Production Management MCQ Quiz in मल्याळम - Objective Question with Answer for Production Management - സൗജന്യ PDF ഡൗൺലോഡ് ചെയ്യുക

Explanation:

Mass production:

• Manufacture of discrete parts or assemblies using a continuous process are called mass production. The machineries are arranged in a line or product layout. It is also called as continuous production.
• Mass manufacturing is characterized by very high production rates and low variety or flexibility

Advantages of Mass Production

• Higher rate of production with reduced cycle time.
• Higher capacity.
• Less skilled operator can manage the process.
• Low in process inventory.
• Production cost per unit item will come down due to economies of scale.

Additional Information

Batch production

• Batch production is a type of production in which the job passes through the functional departments in batches and each batch may have a different routing.
• Batch production is characterized by the manufacture and stocking of a limited number of products at regular intervals, awaiting sales.
• Batch production is used for stable and predictable demand and for general purpose equipments.
• Example – Machine tools, pumps, compressors, stationary IC engines, etc.

Additional Information

Job – shop production

• Job – shop production is characterized by the manufacturing of a large variety of products in small quantities that are designed and produced as per specifications are given by customers
• The main feature of this production system is that it is highly flexible
• A shop – shop comprises general-purpose machines arranged in different departments
• Example – Manufacture of aeroplanes and oil field equipment, machine tools, giant hydro turbine, rolling mills, and other heavy equipment

Mass production

• In mass production, the same type of product is manufactured to meet the continuous demand for the product
• Manufacturing of discrete components or assemblies in a very large volume is called mass production
• Machines are arranged in a line according to the sequence of operations on the product
• Example – Nuts, bolts, screws, washers, pencils, matches, engine blocks, bicycles, electric motors, sewing machines, tractors, etc.

Explanation:

S-curve:

• In the course of Product Design and Development, the S-Curve determines the performance in regards to time and effort.
• It assists in determining the level of maturity of the product.
• Technological innovation time cycle and market behaviour are well characterized by the ‘S’ curve.
• Technological innovation typically manifests themselves into a market along the ‘S’ curve.
• The Technology S-Curve of Innovation/product life cycle is a robust framework that can be used to analyze various products at their different stages and to explain their successes and failures.

It is divided into 3 portions namely Lower, Middle and Top portions.

Lower Portions

• This phase is at the beginning of the S-Curve pattern of innovation.
• It is when the product/ industry is completely new.
• As a result, a dominant design in the market hasn’t been established yet.
• Therefore, the competition between the various players in the industry is fierce.
• As a result, usually at this stage, most of the resources are spent on research and development.
• There will be apparently not much innovation.
• Changes are less and widely spaced.

Middle Portion

• In this phase, due to the ability to overcome a major technical obstacle or the ability to satisfy a demand of the market.
• The product/industry has been adopted by the early majority and managed to cross the differences and a dominant design has been established already.
• Hence, the market will be characterized by rapid growth in production, and the product will move quickly towards a full market acceptance.
• So, A rapid profusion of innovation (slope) will take place during this period.
• Many products are launched and many competitors join the market.

Top Portion

• ​Here, the product is adopted almost completely by society and is usually approaching a physical limit.
• Due to the strong competition among the major players in the market which is clearly defined at this stage, most of the resources at this point are spent on improving the production processes and making them cheaper.
• Therefore, oftentimes the products at this stage become completely standardized and the innovations at this stage are considered incremental.

Explanation:

Production System is classified as Job Shop, Batch Production, Mass and Continuous Production systems.

Job Shop Production System

• High Variety and Low volume
• General-purpose machines
• Highly skilled operators 
• Large inventory of materials 

Batch Production

• Shorter production runs
• When plant and machinery are flexible

Mass Production

• Standard product and large volume of products
• Large Volume of products

Continuous Production

• Dedicated plant and equipment with zero flexibility

Explanation:

Acceptance sampling is a quality control procedure, which uses the inspection of small samples instead of 100 percent inspection in making the decision to accept or reject much larger quantities, called a lot. This is a statistical procedure, which uses random samples, that is, each item in the lot has an equal chance of being a part of the sample that is inspected.

• Acceptance Sampling is normally used for Mass production.
• In its simplest form, If the sample from a larger lot has an acceptable level of defects, it will be accepted. If not, the entire lot will be rejected.
• If acceptance sampling is used prior to accepting goods from a supplier (i.e., incoming inspection), then the acceptable level of defects must be agreed between the supplier and customer because the supplier may have to take back the entire lot if it fails acceptance sampling.
• A sampling plan establishes the rules guiding the sampling and the criteria for accepting or rejecting the lot.

Mass production:

• The manufacture of discrete parts or assemblies using a continuous process is called mass production. The machineries are arranged in a line or product layout. It is also called as continuous production.
• Mass manufacturing is characterized by very high production rates and low variety or flexibility

Advantages of Mass Production

• Higher rate of production with reduced cycle time.
• Higher capacity.
• A less skilled operator can manage the process.
• Low in process inventory.
• Production cost per unit item will come down due to economies of scale.

