CONTENTS
Preface (v)

Part—I: Framework
1. Introducing Production and Operations Management 3
• Definition • Objectives • Scope of Operations Management • Operational or Short-term Decisions • Types of Production Systems • Life Cycle Concept Extended to Production System • Role of Scientific Methods in Operations Management • Lean Production • Remote Processing • Operations Management and Strategic Planning • World Class Manufacturing • Summary
2. Industrial Productivity 21
• What is Productivity • Concept of Productivity • Importance of Productivity • Indices of Productivity • Tolls of Productivity • Factors Affecting the Industrial Productivity • Productivity Movement in India • Productivity Index • Standard of Living • Summary

Part—II: Planning and Designing Operations
3. Facilities Planning: Product Selection 35
• Product Selection Process • New Idea Mortality Curve • Product Design • Repairability • Miniaturization • Computers and Design • Impact of Product Innovation on Process Innovation • Summary
4. Facilities Planning: Process Selection 47
• Selection of the Transformation Process • Types of Transformation Processes • Output Characteristics vs. Process Selection • New Frontiers of Continuous Form • Characteristics of Intermittent and Continuous Manufacturing • Selection of the Process • Summary
5. Facilities Planning: Location 58
• Problem in Selection of Location • Factors of Location Planning • Selection of Actual Site • Selection of Site (Urban, Rural or Suburban area) • Government Control on Location of Industries • Points to Remember • Summary
6. Facilities Layout and Material Handling 82
• Plant Layout • Factors Affecting the Plant Layout Decision • Material Flow System • Types of Plant Layout • Plant Layout Factors • Manual Methods • QTM and Layout • Models of Plant Layout • Computer-based Layout • Material Management in Production System • Production Organisation • Interface with Other Departments • Role of Materials Management • Need for Integrated Approach to Materials Management • Material Handling Systems • Summary
7. Capacity Planning and Design 123
• Economical Size of Industrial Unit • Scale of Activity • Capacity Planning • Summary

Part—III: Organizing Operations
8. Job Design and Work Measurement 145
• Job Design • Design Factors • Environmental Factors • Visual Environment • Organisational Factors • Behavioural Dimensions of Job Design • Socioi-technical Approach Job Design • Principles Motion Economy • Job Analysis, Job Description and Job Specification • Job Evaluation and Compensation Plans • Compensation Plans • Method Study • Work Measurement • Work Measurement System • Standard Data • Physiological Methods of Measuring Work • Taylor’s Use of Time study • Gilbreth’s Motion Study • Summary
9. Manufacturing System and Design 243
• Managing Mass Production • Flexible Machining Systems • Lean Manufacturing • Managing Batch Production • Managing Job Shop Production • Managing Projects • Events • Network Diagram • Drawing Project Network • Consider the following project • Summary
10. Organisation and Management of Safety in a Factory 292
• Goal of Safety • The Safety Unit in a Company • Mode of Operation • Safety Programme • Duties of Safety Personnel • Place in the Organisation • Safety Personnel • Safety Budget • Lines of Contact • Storage and Handling • General Preventive Measures • Prevention From Long-Term Effects • Emergency Measures • Summary

