1. SAMPLE ASSIGNMENT FIRST SEMESTER 2016
Course Code MS - 05
Course Title Management of Machines and Materials
Assignment Code MS-05/TMA/SEM - I/2016
Assignment Coverage All Blocks
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School of Management Studies
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MAIDAN GARHI, NEW DELHI – 110 068
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1. Describe an Intermittent Flow Process. Highlight its characteristics, advantages and disadvantages.
Intermittent means something that starts (initiates) and stops (halts) at irregular (unfixed) intervals (time gaps). In the
intermittent production system, goods are produced based on customer's orders. These goods are produced on a small scale.
The flow of production is intermittent (irregular). In other words, the flow of production is not continuous. In this system,
large varieties of products are produced. These products are of different sizes. The design of these products goes on
changing. It keeps changing according to the design and size of the product. Therefore, this system is very flexible.
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Following chart highlights the concept of an intermittent production system.
Following are examples on the intermittent production system. Please refer above chart while reading examples given below.
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2. Similarly, the work of a tailor is also based on the number of orders he gets from his customers. ------------------------
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----------------------------------------------------------------------. Here, stitching is not done on a continuous basis.
The features of an intermittent production system are depicted below.
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The characteristics of an intermittent production system are listed as follows:
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It is flexible in approach since it uses general purpose machines for a variety of outputs.
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The -----------------------------------------------------------------------------------------------------------
The quantity, size, shape, design, etc. of the product depends on the customer's orders.
The transformation process is organized around standard operations in the intermittent form ( e.g. in a bank we have
saving accounts counter, current account counter, cash counter, advances and time deposits departments etc). Here
each functional group is a specialist group.
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Advantages-
Variety at Low Cost- The intermittent form of processing is appropriate when we want to respond to demands of
small volume and high variety. -----------------------------------------------------------------------------------------------------
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Staff Advantages- Each worker performs a complete operation under intermittent processing-e.g. completing an
analysis on a form, painting a component or product etc. -----------------------------------------------------------------------
-------------------------------------------------------------------------------------------------------. There is usually a high
morale in the group when all the group members are similarly skilled and work in the same location.
Disadvantages-
More Costly for High Volumes- The initial cost for general purpose machines, which are mostly used in
intermittent processing, is low. -----------------------------------------------------------------------------------------------------
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Complex Operations Planning and Control- As mentioned earlier, the planning and control of operations is very
complex for the intermittent form. -------------------------------------------------------------------------------------------------
4. ------------------------------------------------------------------------. Over and above the paperwork involved, "expediters"
are employed to reorder priorities and stack down specific jobs.
Large In-process Inventory- ------------------------------------------------------------------------------------------------------
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The material handling equipment used in intermittent operations is generally mobile and is. more expensive than the
fixed position handling equipment like chutes and conveyor belts. It also requires more space for movement thus
adding to the space requirement.
2. What is work sampling? Describe the steps usually required in conducting a work sampling study.
Work Sampling-
Work sampling is the statistical --------------------------------------------------------------------------------------------
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In a work sampling study, a large number of observations are made of the workers over an extended period of time. For
statistical accuracy, the observations must be taken at random times during the period of study, and the period must be
representative of the types of activities performed by the subjects.
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The study of work sampling has some general characteristics related to the work condition:
One of them is the sufficient time available to perform the study. -------------------------------------------------------------
-------------------------------------. There must be enough time available (several weeks or more) to conduct the study.
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The third characteristic is long cycle time. The job covered in the study has relatively a long cycle time.
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There are several recommended steps when starting to prepare a work sampling study:
1. Define the manufacturing tasks for which the standard time is to be determined.
2. Define the task elements. -----------------------------------------------------------------------------------------------------------
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5. 3. Design the study. This includes designing the forms that will be used to record the observations, determining how
many observations will be required, deciding on the number of days or shifts to be included in the study,
scheduling the observations, and finally determining the number of observers needed.
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5. Start the study. All those who are affected by the study should be informed about it.
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7. After completing the study, analyze and present the results. This is done by preparing a report that summarizes and
analyzes all data and making recommendations when required.
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Example-
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3. Explain Kilbridge and Wester method for obtaining a good balance for an assembly line balancing
problem.
Assembly lines are places where the parts and components of the products are pieced together and treated in different ways.
The basic specialty of an assembly line is to transfer work pieces from one station to another. Assembly line balancing or
line balancing is used to achieve operations required during product formation at assembly stations in a way that the duration
of lost time can be reduced. In other words it is described as allocating work pieces to operation systems.
