Production and Operations Management

Teacher

Dr. Prasanta K. Mohanty

Category

Core Courses

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Course Name : Production and Operations Management

Code(Credit) : CUTM1205(2-0-1)

Course Objectives

  • Understand Manufacturing 4.0 and appreciate technology integration in smart production
  • Understand the various production and operations design decisions and how they relate to the overall strategies of organizations.
  • Understand the importance of product and service design decisions and its impact other design decisions and operations.
  • Obtain an understanding of quality management practice in organizations and how total quality management and six-sigma facilitate organizational effectiveness.
  • Understand the roles of inventories and basics of managing inventories in various demand settings.

Learning Outcomes

  • Understand the core features of the operations and production management function at the operational and strategic levels, specifically the relationships between people, process, technology, productivity and quality and how it contributes to the competitiveness of firms
  • Students will develop an integrated framework for strategic thinking and decision making to analyse the enterprise as a whole with a specific focus on production delivery processes
  • Develop the ability to identify operational methodologies to assess and improve an organizations performance
  • Assess the OPM function performance and capabilities in various organizations

Course Syllabus

Module I: Manufacturing Operations Management - The Smart Backbone of Industry 4.0; Introduction, Basic concepts of Manufacturing Operations Management(MOM)/ Manufacturing Execution System(MES) for Industry 4.0

Smart manufacturing; The roots of smart manufacturing, Pillars of smart manufacturing; Pillar 1: Manufacturing technology and processes, Pillar 2: Materials, Pillar 3: Data, Pillar 4: Predictive engineering, Pillar 5: Sustainability, Pillar 6: Resource sharing and networking,

Operations Management and Strategy; Operations Decisions - A Framework, Cross-Functional Decision Making, Operations as a Process

Service Process Selection and Design­The Nature of Services, ­Service Strategy: Focus & Advantage, ­Service-System Design Matrix. ­Service Blueprinting, ­Service Fail-safing, ­Characteristics of a Well-Designed Service Delivery System

Module II: Process Analysis; key elements of process analysis: flow rates, and flow times, uncover bottlenecks, optimize labour and inventory, and complexities of multiple flow units.

Inventory Management; Purpose of Inventories, Costs of Inventories, Independent versus Dependent Demand, Economic Order Quantity, Continuous Review System, Periodic Review System, Using P and Q System in Practice, ABC Inventory Management, Betting on the Uncertain Demand. Service Levels and Lead Times; Newsvendor Model

Module III: Quality; quality in operations, from examining the common reasons for defects to the most widely used implementation techniques for addressing problems of quality and ensuring reliability and standards. sound strategy for maintaining quality and stability.

Module IV: Scheduling and Sequencing; Objective of Scheduling, Advanced Planning and Scheduling System. Sequencing; Gantt chart, Sequencing model - "n" jobs 1 machine, "n" jobs 2 machines, "n" jobs  “m” machines

Service Operation Scheduling; Waiting Line Problems. Effect of Randomness on Thruput. Thruput Loss due to Impatience / Limited Buffers.

Texts:

  1. OM by Chase, Jacobs, Aquilano, Agarwal
  2. Krajewski, Ritzman, Malhotra- Operations Management, Pearson
  3. Gaither, Frazier, Operations Management, CENAGE

 References:

  1. Roberta S. Russell & Bernard W. Taylor III, - “Operations Management”, Pearson/ PHI- ( PPT)
  2. Everette. Adam Jr., Ronald J. Ebert, - “Production and Operations Management”, PHI
  3. B.MAHADEVAN, “OPERATIONS MAANGEMENT” FOR CASELETS

Session Plan

Session 1

The Smart Backbone of Industry 4.0; Introduction, Basic concepts of Manufacturing Operations Management(MOM)

Session 1 Industry 4.0 & smart factory

Article MANUFACTURING_OPERATIONS_MANAGEMENT

Industry 4.0 

Session 3

Smart manufacturing; The roots of smart manufacturing, Pillars of smart manufacturing; Pillar 1: Manufacturing technology and processes, Pillar 2: Materials, Pillar 3: Data, Pillar 4: Predictive engineering, Pillar 5: Sustainability, Pillar 6: Resource sharing and networking

Service 4.0 

Session 4

Operations Management and Strategy; Operations Decisions - A Framework, Cross-Functional Decision Making, Operations as a Process

Service Process Selection and Design­The Nature of Services, ­Service Strategy: Focus & Advantage, ­Service-System Design Matrix. ­Service Blueprinting, ­Service Fail-safing, ­Characteristics of a Well-Designed Service Delivery System

Session 4 Operation Function and Strategy

Session 4- Service process, selection & design

Strategic Role of OM 

Session 5

Process Analysis; key elements of process analysis: flow rates, and flow times, uncover bottlenecks, optimize labour and inventory, and complexities of multiple flow

Session 5 Product Process & Service Design

Process Mapping

Session 6 & 7

Inventory Management; Purpose of Inventories, Costs of Inventories, Independent versus Dependent Demand, Economic Order Quantity

Session 6 & 7 Inventory Mgmt

Session 8

Continuous Review System, Periodic Review System, Using P and Q System in Practice, ABC Inventory Management, Betting on the Uncertain Demand. Service Levels and Lead Times

Session 9

Newsvendor Model

Session 10

Quality; Concept of quality, Quality of design, Conformance & performance; Cost of poor process, Performance and quality

Session 10 Quality

Seven basic quality tools 

Session 11

Control chart; Process Control charts, Process out of control, X, R & P chart

Session 12

Product control, Acceptance sampling, OC curve

Session 13

Total Quality Management, Six Sigma

TQM

Six Sigma 

Session 14

Scheduling, Objective of Scheduling, Advanced Planning and Scheduling System Sequencing; Gantt chart, Sequencing model - "n" jobs 1 machine, "n" jobs 2 machines, "n" jobs  “m” machines

Gantt chart in Excel

Gantt chart using Excel 

Session 15 & 16

Service Operation Scheduling; Waiting Line Problems. Effect of Randomness on Thruput. Thruput Loss due to Impatience / Limited Buffers.

Session 15 Service Operations Scheduling

Session 17, 18, 19 & 20

Project Presentation by students

Case Studies

Case Studies

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    Our Main Teachers

    Dr. Prasanta K. Mohanty

    Dean Academic and Professor
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    A graduate in Electronics and Communication Engineering. Done MBA and Ph.D. in the area of Supply Chain Management. The academic interest lies in teaching courses; Project Management, Supply Chain Design, and Service Operation Management. The research interests are in Service Optimisation, Vendor Management Inventory, and Disruptive Innovations. Worked with many organizations viz; L & T […]