PRODUCTION AND

TOTAL QUALITY
MANGEMENT

NAME : ROCHELLE GEORGE

ROLL. NO : 3316

CLASS : SYBMS 'B'

TOPIC : ASSIGNMENT
Q 1 : EXPLAIN QUALITIES ESSENTIAL FOR A PRODUCTION MANAGER.

Ans: A production manager should possess strong organizational skills,

effective communication abilities, problem-solving aptitude, attention to detail,
and leadership qualities. Additionally, a good understanding of the production
process, time management, and the ability to adapt to changing situations are
crucial for success in this role.
Production manager skills are competencies that allow you to effectively
oversee the production process and ensure that it proceeds as efficiently as
possible.
Leadership, management, written and verbal communication, project
management, time management and problem-solving are just a few of the
important skills a production manager shou pHld have.
You can improve your production manager skills by identifying potential areas
for improvement, completing an education program, attending industry events
and gaining relevant experience.

Q2 : WHAT ARE MULTIPLE OBJECTIVES OF PRODUCTION MANAGEMENT?

Ans : 1. Right Quality

The quality of the product is a very important parameter for every organization
without quality the product cannot establish itself in the competitive market.
Today’s market is a buyer’s market so one has to be very conscious about the
quality aspect.
2. Right Quantity
The manufacturing organization should always be in the position to produce
the product in the right number to the required quantity to satisfy the
customer’s needs
3) Right Time
The time factor is very important in business timeliness of delivery is an
important parameter as it judges the effectiveness of the production
department.
4) Right Manufacturing Cost
Manufacturing cost is established before the product is actually manufactured
because it can be a major distinguishing feature of the product.
A production is an intentional act of producing something in an organized
manner. It is the fabrication of a physical object through the use of men,
material, and some function that has some utility e.g. repair of an automobile,
legal advice to a client, banks, hotels, transport companies, etc. The main
inputs are information, management, material, land, labor, and capital.
Q3 : WHAT IS PRODUCT DESIGN? WHAT ARE REQUIREMENTS/CHARACTERISTICS
OF A GOOD PRODUCT DESIGN?

Ans : Product design is the process of ideating, developing, and refining products
that meet specific market needs and solve user problems. A product designer helps
create products that delight customers by defining product and business goals,
and anticipating market opportunities and user needs.
Utility: Utility is the foundation of customer needs. The first thing that a buyer
considers while evaluating a product is whether it satisfies his or her needs or not. A
product can be successful only if it ensures market acceptance and usefulness.
Every component of the design should be able to serve a valuable purpose. Any
aspect of design that is not beneficial to the user can detract from the user
experience of the product.
Aesthetically relevant: Aesthetics plays an important role in the future of product
design. It brings up a positive attitude in the users. The product needs to be
functional and easy-to-use while at the same time it should possess aesthetic
power. This is because people want products that do wonders, while not looking
ugly. Imagine all the Apple fans. The same goes for digital products such as
software, apps or websites. A designer who wants to keep improving and
developing skills should never miss out on aesthetic sense.
Simplicity: As said by German Industrial Designer Dieter Rams, “Good design is as
little design as possible”. Therefore, simplicity plays a vital role in product design as
much in life. Crafting something simple and functional allows people to immediately
understand what the product does and how they can use it. A good product
designer must always showcase aesthetic ability, functionality and instinctive
simplicity. Without simplicity, a product will never be able to attract consumers.
Innovative: Products should offer something new and revolutionary to connect with
the consumers. A better-looking product will win over the users immediately.
Product designers should focus on the desires of end-users, business goals and the
available technology to develop an innovative product.
Longevity: Good product design never goes out of style. Good design is timeless,
and if a product is well-designed, it will last for long. Long-lasting and sustainable
products are more valuable, better for the planet, and are a testament to the skills
of the designer. Antiques, vintage clothing, old cars — these things are still with us
today because the people who designed them built them to last.
Q4: EXPLAIN THE ASPECTS OF THE NEW PRODUCT DESIGN.

Ans : The aspects of a new product design in the market typically include its
functionality, aesthetics, user experience, materials used, cost, and how it
addresses consumer needs or pain points. Successful designs often integrate
innovation, usability, and market trends to create a compelling product that
stands out in the competitive landscape also, functionality, usability,
aesthetics, brand consistency, and user experience (UX) are all essential for
creating a successful product. Product designers should take these elements
into consideration when creating their products in order to ensure success.

