PROGRAM - MBA
SUBJECT CODE & NAME OM 0015 – MAINTENANCE MANAGEMENT
1. Write short notes on :
(i) Need for maintenance
management
(ii) Maintenance resources
(iii) Decentralised maintenance
(iv) Reliability Centred
Maintenance
(i)
Need for maintenance management :
The main purpose of maintenance
management is to ensure that business
activities of an organisation go
unhindered. In an organisation, the
following are the factors
that necessitate a
well-defined and efficient
maintenance management system to be in place:
·
Long-term
continuity and survival of business
·
Effective and
efficient utilisation of organisational resources
·
Improving the
lifespan of plant and technology
·
Prevention of
equipment failure
·
Reduction in downtime
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(ii)
Maintenance resources : Maintenance
resources are the means that directly or indirectly contribute to the maintenance
of machines and
equipment so as
to ensure that
core business operations run
without any obstructions.
These resources may include
infrastructure, personnel, tools
and techniques, and
processes required to perform maintenance operations.
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(iii) Decentralised maintenance : Decentralised maintenance: According to Fayol, "Everything that
goes to increase the importance of the subordinate's role is called
decentralisation." Decentralisation
refers to the
distribution of power
and authority among different individuals
of an organisation.
Similarly, in decentralised maintenance, all maintenance
functions are reported to the respective area, unit, or departments. Below
figure shows the
example of decentralised
maintenance in an
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(iv)
Reliability Centred Maintenance
Reliability Centred
Maintenance (RCM), also known as asset
maintenance, is a process in which assets are maintained so they can be
available for use throughout the production
process. Please note
here assets mean machines and equipment.
The aim
of using RCM is to identify the modes of failures and their impact on assets.
The primary requirement for proper analysis of failure modes is to acquire
complete knowledge of
operations and
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2. Optimising Maintenance at XYZ
Electricals
What are the problems at XYZ Electricals? Which was adopted to overcome
the problems? Assess if the solution is effective in resolving the problem.
Answer:
List of problems at XYZ
XYZ Electricals is one of
the leading manufacturers of electrical utilities. The organisation is well
known for delivering quality products to consumers. It has adopted A preventive
maintenance (PM) approach for the maintenance of its machines and equipment.
However, in the last few months, the organisation has observed an increase in:
o Maintenance costs
o Facility downtime
o Frequent failures of components
Reason behind the problems
After
thorough analysis, it has been found that the main cause behind all the
problems is the excessive use of preventive maintenance. The organisation also
realized that it must adopt a maintenance process
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3. Write short notes on:
(i) Production philosophy
(ii) Mean Time to Repair
(iii) Maintenance documentation
(iv) Online or permanent condition
monitoring
(i) Production philosophy : A
production philosophy varies across different organisations depending on
their requirements, business
model, and the nature and
size of business. However, the common focus area of
any production philosophy is to deliver products to
customers with the
required quality and within
the given time while
maintaining efficient production
and low cost.
In the words
of Waldemar Karwowski, (Professor,
University of Central
Florida, USA.),“A production
philosophy
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(ii)
Mean Time to Repair : Mean Time
to Repair (MTTR):
It is the
expected time for
restoring machines and equipment
back to their
working condition. If
a service is donated by u, then the MTTR is the inverse
of the service rate, i.e. 1/u. It acts
as a measure of the maintainability of machines and equipment.
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(iii)
Maintenance documentation : Maintenance documentation is
all about recording
information about machines and
equipment and the
maintenance procedures performed
on these machines and equipment in the form of records, catalogues,
manuals, or files. The following are the main benefits of maintenance
documentation:
• Documentation transforms
maintenance processes from
persondependent to system-dependent. This
implies that the
knowledge required for installation, maintenance, and use of machines is recorded in documents
and can be accessed by all.
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(iv) Online or permanent condition monitoring : In online
monitoring, the condition of
machines is monitored
and recorded continuously
at defined points and
compared simultaneously with
the acceptable levels
of variations. For example,
machines that are
critical for production
can be monitored using online
monitoring to detect the probable defects and
make on-time corrections. The
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4. Which are the common tasks
performed in maintenance management?