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This technique has received a good deal of attention in the literature since its introduction in 1961. The technique has been
applied to several rather complicated line balancing problems with apparently good success. --------------------------------
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I demonstrate Kilbridge and Wester’s method on our sample problem. However, our problem is elementary enough that
many of the difficulties which the procedure is designed to solve are missing. The interested reader is invited to consult the
references, especially, which apply the Kilbridge and Wester procedure to several more realistic problems.
PROCEDURE AND EXAMPLE-
It will be convenient to discuss the method with reference to our sample problem.
Step 1. Constraint the precedence diagram so that nodes representing work elements of identical precedence are arranged
vertically in columns. This is illustrated in Figure 1. Elements 1 and 2 appear in column I, elements 3, 4, and 5 are in column
II, and so on. Note that element 5 could be located in either column II or III without disrupting precedence constraints.
7. Step 2. ---------------------------------------------------------------------------------------------------------------------
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Step 3. To assign elements to workstations, start with the column I elements. Continue the assignment procedure in order of
column number until the cycle time is reached. Tc in our sample problem is 1.0 min. The sum of the Te values for the
columns is helpful because we can see how much of the cycle time is contained in each column.
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To begin on the second station, element 3 from column II would be entered first. The column II elements would be
considered next. Element 6 is the only one that can be entered.
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The assignment process continues in this fashion until all elements have been allocated. Figure 3 shows the line balancing
solution yielded by the Kilbridge and Wester method. Since five stations are required, the balance delay is again equal to
20%, the same as that provided by the largest-candidate rule. However, note that the work elements which make up the five
stations are not the same as those in Table 6.3. Also, for stations that do have the same elements, the sequence in which the
elements are assigned is not necessarily identical. Station 1 illustrates this difference.
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In general, the Kilbridge and Wester method will provide a superior line balancing solution when compared with the largest-
candidate rule. However, this is not always true, as demonstrated by our sample problem.
Example 2-
Now, selecting cycle time is equal to 18 seconds we follow the steps:
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Total elemental time is 68 minutes which is 2 × 2 × 17. The cycle time must lie between 68 (for one station) to 10 min.
(which is max of all TiN).
10 < Tc < 68
The possible combinations of primes (17, 2 and 2) of work content time (68 min) are as follows:
Feasible Cycle Time Infeasible Cycle Time
17 2
9. 17 × 2 = 34 2 × 2 = 4
17 × 2 × 2 = 68
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Now, looking at the previous table, little readjustment it work element is possible if the cycle time is extended to 18 min.
This is apparent when we consider the following grouping:
Column Work Element, i TiN Station Sum (Tsi) (Tc – Tsi) for Tc =
18 min.
I 1
2
3
8
3
3 17 1
II 4
5
6
7
3
6
7
5 18 0
III 8
9
10
11
3
2
5
8 18 0
IV 12
13
5
10 15 2
Line Efficiency = 68 /4 X 18 X 100 = 94.44%
Smoothness Index = √12
+22
= √5 = 2.24
Balance Delay = 4 X 18 - 68 / 4 X 18 X 100 = 5.56%
4. Why are suppliers sometimes helpful in value analysis programs? How can they help? Does it
violate your concept of good business ethics to involve them in your problems?
Value Analysis can be defined as a process of systematic review that is applied to existing product designs in order to
compare the function of the product required by a customer to meet their requirements at the lowest cost consistent with the
specified performance and reliability needed.
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The suppliers may prove to be invaluable source of help in VA programme because he knows more about his product and its
potential capabilities than most of his customers. ----------------------------------------------------------------------------
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-------------------------------------------------------------------------- , for example, by virtue of vast and up-to-date
knowledge they may have in their chosen area of specialisation. In VA philosophy the consultation with others is a strength
rather than a sign of weakness. Supplier of materials, products or services who can play an effective role in cost reduction
and value improvement.
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Most markets require suppliers to offer a range of products and to continuously increase this offering. To avoid an explosion
in the number of unique parts associated each new product many companies have introduced standard components, platform
strategies and supplier rationalization programmes. The ability to design products is seen as key to maintaining the quality,
cost and delivery performance of the product. Some customers, especially those in mature markets, need to continuously
reduce the costs of products in order to compete against comparatively cheaper imports. The increasing trend, across Europe,
for businesses to ‘buy in’ rather than ‘make’ all the elements of a product means that new suppliers of materials must be
educated in the VA process in order to use the specialist skills of the supplier to reduce the costs of supplied materials
continuously.
The high levels of purchased costs may imply a need to engage with suppliers in the VA process. This initiative will be
constrained by a number of issues such as the timing of the project, the availability of resources from the supplier, the
location of the suppliers, and other constraints.
