What is the difference between the terms production management and operations management multiple choice?

Latest Production Management MCQ Objective Questions

Production Management MCQ Question 1:

Which of the following statement is correct regarding Micro motion study?

1. Micro motion study is one of the most accurate techniques to enhance the production rate of the assembly line.
2. The micro-motion study technique is best suited for those operations or activities which are of short duration.
3. The motion time data from the film is transferred to SIMO chart which is further analyzed for the purpose of workplace layout or method improvement.
4. None of the above

Answer (Detailed Solution Below)

Option :

Explanation:

Definition:

• The micro-motion study technique is best suited for those operations or activities which are of short duration and which are repeated hundreds of times so statement 2 is correct.
• “Thus micro motion study is the technique of recording and analyzing the timing of basic elements of an operation with the objective of achieving the best method of performing the operation.” Such respective short-duration activities involve quick movement of limbs which cannot be accurately studied and timed using two-handed process charts.
• This is due to the fact that such record microscopic details such as different operations, Inspection and transport, etc. The study of such microscopic movements in short cycle repetitive jobs is not sufficient.
• Short cycle operations require to be studied for microscopic motions e.g., the operation of picking up a nut from the bin and its fixing consists of three hand motions namely reach for the nut, grasp the nut, and move the hand back to assembly position.
• Such detailed analysis help to develop the best possible pattern of movements and hence enabling the operator to perform various operations repeatedly with minimum effort and fatigue.
• Micro motion study is one of the most accurate techniques of work analysis used for work improvement. so statement 1 is incorrect.
• It makes use of motion pictures of different activities movement, so with the help of the camera.  small time up to 0.0005 minutes can be measured and recorded by this system.
• When a picture camera is utilized, the procedure is known as “Micro motion study”.
• The motion time data from the film is transferred to SIMO chart.
• The  SIMO chart data can be further analyzed for the purpose of workplace layout or method improvement so statement 3 is correct.

Purpose of Micro Motion Study:

1. It can be used for the following purposes:
2. To study the nature and path of movements for obtaining the elements of an operation.
3. To study the activities of the machine and the operator.
4. To impart training to the workers or operators regarding motion; economy so that unnecessary movement by the workers may be avoided.
5. To study the relationship between the activities of the operator and the machine.
6. To keep a permanent record of the most efficient way of performing a task for future reference.​
7.  To obtain motion time data for developing synthetic time standards for various elements.

Advantages of Micro Motion Study:

1. It has the following important advantages:
2. It provides a permanent record of motion study on films.
3. A large number of operators can see the procedure at any time even after the completion of motion study work.
4. Films can easily reveal the difference between the present and the proposed technique.
5. Films can be demonstrated to large workforce at any desired speed.
6. It provides very accurate time for each operation or motion in comparison to stopwatch time study.
7. It helps in making detailed and accurate analyses of the prevailing technique.

Production Management MCQ Question 2:

Which of the following industries will consume maximum power per tonne of product?

1. Zinc
2. Aluminium
3. Alloy steel
4. Cement

Answer (Detailed Solution Below)

Option 2 : Aluminium

Aluminum Production: About 17,000 kWh of electricity is required to produce 1 tonne of aluminum.

Zinc Production: The amount of energy required for casting one tonne of zinc is 208 kWh, and for remelting, the same amount of metal is 155 kWh.

Alloy steel Production: With an average of 770 kWh/ton and a typical EAF consumption under 500 kWh/ton.

Cement Production: While total electrical energy consumption for cement production is about 100 kWh/ton of cement.

Production Management MCQ Question 3:

Safety in a workshop can be classified as

1. General safety 
2. Personal safety 
3. Machine safety 
4. All of the above
5. None of these

Answer (Detailed Solution Below)

Option 4 : All of the above

Generally, accidents do not happen; they are caused. Most accidents are avoidable. To achieve this, it is essential that every person should follow the safety procedure.

Safety in a workshop can be broadly classified into 3 categories.