Common tasks in preventive maintenance
Preventive maintenance
is a complex process, thus includes a number of tasks. These tasks are performed in a systematic
manner and as per the predefined
schedule. Tasks performed
in preventive maintenance
vary across organisations depending
on plant requirements,
organisation’s
budget,
etc. However, there are some common tasks
that are performed in preventive
maintenance,
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5. What are the benefits and
issues related to predictive maintenance?
Predictive maintenance has
gained importance in
several industries as it
has proved to
be an essential
tool in fault
detection during early
stages; thereby reducing
unscheduled downtime and increasing productivity.
Apart from this, predictive maintenance has various advantages. Some of these advantages
are as below:
·
Advanced knowledge of impending failure
·
Effective production scheduling
·
Root cause analysis
·
Cost effectiveness
Advanced knowledge
of impending failure: Data
collected through predictive maintenance
provides organisations an
access to advanced knowledge of potential failures
and the failures
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6. Write short notes on
(i) Structure of maintenance
budget
(ii) Role of maintenance
auditor
(iii) Codification of spare
parts
(iv) Types of maintenance
benchmarking
(i)
Structure of maintenance budget :
Every department in an organisation
follows a particular structure to present its maintenance budget.
A maintenance budget represents an incremental cost statement
over a fixed
period of time.
The maintenance budget structure should
be flexible and
dynamic so that
changes can be incorporated periodically. Moreover, it should have adequate information
so that it can be used for various purposes, such as:
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(ii)
Role of maintenance auditor : A
maintenance auditor plays a vital role in conducting the audit process in
an organisation. He/she
is responsible for
ensuring the success
of maintenance audit. For
that, he should
have complete knowledge
of the auditing process and procedures
and should be unbiased while performing the audit. The following are the main
functions of a maintenance auditor:
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(iii) Codification of spare parts : A single machine
or equipment may
require several spare
parts for restoration at the time
of failure. It is often cumbersome and time consuming for maintenance
personnel to identify
the required spare
parts from the entire stock. Apart from this, at the time of purchasing new spare parts, an organisation should
have clear specifications of the spare parts.
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(iv)
Types of maintenance benchmarking
• Internal maintenance
benchmarking: It is
a process of evaluating the performance of an organisation’s
maintenance system (or function) by using various internal
parameters or benchmarks,
such as machine
downtimes and frequency of failures. This type of benchmarking can be performed
on a weekly, bi-weekly, or
monthly basis. Internal
benchmarking can only
be performed for machines and equipment
that are stable in nature and do not require frequent
replacements. It helps
in
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PROGRAM - MBA
SUBJECT CODE & NAME OM 0016 – QUALITY MANAGEMENT
1. Answer the following
questions:
a. What is the need for quality
management?
b. What are the advantages of ISO
9000 standards?
c. What is the structure of
Quality Management System (QMS)?
d. Explain any four attributes of
a quality leader.
a. Reasons for need for
quality management from the
point of view
of an organisation, seller or manufacturer
Managing
quality is very essential to get
competitive advantage in todays’ highly
competitive environment. This is because,
if a customer does not get
the required quality
of products, he/she
tends to switch
to other brands. Therefore, it is important for every
organisation to better manage the quality of products and services. From the perspective of an organisation,
seller or manufacturer,
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b. List the
advantages of ISO
9000 standards
ISO has
contributed to the
improvement of quality
in all spheres
of life through the
release of ISO
9000 standards. The
following are the advantages of the ISO 9000 standards:
• Provides a knowhow for establishing
a quality management system that results in the improvement of the bottom line
for businesses.
• Many
large organisations rely
on the ISO
9000 certification of
their suppliers to prove
their competence, thus
making them eligible
for participating in tendering processes.
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c. Explain the three levels
of QMS
Level 1 –
Quality manual: The first level of the
structure of a QMS is
the Quality Manual. The key element included in the making of a quality
manual is the structure of the organisation (organisation charts defining hierarchies and responsibilities). The
quality manual is
created to identify
the documents and their structure required for standardisation.
