BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI

WORK INTEGRATED LEARNING PROGRAMMES

COURSE HANDOUT
Academic Term
Course Title

SECOND SEMESTER 2014-2015

Manufacturing Planning and Control

Course ID No.

MM ZG 533

Instructor(s)

Vijay Arora

Course Modules (add more rows as per needs)

Module
No

Module Title

Objectives

Manufacturing context & Strategy

List and discuss the role of various areas

pertaining to the planning and design of
manufacturing systems.

Processes- Planning and design for

Manufacturing

List the steps in process planning in

manufacturing organizations.
Compare
different
physical
configurations of facilities and how they
relate
to
differing
manufacturing
requirements.
Identify the steps in the design of a
facility.
Analyze material flow.
Apply mathematical models for balancing
assembly lines.

Inventory

Illustrate
and
evaluate
simple
mathematical models for developing
forecasts.
Discuss the role
manufacturing.

of

inventory

in

Apply theory to the solution of simple

inventory systems.
List the factors and methods required in
midrange aggregate and capacity planning.
Describe the steps in computerized
systems such as MRP and ERP.
4

Current Approaches in Manufacturing Compare

current
approaches
in
manufacturing such as Lean Manufacturing
and Theory of Constraints to traditional
methods.

Text Book(s)
T1

Chase, R.B., Shankar R., Jacobs, F.R., Aquilano, N.J., Operations and Supply
Management, 12th ed., Tata McGraw-Hill, New Delhi, 2010

Reference Book(s) & other resources

R1

Krajewski, L.J., Ritzman, L.P., Malhotra, M.K., Srivastava, S.K., Operations

Management: Processes and Supply Chains, 9th ed., Pearson Education, 2010

Self-Study & Contact Session Plan

Module Title: Manufacturing context & Strategy

Session 1: Productivity and Manufacturing Management
Topic
No.

Topic Title

Reference

1.1

Productivity and manufacturing context,

T1

1.2

Modern management, performance measures,

T1

1.3

Nature and evolution of manufacturing

T1

Module Title: Processes- Planning and design for Manufacturing

Session 2:Functions in Manufacturing, manufacturing process planning
Topic
No.

Topic Title

Reference

2.1

Product design

T1

2.2

Process planning,

T1

2.3

Determining number of equipment

T1

Module Title: Processes- Planning and design for Manufacturing

Session 3: Methods Analysis and Work measurement
Topic
No.
3.1

Topic Title

Reference

Graphical tools for analyzing work methods

T1- pp. 222-230,

pp. 243-255

3.2

Methods for work measurement, time study, PMTS

T1

Module Title:Processes- Planning and design for Manufacturing

Session 4: Understanding Processes and Material Flow
Topic
No.
4.1
4.2

Topic Title

Reference

Different types of processes

T1

Littles Law

T1

4.3

Make to stock, make to order and assemble to

order systems

T1

4.4

Material flow

T1

Module Title: Processes- Planning and design for Manufacturing

Session 5: Plant layout and design
Topic
No.

Topic Title

Reference

5.1

Different types of layouts

T1

5.2

Quantitative methods for layout planning

T1

5.3

Citeria for assessing layouts,

T1

5.4

Activity relationships in layouts

T1

Module Title: Processes- Planning and design for Manufacturing

Session 6: Plant layout and material handling
Topic
No.

Topic Title

Reference

6.1

Machine cells in manufacturing

T1

6.2

Material handling concepts

T1

6.3

Types of material handling equipment

T1

Module Title: Processes- Planning and design for Manufacturing

Session 7: Material handling
Topic
No.
7.1

7.2

Topic Title

Reference

Different types of material handling systems and

equipment-- method for selecting appropriate
material handling system

Lecture Slides

Storage equipment

Module Title: Processes- Planning and design for Manufacturing

Session 8: Line Balancing
Topic
No.

Topic Title

Reference

8.1

Precedence diagrams and line balancing

T1

8.2

Measures of performance

T1

Session 9: Review Session

Mid-Semester Test (Closed Book) : Topics in Session 1 to 8

Module Title: Inventory

Session 10: Demand Management and Forecasting
Topic
No.

