1.

Explain different types of facility layout and their strength and weakness

1. Process layout

All machines performing similar type of operations are grouped at one location in the
process layout e.g., all lathes, milling machines, etc. are grouped in the shop will be
clustered in like groups
Process layout is normally used when the production volume is not sufficient to justify a
product layout.

Advantages
1. In process layout machines are better utilized and fewer machines are required.
2. Flexibility of equipment and personnel is possible in process layout.
3. Lower investment on account of comparatively less number of machines and lower
cost
of general purpose machines.
4. Higher utilization of production facilities.
5. A high degree of flexibility with regards to work distribution to machineries and
workers.
6. The diversity of tasks and variety of job makes the job challenging and interesting.
7. Supervisors will become highly knowledgeable about the functions under their
department.

dis advantage

1. Backtracking and long movements may occur in the handling of materials thus,
reducing material handling efficiency.
2. Material handling cannot be mechanized which adds to cost.
3. Process time is prolonged which reduce the inventory turnover and increases the in
process inventory.
4. Lowered productivity due to number of set-ups.
 5. Throughput (time gap between in and out in the process) time is longer.
6. Space and capital are tied up by work-in-process.

2. Product layout

In this type of layout, machines and auxiliary services are located according to the
processing sequence of the product.
The product layout is selected when the volume of production of a product is high such
that a separate production line to manufacture it can be justified
Advantages
1. The flow of product will be smooth and logical in flow lines.
2. In-process inventory is less.
3. Throughput time is less.
4. Minimum material handling cost.
5. Simplified production, planning and control systems are possible.
Dis advantage
1. A breakdown of one machine in a product line may cause stoppages of machines in the
downstream of the line.
2. A change in product design may require major alterations in the layout.
3. The line output is decided by the bottleneck machine.
4. Comparatively high investment in equipments is required.
5. Lack of flexibility. A change in product may require the facility modification.

3. Combination layout
A combination layout is possible where an item is being made in different types and sizes
It is to be noted that the sequence of operations remains same with the variety of products
and sizes
Suitability :
● When production of products are in various shapes and sizes
● The Equipments in layouts are arranged as per requirements of design of product and
 its final outcome
● Used when several items of products are produced but not in bulk
Advantages and Disadvantages :
● This type of layout inherits the advantages and disadvantages from Product and process
Layouts

4. Fixed Position Layout

● This type of layout is about transfer of productional resources like- human resources, or
machines towards the production site which is already fixed and stable
● This layout is also called as Static Layout or fixed Location Layout
● Example - In hospital, the robotics (Equipments) are fixed in operation theatre and they
are flexible to move as per doctor's directions while performing an surgery
Suitability :
● Widely applicable to use if industry is of heavy type like in manufacturing of
Locomotives, ships,

Advantages of Fixed position Layout -

● Low investment for layout
● Helps to produce differentiated products ( ex- Aircrafts produced in various models)
● Very Flexible in nature, the workers get easily associated with it
● Production centers work can be designed in independent manner
Disadvantages of Fixed Position layout -
● Transfer of machines from one place of another place, if required is a loss of time and
costly
● These type of Layout need very expensive equipments for its operations
● High Skilled Professional are needed to operate the machines in layout
● Optimum utilization can be obtained in this layout, as the equipments are fixed in
nature and its movements will be some constraints

5. Group Layout (or Cellular Layout)

 is A grouping of equipment for performing a sequence of operations on family of
similar components or products

Group layout is a combination of the product layout and process layout. It combines
the advantages of both layout systems.

Advantages of Group Layout

can increase:
1. Component standardization and rationalization.
2. Reliability of estimates.
3. Effective machine operation and productivity.
4. Customer service.
5.It can decrease the— Paper work and overall production time.
disadvantage of group layout

 May not be feasible for all situations.

If the product mix is completely dissimilar, then we may not have meaningful cell
formation.
2. Discuss the term operation management and discuss briefly the transformation process of
operation management ?
Operations management is a management function. It involves managing people,
equipment, technology, information, and many other resources.

The role of operations management is to transform a company’s inputs into the finished
goods or services.
Inputs include human resources (such as workers and managers), facilities and processes
(such as buildings and equipment), as well as materials, technology, and information.
Outputs are the goods and services a company produces. Figure 1.2 shows this
transformation process.
 Customer feedback

Inputs
The Outputs
-Human resource
Transformation  Goods
-Facilities and process process  Services

Performance information
Figure 1.2.the transformation Process

3. List and discuss types of product lifecycle

4. Discuss and mention the five competitive profiles
5. What is reverse engineering?

6. Explain order winner and order qualifier and give your own example ?
7. What are the challenge of measuring service productivity?
8. Discuss the basic difference between product and service design?
9. What is operation management ?
10. Why it is difficult to increase service productivity system compared to production of
manufacturing ?
o Service industries are labor-intensive
o Services are highly people-intensive unlike physical products which
are material-intensive.
 .
o Measuring and monitoring service quality are difficult
 The importance of quality assurance in service marketing can never be over emphasized.
A service must be performed right the first time and every time. The damage done on any
occasion leaves a permanent mark and the effect of a badly rendered service cannot be
excused. While quality assurance is of utmost importance in services, it is highly difficult
to assure quality to the customers. Even measuring quality is difficult in services.
o Most service establishments are of small size
o Service firms, in general, are small in size. It is obvious that speed is a vital
element in a service offer. Both response time and actual time are important. One
can always improve a service by improving response time and actual service time.
 The firm should ensure that infrastructure and man power for meeting the
standard are adequate.
o Using machine technology and other labor saving devices is difficult
o Most service firms employ relatively a small number of people. Service workers
are generalists, not specialists. So, there is a little scope in the small firms to
develop specialization.