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d. Description of
any four attributes
of a quality leader
• A quality leader is one who believes
in others and therefore, recognisesthe
value of his\her followers. A quality
leader must communicate with the
team in the
most amiable manner
and also share
his\her experiences with them and encourage them.
• A
quality leader is known by his\her team. A team trusts the leader when the leader
shares information with
all the members.
A quality leader takes the team along with him\her and
works for
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2. Write short notes on:
(i) QS 9000
(ii) Attaining quality culture
through employees
(iii) Importance of quality
control
(iv) Double sampling plan
(i) QS 9000 : QS 9000 was
developed in 1994
for the automotive
industry to provide requirements for
the quality systems
on the basis
of the needs
of the automotive sector.
The requirements were
developed by Chrysler,
Ford, General Motors and other major truck manufacturers. The use of QS
9000 in the automotive industry has led to the
elimination of demands and waste due to redundancy in the systems being followed. Companies following
QS 9000 are considered
to offer
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(ii)
Attaining quality culture through employees : Business leaders in the
present agree that the only way to
survive in our competitive world is
by obtaining full
customer satisfaction through
the consistent delivery of
high quality products
and services. The
most challenging task for an organisation is to achieve customer satisfaction
and then retain it.
To achieve these
goals, organisations undergo
various changes like opting for downsizing or mergers.
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(iii)
Importance of quality control : The survival
of any organisation
is solely dependent
on customers’ satisfaction and
quality is something
that a customer
always seeks in products. Therefore, quality is a way to
achieve customers’ satisfaction. The importance of quality control can be
understood in the following points:
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(iv) Double sampling plan : Double sampling:
Double sampling requires sampling the lot again
if the results of the
first sampling are
inconclusive. The procedure
of double sampling plan is as
follows:
1. Collect a random sample from the lot for
inspection
2. Inspect the sample for the required quality
characteristics
3. Accept the lot if the number of defects in
the sample is equal or less than the number set in
parameters say C1
4. Reject the lot if the number of defects in
the sample is more than the number set in parameters say
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3. Forces of change are the
factors that drive or stimulate the need for a change in an organisation. Some
of these are external, arising from outside the organisation whereas others are
internal, arising from sources within the organisation. Discuss the external
and internal forces of change.
External forces of change
External forces of change: These forces
from outside the organization stimulate
the need for
change in an
organisation. Unlike the
internal forces of change, the external forces cannot be controlled from
within an organisation. However,
access to external
information can help organisations to implement changes well
on time and effectively. These forces account for global effects that
might require an organisation to evaluate its business and business
processes. Broadly, external forces of
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4. “Six Sigma In Healthcare
Published: Jun 12 2004, 00:00 IST
Written by Mr. Gopal Kulkarni, Master Black Belt - Six Sigma and Founder
& Managing Director, Synagoge Knowledge Services
Source: Kulkarni Gopal. http://www.financialexpress.com/news/six-sigma-inhealthcare/107164/0
Question:
From the above articles evaluate how six sigma can aid enhance
healthcare.
Answer:
Areas where six sigma can be applied in health care
Six Sigma
is a powerful problem solving technique that helps in reducing variation in any
process by using powerful statistical tools for analysis. Six sigma has been
successfully used by various
organizations as an
enabler for business
strategies leading to
huge additions in their yearly turnover and at the same time improving
customer satisfaction by quantum leaps. This article describes how this
methodology can be used in hospitals to enhance customer care activities and
reduce wastage
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5. Elaborate on Quality Function
Deployment (QFD).
Quality Function
Deployment (QFD)
Quality Function Deployment (QFD) is a systematic approach used by the
development team to identify customers’ requirements and define them
for making products that
satisfy customers’ needs.
