PRODUCTION AND

OPERATIONS MANAGEMENT

Dr Surya Prakash Singh

Department of Management Studies
Indian Institute of Technology Delhi

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Production and Operations Management

ISBN: 978-93259-7159-2

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 Dedication
I dedicate this book to the memory of my grandparents, and to my parents
Shri Gyan Singh and Smt. Gyanendri Devi, who have made enormous sacrifices
to educate their children, especially me, so that I can do what I always wanted to do.
 Preface
The role of practitioners of production and operations management is to accomplish the
organization’s mission by utilizing the resources of the firm in the most effective and efficient
ways. It refers to an effective and efficient coordination of all activities of the firm to combine
various inputs to produce a desired output that is valued by consumers. Thus, making it
responsible for understanding, designing, planning, and managing and controlling the best
processes so that value add occurs in the most efficient and effective way. The prime focus
of production and operations management is to ensure smooth production processes that
contribute to the output of goods and services of an organization. This book focuses on the
basics of production planning and control in modern business operations.
The aim of the book is to cover emerging and important topics related to production and
operations management. To fulfill the basic need of managing the operations effectively and
efficiently, traditional topics such as work study, forecasting, quality control management,
inventory management, operations scheduling and sequencing, facility planning, materials
requirement planning, aggregate production planning, queue management, and project
management are included in this book. This book also deals with important topics such as
supply chain management, advanced production system, operations strategy, product design
and development, just-in-time technique, Six Sigma approach, total preventive maintenance,
total productivity management, and capacity planning. A chapter on linear programming has
also been included to provide an overview of its application in production and operations
management.

Significant features of the book

The most distinctive feature of the book is the extensive use of solved examples to explain
theoretical concepts. Tables and figures illustrate various concepts. The theories and concepts
discussed are based on day-to-day practical applications in the industry. Exercises at the end of
each chapter enable the readers to test his/her understanding.

Purpose of the book

The main purpose of writing this book is to provide a systematic approach to teaching and
presenting the relevant topics of production and operations management, along with case
studies in a simple form, something that is not available in a single book. Most books that are
available cover the popular topics, but a number of relevant topics such as total preventive
maintenance, environmental issues in production system, advanced production system, total
productivity management and work system design are not covered. Just-in-time and Six Sigma
are also given a cursory treatment. In many books, linear programming is given as a supplement,
but its application in production and operations management is missing. This book brings out
the link between linear programming and its application, and this is shown in the chapters on
supply chain management and aggregate production planning, where examples are provided in
relation to linear programming. Care has been taken to provide a case study at the end of each
chapter to illustrate the theory and concepts discussed.

Organization of the book

The book is organized into four parts. Part I starts with understanding operations. Chapter
1 provides an introduction to production/operations management. Environmental concerns
vi Contents
Preface

