ANWSER
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Question 1:
(a) New Product Design and Development pass through some stages before it can be available to customers as a bundle of utilities. Discuss.
Answer:
New Product Design and Development typically involves the following stages:
1. Idea Generation: Gathering potential product ideas from market research, customer feedback, or internal brainstorming.
2. Screening: Evaluating ideas to select the most viable ones based on feasibility, cost, and market potential.
3. Concept Development: Creating detailed product concepts, including features, benefits, and target audience.
4. Business Analysis: Assessing the financial viability, profitability, and risks associated with the product.
5. Product Development: Designing and prototyping the product, followed by testing for functionality and quality.
6. Market Testing: Launching the product in a limited market to gauge customer response and make adjustments.
7. Commercialization: Full-scale production, marketing, and distribution of the product to the wider market.
These stages ensure the product meets customer needs and provides value as a bundle of utilities.
(b) Clearly discuss in details, your understanding of the term “Quality Characteristics”.
Answer:
Quality Characteristics refer to the specific attributes or properties of a product or service that define its ability to meet customer requirements and expectations. These characteristics can be categorized as:
– Performance: How well the product functions.
– Features: Additional attributes that enhance usability or appeal.
– Reliability: Consistency in performance over time.
– Durability: The product’s lifespan under normal conditions.
– Conformance: Adherence to established standards or specifications.
– Aesthetics: Visual or sensory appeal of the product.
– Serviceability: Ease of maintenance or repair.
Understanding these characteristics helps in designing and delivering high-quality products that satisfy customers.
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Question 2:
(a) What is Acceptance Sampling?
Answer:
Acceptance Sampling is a quality control technique where a random sample of items is inspected from a larger batch to determine whether the entire batch meets specified quality standards. It helps decide whether to accept or reject the batch without inspecting every item.
(b) Explain quality control efforts through sampling inspection method.
Answer:
Sampling inspection is a quality control method where a subset of products is examined to infer the quality of the entire batch. Key efforts include:
– Reducing Costs: Inspecting only a sample saves time and resources compared to full inspection.
– Identifying Defects: Detecting non-conforming items early to prevent larger issues.
– Statistical Analysis: Using statistical tools to ensure the sample represents the batch accurately.
– Process Improvement: Feedback from sampling helps refine production processes for better quality.
(c) Identify and briefly explain various forms of models known to you.
Answer:
1. Physical Models: Tangible representations of products or systems (e.g., prototypes).
2. Mathematical Models: Use equations to represent relationships between variables (e.g., forecasting models).
3. Simulation Models: Computer-based models that mimic real-world processes for analysis (e.g., Monte Carlo simulations).
4. Graphical Models: Visual representations like flowcharts or diagrams to illustrate processes.
5. Conceptual Models: Abstract ideas or frameworks to explain systems (e.g., supply chain models).
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Question 3:
(a) Comprehensively identify and discuss the role and the significance of production management to an organization.
Answer:
Production management plays a critical role in organizations by:
– Efficiency: Optimizing resources (labor, materials, machinery) to minimize waste and costs.
– Quality Control: Ensuring products meet standards and customer expectations.
– Scheduling: Coordinating production timelines to meet demand and deadlines.
– Innovation: Implementing new technologies or processes to improve productivity.
– Cost Reduction: Identifying ways to lower production expenses without compromising quality.
– Customer Satisfaction: Delivering products on time and with desired features.
Its significance lies in enhancing competitiveness, profitability, and operational effectiveness.
(b) Mention and explain the two causes of variation.
Answer:
1. Common Causes: Inherent, random variations in a process due to natural factors (e.g., machine wear, minor material differences). These are predictable and part of normal operations.
2. Special Causes: Unpredictable variations caused by specific, identifiable factors (e.g., human error, equipment failure). These require investigation and corrective action.
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Question 4:
(a) Explain what you understand by social Responsibility.
Answer:
Social Responsibility refers to the ethical obligation of businesses to contribute positively to society, beyond profit-making. This includes environmental sustainability, fair labor practices, and community development.
(b) If you are a production manager or in an enterprise, will you like to be involved in social responsibility? Explain.
Answer:
Yes, as a production manager, involvement in social responsibility is beneficial. It enhances the company’s reputation, builds customer trust, and ensures compliance with regulations. Initiatives like reducing waste, using eco-friendly materials, or supporting local communities align with long-term business success.
(c) Why is quality important?
Answer:
Quality ensures customer satisfaction, reduces costs associated with defects, and enhances brand reputation. It also fosters loyalty and competitive advantage.
(d) How does quality affect a firm?
Answer:
Quality impacts a firm by:
– Increasing customer retention and market share.
– Reducing returns, rework, and warranty claims.
– Improving operational efficiency and profitability.
– Strengthening compliance with industry standards.
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Question 5:
(a) With the aid of diagram, discuss in detail a typical production system.
Answer:
A typical production system involves:
1. Inputs: Raw materials, labor, capital, and information.
2. Transformation Process: Conversion of inputs into outputs through manufacturing or assembly.
3. Outputs: Finished goods or services.
4. Feedback Loop: Monitoring and adjusting processes based on performance data.
*(Note: A diagram would show these components as interconnected stages, with arrows indicating flow.)*
(b) What is maintenance?
Answer:
Maintenance refers to activities aimed at preserving or restoring equipment, machinery, and facilities to ensure optimal performance and longevity.
(c) Differentiate between preventive maintenance and breakdown maintenance.
Answer:
– Preventive Maintenance: Scheduled, routine inspections and repairs to prevent failures (proactive).
– Breakdown Maintenance: Repairs performed after equipment fails (reactive), often causing downtime.
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Question 6:
(a) With a diagram, describe how a balance can be struck between preventive and breakdown maintenance.
Answer:
A balance is achieved by:
– Scheduling regular preventive maintenance to minimize unexpected failures.
– Allowing limited breakdown maintenance for less critical equipment.
– Using cost-benefit analysis to determine the optimal mix.
*(Note: A diagram would show a continuum with preventive and breakdown maintenance at either end, highlighting a midpoint for balance.)*
(b) State the PROS and CONS of product and process layouts.
Answer:
Product Layout Pros: High efficiency, low material handling, smooth flow.
Cons: Inflexible, costly to rearrange.
Process Layout Pros: Flexible, handles varied products.
Cons: Higher material handling, complex scheduling.
(c) What are the advantages and disadvantages of “Fixed position Layout”?
Answer:
Advantages: Suitable for large, heavy products; minimal movement of materials.
Disadvantages: High labor and equipment costs, potential space constraints.
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Question 7:
(a) Explain the following terms:
i. Job Production: Customized production of unique items tailored to specific orders.
ii. Batch production: Manufacturing groups of identical products in batches.
iii. Flow production: Continuous, high-volume production of standardized items.
iv. Product layout: Arrangement by production sequence for efficient flow.
v. Process layout: Grouping similar processes or machinery together.
(b) What is your understanding of the term “Model”.
Answer:
A model is a simplified representation of a system, process, or product used for analysis, prediction, or decision-making.
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