To facilitate QFD, there are many
elements that are required to be present. The most important of them are as
follows:
·
Strong commitment
towards QFD by the management
·
Setting up of clear
goals of QFD
·
Adoption of the
cross-functional team approach
·
Establishing
training programmes to educate team members about QFD with the help of a
well-skilled facilitator
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6. a. Explain the different modes of failures.
b. What is terotechnology?
c. What are reasons for using gap
models?
d. Explain the types of Knowledge
Support System (KSS).
a. Outline the THREE modes of
failures
Modes of failure
Failure in an item or product
occurs when it ceases to operate.
In oder to take the appropriate
corrective actions to rectify the failures, it is essential to understand
the different modes of failure. Mode of failure simply refers to the way a system failure
occurs. There are three modes of failure, as below:
Catastrophic
failure: A catastrophic failure is said to have occurred when an operating
system that is functioning normally comes
to a sudden
halt. Such failures are unplanned and occur at random. By
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b. Define terotechnology, list the tasks it
performs and who uses it and why
Terotechnology
Terotechnology
is considered as another word for total maintenance. This concept grew
in 1970s in
the UK by
the department of
Industry while conducting
maintenance practices. The word terotechnology has originated from the Greek
word: Tereian, which means to look after or to take care of.
Terotechnology is defined
as the process
of maintaining assets
in an optimal manner.
In other words,
it is a
combination of management, financial, human resource,
marketing and engineering
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c. List the reasons for using
gap models
Gap models are used:
·
To understand the
factors that satisfy/dissatisfy customers
·
To measure the
differences between delivery end expected quality
·
To know
if the organisation
is falling behind
or exceeding customer requirements
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·
d. Explain the TWO types of
KSS
The types of KSS are explained as
follows:
Manual support systems: These systems
provide all types of support in
decision making; however,
ultimate decision is
based on the
user’s rationale. After acquiring
the available knowledge,
the user can
take decisions more efficiently.
Intelligent systems:
These systems help users in taking
decisions based on a rational approach developed through the knowledge it contains. These are called
intelligent support systems.
The
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PROGRAM - MBA
SUBJECT CODE & NAME OM 0017 – ADVANCED PRODUCTION PLANNING AND
CONTROL
1 a. What is the importance of production planning
and control?
b. What factors affect inventory
planning and control?
c. What is the difference between
batch and mass production?
a. List the importance of
production planning and control
Production planning and
control is important for an organisation
in different ways. Let us discuss its importance:
·
Reduces cost
of production by
minimizing wastage of
material and economic
utilization of resources
·
Leads to lower
investment by means of efficient and balanced utilization of resources
·
Promotes
employee morale by avoiding all types of bottlenecks
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b. Discuss the three factors
that affect inventory planning and control
Three factors that
affect inventory planning and control are as follows:
Product type:
The type of the product
affects the inventory
planning as every product
does not have
similar shelf life.
Therefore, different procedures and
arrangements would be
required for different
types of products. For example
products such as perishable food cannot be stored in a similar way as the apparels and cosmetics are
stored. The products with the
expiry dates are often managed
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c. List the differences
between batch and mass production
Following are some of the differences between
mass production and batch production:
·
Mass production has
the product layout while batch production has the process layout.
·
In mass
production, the quantity of the product
is huge, while in batch production,
batch sizes are often small but have a variety of products.
·
Mass production
makes use of specialised
machineries, while in batch production,
general machines are used.
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2. What is a master schedule?
Explain.
Define master schedule
Master schedule
is the presentation
of the production
schedule at the summary level, depicting various key
elements, resulting from the process of master scheduling. In simple words, it can also be said that the
master schedule is a
plan or format
that integrates and
relates other production processes such as demand
management, inventory planning and capacity planning.
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3. What are the different types of
planning and scheduling tools? Explain.