in production systems, which are increasingly gaining importance, are covered in Chapter 2.
Chapter 3 discusses linear programming, while Chapter 4 presents supply chain management
and discusses its role in production and operations management. Chapter 5 on advanced
production system demonstrates advanced management philosophy, i.e. the theory of constraint,
while Chapter 6 describes the operations strategy and its framework for better production and
operations management.
Part II addresses designing operations. Chapter 7 presents work system design, while
Chapter 8 introduces the concept of product design and development and its importance in
production and operations management. Chapter 9 describes one of the most discussed modern
production management philosophies, i.e. just-in-time, and Chapter 10 demonstrates another
advanced topic on quality i.e. Six Sigma. Chapter 11 introduces total preventive maintenance and
presents how the maintenance can be optimized to make an effective and efficient production
and operations management in an organization.
Part III focuses on planning operations. Chapter 12 presents forecasting and its application
to production management. Chapter 13 describes the capacity planning and various techniques
for short- and long-term planning for effective production management. Chapter 14 discusses
facility planning. Chapter 15 addresses project management and useful tools to describe how
the project should be planned and completed. Chapter 16 introduces queue management
and techniques to control and manage queues in operations. Chapter 17 of this part on total
productivity management concludes by discussing the importance of productivity and some of
the popular models used in practice to measure the productivity of an organization.
Part IV encompasses managing and controlling operations. Chapter 18 discusses quality
control management. Chapter 19 discusses the approaches for aggregate production planning.
Chapter 20 discusses operations scheduling and sequencing. Chapter 21 introduces the concept
of inventory management, which is not an easy task, while Chapter 22 discusses materials
requirement planning in detail.
 Acknowledgements
I am indebted to many people who have contributed to the development of this book. First and
foremost, I would like to thank my wife, Chetana Singh, for standing by me not only while writing
this book, but throughout my professional career. She has been always my inspiration and motivation
for continuing to improve my knowledge and move my career forward. I also thank my daughter
Samriddhi Singh for always making me smile even on those weekend mornings when I was writing
this book instead of playing games with her.
I would like to express my sincere thanks to Prof. Ravi Shankar and Prof. D K Banwet for giving
me inspiration to write a book on production and operations management, which is so important
in the area of operations and supply chain management. I would like to express my gratitude to
Prof. S S Yadav for helping me in developing the overall structure of the book. I would also like to
acknowledge the encouragement of my senior faculty colleagues, especially, Prof. Sushil, Prof. PK
Jain, Prof. Kanika T Bhal, Prof. M P Gupta and Prof. S K Jain, who provided many insights into the
teaching a course and writing a book. I am also thankful to my colleagues Dr Seema Sharma, Dr
Mahim Sagar, Dr Vignesh Illavarsan, Dr Shveta Singh and Dr Jitendra Madaan for their discussions
and inputs to keep my enthusiasm high. I am highly indebted and grateful to my teachers, who taught
me at undergraduate, postgraduate, doctoral work and at postdoctoral level, especially, Prof. Sanjay
Jhakaria, currently at IIM Kozhikode, who first taught me industrial engineering at undergraduate
level; Prof. M K Tiwari, currently at IIT Kharagpur, for teaching me how to write research papers
during my master programme; Prof. RRK Sharma (my PhD supervisor) for encouraging me to write;
Prof. Kripa Shankar and Prof. AK Mittal from IIT Kanpur, who taught me the course on advanced
manufacturing technology, and manufacturing planning and control during my PhD course work,
which gave me sound fundamentals on the subject; and Dr Velusamy Subramaniam from NUS,
Singapore, for guiding and mentoring me to always think big.
I am also thankful to my faculty friends outside IIT Delhi, especially, Dr Sunil Agrawal, IIIT
Design and Manufacturing, Jabalpur; Prof. Sanjay Kumar from MDI, Gurgaon; Dr. JK Jha from
IIT Khargapur; Dr. Amit Sachan from IIM Ranchi; Dr. Sambit Mukherjee from XIM Bhubaneswar;
Dr. Ayon Chakravarty from IIM Tiruchirapalli; Dr. Rajash Matai from BITS Pilani; Dr Anmol
Singh from IIM Rohtak; Dr Shardindu Pandey from Gautam Buddha University, Greater Noida;
Dr Rameshwar Dubey from SIOM; Dr Sabyasachi Patra from Calcutta Business School; Dr Devjani
Chatterjee from IMI Kolkata; Dr Rajesh Kumar Singh from DTU Delhi; and Dr Remica Agrawal
from BITS Pilani for providing useful inputs, whenever required on the subject.
I am lucky to have students who have always raised questions, which has not only improved my
knowledge on the subject but also forced me to express the difficult concepts in a simple way. I am
also happy to say that my PhD students V K Singh, Nilesh Ware, Zeinab Karimi, Vivek Soni, Seema
Shukla, Harpreet Kaur, Akash Tayal and Ravi Kumar always supported my idea of writing the book
and extended every possible support in completing the work.
I sincerely thank all my well wishers who are numerous and not mentioned here by name.
I admire the entire team of editors, including Ms Arshi Ahmad and Mr Rahul Kumar, from Vikas
Publishing House Pvt. Ltd, for their untiring efforts to bring out the book in a short time.
I would like to thank the anonymous reviewers who critically commented on the first draft of
the book, which really improved its overall content.
I am sure that readers will give feedback about the book’s shortcomings. I have incorporated the
suggestions received from faculty members and students, with whom I discussed many chapters while
teaching the course on operations management and total productivity management at IIT Delhi, and I
hope to do the same for my next edition, whenever it is going to be.

Surya Prakash Singh, PhD, PDF

 Contents
Preface v
Acknowledgements vii

PART I UNDERSTANDING OPERATIONS

Chapter 1 Production and Operations Management: An Overview
1.1 Introduction 3
1.2 Historical Evolution of Production/Operations Management 3
1.3 Understanding Production/Operations Management 4
1.4 Functional Areas of Production/Operations Management 5
1.4.1 Facility Location 5
1.4.2 Facility Layout and Material Handling 6
1.4.3 Product Design 6
1.4.4 Process Design 6
1.4.5 Production Planning and Control 6
1.4.6 Quality Control 7
1.4.7 Material Management 7
1.4.8 Maintenance Management 7
1.5 Role of Operations Management 7
1.5.1 Service Level 8
1.5.2 Resource Utilization  8
1.6 Classification of Production System 8
1.6.1 Job Production 9
1.6.2 Batch Production 9
1.6.3 Continuous Production 10
1.7 Characteristics of Production System 10
1.8 Building Blocks of Operations Management 11
1.9 Benefits of an Efficient Operations Management 12
Summary13
Exercise13
Case Study 13
References14
Chapter 2 Environmental Issues in Production Systems
2.1 Introduction 15
2.2 Sustainable Development 16
2.3 Environmental Management System  17
2.4 Cleaner Production 18
2.5 Green Production Strategies 18
2.6 Environmental Impact on Operations Management 19
2.6.1 Green Strategic Framework 19
2.6.2 Green Operations Management 20
2.7 Carbon Footprint 20
Summary21
Exercise21
 PRODUCTION AND OPERATIONS
MANAGEMENT By S P SINGH

Publisher : Vikas Publishing ISBN : 9789325971592 Author : S P SINGH

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