1. General safety
2. Personal safety
3. Machine safety

General safety

• Keep the floor and gangways clean and clear.
• Don't leave the machine which is in motion.
• Don't touch or handle any equipment/ machine unless authorized to do so. 
• Use the correct tools for the job and keep at their proper place.
• Wipeout spilt oil immediately.
• Replace worn out or damaged tools immediately.
• Never direct compressed air at yourself or at your co-worker.
• Ensure adequate light in the workshop.
• Sweep away the metal cuttings.

Personal safety

• Wear a one-piece overall or boiler suit.
• Keep the overall buttons fastened.
• Don't use ties and scarves.
• Roll up the sleeves tightly above the elbow.
• Wear safety shoes or boots. 
• Cut the hair short.
• Don't wear a ring, watch or chain.
• Never lean on the machine.
• Don't clean hands in the coolant fluid.
• Don't use cracked or chipped tools.
• Don't start the machine until
  • − the workpiece is securely mounted
  • − the feed machinery is in the neutral
  • − the work area is clear.
     
• Don't adjust clamps or holding devices while the machine is in motion.
• Never touch the electrical equipment with wet hands.
• Don't use any faulty electrical equipment.
• Don't engage yourself in conversation with others while concentrating on your job.

Machine safety

• Switch off the machine immediately if something goes wrong.
• Keep the machine clean.
• Replace any worn out or damaged accessories, holding devices, nuts, bolts etc as soon as possible.
• Do not attempt operating the machine until you know how to operate it properly.
• Do not adjust tool or the workpiece unless the power is off.
• Stop the machine before changing the speed.
• Disengage the automatic feeds before switching off.
• Check the oil level before starting the machine.
• Never start a machine unless all the safety guards are in position.
• Take measurements only after stopping the machine
• Use wooden planks over the bed while loading and unloading heavy jobs. 

Production Management MCQ Question 4:

A system that uses the minimal amount of resources to produce a high volume of high-quality goods with some variety is known as:

1. Repetitive Production system
2.  Mass Production system
3. Continuous Production system
4. Lean Production system
5. Just-in Time System

Answer (Detailed Solution Below)

Option 4 : Lean Production system

The correct answer is Lean Production system

Explanation:

Lean Production system:

• The system uses minimal amounts of resources to produce a high volume of high-quality goods with some variety.
• Lean production system uses a highly skilled workforce and flexible types of equipment.

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.

Continuous Production system:

• The same product is produced continuously in the same sequence of operations, e.g. chemical and power plant

Repetitive Production system:

• A repetitive Production system refers to the fabrication, machining, assembly and testing of discrete, standard units, which are produced in volume.
• It also refers to the fabrication, machining,  assembly and testing of products assembled in volume from standard options.
• A typical repetitive manufacturing system is characterized by long runs of complex products produced in lower volume quantities.

Just-in Time System:

• A just-in-time (JIT) inventory system is a business approach that involves receiving products as close to when they are needed as possible.
• As a result, if a car assembly facility wants to install airbags, it does not have a supply of airbags on hand, but instead orders them as the cars come off the assembly line.

Production Management MCQ Question 5:

_______ is considered as an adult according to the Factory Act, 1948.

1. A person completed 15 years of age
2. A person completed 18 years of age
3. A person completed 21 years of age
4. A person completed 25 years of age

Answer (Detailed Solution Below)

Option 2 : A person completed 18 years of age

Explanation:

• Adult means a person who has completed his eighteenth year of age.
• Adolescent means a person, who has completed his fifteenth year of age but has not completed his eighteenth year.

Top Production Management MCQ Objective Questions

The original cost of equipment is rupees 1,00,000. Its salvage value at the end of its useful life of five years is 40,000. Its book value at the end of two years of its useful life as per straight line method of evaluation of depreciation will be

1. 68000
2. 76000
3. 58000
4. 940000

Answer (Detailed Solution Below)

Option 2 : 76000

Concept

By Straight line method 

Depreciation is given by 

\({D_m} = \frac{{{C_i} - {C_s}}}{n}\)

Where Dm is depreciation 

Ci is Initial cost of an asset

Cs is Salvage or scrap value (Estimated at the end of utility period)

Book value (Bm) at the end of 'm ' years life is given by 

\({B_m} = {C_i} - m × {D_m}\)

Calculation

Given,

Ci = 1,00,000 /-, Cs = 40,000 /- 

n = 5 years

Depreciation is 

\({D_m} = \frac{{1,00,000 - 40000}}{5} = 12,000\)

Book value at the end of 2 years of lifetime is given by

\({B_m} = {C_i} - m × {D_m}\)

= 1,00,000 - 2 × 12,000 = 76,000 /-

Which of the following layout is useful when the product being processed is very big, heavy or difficult to move?

