.3 Operations Management in Banking Industry
18.4 Operations Management in Retail Industry
18.5 Operations Management in BPOs
18.6 Operations Management in IT Industry
18.7 Operations Management in Hotel
18.8 Operations Management in Hospitals
18.9 Summary
18.10 Keywords
18.11 Self-assessment questions
Appendix A: Standard Table 377
Appendix B : Suggested Reference Books 381
Appendix C: Glossary 384