Batch Production:

• It is a common type of production. In this type of production, the flow of material is intermittent. 
• Articles are manufactured in batch as per the specific order procured.
• A good production control system must be developed. Product planning is done for each batch.
• Proper maintenance of equipment and machinery is essential.
• The plant layout best suitable for this type of production is the Process Layout.

​Job – shop production:

• Job – shop production is characterized by the manufacturing of a large variety of products in small quantities that are designed and produced as per specifications are given by customers
• The main feature of this production system is that it is highly flexible
• A shop – shop comprises general-purpose machines arranged in different departments
• Example – Manufacture of aeroplanes and oil field equipment, machine tools, giant hydro turbine, rolling mills, and other heavy equipment

Just In Time (JIT) Production system:

• Just in time (JIT) manufacturing is a workflow methodology aimed at reducing flow times within production systems, as well as response times from suppliers and to customers.

Important characteristics of JIT Production system

• Daily or hourly deliveries of small quantities of parts from suppliers.
• Certification of supplier quality, so that no receiving inspections are needed.
• The use of Kanbans to drive the demand at each workstation.
• Production stops as soon as the immediate demand level has been fulfilled.
• On-site inspection of each in-process product from the preceding work center, so that flaws are discovered at once.
• The use of rapid machine setups, so that production runs can be as short as one unit.
• The cross-training of employees, so that they are certified to work on multiple tasks.
• Immediate shipment of completed goods to customers as soon as an order has been fulfilled.

Explanation:

Lean production:

• Lean production means supplying the customer with exactly what the customer wants, when the customer wants it, without waste, through continual improvement.
• Waste is anything that does not add value to the product.
• Lean production is driven by the "pull" system of the customer's order.
• These waste reduction efforts improve productivity and processes.

Customized Production:

• In this flow of material and parts from one location to another is intermittent or discontinuous.
• Each job order is different from the previous as regards its type, specifications, quality, and quantity.
• Product design takes a lot of time.
• Prior planning becomes difficult.
• General-purpose machinery and a flexible layout are preferred.
• The number of items to be manufactured is very small.

Mass production:

• Mass production means the production of items on large scale.
• In this type of production, there is a continuous and steady flow of materials.
• It offers the lowest production cost per unit.
• Material handling is reduced to a minimum since very little time is spent on the resetting of the machine.
• Work cycles are short and of a repetitive nature.
• Plant layout and facilities are designed to suit production requirements.
• Mass production is preferred where there is a continuous and regular demand for products.

Batch Production:

• It is a common type of production.
• The flow of material is intermittent.
• The plant layout is of the process type.
• Product planning is done for each batch.
• Proper maintenance of equipment and machinery is essential.
• A good production control system must be developed.
• Articles are manufactured in batch as per the specific order procured.

Explanation:

Marginal Cost: It is the addition to total cost resulting from the production of an additional unit of output.

Opportunity Cost: Opportunity costs represent the benefits missed out when one alternative is chosen over another alternatives.

Explanation:

In a manufacturing shop floor the production line is arranged in a manner that the product is moved sequentially along the line and stops at the work centers where operations are performed. The production line is designed to optimize the utilization of movement of work-piece during manufacturing. The line is designed according to the products volume and variety.

Assembly line:

• An assembly line is a manufacturing process in which interchangeable parts are added to a product in a sequential manner to create an end product.
• At each station along the line some part of the production process takes place.
• The workers and machinery used to produce the item are stationary along the line and the product moves through the cycle, from start to finish, therefore the assembly line have number of process which are repetitive in nature.

Customized Process:

• Customized processes are used when the company manufactures a wide range of products that can be modified according to the customer’s requirements.
• For customized products one kind of machinery are grouped together. The customized process are suitable for low volume and high variety of products.

Product Focused Process:

• In a product focused process the various operations on raw material are performed in a sequence and the machines are placed along the product flow line, i.e. machines are arranged in a sequence in which raw material will be operated upon. This is suitable for continuous production.

Specialized process:

• In a specialized process, the operations are very product specific and the special purpose machines are utilized in this process

Explanation:

Design is essentially a decision-making process. If we have a problem, we need to design a solution.

In other words, to design is to formulate a plan to satisfy a particular need and to create something with physical reality.

There may be several types of design based on methods such as,

Rational design

• It is a design procedure to meet the strength requirements of a load-carrying member.
• It is based on determining the stresses and strains of components and thereby deciding their dimensions.
• In this method, the design is done mathematically and based on the principle of mechanics of the machine.
• This design procedure can be applied to all complicated and involved situations encountered in present-day structures and machines.

However, not all topics in design have a firm analytical base from which to work. In those cases, we must depend on a semi-rational or empirical approach to solving a problem or selecting a design component.

Empirical design

This is based on empirical formulae which in turn is based on experience and experiments.

For example, when we tighten a nut on a bolt the force exerted or the stresses induced cannot be determined exactly but experience shows that the tightening force may be given by

P = 284 × d

where d is the bolt diameter in mm and P is the applied force in kg.

There is no mathematical backing of this equation but it is based on observations and experience.

Industrial design:
These are based on industrial considerations and norms viz. market survey, external look, production facilities, low cost, use of existing standard products.