1. Fixed position
2. Process layout
3. Product layout
4. Cellular layout

Answer (Detailed Solution Below)

Option 1 : Fixed position

Concept:

Layout planning in manufacturing and service organisations involves the physical arrangement of various resources available in the system to improve the performance of the operating system, thereby providing better customer services.

Layouts can be classified into the following four categories:

1. Process layout
2. Product layout
3. Group layout (Combination layout)
4. Fixed-position layout

Fixed-position layout:

In a fixed position layout, the service is performed around a customer that remains stationary while the work is being done.

For example, surgery is performed on a patient, where a patient remains stationary in operation theatre. Different doctors or specialist perform different activities in a sequence on a stationary patient.

Example: Manufacturers of aeroplanes, ships, locomotives, large turbines, heavy machinery, pressure vessels and others which involve heavy materials and sub-assemblies.

This type of layout is suitable:

• When one or a few pieces of an identical product are to be manufactured
• When the assembly consists of a large number of heavy parts, the cost of transportation of which is very high

Product Layout: In product layout, the workstations are located according to the processing sequence for the service.

Process Layout: In process layout, similar activities are grouped together according to the process or function they perform.

The process of taking measures to check the quality, performance or reliability of the equipment is called:

1. testing
2. inspecting
3. servicing
4. analysing

Answer (Detailed Solution Below)

Option 1 : testing

Testing: It is the process of taking measures to check the quality, performance, or reliability of the equipment.

Inspections: It includes measuring, testing, examining, or gauging the features of a process or product.

Servicing: It is the kind of timely maintenance of the equipment for better performance.

Analyzing: It provides information on the composition of a sample of matter. They are employed to obtain qualitative and quantitative information about the presence or absence of one or more components of the equipment.

Acceptance sampling is normally used for 

1. Job-shop production
2. Batch production
3. Mass production 
4. Just-in -time production  

Answer (Detailed Solution Below)

Option 3 : Mass production 

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.

Technology S-curves are helpful in

1. Product platform planning
2. Concept generation
3. Product architecture
4. Product design

Answer (Detailed Solution Below)

Option 4 : Product design

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.

A system that uses the minimal amount of resources to produce a high volume of high-quality goods with some variety is known as:

1. Repetitive Production system
2.  Mass Production system
3. Continuous Production system
4. Lean Production system

Answer (Detailed Solution Below)

Option 4 : Lean Production system

Explanation:

Lean Production system:

• The system uses minimal amounts of resources to produce a high volume of high-quality goods with some variety.
• Lean production system uses a highly skilled workforce and flexible types of equipment.

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.

Continuous Production system:

• The same product is produced continuously in the same sequence of operations, e.g. chemical and power plant

Repetitive Production system:

• A repetitive Production system refers to the fabrication, machining, assembly and testing of discrete, standard units, which are produced in volume.
• It also refers to the fabrication, machining,  assembly and testing of products assembled in volume from standard options.
• A typical repetitive manufacturing system is characterised by long runs of complex products produced in lower volume quantities.

Which of the following Characteristics is not usually associated with batch production? 

1. products made to customer order
2. low volume
3. stable, predictable demand
4. general purpose equipment

Answer (Detailed Solution Below)

Option 1 : products made to customer order

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.

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.

Mass production is characterized by

1. low-volume items with maximum flexibility in their design
2. high-volume items with maximum flexibility in their design
3. high-volume items with minimum flexibility in their design
4. low-volume items with minimum flexibility in their design

Answer (Detailed Solution Below)

Option 3 : high-volume items with minimum flexibility in their design

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.

