Industrial Management Notes - Split - 1
Industrial Management Notes - Split - 1
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OVERVIEW OF INDUSTRIAL
MANAGEMENT
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Concept of lndustrial Management
Development of lndustrial Management
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After reading this chapter, you will understand :
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1.1 TNTRODUCTTOX
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The term "Industrial Ivlu-ug"^ent" is quite confusing as different authors
introduetionJo1hesu-$eet. By the time you finish reading the third article of this
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interested in detail may refer to the books on these subject by the author ofthis
book. we have purposely avoided repetition of detailed subiect matter here.
Industrial Management is the combination of twp word d
Mqntgerygnffndustrial implies referring_to industryl{ndust d
as of complex and sophistica[ed pethods to the production of
gc services''. The comprex and sophisticated methods refer to
the use of machines which improve the quantity and quality of production. In our
(1.1 )
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Industrial Management: Notes
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working organisations s. al, governmental and
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religious. On the other hand,_,management means planning, cii$aniiiing,
in'an
lar.r, tQ
nd to control". Flowever, this definition
r in terms of what at
ate
? Oliver Sheldon is
I ation of policy, it of
the organisations analJJemployment". However, our simple worhing definition
is aManagement is a process used to accomplish organizational goals".
The combination of these two words results in a new branch of engineering.
Industrial Management may be defrned as :
c\ ,],.2
CONCEPT OF INDUSTRIAL MANAGEMENT
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y- "The brqnch of engineering'that deals with the creation and management of
systems that integrates people, mqterials and energy in productiue ways." I
gtrategi_c
la man and
financial
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a
manaEeme
manageme s and storinE facts and
information fiii rs within the or
mariagement planning involves adjustm_ent coutrol 4qd
coJpglqlig4--It draws upon specialized knowledge and skill in the mathematical,
Human -
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resources
Marketing
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Production Management
,NDUSTRIAL
MANAGEMENI
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Industrial Management: Notes
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results obtained from such systems.
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t In its most comprehensive meaning, industrial management refers to the
systematic management of all aspects of the industry (or factory). The
techniques employed go beyond increasing productivity or controlling the
t mechanical cost factor. They also include organization structure, administration
and human/labour problems. This has been shown in frg. (1).
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(Industrial management involves studying the performance of machines as
rvell as people. to keep machines in good working
condition and t eir production. The flow of materials
through the plant is superuised to ensure that neither workers nor machines are
idle. Constant inspectiorz is made to keep output up to standard. Charts are used
lor recording the accomplishment of both workers and machines and for
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comparing them with established standards. Careful accounts are kept of the
cost of each operation. When a new article is to be manufactured, it is given a
design that will make it suitable for machine production, and each step in its
manufacture is planned, including the machines and materials to be used. i
profession.
(2f Industrial Management and Industrial Engineering are synonymous terms.
(3) Industrial Management is different from production or operations
management and is explained later on in detail.
The term "industrial management" came into use in the United States
around the turn of the twentieth century after the Industrial Revolution.
/
llndustrial Revolution-The rise of factories,)
Before the Industrial Rev___ people worked with hand tools,
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Industrial Management: Notes
increased competition of the post-Civil War era, began to seek ways of improving
plant efficiency.
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The result of Industrial Revolution was :
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chine pffir beg-a-n a;--osubJutute for human power
goods
systems became available whiqh
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o-g_s dgveloped to serve larger markets
and work that had become complex was felt to improve
Scientific Management
m The first sustained effort in the direction of improved efficiency was made
by Frederick W Taylor.
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m His principles of scientific management resulted in :
"
od to define
by selecting
ne.
and
t in one best
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ry Ford iqJrcdrce-d the divisioa qf_labour in the factories.
Human Relations Movement
Little attention was paid to the motivational content of work. The accidental
discovery of the importance of human relations was made by tIf Hiwl'horne
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sififies from 1927 to 1932. The research was supervised by Elton Mayo. Wtlt"
conducting productivity studies at Western Electric, Mayo demonstrated that
of rel3tions wi.!h
rygrk"fr_'
"*tqqig-l:y_9e gwide*range
as on compensation.
compfrsation. tql_p_g_.an
le.5!.-!,o. eventual split
an eventu?l spli[
ell
ot
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industrial management, with. one branch emphasizing an underslandlng gf
glCqp_l?ptig{hggry and behaviour and the _o,ther gmphasizing the mechanics of
pioduction,iiJo-'krro*n;J aperaficrrr. i'-- ilJscienee continied to provide the
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management.
