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Production & Operations Management + TQM

From transcript: 20ME811 Production & Operations Management (B) · 20BT742 Total Quality Management (A)

Cheat sheet

Printable study sheet: formulas → definitions → topic notes → traps.

Formulas

Utilization = busy time / available ; Efficiency vs effectiveness
Little’s law: L = λ W (WIP = throughput × flow time)
OEE ≈ Availability × Performance × Quality
EOQ √(2DS/H) ; Kanban count ideas from demand & lead time
Cp = (USL−LSL)/(6σ) ; Cpk = min(USL−μ, μ−LSL)/(3σ)
Control chart: UCL/LCL = μ ± 3 σ/√n for X̄
Line balancing: cycle time ≥ max station; idle = n·CT − Σt
Break-even: Fixed / (Price − Variable cost)
Cycle time = available time / demand (takt)
Utilization = run time / available time
Little's law: WIP = TH × CT
Cp = (USL−LSL)/(6σ) ; Cpk = min(USL−μ, μ−LSL)/(3σ)
EOQ / reorder: see OR sheet

Definitions

Capacity
Maximum sustainable output rate
Bottleneck
Resource limiting system throughput
Layout types
Process, product, cellular, fixed-position
MPS / MRP
Master schedule / material requirements planning
JIT / lean
Pull, waste elimination, continuous flow
TQM
Organization-wide quality culture
Six Sigma
DMAIC; defect reduction toward 3.4 DPMO ideal
Kaizen
Continuous incremental improvement
Poka-yoke
Mistake-proofing
Value stream
Map value-adding vs waste steps
Takt time
Customer demand pace
Seven QC tools
Check sheet, Pareto, histogram, control chart, scatter, fishbone, flowchart

Topic-wise short notes

Study these first — one block per syllabus topic. Then read the deep notes below.

Capacity, layout, scheduling

  • Rough-cut capacity vs CRP detailed.
  • Assembly line takt time = available time / demand.
  • Project vs job shop vs batch vs mass vs continuous process choice.
  • Forecasting: moving average, exponential smoothing, error metrics.

TQM & quality tools

  • 7 QC tools: fishbone, Pareto, histogram, control chart, scatter, check sheet, stratification.
  • FMEA: severity×occurrence×detection risk priority.
  • ISO 9001 process approach & documentation.
  • Cost of quality: prevention/appraisal vs failure.

Lean wastes (TIMWOOD)

  • Transport, Inventory, Motion, Waiting, Overproduction, Overprocessing, Defects (+Skills).
  • 5S workplace; SMED setup reduction for smaller batches.
  • Pull systems need stable processes — fix quality first.

Exam traps & quick notes

Comprehensive notes

Capacity, layout, scheduling

Process vs product layout; line balancing; MRP vs JIT; Gantt & dispatching rules.

External: MIT OpenCourseWare ops ↗ Lean Enterprise Institute ↗

TQM & quality tools

PDCA, SPC charts, Pareto prioritization, Kaizen events, poka-yoke.

External: ASQ quality tools ↗ iSixSigma DMAIC ↗

Capacity, layout, flow

Process vs product layout; takt; bottleneck (Theory of Constraints lite); MRP vs JIT.

External: NPTEL ↗ Engineering Toolbox ↗

TQM & Six Sigma awareness

PDCA; seven QC tools; DMAIC outline; poka-yoke; standard work. Fleurette and SmartEco metrics as proof of process thinking.

External: NPTEL ↗ Engineering Toolbox ↗

Interview Q&A for this subject

Q: What is takt time?
A: Available time / demand — the customer pace the line must meet.

External: ASQ / quality ↗ MIT OCW ↗