ASSIGNMENT – 1

OF

OPERATIONS MANAGEMENT
(MGT-519)

SUBMITTED TO: SUBMITTED BY:

Lect. Sanjay Jindal Japneet Dhillon

Reg No. 10902350

RS1906A25

MBA(IT)
Article 1. Democratization of manufacturing

The article provides a great comparison of traditional consumer-co-design driven mass

customization (you designing your shirt in an online-configurator), traditional engineer-to-
order and small-batch production, and the new opportunities provided by 3D printing and rapid
manufacturing.

1. From the consumer’s perspective, the capability to buy exactly what they want at a price
only slightly higher than an off-the-shelf alternative is called mass customization. It can
also be defined as a company’s capability to develop, produce, market, and deliver goods
that feature enough variety and customization that nearly everyone can get exactly what
he or she wants. Democratization trend shifts an increasingly greater amount of control
and opportunity to the individual.

2. The idea behind Democratization is that technologies, products, services, etc., that were
formerly exclusively accessible to small groups of experts are becoming available to
anyone. Now, buyers can customize, almost all types of durable consumer products,
including clothing, footwear, household furnishings, toys, vehicles, and electrical and
electronic devices, at the time of purchase Clearly, the Internet is a major driving force in
Democratization.

3. Some companies now allow consumers to upload their 3-D models, which are then
printed on a 3-D printer and shipped. In this way, consumers create their own custom
products. The simple design tools along with 3-D printing techniques have played a big
role in mass customization.
3D printers which can duplicate nearly any object plays a significant role in mass customization.

4. The Internet is a major driving force in terms of making mass customization available to
the masses. The Internet provides access to the basic design tools that are user by
consumers to build 3-D models. Also, Companies can now reach millions of people at a
small cost. The development of online configuratorshave also helped make customization
available to consumers. Software-based product configurators allow consumers to add or
change features about a core product.

5. There are certain reasons for slow adoption in mass customization due to some barriers.
The consumer society is very much based on the idea of gratification. Mass
customization business model provides customers with the facility to go online and
configure the product, order it and get exactly what they want delivered after one week
two or three weeks. So the time element associated is one such barrier. Secondly, there’s
no social element associated to the purchase. Mass customization does not have the same
appeal as retail shopping. There are many shoppers who just don’t prefer to go for a
product tailored to suit their exact needs and wants. They’re happy to choose from the
wide range of consumer products available today. Established companies need to
reconfigure their value chain to implement mass customization and it is not an easy task.
But companies looking to implement a mass customized business model can find ways
around these barriers.

6. So, we can conclude that Democratization is a positive trend for all of us. 3-D printing,
user manufacturing and rapid prototyping will facilitate democratization in years to come.
Article 2. The state of Product Development

1. India is a developing country that uses its brain power instead of low-cost labor or
natural resources to foster innovation in all sectors . Most of R&D in India is IT based,
be it outsourcing or developing & selling software products. Product design work eg
Nokia has huge design centre in India and manufacturing industry also adopted
innovation in product development. Nano is one example of innovation strategy adopted
by Tata. Vortex (developed ATM machine), Reliance Ltd. (doing R&D in chemistry and
polymers) are another such examples. So, India is increasingly becoming a top global
innovator for high-tech products and services.

2. Indian companies don’t spend much on R&D like other US firms do. India cannot
compete with China’s exceptionally low-cost prices. To succeed in global markets, India
need to increase R&D spending to facilitate product and process innovation. Innovative
products that better suit customer needs.

3. India has three Innovation Assets which will place India in an excellent position in the
field of innovation. These are:

 A strong technological Education System- Indian Engineers and IT people seem

to be almost everywhere. India’s Education System is well known globally.
 The English language as India’s “link language”- English serves as a link
language within the country and the language of business. It is a key advantage
for India.
 Democracy and the rule of law- India is the world’s largest democracy. It is a
free country with freedom of speech, press etc. There is a rule of laweg patent
law.
Article3. An eight step approach to Inventory accuracy: A case study at Leviton
Manufacturing Company

When inventory accuracy doesn’t exist there is loss of worker productivity, disappointed
customers, wastage of money and time etc. This article presents a successful eight step program
developed and installed at Levinton’s warehouses. It helps the company to raise its accuracy
level from 60+% to 95+%.

