Chapter 1
Chapter 1
Md.Nazmul Huda
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Chapter One
Topics to be covered:
History and Development of Production Management,
Production Systems,
Types of Production,
Production Function and its Environment,
Operation Management and Other Business Specialties,
Scope & Function of Production Management,
Role of Production Management in Economic Development.
Product
Generally products means tangible goods which is
purchased and sold in exchange of money.
A product is anything that can be offered to a market for
attention , acquisition, use or consumption that might
satisfy a want or need . Its includes objects, services
persons, places, organizations and ideas”- Philip Kotler
A product is a set of tangible and intangible attributes
including packaging, colour, price, manufacture’s prestige,
retailer’s prestige and manufacture’s and retailer’s
services which the buyer may accept as offering want-
satisfaction.-W. J. Station
Service
Service is an act which is intangible in nature. It has no
physical existence . We can just feel it.
Services are the non-physical, intangible parts of our
economy, Services, such as banking, education, medical
treatment, and transportation make up the majority of the
economies of the rich nations. They also represent most of
the emerging nations’ economies.
When a company provides a service, and the customer has
paid for it, there is no transfer of ownership. We cannot
transport or store a service.
Production
Production is the processes and methods used to transform
tangible inputs (raw materials, semi-finished goods,
subassemblies) and intangible inputs (ideas, information,
knowledge) into goods or services. Resources are used in this
process to create an output that is suitable for use or has
exchange value.
Edwood Buffa defines production as ‘a process by which goods and services are
created’. Some examples of production are: manufacturing custom-made products
like, boilers with a specific capacity, constructing flats, some structural fabrication
works for selected customers, etc., and manufacturing standardized products like,
car, bus, motor cycle, radio, television, etc.
Production Management
In any manufacturing system, the job of a Production
Manager is to manage the process of converting inputs
into the desired outputs.
Inputs Outputs
• Men Transformation Desirable
Process Undesirable
• Material
• Machine
• Money
• Information Feedback
It is concerned with the production of goods and services,
and involves the responsibility of ensuring that business
operations are efficient and effective.
It is also the management of resources, the distribution of
goods and services to customers.
Job shop production are characterized by manufacturing of one or few quantity of products
designed and produced as per the specification of customers within prefixed time and cost.
The distinguishing feature of this is low volume and high variety of products.
A job shop comprises of general purpose machines arranged into different departments.
Each job demands unique technological requirements, demands processing on machines in a
certain sequence.
Characteristics
The Job-shop production system is followed when there is:
High variety of products and low volume.
Use of general purpose machines and facilities.
Highly skilled operators who can take up each job as a challenge because of uniqueness.
Large inventory of materials, tools, parts.
Detailed planning is essential for sequencing the requirements of each product,
capacities for each work centre and order priorities.
Advantages
Characteristics
Batch production system is used under the following circumstances:
When there is shorter production runs.
When plant and machinery are flexible.
When plant and machinery set up is used for the production of item in a batch
and change of set up is required for processing the next batch.
When manufacturing lead time and cost are lower as compared to job order
production.
Advantages
Following are the advantages of batch production:
Better utilisation of plant and machinery.
Promotes functional specialisation.
Cost per unit is lower as compared to job order production.
Lower investment in plant and machinery.
Flexibility to accommodate and process number of products.
Job satisfaction exists for operators.
Limitations
Following are the limitations of batch production:
Material handling is complex because of irregular and longer flows.
Production planning and control is complex.
For over two centuries operations and production management has been
recognized as an important factor in a country’s economic growth.
The traditional view of manufacturing management began in eighteenth century
when Adam Smith recognized the economic benefits of specialization of labour.
He recommended breaking of jobs down into subtasks and recognizes workers to
specialized tasks in which they would become highly skilled and efficient. In the
early twentieth century, F.W. Taylor implemented Smith’s theories and developed
scientific management. From then till 1930, many techniques were developed
prevailing the traditional view.
Date Contribution Contributor
1776 Specialization of labour in manufacturing Adam Smith
1799 Interchangeable parts, cost accounting Eli Whitney and others
1832 Division of labour by skill; assignment of jobs by skill; basics of time study Charles Babbage
Scientific management time study and work study developed; dividing
1900 planning and doing of work Frederick W. Taylor
1900 Motion of study of jobs Frank B. Gilbreth
1901 Scheduling techniques for employees, machines jobs in manufacturing Henry L. Gantt
1915 Economic lot sizes for inventory control F.W. Harris
1927 Human relations; the Hawthorne studies Elton Mayo
1931 Statistical inference applied to product quality: quality control charts W.A. Shewart
1935 Statistical sampling applied to quality control: inspection sampling plans H.F. Dodge & H.G. Roming
1940 Operations research applications in World War II P.M. Blacker and others.
1946 Digital computer John Mauchlly and J.P. Eckert
1947 Linear programming G.B. Dantzig, Williams &
1950 Mathematical programming, on-linear and stochastic processes A. Charnes, W.W. Cooper
1951 Commercial digital computer: large-scale computations available. Sperry Univac
1960 Organizational behaviour: continued study of people at work L. Cummings, L. Porter
Integrating operations into overall strategy and policy, Computer W. Skinner J. Orlicky and G.