Different types of
planning and scheduling tools are as follows:
1. Turnkey or off-the-shelf solutions
2. Custom systems
3. Excel and visual basic tools
1. Turnkey or off-the-shelf
solutions
Turnkey or
off-the-shelf solutions are
ready-made solutions that a
manufacturer can use without spending any time in their
customisation or development. It
takes a lot of time for planning and
scheduling tools to be customised if a
manufacturer wants to develop it from the beginning. After the
vendor is approached, a lot of time is required to understand,
conceive and implement the
actual
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4. a. What are the pillars of lean production?
b. What factors
should be considered
while implementing a
production planning and control
system?
a. Two pillars of lean
production
The foundation of lean
production stands on just-in-time and
Jidoka, whichare referred as the two pillars of lean production. Both these
pillars provide the basis for lean
production by providing some important concepts in lean production such
as pull system,
3 Ms, 5S,
fail proofing system,
etc. The
pillars
have been shown in below
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b. List the
factors that help
in the successful implementation
a production planning and control system
Development of
an education plan:
After the production
system is selected and
designed, it is
essential to educate
the employees and
the organisation about the design. This exercise helps in better implementation of the system, because this way, employees also feel involved and actively participate in
the implementation. Different
types of training
and induction programmes can
be conducted to
educate everyone about
the system which is
going to be
implemented. These
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5. Case Study: Planning and Scheduling at John Smith Pvt .Ltd
Question
What is main issue in the case study? Evaluate why this issue was caused
and provide a solution to resolve it.
Ans:
Describe the main issue in the case study
Mr.Max was hired
as the new planner for
the organisation on the basis
of his qualifications and
experience. After Mr. Max
completed 1 year,
theorganisation observed dissatisfaction
Among its
employees. The reason
was that employees
were not happy
with the way production was carried out. There was too much pressure on
employees, and Mr. Maxwas accepting more orders than the workers
could manage.
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6. Write short notes on:
(i) Cost centre
(ii) Objectives of sales and operations planning
(iii) Bills of Distribution
(BOD)
(iv) Advanced scheduling
(i)
Cost centre
According
to the Chartered Institute of Management Accountants, London, a cost
centre is“a location, person, or item of
equipment (or a group of these) for
which costs may
be ascertained and
used for the
purpose of cost control.”
In simple words, a cost centre
can be defined as a machine, a
department, a person, or a
group of persons for which the
cost is ascertained. A cost centre helps
in controlling cost
by artificially
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(ii)
Objectives of sales and operations planning
Sales and
Operation Planning are a wider
concept in organisational planning, because
it aggregates two
types of planning,namely sales
and operations. It serves
different objectives in
a manufacturing organisation, which is as follows:
To minimise costs and maximise
profits: If reducing costs do not affect
the customer demand, then minimising the costs can increase the profit. To increase
delivery services to
customers or making
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(iii)
Bills of Distribution (BOD)
In DRP,
Bills of Distribution
(BOD) utilise the
concept of Bill
of Materials (BOM) in
MRP. BOD links
supplying and satellite
warehouses together.
These warehouses
play an important
role in DRP
because of being responsible for
the storage and
movement of distribution
material as and when required by the organisation. The supplying warehouse is referred as a parent warehouse and satellite warehouses are
referred as components.
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(iv)
Advanced scheduling
Advanced scheduling in
APS is done to prepare the list of the operations, in terms of which the
operation is to be worked on, at which work centre and at what time.
Input of advanced
scheduling includes all
the demands that needs
to be met
and additional orders
added during advanced
planning.
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PROGRAM - MBA
SUBJECT
CODE & NAME - OM0018–
TECHNOLOGY MANAGEMENT
1. a. Explain Technology Management at various
levels
b. Discuss briefly about strategic
technology management.
a. Explaining Technology
Management in 3 levels
1. Technology management at national level
At the
national level, technology
management plays a
crucial role in the
overall economic development
of a nation.
For example, developed countries, such as the USA and the
UK, have effective technology policies,
and the
government in these
countries plays proactive
roles in the
development and
acquisition of technology.