1. Measure the Problem- Convince the facility manager that he has a problem

It is necessary to convince the management that there is a problem. 95% accuracy is

demanded by management and is required for any computerized MRP or DRP
program. Management should know that a significant problem exists which need to
be addressed.

2. Get Top Management involved

Top management should be involved in this program. It should be a team effort rather
than an individual effort . The facility manager was to be convinced that this program
was prime objective of top management and he is held responsible for its future
success.

3. Develop new Procedures- This process may be the heart of the matter

How the work should be performed in order to achiece inventory accuracy? Each
operation should be reviewed on step to step basis. Facility managers should review
and approve the new procedures.

4. Educate- Everybody has to learn

 Now after developing procedures, there is a need to communicate then to all
concerned parties. The supervisors must teach the procedures to workers and timely
monitor their performance.

5. The test area – Correction through research

The test area is required to avoid carelessness, misinterpretation. Uts main purpose is
to identify the causes of errors. The analyst identifies the causes of error and the
supervisor corrects them.

6. Cycle counting- End of the annual physical

Purpose of cycle count program is to obtain continuous estimate of prevailing

inventory accuracy and to correct inventory records when needed.

7. Controls- Awareness for effectiveness

Simple control reprts are to be prepared to identify errors. Reports should contain the
number and nature of errors and the name of employee who made them. The
employee should be given feedback based on the report and necessary action should
be taken.

8. Management Audits

This is the last step of Inventory Accuracy program. The audit team should either be
financial auditors or members of the corporate management team. It facilitates an
independent evaluation of the program’s status.
Article 4. The Model Plant

The case is about the control over the processes so that they can better serve their customers.

1. The general Mills want his engineers and project manager to understand the structure or
its manufacturing and the shipping operations on the basis of the simulation.So the
company provides tool that can simulate the working of the plant to predict bottlenecks or
unnecessary features. Simulate is to reproduce someone's behavior. It means company
changes the services which were wasted.

2. General Mills has used simulation models to get the appropriate efficiency level. General
Mills has created a library of equipment templates that greatly simplify the creation of a
model. Each template consists of the equipment's definition, operating characteristics
such as speed and waste, downtime characteristics such as mean time to failure and mean
time to repair, time required for startup, and people required to operate it.

3. The problem was that when it was that when it was first installed, the automated , the
production area involves continuous manufacturing processes and loading into rail cars
and trucks is a discrete process. This information allows the company to cut $500,000 or
the cost of the third bay , from the building project.
4. General Mills simulated the operations and found that the new automated system had an
optimal performance point that was influenced by the production schedule. Simulations
also take into account the impact that manufacturing changes can have on people.

5. A simulation model integrates people , production and warehouse operations. The

simulation helps the company in many ways as they can predict the failures before they
actually happen , avoided significant construction cost.and also the new techonology can
also tested firstly on the simulation model then it actually take place. Simulation has not
only helped General Mills get more out of equipment and processes, but also has helped
the company achieve results by redirecting the efforts of process engineers.

6. Simulation of manufacturing and other processes is a powerful tool, because it lets

engineers focus on the business consequences of their decisions, before they are applied
and become more costly to adjust or redo. It provides management with answers to many
business questions.
Design for assembly

1. It is an approach to designing products with ease of manufacture in mind. By making

things easier to assemble, one also makes the assembly process faster and more cost-
efficient. This results in higher profit to the manufacturer, and can also add value for the
customer. The aim of design for assembly (DFA) is to simplify the product so that the
cost of assembly is reduced. Design for assembly (DFA) shortens the product cycle,
minimizes development cost, and ensures a smooth transition from prototype to
production stage.

2. Various design considerations has to be taken into account.

 Adequate test points should be deployed across the board to allow complete
access and coverage during flying probe or ICT test or for direct probing. A
characteristic of medical device design for test (DFT) is multiple, redundant test
modules to precisely capture data. The test engineer checks this coverage by
accessing two or three test nodes.
  When fabricating a board, it is important to consider panelization versus
fabricating one board at a time. While placing the components at the layout stage,
it is prudent to use one side of the board versus utilizing both sides, if possible.

 Another major consideration involves careful monitoring of equipment-related

features to maintain tight tolerances. Lastly, maintaining detailed documentation
in terms of design, fabrication, and assembly notes is a vital aspect of DFA and
DFT.