Modern Trends
Following World War II, many of the dehumanizing aspects of factory life
were a leading concern of both union movements and studies to improve quality
of work life. Ulork.d-e-sign an{E-o_cio-technical 4pprqaqfres.!o ryqqk becaqe ths"
focus of industrial management. By the 1960s, however, the U.S. economy had
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Industrial Management: Notes
shifted to a service economy, with more than half of the labour in the country
employed in services. This shift was to be followed by the information revolution
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and extraordinarily high rates of global competitiveness, changes that had
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dramatic impacts on work content. The term "industrial management" became
increasingly irrelevant as the nature and content of work shifted to
computerization and other spheres of the economy.
f Modern technological devices, particularly in the areas of computers,
electronics, thermodynamics and mechanics, have made automatic and
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semi-automatic machines a reality. fhg-development of such automation is
bringing about a-second industrial revolution and is causing vast changes in
commerce as well as fhe way worli is organized. Such technological changes and
:he need to improve productivity and quality of products in traditional factory
s-r'stems also changed industrial management practices.
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Today, the segment of management that seeks improvements in efficiency
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and productivity is known as production and operations mclnagenxenf. Its most
recent developments includei.-ntegrated-meffroas of management that contain
elements of programmable technology, quality improvement, just-in-time
delivery lean production, and supply chain management.
In India, many colleges and universities provide degree in Industrial
Engineering. All big organisations like TISCO, TELCO, RIL, etc., employ
-ndustrial engineers. The reporting of such engineers is directly to the
:op-management.
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SELF.STUDY
Assignruent r: what are the ancient civilization examples that
required Industrial Management applications?
Assignment rr : which was the largest industrial plant of the medieval
rvorld? List its industrial management applications.
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Industrial Management: Notes
.5 INDUSTRTAL ORGANISATION
When we talk about management of an industry, we should be clear about
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what is to be managed. There are various departments in a big organisation
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engaged in various activities which play their own role in helping the production
department meet its objectives. Even in service organisations like banks,
software companies, hospitals, etc. there are various departments which have to
managed through industrial management. Here we will be discussing the
general organisation of a big manufacturing factory which can be modifred for
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any service-industry also according to its needs"
(l) Head of Production Depat'tment: Production head is the supreme
officer of production organisation. He is called worhs manager or general
manager. He is the person who is responsible for all the function of production
department and all the other sub-divisions of production organisation is
controlled and directed by him.
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(2) Manufacturing Department : Manufacturing department is that
portion ofproduction organization where the actual activities or operations are
performed for the transformation of raw material into finished goods. The head
of this department is called production rrlonager. The prime responsibility of
production manager is to ensure the production according to the predetermined
plan and directions received.
If the organisation is diversified, meaning producing different types of
product then in such a case the manufacturing department can be further
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divided in various sub-manufacturing department like manufacturing unit,
repairing unit, assembling unit, etc.
(3) Technical Department : The primary task of technical department
is to enhance the quality of finished goods by performing research and
development on modern techniques of production. Technical director is the head
of this department. Generally following sub-sections are included in this
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department :
(i) Development section
(iit Design section
(iii) Research section
(iv) Testing section
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Industrial Management: Notes
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in machines and tools used in production are included in the function of this
department. Department also prepares various dies used in production.
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(7) Purchase Department : Generally the purchase department works
under the chief works manager. The main function of this department includes
the purchase of raw material, machine tools and other necessary items used in
production. This department evaluates the price and quality of purchased
material at the point of purchase.
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Various department send their requirement to purchase department which
purchases the items at favourable price.
(8) Sfore Department : Each firm establishes a store department
headed by chief store lzeeper to balance the demand and supply of raw material
and frnished goods. Availability of required type of material of required quality in
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adequate quantity, adequate andsafe handling, disposal of scrape, measurement
ofmaterial and record ofentries related to store in related books are the various
functions performed by the store department. Inventory management is also
performed by them.
(9) Maintenarlce Department : Maintenance department is a main and
necessary department of a manufacturing firm. Maintenance department looks
after the various assets of the frrm like machinery, building, vehicles, etc.
Department is headed by Maintenance Manger.
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(lO) Security Department i This department is responsible for security
in the industry. Department is headed by Security Director. Department
formulates the security related rules and execute the rules at all the level in the
concern. In case of any accident, investigation and analysis is done by this
department and department also prepares necessary documents.
Along with all above departments, some other departments are also
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quantity of right quality goods at the right time. These are attained through :
(l) Manufacturing Costs: The unit cost of the product should be
estimated carefully and every effort should be made to stick to the cost
standards. For this purpose, the efforts should be made to segregate the costs
into two-direct costs and variable costs. Efforts should be made for the
following:
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Industrial Management: Notes
1:.8:, Shu\frant'slndustriqlManagement
(iv) The allocation of the fixed overheads should be made on scientific basis.