1970 applications to manufacturing Wright
, Scheduling and control, Material requirement planning (MRP)
1980 Quality and productivity applications from Japan: robotics, CAD-CAM W.E. Deming and J. Juran.
1990 Internet, supply chain management.
Production management becomes the acceptable term from 1930s to 1950s. As F.W.
Taylor’s works become more widely known, managers developed techniques that
focused on economic efficiency in manufacturing. Workers were studied in great
detail to eliminate wasteful efforts and achieve greater efficiency. At the same time,
psychologists, socialists an and other social scientists began to study people and
human behaviour in the working environment. In addition, economists,
mathematicians, and computer socialists contributed newer, more sophisticated
analytical approaches.
With the 1970s emerges two distinct changes in our views. The most obvious of
these, reflected in the new name operations management was a shift in the service
and manufacturing sectors of the economy. As service sector became more
prominent, the change from ‘production’ to ‘operations’ emphasized the broadening
of our field to service organizations. The second, more suitable change was the
beginning of an emphasis on synthesis, rather than just analysis, in management
practices
Objectives of Production Management
The objective of the production management is ‘to produce goods services of right
quality and quantity at the right time and right manufacturing cost’.
1. RIGHT QUALITY : The quality of product is established based upon the customers
needs. The right quality is not necessarily best quality. It is determined by the cost of
the product and the technical characteristics as suited to the specific requirements.
2. RIGHT QUANTITY : The manufacturing organization should produce the products in
right number. If they are produced in excess of demand the capital will block up in the
form of inventory and if the quantity is produced in short of demand, leads to shortage
of products.
3. RIGHT TIME : Timeliness of delivery is one of the important parameter to judge the
effectiveness of production department. So, the production department has to make
the optimal utilization of input resources to achieve its objective.
4. RIGHT MANUFACTURING COST : Manufacturing costs are established before the
product is actually manufactured. Hence, all attempts should be made to produce the
products at pre-established cost, so as to reduce the variation between actual and the
standard (pre-established) cost.
SCOPE OF PRODUCTION AND OPERATIONS MANAGEMENT
Production and operations management concern with the conversion of
inputs into outputs, using physical resources, so as to provide the desired
utilities to the customer while meeting the other organizational objectives
of effectiveness, efficiency and adoptability.
QUALITY CONTROL
Quality Control (QC) may be defined as a system that is used to maintain a desired level
of quality in a product or service. It is a systematic control of various factors that affect the
quality of the product.
Quality control aims at prevention of defects at the source, relies on effective feed back
system and corrective action procedure. Quality control can also be defined as that industrial
management technique by means of which product of uniform acceptable quality is
manufactured. It is the entire collection of activities which ensures that the operation will
produce the optimum quality products at minimum cost.
The main objectives of quality control are:
To improve the companies income by making the production more acceptable to the
customers i.e., by providing long life, greater usefulness, maintainability, etc.
To reduce companies cost through reduction of losses due to defects.
To achieve interchangeability of manufacture in large scale production.
To produce optimal quality at reduced price.
To ensure satisfaction of customers with productions or services or high quality level, to
build customer goodwill, confidence and reputation of manufacturer.
To make inspection prompt to ensure quality control.
To check the variation during manufacturing.
Distinction between Manufacturing Operations and Service Operations
5 Ps
The Product
The Plant
The Processes
The Programs
The People
The Product
The processes and methods used to transform tangible inputs (raw
materials, semi-finished goods, subassemblies) and intangible inputs
(ideas, information, knowledge) into goods or services. Resources are
used in this process to create an output that is suitable for use or has
exchange value.
For retransition and welfare of employee, some factors should be discuss with the
employees. Such as-
Wages/salaries
Safety
Condition of work
Motivation
Trade union
Education and training
Factors of Production
Land
Land refers to all natural resources. All natural resources either
on the surface of the earth or below the surface of the earth or
above the surface of the earth is Land. It is the primary and
natural factor of production. All gifts of nature such as rivers,
oceans, land, climate, mountains, mines, forests etc. are land.
