Birla Institute of Technology & Science, PilaniWork-Integrated Learning Programmes Division

Second Semester 2011-2012

Mid-Semester Test(EC-2 Regular Solution Key)

Course No. : MM ZG511 Course Title : MANUFACTURING ORGANIZATION & MANGEMENT Nature of Exam : Closed Book Weightage : 30% Duration : 2 Hours Date of Exam : 12/02/2012 (AN) Note: 1. Please follow all the Instructions to Candidates given on the cover page of the answer book.2. All parts of a question should be answered consecutively. Each answer should start from a fresh page. 3. Mobile phones and computers of any kind should not be used inside the examination hall. 4. Use of any unfair means will result in severe disciplinary action.

Q.1. Mention the nine characteristics of modern manufacturing. [3]

Ans: Modern Manufacturing has a number of characteristics that makes for increasing success year after year. The nine characteristics are

o Manufacturing is importanto Emphasize on quality o People are assets o Cost controlo Focus and specialization o Old large mass production plants can be horrible impediments to progresso Mechanization o Increasing use of computers o Simulation and mathematical modeling

Q.2. Discuss the contribution made by Harrington Emerson in manufacturing management. [3]

Harrington Emerson (1853-1931): He was one of America's pioneers in industrial engineering and management and organizational theory. His major contributions were to install his management methods at many industrial firms and to promote the ideas of scientific management and efficiency to a mass audience.

• Emerson established a modestly successful consulting business as an "efficiency engineer," an author of books on industrial efficiency, and a promoter and popularizer of the efficiency movement. Nearly two hundred companies adopted various features of the Emerson Efficiency system,

• Which included production routing procedures, standardized working conditions and tasks, time and motion studies, and a bonus plan which raised workers' wages in accordance with greater efficiency and productivity.

• In conjunction with his consulting work, Harrington Emerson evolved an elaborate philosophy of efficiency and disseminated his ideas in books and periodicals.

No. of Pages = 1No. of Questions = 8

• As a writer and lecturer, he broadened the public understanding of scientific management and defined a larger social role for engineers beyond the solution of technical problems.

Q.3. Compare the management styles of the world’s leaders (the United States and Japan) in

manufacturing. [4]

Comparison of Japanese and American Management stylesPlanning: Although both countries use long and short term planning, their approach to monitoring and evaluating strategic plans is different. Japanese managers focus on long term results while American managers tend to focus on short term results. Staffing: Japanese managers view employment as a lifelong bond between them and the employees. Hence recruitment has long term focus resulting in high level of loyalty among Japanese workers. Although American firms have their share of motivated and qualified workers, company loyalty in American firms is not as strong as in Japan possibly due to economic uncertainties. Directing: Japanese culture with its focus on harmony, homogeneity, adaptability and placing the group above the individual gives an edge to Japanese firm and Japanese manager. Experts are of the opinion that American workers tend to focus on individuality. Communication: Japanese style tends to rely more on verbal face to face communication while American style tends to rely more on written communication.

Q.4. Explain the seven steps of product development cycle. [4]

• The development of a new product or improvement of an old one typically follows the seven steps namely: [1]

1. Obtaining Ideas2. Screening Ideas3. Technical Evaluation4. Market Evaluation5. Final Decision6. Getting into Production7. Introduction in the Market

Explanation of subdivisions 3 marks

Q.5. What is the purpose of identifying the subdivision of research activity? Discuss the subdivision of research activity. [4]

Ans: Purpose (please see the textbook) 1 markSubdivision:

Pure ResearchApplied ResearchProduct ResearchManufacturing ResearchMaterials Research

Market ResearchOperations Research Explanation of subdivisions 3 marks

Q.6. Explain the significance of organization planning in manufacturing environment. [4]

Ans: i) Provides for successionii) Facilitates promotion from within and the improvement in morale that accompanies adoption of

such a policy.iii) All will have a better understanding of what is required on their jobs and consequently will

perform better.iv) Provides a long range plan for the handling of special problems.v) Provides for the long-run strength of business.

Explanation of these points 4 marks.

Q.7. Explain all steps followed in the design of manufacturing processes ? [4]See slides of lecture 7 and chapter no.7 of your text book.

Q.8. Explain the factors to be considered for determining the number of machine required in a plant. [4]

Ans: The number of machines required in a plant is dependent upon:i) Quantity of parts to be manufactured.ii) Number of working hours in the plant.iii) Production rates on the operations to be performed.iv) Set up time v) Operating efficiency of the plant.vi) Scrap loss

Explanation of the above points 4 marks.

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