11. Please explain why the in process inventory is likely to be higher for an intermittent operation
than for continuous operation ?

12. It is generally felt that rural area are good for locating
large plant , semirural ………… comment?
Location of any plant is an important management decision. There are broadly three
possible alternatives option or the selection of the locality of the plant…

Rural Area for large plant due to

 The initial cost of land, erection cost of building and plant is less in rural area as compared
to urban or city area.
 Acquisition for additional area for extension work expansion of plant is possible without
much difficulty whereas urban area being congested; the additional land is not easily
available.
 Rural areas are free form labour trouble which is most common in towns and cities.
 Over crowding of working class population in cities is avoided.

Semi rural area for medium sized plants due to

 Land is easily and cheaply available in comparison to big cities.

 Lower tax rates in comparison to big cities and urban areas.
 Unskilled labour cheaply available.
 Urban area for small scale plant due to

 Better modes of transportation for collection and distribution of materials and finished
products.
 Availability to requisite type of labour for special and specific jobs is there.
 Utilities like water, power, fuels etc. are easily available.
 Industries do not need to construct colonies to provide residential facilities to their workers
since houses are available on rental basis whereas in rural areas, houses have to be build for
workers.

13.

 To be able to produce products with different processing requirements,

intermittent operations tend to be labor intensive rather than capital intensive.
(Intermittent)
 To efficiently produce a large volume of one type of product, these operations
tend to be capital intensive rather than labor intensive. (Continuous)
14.

15. Identify the input ,transformation process and the outputs in the following operation systems :
A. Bank

b. Hospital

c. Educational institution
16. What are different factor that should be considered for designing plant layout ?

 Nature of the product: The nature of the product to be manufactured has a

significant influence on plant layout. Small and light products can be moved from
one machine to another with minimum effort and time and therefore line layout
would be more suitable. Stationary layout would be suitable for heavy and bulky
products. In case of production of large variety of non-standardized products,
process layout is ideal.
  Production volume: Line layout should be preferred if standardized commodities
are manufactured on a large scale. Functional layout is suitable if production is
based on customers orders. It is better suited for low volume job production.
  Location of the site: The topology and size of the site influences the choice of a
particular layout. The idea is to maximize the utilization of space. Layout should
also suit the factory building. The positioning of elevators, stairways, parking lots
and storage points also influence the layout.
 Type of machines: Stationary layout is preferable if machines are heavy and emit
more noise. Such heavy machinery can be fitted on the floor. Adequate space
should be provided for the location of machines and also there should be sufficient
space between them to avoid accidents.
 Climate: Temperature, illumination, ventilation should be considered while
deciding on the type of layout. The above factors should be considered in order to
improve the health and welfare of employees.
 Service facilities: The layout should provide for the comforts and welfare of the
employees. It should have adequate provision for rest rooms, drinking water,
lavatory. There should be sufficient space for free movement of workers.
 Safety of employees: While deciding on a particular type of layout, the safety of
employees should be given importance. The layout should provide for obstruction
free floors, non-slippery floors, protection against dangerous fumes, excess heat,
strong odors Etc.
 Type of production: Layout plans differ according to the type of production. In
case of job orders, production of non-standardized products are undertaken, and
therefore functional or process outlet is suitable. Line layout would be suitable
when there is mass production of standardized goods.
  Type of process: In the case of intermittent type of production (bi-cycle
manufacturing, electronics), functional layout is suitable. For synthetic type of
Production (cement and automobile industries), line layout is preferable.

17. Please would you explain the consideration of ethics in

quality control?
 Ethics is the study of human behavior within a moral context. Morality
refers to the values that are subscribed to and fosters by society in general
and by individuals within the society Ethics attempts to - apply reason in
determining rules of human behavior that translate morality into everyday
behavior. Ethical Behavior – It is that which falls within the limits
prescribed by widely accepted moral values. Ethical Behavior builds trust
and trust is an essential ingredient of total quality. In attempting to build
trust in the workplace, managers should take the initiative.

18. give precise comment on inspecting the inspector ?

The main objective of inspection is to meet customer requirements, wants, and

needs. The objective is to prevent defective product flowing down the successive
operations and prevent loss to the company Inspections are important as they allow
you to:

 listen to the concerns of workers and supervisors

 gain further understanding of jobs and tasks
 identify existing and potential hazards
 determine underlying causes of hazards
 recommend corrective action
  monitor steps taken to eliminate hazards or control the risk (e.g.,
engineering controls, administrative controls, policies, procedures,
personal protective equipment

19. what are the common operation strategies ?

20.