Naturally, business
organisations in these
countries
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b. Explaining strategic
technology management
Strategic Technology Management
System (STMS)
STMS is a long-term
approach that emphasises systematic
management of technology. STMS recognises
the life cycle
of technology from
birth to decline. STMS involves
the following stages:
1. Technology
Creation: Involves development
and creation of new
technology. The activities involved in this stage are:
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2. a. Write about the changing trends in the
industry
b. Explain the methods for
Strategic Analysis and Decision Making
a. Write about
the changing trends
in the industry
The following table
shows the changing trends in the industry:
|
Factor
|
Traditional
|
New Trends
|
|
1. Technology life cycle
|
Long life cycle
|
Short life cycle
|
|
2. Innovations
|
Less number of innovations
|
Continuous innovations
|
|
3. Competition
|
Less competition, no cooperation
|
High competition, emergence of an alliance with the competitors
|
|
4. Market
|
Predictable and local market
|
Unpredictable and global market
|
|
5. Production
|
Mass production and large lot production
|
Customised production and small lot productions
|
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b. Explaining the three
methods for strategic analysis and decision making
The approaches to strategic
decision making are discussed as follows:
Intuitive
decision making: This implies the use of common sense to make
decisions. It can be an inner sense or voice of a manager that supports the
decision-making process. Intuitive
decision making might
involve creative thinking to
obtain alternate solutions
to a problem.
For example, the decisions taken by managers on the basis
of their previous experiences in similar situations are
intuitive
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3. a. Explain about the concept of
strategic planning
b. Describe the concept of
technology maps.
c. What is technology forecasting?
a. Explaining the concept of
strategic planning
The
process, which defines the strategy and direction of an organisation, is
known as
strategic planning. It
makes decision on
resource allocation of capital and people to monitor the defined
strategy. Strategic planning can be understood as the overall planning that
helps in the effective management of any process. It provides a clear image of
what you are doing and where are
you going as
an organisation. It
also assists the
organisation in understanding,
what it wants to achieve and
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b. Describing the concept of
technology maps
In order
to develop an effective technology
forecast, an organisation needs to be aware of undergoing changes in the current
technological scenario. It also
requires environmental scanning
to identify the
critical emerging
technologies. Therefore, organisations
need to develop technological maps to
navigate through the
existing promising technologies
and identify the future critical technologies. Development of technology maps is required in
the macro/national level
as well as
the
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c. Briefing on technology
forecasting
Technology forecasting
is the first
step in technology
planning. In simple words, forecasting refers to the
technique of anticipating a future scenario. In
a very dynamic
market scenario, organisations
continuously focus on forecasting the technological trends in
the future.
So why is
technology forecasting needed in the first place? Analysing critical emerging
technologies and
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4. What is the impact of the
technology change on the following:
a. Organisational productivity
b. Quality of work life
a. Impact of Technological Change on Organisational Productivity
Productivity refers
to the amount
of output at
a given amount
of input. Technological change
is part of
the fundamental factors
that can permanently improve
organisational productivity. It is a
commonly accepted fact that better
tools and techniques
yield more output
at lower input.
In addition, output increases
when manual processes
are replaced by machines.
Therefore, as you
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b. Impact of Technological Change on Quality of Work Life
Technological
development has significant impact on the quality of work life of an
individual. Change in technology is continuously replacing manual jobs by machines.
Earlier, most organisational activities
were conducted manually. The
extent of manual labour was the highest in the manufacturing industry. In
such working conditions,
low productivity and
longer working hours were the
norm.
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5. Demonstrate Global Information
System with neat diagram.
Global
Information System
With the
increasing number of
multinational corporations (MNCs)
and the profits involved in
international business, organisations required a system to manage profitable
execution of business strategy. The idea of developing a global information
system (GIS) aims
at meeting the
challenges of international business
so that a
profitable running can
be made possible. The demand of a global organisation
is driven by the global demand pattern and
the global approach
of the
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6. Explain the conceptual
framework of Management of Technology with a neat diagram
The Conceptual Framework
MOT creates
an intersection of
science, management, and
engineering disciplines. The traditional
fields in science
and engineering contribute
to scientific and technological
discoveries. Similarly, traditional
fields in business administration
also contribute to the management of enterprises, economics, finance,
marketing, and public policy. MOT links
disciplines that focus on technology
development, which leads
to the creation
of wealth. Below figure shows the
conceptual framework
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