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Production Management, Inventory Control & Supply Chain Management By Prof. J. Hayavadana

Production Management, Inventory Control & Supply Chain Management By Prof. J. Hayavadana University Head, Department of Technology Osmania University Hyderabad-7. Production Management. Is it Operations Management ? How it is defined Production Vs Service function

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Production Management, Inventory Control & Supply Chain Management By Prof. J. Hayavadana

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  1. Production Management, Inventory Control & Supply Chain Management By Prof. J. Hayavadana University Head, Department of Technology Osmania University Hyderabad-7

  2. Production Management • Is it Operations Management ? • How it is defined • Production Vs Service function • Production function- determinants • Production Decisions : Strategic, Operating , Control • Production & productivity • How Production Management is related to Industrial Engineering • Why Production Management is required ( timely production & Lead time fulfulment )

  3. Areas of Productivity • Improving volume of production • Apply Control Charts – reduce rework, rejections , waste or scrap • Maintain LT • Control Idle time , WIP– update with norms – time study • Use MIS & Quality systems • Good House keeping ., Material Handling • Check absenteeism. Theft., pilferage • Ensure Safety – Safe-t-Score test

  4. Efficient Training & Team Building ( Identify for Re-Training , Training costs) Work out correct Inventory – EOQ Use Cause & effect Diagram Use Deming Cycle Use Six Sigma concept Use Lean Management concept Use Acceptance Sampling Use Normal Distributions Choose the right method of sampling

  5. Components of Production Management • 1. Process Design • 2. Product design • 3.Product Life cycle • 4.Plant Utilities or industrial Climatology i. Plant Lighting ii. Plant Ventilation iii. Plant Air-conditioning iv.Sanitation v. Noise control and Acoustics vi.Need for Automation and types of Automation vi. Type of Building vii. Type of Floor viii. Type of Roof

  6. 5. Plant location : Types , Selection , Tools, recent trends • 6. Plant Layout : Types, Selection , Tools, Role of Computers • 7.Material Handling : types , Selection, Safety , Maintainance • 8.Maintainance Management : Types , selection , Audit , Link to quality production • 9.Ergonomics : Need, Meaning , Approach • 10.Job Design : Job rotation, Enlargement , Enrichment , Vestibule training , Job description , Specification

  7. 11. Work Study : Method Study & Time Study – Need , Role Significance , Fixation of Wage , Incentive Method Study :phases: S , R , E, D, Dev.,M I How this is useful in a production set up ? Time Study: Phases: S , R , D , Dev.., I Tools : Clock, elements, allowances, Normal time ,Observed time , Rating of a worker, Standard time , S M V or S A V – link to production

  8. Time Study for set up 1. Motion & Time analysis 2. Ergonomics 3. Elements – Time measurement 4. Apply Allowances 5. Establish the Standard time 6. Identify the idle time 7. Determine the number of rounds of observation

  9. Overview of Inventory Control • What is Inventory & Inventory Control ? • What is W I P ? • How Inventory is Created ? • What are P & Q systems ? • Saw Tooth Curve • Inventory Decisions ( Credit & Discount )

  10. Supply Chain Management • Introduction • Need • Production Equation • Supply Chain for a Manfg. Unit • Supply Chain for a Service Unit

  11. Overview of SCM • Inventory Control • Materials Management • Components of Material Management or LM 1. Purchasing & Procurement 2.Principles 3.Purchasing methods 4. Purchasing Cycle 5.Purchasing Interfaces 6. Value Analysis 7. Outsourcing ( 3 PL & 4 PL)

  12. Vendor Dynamics Choosing a Supplier – determinants, Certification Vendor Rating Vendor Analysis Vendor Development Supplier types : i. Partnership ii. Adversary Evaluation of Logistics: Incoming & Outgoing shipment

  13. Innovations in Logistics • 1. Warehousing : types – i. Bonded ii. UnBonded 2.Warehousing design , Construction 3. Developments in Warehousing i. Barcoding ii. Electronic data interchange iii. Distribution requirement Planning iv. JIT or Kanban

  14. Supply Chain Strategies • Strategy 1 : Multiple Suppliers ( Short term) • Strategy 2. Few Suppliers ( Long term) • Strategy 3. Vertical Integration • i. Backward Integration • ii. Forward Integration • Strategy 4. : Keiretsu Network • Strategy 5.: Virtual Company – R M G

  15. Managing Supply Chain • 1. Postponement or Curtailment if a part can be available locally • 2.Channel Assembly – Distributor as Manfg. • Drop Shipping and Special packaging • Blanket Order • Invoice less Purchasing • Electronic Ordering and Fund transfer • Stockless Purchasing- Direct to purchaser without store • Standardization : Reduce no. of materials and components to aid Cost reduction

  16. Benchmarking in SCM • Comparison of Supply Chain Performance For different factors like • Number of suppliers per purchasing agent • Purchasing cost & lead time • % of late deliveries • % of rejections • Number of shortages per year

  17. Tools for SCM • 1. Make or Buy decision • 2.Supplier scheduling • 3. Value Analysis • 4.Supplier evaluation • 5. Linear Programming • 7. Assignment techniques • 8. Transportation Techniques • 9. Network Techniques • 10. Sequencing

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