Part—IV: Controlling Operations
11. Value Engineering and Value Analysis 309
• Value Engineering • Value Analysis • Value Engineering Job Plan • Battery Cable • Pipe Coupling • Castle Nut With Collar • Importance of Oil & Gas Business For India • Growing Primary Energy Demand … India • ONGC: An Indian Giant • Strategic Analysis of ONGC • Value Chain Analysis • Summary
12. Equipment Replacement 336
• Reasons for Equipment Replacement • Development of the Systematic Equipment Development Programme • Advantage of the Sound Equipment Replacement Programme • Summary
13. Maintenance Management 344
• Objectives of Maintenance • Plant Maintenance • Failure Analysis • Total Productive Maintenance(TPM) and TQM • Summary
14. Inventory and Store Management 360
• Concept of Inventory • What Function Does Inventory Perform? • Classification of Inventory System • Selective Inventory Management • Limitations of ABC Analysis • Exchange Curve • Recent Advances • JIT (Just-In- Time) System of Inventory • Stores Management • Rationalised Codification System • Item Code: • Railway’s Lead • Paranjape Committee’s Recommendations • Summary
15. Budgeting and Budgetary Control 407
• Capital Budgeting • Budgetary Control • Summary
16. Costing and Cost Control 439
• Meaning • Elements of Cost • Cost Control • Depreciation on Fixed Assets • Methods of Depreciation • Cost Accounting Systems • Break-even Analysis • Summary
17. Waste Management 489
• Measurement of Waste • Wastivity and Productivity • Waste Collection System • Recycling of Wastes • Surplus Waste Management • Disposing of Surplus • Summary
18. Quality and Quality Assurance 499
• History of Quality • Evolution of Quality • Definitions of Quality • Statistical Process of Control and Quality Improvement • Statistical Process Control • Statistical Quality Control • Data Collection • Data Display • Problem Analysis • Pareto Analysis • Manufacturing to Specification vs. Manufacturing to Reduce Variations • Summary
19. Quality Standards 517
• Quality by Consensus • Getting a Feel for ISO 9000 Integration • Fundamentals of the Quality Assurance • Getting Started with ISO 9000 • Standards • Building Blocks of an ISO 9000 System • Implementation Issues for ISO 9000 • ISO 9000— Driving Force Behind TQM • Summary

Part—V: Modern Management System and Global Competition
20. Total Quality Management 553
• Evolutionary Development • Total Quality and Management • Pioneers in Total Quality • Summary • Some Observed Pitfalls While Operating TQM • Conclusion
21. Enterprise Resource Planning 581
• Evolution of ERP Systems • Materials Requirements Planning (MRP) • Enterprise Resource Planning • Implementation of ERP • Benefits of ERP • ERP or Supply Chain Management System (SCMS) • Summary
22. World-Class Manufacturing 592
• Production and Manufacturing • Genesis of World-Class Manufacturing • World Class Manufacturing Frameworks • Summary
23. Six-Sigma 601
• Quality and Capability of Six Sigma • Basic Six Sigma Methods • Intermediate Six Sigma Methods • Tolerance and Confidence Intervals, Significance Level • Terms and Concepts • Advanced Six Sigma Methods • Types of Designs • Summary
24. Supply Chain Management and JIT 626
• Importance of Qualitative Logistic Management in India • Functions and Contributions of Supply Chain Management • Supply Chain Effectiveness and Indian Infrastructure • Outsourcing and 3PLS • Fourth-Party Logistics (4PLS) • Bullwhip Effect and Supply Chain • Supply Chain Relationships • E-Supply Chain Management • About Mahindra and Mahindra • Supply Chain Drivers • Supply Chain Management (SCM) System • Process View of Supply Chain System of M&M • Inventory Management System • Summary
25. Reengineering for 21st Century 668
• Resistance to Change • History of Business Process Reengineering • Process of Reengineering • Application of Reengineering • Reengineering in the Service Industry • Kaizen • Summary
Bibliography 683
Index 694

The productivity of operations is often improved by using industrial engineering and operations research techniques. Thus operations management is composite area and this book is also diverse and cross-functional in characteristic, it links both manufacturing and the service sectors. On one extreme it is linked with sales and marketing management and on the other extreme linked to purchase and material management. These days lean thinking is more prominent and the book covers many such new concepts and cases of operations management. The present publication attempts to provide basic reading material for students of Production and Operation management in MBA, BBA and Engineering Programs. The chapters relate to the identified and new areas of production and operations management. They include the cases on location, layout and capacity planning and the focus on advanced topics like SCM, WCM and Six Sigma etc. make this book a value addition to rather a merged literature on this vital and ever changing subject.