The document summarizes an internal assessment for an MBA course on operations management. It includes:
1) Questions about lean manufacturing, leadership roles, and applying lean principles to services.
2) Questions on Toyota Production System techniques like 5S, pokayoke, JIT and advantages/disadvantages.
3) A compulsory case study analysis about a company using JIT for custom jeans manufacturing and partnerships with retailers.
The document summarizes an internal assessment for an MBA course on operations management. It includes:
1) Questions about lean manufacturing, leadership roles, and applying lean principles to services.
2) Questions on Toyota Production System techniques like 5S, pokayoke, JIT and advantages/disadvantages.
3) A compulsory case study analysis about a company using JIT for custom jeans manufacturing and partnerships with retailers.
The document summarizes an internal assessment for an MBA course on operations management. It includes:
1) Questions about lean manufacturing, leadership roles, and applying lean principles to services.
2) Questions on Toyota Production System techniques like 5S, pokayoke, JIT and advantages/disadvantages.
3) A compulsory case study analysis about a company using JIT for custom jeans manufacturing and partnerships with retailers.
The document summarizes an internal assessment for an MBA course on operations management. It includes:
1) Questions about lean manufacturing, leadership roles, and applying lean principles to services.
2) Questions on Toyota Production System techniques like 5S, pokayoke, JIT and advantages/disadvantages.
3) A compulsory case study analysis about a company using JIT for custom jeans manufacturing and partnerships with retailers.
2nd INTERNAL ASSESSMENT, OUTCOME BASED EDUCATION (OBE) AND
CHOICE BASED CREDIT SYSTEM (CBCS) SCHEME
2020 - 22 Batch Course: TOS Course Code: 20MBA302 Program & Semester : MBA,III Max. Marks: 50 Date: 11/1/2022 Time: 9. 30 AM to 11 AM Answer any two full Questions from Q1, Q2, and Q3 in part A, Q4 in Part B is compulsory
Q. Questions Marks CO/BT
No 1.a Define Lean Manufacturing? What is the purpose of lean manufacturing? 2 CO3 /L1 Sol Lean manufacturing is a production process based on an ideology of maximizing productivity while simultaneously minimizing waste within a manufacturing operation. The benefits of lean manufacturing include reduced lead times and operating costs and improved product quality. The four key benefits to lean manufacture: Eliminate Waste Improve Quality Reduce cost Reducing time b Explain briefly the role of leadership. 6 CO3/L2 Sol Develop processes and practices that improve teamwork. Required at all levels Representative of the organization Integrates and reconciles (settles) the personal goals with organizational goals- He solicits (requests) support- 6. As a friend, philosopher and guide- c Explain briefly about lean operations in the service sector. 8 CO3/L2 Sol The various factors that lead to success of lean operations in services are 1. Identify and map end-to-end processes: 2. Reduce complexity(Eliminate any variations, disruptions, rework ) 3. Set and track performance metrics 4. Cross-train to increase productivity: 5. Creating a lean culture 2.a List the different techniques in TPS. 2 CO4/L1 Sol 5S JIT KAIZEN KANBAN POKE YOKE JIDOKA b Explain the “5S” Technique of Eliminating the Waste. 6 CO3/L2 Sol 1. Seiri > Sort 2. Seiton > Set in Order 3. Seiso > Shine 4. Seiketsu > Standardize 5. Shitsuke > Sustain c What is Pokayoke? Illustrate the various methods/techniques of Pokayoke to avoid 8 CO4/L3 or detect the defects. Sol Poka-yoke is an effective method for eliminating certain defects from occurring. When a defect cannot be eliminated, poka-yoke can often assist in identifying the error earlier in the process, decreasing the cost of the rework and the potential of the error reaching the end customer. Often inexpensive and appreciated by personnel across an organization, poka-yoke can help decrease errors, making quality easier to manage and leading to a less stressful environment. Methods/techniques to pokayoke to avoid mistakes Contact method detects any deviation in shapes, dimensions, forms, position or other physical characteristics through mechanisms that are kept in direct contact with the part. Contact method can be used in situations of rapid repetition, infrequent production or environmental problems such as poor lighting, critical temperature, dust, noise and so on. Fixed value method is used in operations, where the same activities are repeated several times. The method employs automatic counters or optical devices and controls the number of moves, rate and length of movement as well as other critical operating parameters. Motion step method is useful for processes requiring several different activities performed in sequence by a single operator. The method ensures that the operator does not mistakenly perform a step that is not part of the normal process. 3.a What is JIT? List out the advantages & disadvantages. 2 CO4/L1 Sol Just-in-time (JIT) manufacturing is a production model in which items are created to meet demand, not created in surplus or in advance of need. Some of the advantages of JIT: Reduction in inventory Reduction in labor costs Reduction in space needed to operate Reduction in WIP (work in process) Increase in production Improvements in product quality (lower rates of defects) Reduction of throughput time Reduction of standard hours Increase in number of shipments b Illustrate the various types of production system. 6 CO4/L3 Sol Job Production Batch Production Mass Production Continuous Production c Explain briefly the concept of KAIZEN, KANBAN with Pros & Cons of it. 8 CO4/L2 Sol Kanban Kanban is an inventory control system used in just-in-time (JIT) manufacturing. It was developed by Taiichi Ohno, an industrial engineer at Toyota. Kanban (Japanese for sign) is an inventory control system used in just-in-time (JIT) manufacturing to track production and order new shipments of parts and materials. Kaizen From the Japanese words “kai-” this means “change” and “-zen” which means “good??” The popular meaning from Toyota is “continuous improvement” or “small incremental improvements” of all areas of a company, not just manufacturing. Kaizen is a Japanese term meaning "change for the better" or "continuous improvement." It is a Japanese business philosophy regarding the processes that continuously improve operations and involve all employees. Kaizen reviews and training teaches new employees how to apply Kaizen principles to their work, which means Kaizen stays sustainable for years to come. Part B Compulsory Case Study 4 JIT in Action A new phenomenon called „Apparel on Demand‟ is slowly making its presence felt. It is an extension of JIT linking retailers and manufacturers for a 18 CO4 / L4 just-in-time responsiveness. NaaR Clothing Inc., promoted by a young management graduate has recently ventured into the business of making reasonably priced custom jeans for women. It has partnered with many stores selling women garments. In the stores, women are electronically measured and information like color, fabric, style, etc., are recorded. The information reaches the NaaR manufacturing facility at Ahmedabad almost immediately through a state-of- the-art information system. NaaR guarantees delivery of the custom jeans within 10 days. With the growing acceptance of jeans among the women in India, especially in the urban areas, the market for women‟s jeans is growing at a fast pace. NaaR with its unique business model hopes to garner a significant share of this market. The promoter of NaaR along with her top executives is confident that their concept of JIT jeans would work. Questions: (a) Do you think NaaR‟s strategy would work? Why or why not? What is the importance of retailers in its business strategy? (b) Will customers wait for 10 days to have the jeans delivered? What can NaaR do to compete on customer service if delivery takes this much time? (c) Analyse the advantages & disadvantages of JIT NaaR clothing Inc. Sol a) Yes b) Importance is to make partnership, Gain Market share , Distribution, extension of business. Advantages Disadvantages Reduction in inventory Reduction in labor costs Reduction in space needed to operate Reduction in WIP (work in process) Increase in production Improvements in product quality (lower rates of defects) Reduction of throughput time Reduction of standard hours Increase in number of shipments Course outcomes Students will be able to CO3: Evaluate the importance of Lean Manufacturing CO4: Develop strategies of Total quality management
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