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-------------------------------------------------- . The integration of suppliers and customers offers many additional
benefits to the VA process teams:
Customers tend to be poor at articulating and summarizing the value they get from products and services but when
integrated into a project tend to be able to offer a greater insight into their real intentions. As such the solicitation of
customer information is key to a successful ------------------------------------------------------------------------
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-------As such, it is common to find customer integration within the VA process when partnerships, high trust
relations exist, or the supplying company provides a strategically important part to the customer.
11. Suppliers and subcontractors tend to know more about their products (and substitutes) than the purchasing
business from a technical, applications and commercial. Also, tasked with greater responsibility for the design of
products, these suppliers will tend to make better designs both in terms of cost and functionality. -------------------
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In the current competitive environment there is little to gain by a company that continues to treat its suppliers as adversaries
and to withhold information from suppliers. The integration and focusing of suppliers on the need to improve final product
value and cost effectiveness is therefore an issue that necessitates the integration of suppliers as extensions of the factory
team. -----------------------------------------------------------------------------------------------------------------------
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-------------------------------So we can say that it does not violet my concept of good business ethics to involve them in
VA problems.
5. Discuss the major functions of stores in an organization. What are the advantages and
disadvantages of centralized store room facilities?
Functions of stores in an organization-
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Typically and at times essentially, a Stores has to follow certain activities that are managed through use of various resources
and are thus called Stores Management. The task of storekeeping relates to safe custody and preservation of the materials
stocked, to their receipts, issue and accounting. The objective is to efficiently and economically provide the right materials at
the time when it is required and in the condition in which it is required.
The major functions of the stores are as follows:
a) Receipt: ------------------------------------------------------------------------------------------------------------------------------------
b) ---------------------------------------------------------------------------------------------------------------------------------------------------
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12. c) Retrieval: Facilitating easy location and retrieval of materials keeping optimum space utilisation.
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e) Records: To maintain proper records and update receipt and issue of materials.
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g) Control: ---------------------------------------------------------------------------------------------------------------------------------------
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i) Verification: ----------------------------------------------------------------------------------------------------------------------------------
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j) Coordination and cooperation: To coordinate and cooperate with the interfacing departments such as purchasing,
manufacturing, production planning and control, inspection, etc.
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Once the material has been received and cleared through inspection and accepted for use, it needs safe custody till it's
actually used. It calls for a separate physical storage space, open or closed, as per need. It maintains all documents that are
able to trace an item, show all its details and preserve it up to its shelf life in the manner prescribed or till it is issued for use.
This part of Stores is called Custody. ---------------------------------------------------------------------------------------
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In the long drawn process of preserving the materials till its use, some materials might get obsolete and unserviceable and
may require removal from stores, in order to clear space for other incoming goods. This activity is known as Disposal of
goods for which auction etc is done. Since the material has a cost, the organisation would definitely like to incur optimum
cost on this account and thus there is a need to manage the materials within stores such that the total cost of maintaining
materials remains optimum.
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Any Stores as such is a physical entity which deals with material receipt, preservation and issue. Material handling
therefore is another vital function. Just as Lay out of a Stores is designed considering the nature of material Stores has to
handle, material movement equipment and implements also are important. Within a typical manufacturing organisation, its
Stores is seen having Forklifts, Over head Cranes, Trolleys etc inside the Stores and trucks, Dumpers and Railway wagons
as outside Stores equipment to handle materials.
Centralized Stores-
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For example a hospital may have central stores with separate ones for each category of ward i.e. stores for linen, surgical
instruments, drugs, and general requirements.
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Advantages-
1. Centralized Store can offer a wider range of goods is provided for all users than is possible in smaller stores.
2. Inventory can be minimum as material is ordered based on requirement of all other attached parties and material can be
shunted to and from one store to other one attached to the Central Stores. This is especially so in the case of tools fixtures,
equipment and spares.
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7. Receipt and inspection of goods can be more efficiently organised.
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10. Less personnel will be required for managing. Unnecessary duplication of records takes place in decentralized Stores.
14. For example, one may have ten different Kardex cards for one martial stocked in ten places. Similarly, accounting work is
multiplied.
Disadvantages-
1. Extra ------------------------------------------------------------------------------------------------------------------------------------------
2. If the system is not well organized there can be severe shortages at work places causing unnecessary interruptions in
production. Inefficiency can also result in Production keeping some buffer inside the unit, which can lead to cluttering of
space, and to pilferage because of the absence of security.
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5. It is apparent that there can be myriad’s of types of materials which are stores, depending upon the type and complexity of
the industry which the Store serves. -----------------------------------------------------------------------------------------------------------
-----------------------------------------------------------------------------------------------------------. The variety is almost infinite.
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