All human effort that assists in production is labor. This effort can
be mental or physical. It is a human factor of production. It is the
worker who applies their efforts, abilities, and skills to produce.
The payment for labor is the wage.
Characteristic
1. It is a human factor.
2. One cannot store labor.
3. No two types of labor are the same.
Capital
Capital refers to all manmade resources used in the production
process. It is a produced factor of production. It includes
factories, machinery, tools, equipment, raw materials, wealth
etc.
The payment for capital is interest.
Characteristics
1. Capital is a manmade factor of production.
2. It is mobile.
3. It is a passive factor of production.
Entrepreneur
An entrepreneur is a person who brings other factors of production in one
place. He uses them for the production process. He is the person who decides
What to produce
Where to produce
How to produce
A person who takes these decisions along with the associated risk is an
entrepreneur.
The payment for land is profit.
Characteristics
1. He has imagination.
2. He has great administrative power.
3. An entrepreneur must be a man of action.
4. An entrepreneur must have the ability to organize.
5. He should be a knowledgeable person.
6. He must have a professional approach.
Meaning of Production Function:
In simple words, production function refers to the functional relationship
between the quantity of a good produced (output) and factors of production
(inputs).
Prof. Koutsoyiannis “The production function is purely a technical relation
which connects factor inputs and output.”
Prof. Watson defined production function as “the relation between a
firm’s physical production (output) and the material factors of production
(inputs).”
In this way, production function reflects how much output we can expect if
we have so much of labour and so much of capital as well as of labour etc.
In other words, we can say that production function is an indicator of the
physical relationship between the inputs and output of a firm.
Mathematically, such a basic relationship between inputs and outputs
may be expressed as:
Q = f( L, C, N )
Where Q = Quantity of output
L = Labour
C = Capital
N = Land.
Hence, the level of output (Q), depends on the quantities of different
inputs (L, C, N) available to the firm. In the simplest case, where there
are only two inputs, labour (L) and capital (C) and one output (Q), the
production function becomes.
Q =f (L, C)
The long-run production function (Q) is usually expressed as
follows:
Q= f (LB, L, K, M, T, t)
Productivity =
Input
Computation of Productivity
Inputs in any production process comprises capital, labor, material and energy.
Productivity of each resource can be measured separately. Such measurement
gives single factor productivity. The method of calculating productivity
considering more than one resource is called multi-factor productivity approach
to measuring productivity. Total productivity (total productivity index) refers to
the productivity of all resources put together. So productivity of all resources
put together gives total productivity.
There are broadly three types of productivity measurements and these are
explained below:
1. Single-Factor Productivity Measurement.
2. Multi-Factor Productivity Measurement.
3. Total (Composite) Factor Productivity Measures.
4. Total Productivity Model.
1. Single-Factor Productivity Measurement:
Single-Factor Productivity is a measure of output against
specific input. Partial productivity is concerned with
efficiency of one class of input.
2. Multi-Factor Productivity Measurement:
The concept of multi-factor productivity was developed by Scott D.
Sink, multi-factor productivity measurement model considered labour,
material and energy as major inputs. Capital was deliberately left out
as it is most difficult to estimate how much capital is being consumed
per unit/ time.
3. Total (Composite) Factor Productivity Measures:
The Total Factor Productivity model developed by John W.
Kendrick in 1951, he has taken only labour and capital as only two
input factors.
4. Total Productivity Model:
Total Productivity Model was developed by David J. Sumanth in 1979 considered
five items as inputs. These are human, material, capital, energy and other
expenses. This model can be applied in any manufacturing or service organization.
3. Government Factor:
Government policies and programs are significant to productivity practices of
government agencies, transport and communication power, and fiscal
policies (interest rates, taxes) influence productivity to the greater extent
Ways to Improve Productivity and Quality of Products
It is vital to develop a high rate of productivity because it is the foundation of the business’s
future growth.
There are many ways by which productivity can be increased:
i. Adoption of up to date technology in machines and equipment.
ii. Implementing a proper system of managerial planning and control.
iii. Effective time management.
iv. Maintenance of work facilities in factories.
v. Standardization and automation for mass production.
vi. Empower employees by providing training and an environment conducive for personal is
well as organizational growth.
vii. Let workers participate in management.
viii. Provide a flexible work schedule instead of rigid working hours.
ix. Clear communication should be there between management and workers.
Assignment is to be submitted after Vocation
As an MBA student why should you study production and operations
management?
Discuss the relationship between production function, other organization
function and the environment.
Explain Pareto phenomena or 80/20 rule.
Short notes:
1. Agility
2. Mass production
3. Craft production
4. Lean production
5. Division of labor.
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