Q5 : WHAT IS A PLANT LAYOUT AND EXPLAIN THE PRINCIPLES OF

A GOOD LAYOUT.

Ans : Plant layout is a plan for effective utilisation of facilities for the manufacture of
products; involving a most efficient and economical arrangement of machines,
materials, personnel, storage space and all supporting services, within available floor
space. Plant layout is very complex in nature; because it involves concepts relating to
such fields as engineering, architecture, economics and business management.
Principles of a good plant layout are -
(i) Principle of Minimum Movement:
Materials and labour should be moved over minimum distances; saving cost and time
of transportation and material handling.
(ii) Principle of Space Utilization:
All available cubic space should be effectively utilized – both horizontally and
vertically.
(iii) Principle of Flexibility:
Layout should be flexible enough to be adaptable to changes required by expansion
or technological development.
(iv) Principle of Interdependence:
Interdependent operations and processes should be located in close proximity to
each other; to minimize product travel.
(v) Principle of Overall Integration:
All the plant facilities and services should be fully integrated into a single operating
unit; to minimize cost of production.
(vi) Principle of Safety:
There should be in-built provision in the design of layout, to provide for comfort and
safety of workers.
(vii) Principle of Smooth Flow:
The layout should be so designed as to reduce work bottlenecks and facilitate
uninterrupted flow of work throughout the plant.
(viii) Principle of Economy:
The layout should aim at effecting economy in terms of investment in fixed assets.
(ix) Principle of Supervision:
A good layout should facilitate effective supervision over workers.
(x) Principle of Satisfaction:
A good layout should boost up employee morale, by providing them with maximum
work satisfaction.
 Q6 : EXPLAIN OBJECTIVES OF A PLANT LAYOUT AND DESCRIBE THE FACTORS
TO BE CONSIDERED AT THE TIME OF DESIGNING A PLANT LAYOUT.

Ans : 1. To achieve economies in handling of raw materials, work in- progress and
finished goods.
2. To reduce the quantum of work-in-progress.
3. To have most effective and optimum utilisation of available floor space.
4. To minimise bottlenecks and obstacles in various production processes
thereby avoiding the accumulation of work at important points.
5. To introduce system of production control.
6. To ensure means of safety and provision of amenities to the workers.
7. To provide better quality products at lesser costs to the consumers.
Factors to be considered while designing a plant are :
Nature of the product,,Management policies,Production volume,Nature of plant
location,Space requirements,Nature of machines,Plant layout,Production
control,Climate,Floor space availability,Material handling,Nature of
manufacturing process,Accessibility,Layout design,Plant Protection,Product
groups,Production
Safety,Service facilities,Type of industry,Working conditions,Determine required
operations,Emergency assembly area,Environmental factors

Q7 : WHAT ARE THE TYPES OF PLANT LAYOUT?

Ans : Types of Plant layout:

There are four types of Plant layout –
1. Process Layout.
2. Production Layout.
3.Combination Layout.
4. Fixed position Layout.
1. Process Layout:
In Process, layout keep similar machines and similar operations in one place. In other words, machines
are arranged according to their function.
That means all lathe should be in one place, all milling at another and so on. Process layout generally
employed for industries engaged in job order production and non-repetitive kind of maintenance or
manufacturing activities.
2. Product Layout:
Product Layout is also known as line layout. Various operations on raw material are performed in a
sequence and machines are placed accordingly the production flow line.
This type of layout is preferable for continuous production, that is, involving a continuous flow of in-
process material towards the finished product stage.
3. Combination Layout:
A combination layout combines the advantages of both process layout and product layout. These days
pure process and product layouts are rare.
A combination layout is possible where the item is made in different types and size. In such case
machinery arrange in a process layout but process grouping is then arranged in the sequence of
various types and sizes of the products.
4. Fix Position Layout:
In other types of layouts, the product moves past the stationary production equipment, but in fixed
position layout, product kept stationary, and equipment moves around it.
Fixed-position layout is applicable in shipbuilding, aircraft manufacturer, etc.
Q8 : EXPLAIN BRIEFLY 6 PRINCIPLES OF PURCHASING.