(2) Machinery and Equipment : The objectives in the area of
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machinery and equipment are divided into :
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(i) Selection and acquisition of machinery and equipment according to
production process.
(ii) Utilization of machinery and equipment.
The adequacy of the existing machinery should be considered and proper
additions and replacements should be made according to the requirements.
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Efforts should also be made to increase the utilization rate of machinery through
repaiq maintenance and maximum occupancy of the machines.
(3) Materials : The materials objectives must be prescribed in terms of
units, rupee value and space requirements. The per unit materials costs should
be specifred and efforts should be made to increase the inventory turnover of all
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types of inventories-raw materials, work-in-progress and finished goods.
(4) Marupower: Manpower is an important as well as typical input in
manufacturing activities. So the objectives of the production activities are as
regards manpower must be closely allied with the objectives of selection,
placement, training, rewarding and utilization of manpower. Usually, these
objectives are considered in terms of employee turnover rates, safety
measurements, industrial relations, absenteeism, etc.
(5) Manufacturing Seraices: The provision of proper and adequate
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services directly affects the utilization of other inputs such as men, machines and
materials. Proper objectives should be set for the installation of important
facilities such as power, water supply, material handling, etc. In a condensed
form, it can be stated that the objectives of the manufacturing activities are-to
manufacture a quality product on schedule, at the lowest possible costs, with
maximum asset turnover, to achieve consumer satisfaction. This statement is
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for the shipment alone; it should be broken up into all the sub-systems like
operating cycle time, inventory turnover rate, machine utilization rate, direct
and indirect man-hours per unit, capacity utilization, machine and Iabour idle
time, set-up, repair and maintenance time, etc. Time schedule objective directly
affects the cost, quality and the goodwill of the business in terms of regularity of
shipment.
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Industrial Management: Notes
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industries for impro ions; to 4evelop qork standqr_{s or
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to formulate produc policies. Later on, it's use started in
non-manufacturing activities such as construction and transportation, farm and
air-line operation and maintenance, public utilities, government and military
operations. Today also, Industrial Management find major applications in
manufacturing plants and industries. In the present era of cut-throat
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competition at various stages ofoperations, an enterprise should produce goods
and services keeping into consideration the requirements and satisfaction of the
potential customer. The objective should be to produce goods at least costs and to
the maximum satisfaction of the buyer. To meet this objective, application of
areas :
giv n.
od Study and Work Meosurement\ Method study and
me techniques are applied to find out the reld-tionship between output
of goods and services and input of human and material resources. If material
including scrap and waste, can be accurately measured and controlled, it is
possible to do so for labour component too. The problem associated with
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measuring labour efficiency are more diffrcult than with material, but they are
not unmeasurable. The measurement should try to frnd the most appropriate
method of performing various operation involved in a production systern so as to
obtain optimum use of resources and man-machine relationship in increasing
produc
J4) Forecasting is necessary if the business
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Industrial Management: Notes
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need for people, materials and equipment so that sufficient time between order
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and delivery of goods and services is available to make necessary changes, if
required. The planning and scheduling of a firm perform a co-ordinated effort
with resources and available time in attempting to utilise the full capacity to the
ate
r finished products kept in stocks for some
e items requires careful consideration and
analysis. The purchases should be planned in economic ]ot sizes and the time of
purchase should be so scheduled that the investment in the inventory is at lowest
possible level. This implies determination of economic lot sizes and re-order
level. It also involves exploring reliable sources for obtaining materials and
supplies.
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While planning, scheduling and inventory control
g quantity and timing of production, quality control
is responsible for providing quality. Quality must be designed and manufactured
into the product. Although customers may desire higher quality, they may not be
willing to pay the resulting price. In such a way quality standard should be set up
that will be acceptable to the customers and yet economically feasible to thl
product. It is a matter of flrnding a balance between too much and too little
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qualitv.
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(8) ? Control ) lt is very necessary in today,s highly
compet organisftion should invest its resources intelligently and
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carefully. A major part of these resources are utilised in production activities.
Through it is the prime responsibility of production manager to control the
quantity of the produced goods, proper Industrial Management avoids the
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Industrial Management: Notes
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market and total demand was comparatively less, there was no accute need of
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industrial management. But now the world has been changed a lot. Now the
enterprises are broader and more diversified. Today the world is of high
production and competition. So the concept of industrial management is
continuously developing and spreading. In the world of cut throat competition
only those product can survive which can be proved to be the best. Now
organisations are focussing on quality control, standardisation and use of
ate
modern techniques in their production systems. The production function is
based upon the effective plans that serves organisation for achieving the
organisational objectives. So we can say that the industrial management is the
key function that plays a vital role in the success of organisation. The results of
industrial management are reflected in the serving of many interested parties of
an organisation such as :
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(l) The Consumers.' The consumers benefits from higher productivity,
better and reliable quality, reasonable price, satisfactory service and timely
delivery of goods.
