MANAGEMENT of MANUFACTURING SYSTEM — MBA 4th Semester (KMBN OM405)
Introduction
Is course ka basic maksad hai samajhna ki manufacturing system ko kaise manage karte hain — production se le kar distribution tak. MBA ke 4th semester ke students ke liye OM405 bahut practical subject hai: theory ke saath bohot saari short-cuts, real-life examples aur exam-friendly tricks milenge.
Key Concepts You Must Master
Manufacturing system ko samajhne ke liye kuch core topics pe dhyan do: production planning, scheduling, routing, quality control, maintenance, process design, layout, material handling aur inventory management. In sab ko ek flow me socho — input aate hain, process hota hai, output quality check ke baad customer tak jata hai.
Short trick: PPQ — Plan, Produce, Quality-check. Exams me agar tumhe kisi bhi process ka flow dikhana ho, bas PPQ likho aur expand karo.
Production Planning & Control
Production planning ka matlab hai demand forecast ke hisaab se resources allocate karna. Isme Master Production Schedule (MPS), Rough-Cut Capacity Planning (RCCP), Material Requirements Planning (MRP) jaise tools aate hain. MBA students ke liye MRP ka logic samajhna bohot zaroori hai — bill of materials, lead time, safety stock, aur lot-sizing.
Example (easy): Ek mithai factory socho—Diwali ke time demand zyada. MPS decide karega kitne boxes per week, MRP batayega kitna atta, sugar aur boxes chahiye. Agar lead time 7 din hai, to buffer rakho — warna orders late jayenge.
Quality Management
Quality ka funda simple hai — customer expectations meet karo, defects hatao. Tools: SPC (Statistical Process Control), TQM (Total Quality Management), ISO standards. SPC charts aur control limits ko jaldi samajhne ke liye 'center line, UCL, LCL' ka formula yaad karo.
Trick: 3R rule — Reduce variation, Record problems, React quickly. Exam me case study aaye to 3R apply karo aur answer structured lagega.
Lean & Six Sigma
Lean ka objective hota hai waste reduce karna — 7 wastes: Transportation, Inventory, Motion, Waiting, Overproduction, Over-processing, Defects (TIMWOOD). Six Sigma focus karta hai variation ko kam karne pe (DMAIC: Define, Measure, Analyze, Improve, Control).
Shortcut yaad rakhne ke liye: TIMWOOD + DMAIC = LeanSix. Exam me process improvement ka question aaye to TIMWOOD identify karo aur DMAIC steps suggest karo.
Inventory Control
Inventory control me EOQ (Economic Order Quantity), Reorder Point, Safety Stock, ABC analysis common topics hain. EOQ formula ka basic idea: trade-off between ordering cost and holding cost. ABC analysis se tum high-value items pe focus karoge.
Simple trick to remember EOQ: Square root rule — jyada ordering cost se order size bada hota hai, aur jyada holding cost se order size chhota.
Short Tricks & Case Examples (Exam-Friendly)
1) Car assembly line: Flow layout, takt time concept — takt time = available time / customer demand. Exam me quick calculation poocha to isi formula se nikal lo.
2) Packaging example: If defect rate badh raha hai, propose SPC + poka-yoke (mistake-proofing). Real life trick: chhote experiments karo (pilot) before full-scale change.
3) Mnemonic for layout types: FIR — Fixed, In-line, Repetitive. Agar question me product variety zyada aur volume low ho — fixed layout. Volume high, variety low — repetitive/line layout.
Exam Tips (KMBN OM405)
- Short answer sections me diagrams use karo: flow charts, process layout, and control charts.
- Case studies: Structure your answer — Problem, Analysis (tools used), Recommendation (lean steps/EOQ/MRP), Expected Result.
- Time management: Easy objective + 2 case studies first, phir numerical problems (EOQ, MRP calculations).
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