M.B.A. II (Semester IV) Examination, 2016
Group E Production and Material Management (Paper
WORLD CLASS MANUFACTURING
Day and Date Tuesday, 13-12-2016 Total Marks 70
Time 10.30 a.m. to 1.30 p.m.
Instructions Question No. 1 is compulsory.
Attempt any two questions from Q. Q. 3 and Q. 4.
Attempt any two questions from Q. Q. 6 and Q. 7.
1. Study the following case carefully and answer the question given at the end.
In 1947, a division of Generic Electric was acquired by Larsen Electric Industrial
Company. It employed 1200 people in Franklin Park to produced color television
receiver and microwave oven. Five year after the change over, in process defects
had dropped from 1.4 to .07 defects per set and productivity had jumped almost
30 percent. The labor required to produce a color television receiver was cut in
half. These gains were achieved by blending new equipment, technology, training
and managerial practices to revitalize an already skilled labor force.
Equipment Automatic equipment developed in Japan for Chassis assembly
was used. Design changes reduced the number of required workers by 26 percent.
Equipment and design engineers worked together to improve producibility making
quality products easier to manufacture.
Technology New assembly lines allowed controlling their work flow individually.
In place of continuous, conveyor paced line; operators were given foot levers to
detour work to their station and to forward piece to the next work stations. Closed
circuit television systems were installed to broadcast quality information to workers
on the production line.
P.T.O.
Seat
No.
SLR-T 77
Training The importance of quality was continually emphasized, placing
responsibility on production workers, not inspectors. End product inspection
teams were replaced by a few in process inspector who moved from one assembly
line to another carrying out sampling inspection. New employee are trained both
in the class room and on the job, up to 5 days of each, during which they learn
about quality expectations, are judged on whether they can do the work adequately
and see whether they like the work conditions.
Managerial practice Once a week all work stops for 10 to 15 minutes while
supervisors communicate with their subordinates. A supervisor typically
communicates with 45 workers about quality, productivity, absenteeism, scrap
and other subject that might come up. If the supervisors can not answer a
question, they make a note of it and come prepared with an answer in the next
meeting.
Every six month, manufacturing and quality control people meet to set quality
goals for different areas. Bar charts are kept to signal which area are above,
near or below their targets. Special effort is concentrated on a particular line,
called the model line, to improve its performance. Workers on that line and
support groups meet once a week to explore progress. Reason for successes in
the model line are identified and adapted to fit other lines.
A quality emphasis month is declared twice a year. Awareness is aroused by
slogan and poster competition, cross word puzzles with quality terms and
suggestion contests. Winners are entertained at a felicitation party and given a
modest reward.
The underlying purpose of all activities is to create an environment that will be
conducive to cooperation and encouraging people to work together to identify
problems and offer suggestions to solve them.
Questions
Analyze the case. 5
Identify the problem. 2
Find out alternative solution. 5
Give the best solution. 2
SLR-T 77
2. Short Notes (any 14
Strategic decision in manufacturing management.
Globalization of business and its challenges.
World class performance.
3. Short Notes (any 14
Just-In-Time system.
Role of IT in world class manufacturing.
Air pollution.
4. Short Notes (any 14
Group Technology.
Concept of Total Productive Maintenance.
Kanban System.
5. What are the characteristics of World Class Manufacturing What is the
contribution of technology and automation towards manufacturing excellence 14
6. Explain the impact of WCM as environment. Describe the factors causing
pollution and its effect on human health. 14
7. Explain the concept of Reliability. Explain the various methods of Reliability
improvement along with a suitable example. 14