Which of the following is not the part of products planning competitive strategy?

1. Technology leadership
2. Cost leadership
3. Customer focus
4. Endurance

Answer (Detailed Solution Below)

Option 4 : Endurance

Explanation:

Four parts of products planning competitive strategy are

1. Cost Leadership Strategy or Low-cost strategy or Technology leadership.
2. Differentiation strategy.
3. Best-cost strategy or Cost leadership.
4. Market-niche or focus strategy or Customer focus.

Hence, endurance is something unrelated here, so it will be the answer.

Which of the following production system is characterised by the low production volume?

1. Project Production System
2. Job Shop Production System
3. Batch Production System
4. Mass Production System

Answer (Detailed Solution Below)

Option 2 : Job Shop Production System

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

Which of the following is the objective of MIS?

1. To keep the information to up to data
2. To increase the quantity of the data
3. To filter the data
4. To interpret data

Answer (Detailed Solution Below)

Option 2 : To increase the quantity of the data

Explanation:

Management Information system or ‘MIS’ is a planned system of collecting, storing and disseminating (spreading or increasing) data in the form of information needed to carry out the function of management

Objectives of MIS:

• Capturing data
• Processing data
• Information storage
• Information Retrieval
• Information Propagation

Lean production is related to

1. mass production
2. batch production
3. customized production
4. stock-driven production

Answer (Detailed Solution Below)

Option 3 : customized production

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.

In the context of factors utilized in FMEA, choose the odd one out.

1. Occurrence
2. Severity
3. Serviceability
4. Detection

Answer (Detailed Solution Below)

Option 3 : Serviceability

Explanation:

Failure Mode and Effects Analysis (FMEA) is product recalls resulting from poorly designed products and/or processes.

Failure Mode and Effects Analysis, or FMEA, is a methodology aimed at allowing organizations to anticipate failure during the design stage by identifying all of the possible failures in a design or manufacturing process.

Here’s an overview of the 10 steps to a Process FMEA.

1. Review the process  

• Use a process flowchart to identify each process component.
• List each process component in the FMEA table.
• If it starts feeling like the scope is too big, it probably is. This is a good time to break the Process Failure Mode and Effects Analysis into more manageable chunks.

2. Brainstorm potential failure modes

• Review existing documentation and data for clues about all of the ways each component can fail.
• The list should be exhaustive – it can be paired down and items can be combined after this initial list is generated.
• There will likely be several potential failures for each component.

3. List the potential effects of each failure

• The effect is the impact the failure has on the end product or on subsequent steps in the process.
• There will likely be more than one effect for each failure.

4. Assign Severity rankings

• Based on the severity of the consequences of failure.

5. Assign Occurrence rankings

• Rate the severity of each effect using customized ranking scales as a guide.

6. Assign Detection rankings

• The chances o failure will be detected prior to it occurring.

7. Calculate the RPN: Severity × Occurrence ×  Detection

8. Develop the action plan

• Decide which failures will be worked on based on the Risk Priority Numbers. Focus on the highest RPNs.
• Define who will do what by when.

9. Take action

• Implement the improvements identified by your Process Failure Mode and Effects Analysis team.

10. Calculate the resulting RPN

• Re-evaluate each of the potential failures once improvements have been made and determine the impact of the improvements.

Line balancing is related to

1. product layout
2. process layout
3. hybrid layout
4. cellular layout

Answer (Detailed Solution Below)

Option 1 : product layout

Explanation:

Line balancing:

Line balancing is a production strategy that involves balancing operator and machine time to match the production rate to the Takt time. Takt time is the rate at which parts or products must be produced in order to meet customer demand.

Benefits of Line Balancing

1. Reduce waiting waste.
2. Reduce inventory waste.
3. Absorb internal and external irregularities.
4. Reduce production costs and increase profits.

Line balancing is used in Product Layout as in this layout rate of production is very high and requires proper balancing between machine and operator for better efficiency.

An assembly line is an example of which one of the following processes?

