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HAPPY NEW YEAR AND

A PRODUCTIVE SEMESTER

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ME 408-Industrial Engineering &

Operations Research

Slot 4

Monday : 9.30

Tuesday : 8.30

Thursday: 9.30

Room Number : 208 -MED

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COURSE OUTLINEFOCUS: Applications of IE&OR in Manufacturing

and Service Systems

TOPICS TO BE COVERED

Introduction to Manufacturing and Service Systems

Location Decisions

Layout Decisions

Project Management

Maintenance Management Operations Scheduling

Supply chain management

Spare parts management

Approaches for Enterprise Productivity Management

Applications of Queuing Theory, Integer Programming andMulti criteria decision models

Case Studies

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ASSESSMENT PLAN

ENDSEMESTER- 50%

INSEMESTER - 50%

Mid-semester - 15 %

QUIZ (2 ) - 10 %

Project & Seminar - 25 %

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LECTURE 1

Management of Manufacturing Systems- Some

Perspectives

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MANUFACTURING SYSTEMSCommon components are Input, Conversion capability ,Output Output monitors, Feedback and Input regulators

Engines for achieving organizationalexcellence. Conversion systems. Value adding systems.

Vehicle for achieving organizational goals

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INPUTS

Primary Resources (need to organize)

Machines, Materials, Personnel, Capital, Utilities

Market( need to ascertain)

Competition, Customer Desires, Product Info.

External( need to appreciate)

Legal, Economic, Social, Technological

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CONVERSION SUBSYSTEM

Physical (Manufacturing)

Locational Services (Transportation)

Exchange Services (Retailing)

Storage Services (Warehousing)

Other Private Services (Insurance)

Government Services (Federal, State, Local)

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OUTPUTS

Direct

Products

Services

IndirectRevenue / Profit

Technological Advances / Knowledge

Waste

Pollution

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THE TASKS

Manage inputs

Build capability

Monitor output Apply feed back / feed forward concepts to

a) regulate input and

b) have appropriate capability

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DECISION MAKING IN PRODUCTION

MANAGEMENT

Strategic Decisions

Operating Decisions

Control Decisions

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STRATEGIC DECISIONS

These decisions are of strategic importanceand have long-term significance for the

organization.

Examples include deciding: New product development

Designing production process

Where to locate a new factory

Deciding about the machines

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OPERATING DECISIONS

These decisions are necessary if the ongoing

production of goods and services is to satisfy

market demands and provide profits.

Examples include deciding:

>Which product to make/ dispatch

>How much finished-goods inventory to carry

>Amount of overtime to use next week>How much raw material to purchase next month

And so on

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CONTROL DECISIONS

These decisions concern the day-to-dayactivities of workers, quality of productsand services, production and overheadcosts, and machine maintenance etc.,

Examples include deciding: Labor cost standards for a new product

Frequency of preventive maintenance

New quality control acceptance criteria Efficiency of a work unit

etc.,

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DIFFERENT MANUFACTURING

ENVIRONMENTS

There are different classification schemes

a) Based on the nature of customer order

b) Based on the volume of production

c) Based on the philosophy of facilities

arrangement

d) Based on the nature of product

e) Based on the planning and control system

f) Based on the urge to respond to customersg) Based on the extent of use of IT and

technology

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BASED ON THE NATURE OF CUSTOMER ORDER

Engineer to order

Made to order

a) One time ,b) Repeat order

c) Call off schedule

d) Project

Made to stock

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BASED ON THE VOLUME OF PRODUCTION

Unit production ( Job order )

Batch production ( repetitive production )

Mass Production

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BASED ON THE NATURE OF PRODUCT

Discrete products

Continuous Product

Bulk / Heavy product

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BASED ON THE PLANNING AND CONTROL

SYSTEM

Traditional forecast based system

Hierarchical Planning System

Material Requirement Planning System Just in Time System

Quick Response Manufacturing System

TOC Based system ( Theory of constraints)

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BASED ON CUSTOMER RESPONSIVENESS

Just in time manufacturing

Flexible manufacturing system

Agile manufacturing Quick response manufacturing

Reconfigured manufacturing system

Lean manufacturing

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BASED ON IT APPLICATION

Flexible manufacturing system (FMS)

( Hardware and software integration )

Computer integrated manufacturing ( CIM) Enterprise Resource Planning assisted

manufacturing ( ERP)

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POPULAR MANUFACTURING SYSTEMS

Assembly Lines Group technology / cellular manufacturing

systems (GT /CMS) MRP 1 / MRP 2 supported systems Flexible manufacturing system (FMS) Just in time production systems (JIT) ERP supported manufacturing systems Agile manufacturing systems (AMS) Quick response manufacturing systems

(QRMS) Lean production systems (LEAN)

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TYPICAL PERFORMANCE MEASURES

DELIVERED TO CUSTOMER COST

QUALITY

DELIVERY PRODUCTIVITY

CUSTOMER RESPONSIVENESS

BUSINESS RESULTS