Ans: 1. Right Quality:

The term right quality refers to a suitability of an item for the purpose it
is required. For producing the goods of best quality, the best grade of
raw material may be the right quality whereas for producing items of
medium quality, the average lowest grade may be the right quality.
2. Right Quantity:
Materials purchased should be of right quantity. The right quantity is
the quantity that may be purchased at a time with the minimum total
cost and which obviates shortage of materials. Ensuring and
maintaining a regular flow of materials for carrying the production
activity is the vital aim of any purchase organisation. Excess purchases
should be avoided, it results in overstocking and capital is unnecessarily
blocked and inventory carrying cost goes up.
3. Right Time:
The time at which the purchases are to be made is of vital importance.
In case of items used regularly, right time means the time when the
stock reaches the minimum level. The reorder level of material is fixed
for each item under the principle of right time.
4. Right Source:
Selecting the right source for the purchase of materials is an important
consideration in the purchase procedure. The right source for the
procurement of materials is that supplier who can supply the material
of right quality as ordered, in right quantity as ordered, at a right time at
which the materials were required to be supplied, at an agreed price
with the supplier, who is in a position to honour the commitment
without much follow- up, who has necessary financial resources and
adequate man-power to handle the order and who is well established
with higher reputation and proven business integrity.
6. Right Place:
Besides obtaining the materials of the right quality and quantity from
the right source at the right price, it should be ensured that the
materials are available at the right place. Transportation and material
handling costs are greatly affected by the selection of the right place
from where the materials are to be acquired. For minimising these
costs, selection of right place for the acquisition of material is of utmost
imp
ortance.
 Q9: WRITE SHORT NOTES ON

A) PRODUCTION SYSTEM :

Ans: The methods, procedure or arrangement which includes all

functions required to accumulate (gather) the inputs, process or
reprocess the inputs, and deliver the marketable output (goods).
Production system is a result of arranging inputs, their conversion
process and output based on some logic and functions. Production
system fails if any such arrangement made don't give a desired level
of outcome.

B) MASS TYPE PRODUCTION SYSTEM :

Ans: Mass production is the manufacturing of large quantities of

standardized products, often using assembly lines or automation
technology. Mass production facilitates the efficient production of a
large number of similar products. Mass production is also referred to
as flow production, repetitive flow production, series production, or
serial production. In mass production, mechanization is used to
achieve high volume, detailed organization of material flow, careful
control of quality standards, and division of labor.

C) PROCESS DESIGN :

Ans: Process design is at the heart of operations management (OM). It

is the process of creating and improving systems that convert inputs
into outputs. Process design involves understanding how work is done
within an organisation and then designing and implementing ways to
improve it. There are several types of process designs, but all share
some standard features. Process designs must take into account the
resources required to complete the process, the desired output of the
process, and any constraints on the process.
D) OBJECTIVES AND IMPORTANCE OF PLANT LOCATION :

Ans: The basic objective of plant location decision is to determine the

minimum cost level in keeping view of all input costs. The chosen
location decision should permit minimization of both long-term and
short- term costs. No location can be considered to be unique and can
remain competitive indefinitely. Location study requires continuous
monitoring. Any location which is found optimum or most appropriate
today may not remain optimum tomorrow. Thus, the problem of
decision to move or to stay at a particular location is always before the
management specially when some expansion programme is
contemplated. The shift of the location of plant to some other place is
known as relocation.

E) FACTORS AFFECTING SECTION OF REGION :

Ans: Factors affecting selection of region are as follows -

(i) Availability of Raw Materials
(ii) Proximity to Market
(iii) Infrastructural Facilities
(iv) Government Policy
(v) Availability of Manpower
(vi) Local Laws, Regulations and Taxation
(vii) Ecological and Environmental Factors
(viii) Competition
(ix) Incentives, Land costs. Subsidies for Backward Areas
(x) Climatic Conditions
(xi) Political conditions

F) NEED FOR DETAILED ANALYSIS OF PLANT LOCATION :

Ans: When the business is newly started. Expansion of an existing plant. The
increased volume of business and extent of the market size. Changes in the
cost and availability of materials Lease for the site has expired, Changes in
the costs and availability of transportation etc. Social and economic factors.
Lease not renewable or may not be on favourable terms Establishment of
branches or subsidiaries. Plant location partially determines operating and
capital cost. It determines the nature of investment. Each plant location
requires some basic facilities like transportation, availability of water,
electricity, fuel, cheap labors etc. Each prospective location implies a new
allocation of capacity to respective market area. Government plays an
important role in the choice of the location keeping in view the national
benefits.