3. DFA is especially critical in high-speed PCB designs and layout whereby advances in
serial /deserializer (serdes) technology are further fueling the demand for high-speed
PCB designs.A high speed serdes design can perform exceedingly well if issues like
jitter, impedance mismatching, crosstalk, signal reflection, ground bounce or Vcc SAG,
and high-frequency noise on the power supply are properly dealt with at PCB layout
stage.
4. To address DFA issues for mixed signal designs, a very well defined and clear cut
strategy should be implemented to reduce signal to noise ratios, properly define power
and ground signals according to component placement, and shield high-speed digital
signals.Mixed signal is difficult due to the fact analog devices possess different
characteristics compared to digital components such as different power rating, current,
voltage callouts, and heat dissipation requirements, among others.
5. Analog circuitry is high power, high current, and thus, inherently creates noise.
Consequently, this generated noise can adversely affect adjoining low power, low-current
digital circuitry if proper partitioning between the two segments is not correctly
implemented. Effective partitioning places power supplies, analog interface converters,
and other analog circuits on the left side of the PCB. High- and low-frequency digital
devices are placed on the right side with system clocking in the middle and connectors at
the bottom edge. Placement of decoupling capacitors is also very critical. A decoupling
capacitor must be placed as close as possible to the BGA pad.
6. The following describes different testing types. Flying probe is best for low volume,
high-complexity assemblies. This test verifies component placement and identifies
missing components. However, it does not perform power up testing or check for
 functional failures.ICT is the most tedious, cumbersome, and expensive testing.
However, it is excellent at detecting parametric failures, design related faults, and
component failures. Functional test verifies board functionality and its behavior. The
PCB is subjected to a sequence of signals and power supplies and responses are
monitored at specific points to ensure functionality is correct. This test is best at detecting
wrong component values, functional failures and parametric failures.
7. Properly executed DFA and DFT can save the compact medical device OEM 10-30
percent of the pick and place, testing and debugging time, which translates to major cost
savings. A poorly designed product or one that uses non-standard parts and processes will
incur more design and assembly time, therefore incurring greater cost in manufacturing.
Conversely, DFA techniques based on standard, proven components and practices will
maintain lower costs and make the process smoother. Therefore, if proper DFA is
implemented, a product can go more smoothly from design stages into fabrication,
assembly and testing. This will reduce engineering costs and make the product more
robust and reliable.

Articel6. A TQM perspective of the ISO/TS Global Automotive Quality systems standard

One strategy which enhance the value to customer by continually improving organisational
processes and systems known as total quality management(tqm). It helps in leadership as
through customer satisfaction in an organisation.also includes employee empowerment and
involvement.it is a fact based activity.

Iso introduced in 1987 as a quality assurance standard in design, development, production,

installation and service.it apply not to products but applicable to processes that create them.iso
standard used b manufacturing and service organizations around the world.in Europe iso9001
standard is must to deal with other nations.

Then standard revised and updated in 2000 known as iso 9001:2000.thn again minor updation is
done in 2008.
There are the different quality standards for different countries but there is the need of one
standard which is applicable throughout the world that is ISO/TS 16949:1999.

ISO/TS 19649:2002 STANDARD

SO/TS 16949 is a technical specification, as denoted by the TS. It is a quality management

system for the gloal automotive industry developed by IATF(intenational automotive task force)
conjuction with iso.it includes the features of japan,us ,british standards.also elimminate the
requirement of multiple certificates. TS 16949 applies specifically to organizations in the
automotive industry (or, “sector”). It includes all of the requirements of ISO 9001, yet TS 16949
has been expanded to include automotive sector-specific requirements. Roughly, TS 16949 is
ISO 9001 for organizations in the automotive supply chain.

It includes continuous improvement ,defect prevention reduction in waste in supply chain or

logistics.customer satisfacation is also a key issue in this standard and product should be
according to the requirement of customer.

The standard contains 8 sections. The first 3 sections deal with general scope, terms &
definations. The following components are included in the system.

Quality management system

It’s a documented system with procedures and policies to ensure that products meet the customer
requirements. There should be continuous improvement in methods,policies,procedures are
decided to improve the quality.

Management reaponsibilty

Organization must have the responsible and committed management with evidence toward
implementation and maintenance quality management.

Resource management

To determine nad to provide the necessaty resources needed for continual improvement of
quality system.
Product realization

Plan and develop processes needed in Product realization

Measurement analysis and improvement

Establish and maintain a documented procedure for continuous improvement. Implemnt the
measurement and monitoring activities for improvement.