SUBJECT TITLE : PRODUCTION MANAGEMENTSUBJECT CODE : 4118COURSE CATEGORY : APERIODS/ WEEK : 4PERIODS/ SEMESTE : 72CREDITS : 4

TIME SCHEDULE

MODULE TOPIC PERIODS

1.1 Introduction to production EngineeringI 1.2 Productivity 16

1.3 Production planning and control

TEST I 2

II 2.1 Plant Location and Layout2.2 Plant maintenance 162.3 Material handling

Test – II 2

III 3.1 Method study3.2 Work study and Work measurement3.3 Work sampling 163.4 Value Engineering

TEST III 2

IV 4.1 Cost and Break Even Analysis 16Test – IV 2

Total 72

OBJECTIVES

MODULE I1. 1.0 Know Production Management.

1.1 State Importance of productivity and what changes should be made to an existingsystem to enhance productivity.

1.2 .0 Understand Productivity.1.2.1 Define productivity,1.2.2 Differentiate between productivity and production.1.2.3 Compute productivity

1.2.4 Explain productivity measures1.3.0 Understand Production Planning and Control

1.3.1 State PPC1.3.2 Explain objectives1.3.3 State job production, batch, mass, continuous, one-time production1.3.4 Explain above1.3.5 State directing controlling, coordinating, routing, scheduling, dispatching,1.3.6 Explain above1.3.7 State preplanning, production planning, production control.1.3.8 Explain function of PPC such as materials, manpower, methods, etc.

MODULE II2.1.0 Understand Plant Location and Plant Layout.

2.1.1 Define plant location2.1.2 State need for selecting a suitable location2.1.3 Differentiate Urban, Sub urban, rural location.2.1.4 Explain factors affecting plant location.2.1.5 Define plant lay out.2.1.6 Explain objectives.2.1.7 State principles of plant location.2.1.8 Explain factors influencing plant layout.2.1.9 Explain different types of plant layout.2.1.10 State plant layout procedures.

2.2.0 Understand Plant Maintanance2.2.1 State plant maintenance.2.2.2 Explain preventive, Predictive, Breakdown 3.13maintenance, Shutdown,scheduled maintenance.2.2.3 Explain the preparation of maintenance log.

2.3.0 Understand Material Handling2.3.1 State material handling.2.3.2 Explain factors affecting material handling.2.3.3 Explain selection and type of MH equipments.MODULE III

3.1.0 Understand Method Study3.1.1 Define method study.3.1.2 State objectives of method study.3.1.3 Steps in Method study3.1.4 Explain recording techniques and preparation of charts.

3.2.0 Understand Work-study and work Measurement.3.2.1 Define work study3.2.2 State importance of work study.3.2.3 Explain advantageous of work-study.3.2.4 Explain steps in work-study3.3.0 Know Work Sampling.3.3.1 State and explain work sampling.

3.4.0 Understand Importance of Value Engineering.

3.4.1 State meaning of value engineering.3.4.2 State and explain cost value, Exchange value, Use value, Esteem value.3.4.3 State uses of value analysis.3.4.4 Explain above.3.4.5 Define FAST.3.4.6 Explain Fast.3.4.7 Explain principles of value analysis.3.4.8 State functions of cost analysis.3.4.9 Explain estimation procedure.3.4.10 State material cost, Labor cost, Expense, Factory cost, Prime cost.3.4.11 Calculate costs.3.4.12 Define depreciation.3.4.13 Explain method of calculation.3.4.14 Calculate depreciation by straight line, Reducing balance, annuity, sinking fund

methods.MODULE IV

4.1.0. Apply Breake Even Analysis4.1.1. Define cost.4.1.2. List types of cost4.1.3. Define Marginal Opportunity costl4.1.4. Define Past and Future cost,4.1.5. Define Replacement and Historical cost.4.1.6. Define Incremental and Sunk cost.4.1.7. Define Controllable and Uncontrollable cost.4.1.8. Define accouting and economic cost.4.1.9. Define explicit cost and its classification4.1.10. Explain above cost.4.1.11. Expain average fixed cost4.1.12. Compute Total Fixed cost and Average cost.4.1.13. Plot the average cost curve.4.1.14. Compute Marginal cost.4.1.15. Explain Short run cost and long run cost.4.1.16. Define breake Even Analysis4.1.17. Compute breake Even Chart.4.1.18. Explain importance of breake Even Analysis and its assumptions.4.1.19. Compute the optimum product mix.4.1.20. Explain the advntages and disadvantages4.1.21 Explain the application of BEA.

MODULE I

1. Introduction

Explanation on scope and objective of the subject production engineering – and field ofapplications

2. productivityIntroduction –definition -- Production and productivity - difference between productions -–types of production—concept of productivity—tools of productivity –productivity index

– productivity measurement—factors affecting productivity – – methods of increasingproductivity – - Simple problems.