1. Product focused process
2. Customized process
3. Repetitive process
4. Specialized process

Answer (Detailed Solution Below)

Option 3 : Repetitive process

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

Which of the following is an example of Batch type of production system?

1. Automobiles production unit
2. Petrol refinery
3. Clothes factory
4. Aircraft manufacturing unit

Answer (Detailed Solution Below)

Option 3 : Clothes factory

Explanation:

A flexible manufacturing system (FMS) is a manufacturing cell or system consisting of one or more CNC machines, connected by an automated material handling system, pick-and-place robots, and all operated under the control of a central computer. It also has auxiliary sub-systems like component load/unload station, automatic tool handling system, tool pre-setter, component measuring station, wash station, etc.

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

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
• Example – Machine tools, pumps, compressors, stationary IC engines, Clothes factory, etc.

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.

The FMS is most suited for the mid-variety, mid-volume production range

Fully computer-automated plants can be achieved for which of the following production systems ?

1. Batch production
2. Job shop production
3. Mass production of discrete product
4. Continuous flow processes

Answer (Detailed Solution Below)

Option 4 : Continuous flow processes

Explanation:

Continuous Flow Process:​

• The continuous flow process involves moving one work unit at a time between each step of the process — with no breaks in time, sequence, substance, or extent. For most applications, continuous flow saves time, energy, and costs and when implemented correctly, it can:
• Reduce waste
• Save money by reducing inventory and transportation costs
• Increase productivity by completing more units in less time
• Improve quality by making it easier to spot and correct errors
• Cut down on overhead via increased stability and reduced lead time
• Adapt to customer needs more effectively than batch processing
• Fully computer-automated plants can be achieved by Continuous Flow processes.

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• batch production is a method used to produce similar items in groups, stage by stage. In batch production, the product goes through each stage of the process together before moving on to the next stage.
• The degree to which workers are involved in this type of production depends on the type of product. It is common for machinery to be used for the actual production and workers participate only at the beginning and end of the process.

Job shop production:

• A job shop is a type of manufacturing process in which small batches of a variety of custom products are made. In the job shop process flow, most of the products produced require a unique setup and sequencing of process steps.

Which of the following is not basic element of the JIT production system?

1. cellular layouts
2. push production system
3. small-lot production
4. flexible resources

Answer (Detailed Solution Below)

Option 2 : push production system

Explanation:

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.
• Just-in-Time manufacturing also uses a pull system to move materials through the production cycle. This leads to a more efficient manufacturing layout that can significantly reduce lead time.
• Another main objective of Just-In-Time Production systems is to improve the production process in the company hence increases productivity.
• 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.

MIS is not used in which of the following applications?

1. Forecasting
2. Scheduling problem
3. Inventory
4. Heat transfer

Answer (Detailed Solution Below)

Option 4 : Heat transfer

Explanation:

MIS stands for "Management Information Systems".

The management information system (MIS) provides the required information for the effective functioning of business organizations such as forecasting, scheduling and inventory data.
It provides the information to the management as per the level in the organization.

• Top management seeks this information for policymaking, goal setting and strategic decision making.
• Middle management needs these data in the problem solving, monitoring progress towards achievement of goals, planning and scheduling.

Therefore, MIS is an essential field of study in business management and is useful for a manager, entrepreneur or a business professional.

Hence the answer will be Heat Transfer.

Which of the following industries will consume maximum power per tonne of product?

1. Zinc
2. Aluminium
3. Alloy steel
4. Cement

Answer (Detailed Solution Below)

Option 2 : Aluminium

Aluminum Production: About 17,000 kWh of electricity is required to produce 1 tonne of aluminum.

Zinc Production: The amount of energy required for casting one tonne of zinc is 208 kWh, and for remelting, the same amount of metal is 155 kWh.

Alloy steel Production: With an average of 770 kWh/ton and a typical EAF consumption under 500 kWh/ton.

Cement Production: While total electrical energy consumption for cement production is about 100 kWh/ton of cement.

What is the difference between the term production management and operations management?

What is production and operations management explain the difference between the two?

What is the difference between operations & production?

What is the difference between production and production management?