Topic Title

Reference

10.1

Role of forecasting in predicting demand

T1

10.2

Different forecasting methods

T1

10.3

Quantitative and qualitative forecasts

T1

Module Title: Inventory

Session 11: Forecasting
Topic
No.

Topic Title

Reference

11.1

Time series models in forecasting, moving average, T1

exponential smoothing

11.2

Regression, forecast errors, capacity planning

T1

Module Title: Inventory

Session 12: Capacity Planning and Aggregate Sales and Operations Planning
Topic
No.

Topic Title

Reference

12.1

Different strategies for capacity planning,

aggressive and risk averse strategies,

T1

12.2

Decision trees for capacity planning, pure

strategies in aggregate sales and operations
planning

T1

12.3

Pure strategies in aggregate sales and operations

planning

T1

Module Title: Inventory

Session 13: Inventory Control and Models
Topic
No.
13.1

Topic Title

Reference

The role of inventory in manufacturing

T1

13.2

Costs of inventory

T!

13.3

Inventory models, EOQ

T1

Module Title: Inventory

Session 14: Inventory Models and Supply management
Topic
No.

Topic Title

Reference

14.1

Inventory models under uncertainty

T1

14.2

Inventory contol and supply chain management

T1

Module Title: Inventory

Session 15: MRP and ERP Systems
Topic
No.

Topic Title

Reference

15.1

Dependent demand systems

T1

15.2

Material requirements planning

T1

15.3

Lot sizing, capacity requirements planning

T1

15.4

Implementation issues

T1

Module Title: Current Approaches in Manufacturing

Session 16
Topic
No.

Topic Title

Reference

16.1

Introduction to Lean Manufacturing

T1

16.2

Basic principles and tools, JIT, Pull,

etc./Requirements

T1

Module Title: Current Approaches in Manufacturing

Session 17
Topic
No.

Topic Title

Reference

17.1
17.2

Theory of Constraints,

T1

Financial and operational measurements

T1

Session 18: Review Session

Details of Lab (Online) If any: Evaluation Scheme:
Legend: EC = Evaluation Component; AN = After Noon Session; FN = Fore Noon Session
No

Name

EC-1

Assignment-I/ Quiz-I
Quiz-II

Type

Durati
on

Weigh Day, Date, Session, Time

t

15%

Online

February 1-10, 2015

March 1-10, 2015

Assignment-II/ Quiz-III

April 1-10, 2015

EC-2

Mid-Semester Test

Closed
Book

EC-3

Comprehensive Exam Open

Book

2
hours

35%

22/02/2015 (AN) 2 PM 4 PM

3
hours

50%

19/04/2015 (AN) 2 PM 5PM

Syllabus for Mid-Semester Test (Closed Book): Topics in Session Nos. 1 to 8

Syllabus for Comprehensive Exam (Open Book): All topics (Session Nos. 1 to 18)
Important links and information:
Elearn portal: https://elearn.bits-pilani.ac.in
Students are expected to visit the Elearn portal on a regular basis and stay up to date with the
latest announcements and deadlines.
Contact sessions: Students should attend the online lectures as per the schedule provided on
the Elearn portal.
Evaluation Guidelines:
1. EC-1 consists of either two Assignments or three Quizzes. Students will attempt them
through the course pages on the Elearn portal. Announcements will be made on the
portal, in a timely manner.
2. For Closed Book tests: No books or reference material of any kind will be permitted.
3. For Open Book exams: Use of books and any printed / written reference material (filed
or bound) is permitted. However, loose sheets of paper will not be allowed. Use of
calculators is permitted in all exams. Laptops/Mobiles of any kind are not allowed.
Exchange of any material is not allowed.
4. If a student is unable to appear for the Regular Test/Exam due to genuine exigencies,
the student should follow the procedure to apply for the Make-Up Test/Exam which will

be made available on the Elearn portal. The Make-Up Test/Exam will be conducted only
at selected exam centres on the dates to be announced later.
It shall be the responsibility of the individual student to be regular in maintaining the self study
schedule as given in the course handout, attend the online lectures, and take all the prescribed
evaluation components such as Assignment/Quiz, Mid-Semester Test and Comprehensive Exam
according to the evaluation scheme provided in the handout.