3. Production planning and controla) Introduction to production planning and control--plan the work and then work the

plan concept– types of production – job production batch production, massproduction, continuous products – one time large production – explanation ofproduction planning and control – benefits of PPC – functions of PPC

b) Planning activities – forecasting, plant location, product planning, design anddevelopment, material selection, process planning, determination of men, machines,and material and tool requirements.

Methods of Fore-casting: - Historic estimate, trend line techniques, sales forceestimate, co-relation techniques, sampling techniques. Process planning – choice ofmachine in process planning – break even analysis – process sheet – process planningprocedure

c) Routing – explain routing – routing procedure – route sheet – comparison of routesheet and process sheet—comparison planning and production control

d) Scheduling – factors affecting scheduling – types – master schedule parts schedule,m/c loading schedule – preparation of schedule chart in Gantt chart form

e) Just in Time manufacturing – Explanation of the concept of JIT ,MRPf) Dispatching – functions – work in dispatching – list various documents prepared in

dispatchingg) Follow up and control – types of control material utilization control, labor utilization

control, manufacturing cost control

MODULE II

1. Plant location and Plant layout

a. Factors to be considered in locating Industrial plants1. Availability of raw materials2. proximity to market and transport facilities3. availability of power and fuel4. availability of suitable labor5. Climate and atmosphere condition5. commercial facilities6. local laws7. attitude of local people8. defense from enemy attacks9. Protected area& environmental factors.

b. Plant lay out – objectives -principles of plant layout – types of layout– –product layout, process layout, combination and fixed position layout-- advantages –preparation of activity relation ship chart –SLP- Application of Computers in PlantLayout- Corelap-aldep etc

Factors: Influencing the plant layout --type of production – production system –availability of area – material handling system – type of building – future expansion plan-

2. maintenance management

Introduction – need for maintenance-cost of maintenance-direct, indirect, total cost ofmaintenance-unavailability cost - types of maintenance – preventive, predictive,breakdown, shutdown, scheduled maintenance – condition based maintenance –opportunity maintenance, occasional maintenance schedule – failure statistics --maintenance log preparation –structure of maintenance department

3. Material handlingMaterial Handling-Importance of Material Handling-Material Handling Principle-MaterialHandling equipments-Classification.

MODULE III

1. work study

a. Introduction to work study – advantages – application of work study -- work study asa productivity enhancing tool

b. Introduction to method study – objectives of method study – method study procedure– state herbless and their symbols – process chart symbols – preparation of chartsoperation process chart, flow process chart, man-machine chart, right hand left handchart, and silo chart – flow diagram – string diagram

c. Principles of motion economy – Rules concerning Human body, work place layoutand material handling, tools and equipment design

2. Work measurement

a. Objectives of work measurement – procedure of stop watch time studyb. Standard time calculation – production studyc. Use of standard data – application – analytical estimating – P.M.T.S – M.T.M

3. Work Sampling

Explain work sampling – applications – steps in work sampling – Random sampling -use of random numbers

4. Value Engineering

Definition –uses—unnecessary cost—steps in value engineering –block diagram—product selection—fusion –analysis—system technical-- evaluation of alternatives –principle of value analysis --

5. Fundamentals of Estimating

Explain estimating – differentiate estimating and costing – objectives and functions ofestimating – principal constituents of estimating the cost of a component – design time,method studies, time studies, drafting time, planning and production time, design andmanufactures of special tools, experimental work, labor, material, over heads,miscellaneous allowances, steps in estimating procedure.

6. Elements of costing

Explain costing – objectives of costing – elements of cost – material, labor, and expenses– steps in the calculation of selling price of a product. Example, methods of allocation ofover head expenses – percentage of direct labor cost, direct material cost, prime cost, andlabor hour rate and machine hour rate.Definition and concepts of depreciation – causes of depreciation – methods of calculating(or providing for) depreciation – straight line method – reducing balance method –annuity method – sinking fund method – sum of the digits method – simple method –simple problems.

MODULE – IV: COST AND BREAKE EVEN ANALYSIS

Meaning of Cost analysis-Concept of Opportunity cost-Marginal cost-Past and Futurecost-Avoidable and Unavoidable cost-Replacement and historical cost-Incremental andSunk cost-Controllable and Uncontrollable cost-Concept of costs-Classification ofExplicit cost-Relation between short run cost-Problems on above.

Break Even Analysis-Problems.

TEXT BOOKS

1. Industrial Engineering and Production management – Mart and Telsang2. Industrial Engineering and Management – Dr. O.P. Hanna3. Industrial Organization and Engineering Economics – T.R. Bang & S.C. Sharma4. Managerial Economics Financial analysis S.A.Siddique,A.A.Sidique NewAgePublishers