(2) The Inaestors.' The investors get higher return on investment and
their investments obtain capital appreciation also. Market value of securities is
governed by the earning power and asset value ofthe business.
(3) The Community.' When all business which are operating in the
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community are prosperous, due to industrial management, we have economic
and social stability and the citizens of that community have pride and
satisfaction.
(4) The Suppliers.' Small or large companies depend upon other
companies as sources of raw materials, Components and services. We have
effective co-operation, best inter communication and mutual confidence between
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the business buyers and their suppliers. The company and its suppliers can have
enduring partnership for the satisfaction ofboth.
(5') The Employees.' The employees including the management get
higher remuneration, stable employment, security of jobs, better working
conditions and above all enhanced personal satisfaction through joy of
achievement. High employee morale due to job satisfaction gives higher output.
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(6) The Nation.. When all industries in the national economic system
demonstrate industrial management, the entire national economy wiil
accomplish all round security and prosperity.
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Industrial Management: Notes
1.12 Sfiu1fiam'slndustrialManagement
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conditions, etc. All the conditioRs can not be favourable at all the times.
(2) Problem of selection of production Method. : After selection
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of the
location next main problem arises which is related to the selection of production
method. There are various alternative method of production available to produce
a particular product. Industrial management has to select the best
method as per
the requirement, sources available and quality of the method.
(3) Problem of, Plant Layaut: probrem of plant layout is one of
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the
important problem in front of the industrial management. The layout should be
such that it is most suitable for the production of that product and eliminate/
minimises the breakdown in production process.
(4) Problem of Designing of pr-oduct: After selection of labour, the
next problem arises related to the designing ofthe product. Designing ofproduct
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should be done carefully because frequent changes are not possible in the
designed product. while designing the product, factors such as specific, identity,
market demand, simplicity in production have to be considered.
(5) Problem of Production and rnaerutory corttrol: problem related
to production and inventory control is also a major problem. Sufficient raw
material for the production function and regular supply of finished product
according to market demand are two major .".po.r.iniuties of industrial
management. The stock of raw material and finished goods should not be more
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than the requirement. To ensure this the industrial .rru.rug"-"rrt is facilitated by
various methods such as Economic Order euantity tBOel, Re_order point
(ROP), ABC technique of Inventory Control, etc.
(6) Problem of Quality contror : Maintaining the quality of a product
can be seen as another important problem of industriai
the quality of frnished product, industrial management -u.rug"1n"rrt. To ensure
e-nsures inspection
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keep eyes on the producbion capacity of the labour and try to improve their
overall performance. Various methods such as work measurement, work
analysis, work supervision and motivational method of'wage payment, etc. can
be aplied by industrial management for this purpose.
(8) Problem of cost control : Any prodtict can survive in the market for
long time when it is available at lower price than its competitors. That can be
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Industrial Management: Notes
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The scope of industrial management can be discussed in two
broad areas :
4tf-Deglgning of the industrial system and product
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,I2) Analyzing and controlling the industrial system
,(ll Actiaities Relating to l11Q_us_U:igtl Sjlslem Designing: The
industrial managemenl work starts aGoo.tai ir,e ia6a oiproar"tro.,
of a certain
commodity comes in the mind of an entrepreneur. primary
task incrudes
preparation of product profile with the help of experts
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of technological
department and market serveys. plant location and piant layout
have to be
decided. Decision relating to the industria
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Industrial Management: Notes
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ontrol of work-in-progress through production control.
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f ydlfu*9*qfrltoJ.: The other important decision concerns quality
the composite
deteiminffthi;
of the tustome
and
ate
s_.
__nspection
,!tv\ -C-o1o1dt:ryqtipfr qtith Olher Departments: No plan can be successful
until and unless,, it geJs an active support from rest of the departments of
organisation Fgl rl.LanC_e,-r,r-rarkqqg t provides the data related to
estimated demand withogt_whictr the pl-4n c4n not be prepared.'So
co-ordination with othertepartments is also included under the-scope of
industrial management.
&YQependgrut _ S9yui9_9s yM
aryd Departments: Various services
departments on which produciton plan is totally dependent is also included in
the scope of industrial management such as standardisation, simplification,
inspection, specialisation and quality control, inventory control, research and
and
Evtew
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estioni
1. Defrne Industrial Management and explain its concept.
2, Trace the evolution and historical development of Industrial
Management.
3. How is Industrial Management different from Production Management?
4.
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trtrtr
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