UNIVERSITY KUALA LUMPUR

Malaysia France Institute

Section of Fabrication and Joining

Course Code: FMF 0032

Concept and Stages in Production Organization

Student Study Guide

Prepared by:

Mohd Kamarul Nizam

knizam@mfi.edu.my
012-2087805

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Contents Page

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Table of Contents 2

Introduction to the subject 3

Texts, references and other resources 4

How to use this study guide 5

Information about assessment 7

Study Program Plan 8

Module Number Title Text Book Chapter

1 Introduction to Organization 10

2 Process Strategy 7 11

3 Job Design 10 13

APPENDIX 1: Details of coursework requirements 15

APPENDIX 2: Peer assessment form 19

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Introduction to the subject

Welcome to Concept and Stages in Production Organization, FMF 0032 This subject
introduces you to the major tools in fabrication, production, manufacturing and industrial
systems that concern in global working environment.

The aim of the subject is to provide students with the necessary knowledge and skills to be
able to manage the implementation of major industrial system in industry. The subject aims
to provide the link between courses that deal with the design of engineering systems, such as
Intelligent Manufacturing Systems, and their implementation in industry.

There are four Modules to complete in this subject. Module 1 provides a general introduction
and an overview of the organization design. In Module 2, details of the procedures that are
required to use process strategy as a competitive weapon. The final module discuss of the
procedures and concepts that are introduced in this course are particularly appropriate for
major production and manufacturing projects. As part of the discussion content of the course,
efforts will be made to identify how the techniques can be adapted for smaller projects.

There are 3 Modules in this subject. The first Modules have 4 units and to be attempted by
the student prior to the start of lectures. The remaining 2 will be covered during lecture
periods.

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 Texts, References and other Resources

Textbooks

The textbook below is an integral part of the subject, and sections of the textbook are set as
required reading for most topics.

Title Principles of Operation Management, 5th edition

Author Jay Heizer Barry Render
Publisher Pearson Prentice Hall
Mode Compulsory

References

1. Larry P. Ritzman , Lee J. Krajewski., “Foundation of Operation Management”

2. Groover, M. P., “Automation, Production Systems, and Computer-Aided
Manufacturing”, Prentice-Hall, 2nd edition, 2001.
3. Dilworth JB, “Operations Management, Strategy and Analysis”, 6th edition,
Hardcourt College Publishers, 2000.

Course website

There is a course website, including a discussion facility. You are encouraged to use this
discussion facility if you want to ask your lecturer any questions. The answer to your
question may be of interest to other students. The discussion facility will allow other
students to participate in the discussion. The discussion facility will also be used for
important announcements for students.

The course website can be accessed via Myphlip PersonNet using the student log in.

This website is a good source of information on many topics, including:

 Making the most of lectures and tutorials
 Managing your time and workload
 Getting the most from your academic reading
 Notemaking from reading
 Writing essays & reports
 Writing article reviews
 Writing practical reports
 Referencing
 Making the most of oral presentations
 Working in teams
 Succeeding in exams
 Participating in online discussions

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 How to use this study guide

This study guide has been designed to assist you in studying this subject. The study guide
clearly defines the number of topics covered by the subject, the objective(s) of each topic,
specific text and reference materials for each topic, the amount of work you have to do for
each topic, and the sequence of study. The guide gives you a clear idea of the contents of the
subject and the amount of work you are expected to do to achieve the subject’s objectives. It
is NOT meant to be a complete set of lecture notes for the subject. To study this subject, you
need not only this study guide, but also the resources listed in the section “Texts and
references”.

The layout of each Module in the study guide is as follows:

Aim:
To provide students with a fundamental concept of planning, operation systems, and skills in
the selection and design of manufacturing systems.

Objectives
On completion of this subject the student should be able to:
• Select and design an appropriate organization design system for a given set of
constraints and requirements;
• Analyse the performance of process strategies
• Develop a systematic approach for design and implementation of human resource and
job design for manufacturing systems.

By undertaking this subject, students will progress in the development of the following
qualities:

Graduate 1 2 3 4 5 6 7
quality Body of Life- Effective Work alone Ethical Communicate International
knowledge long problem and in action effectively perspective
learning solvers teams
Point 1.0 0.2 0.3 0.2 0.1 0.1 0.1
weighting

Study Methodology:
This outlines the study process that is recommended for the particular Module.

Reading list:
This gives you the details of the relevant texts that you have to study for the topic.

Study notes:
This provides the main content of each topic, which will assist you in your reading.

Tutorial questions:

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This section gives you the coursework requirements and tutorial questions that you should
attempt in order to evaluate your learning.

Syllabus
Introduction to basic organization design, facility layout, manufacturing information
systems. Production concepts and manufacturing performance indicators. Manufacturing
costs and work-in-progress costs. High volume production systems, analysis of flow lines,
assembly systems and line balancing.

Teaching and Learning arrangement

This subject will be delivered using the following means:
Lectures to give an outline of work to be covered.
Tutorials to give an opportunity for reflection on lecture material and assignment.
Seminars to enforce the problem based learning approach, give opportunity for running
projects with case studies.

Assessment
Tutorial, Assignments and Project 60%
Examination (1 x 2 hrs) 40%

Guidelines on assessment preparation

 Summary – Only one page required by individual. To be submitted a week earlier

before the lecture class. In this assignment summary, you must summarize your
project, including what you did, how you did it, the major problems, and the solutions
proposed. This is important for you to understand on each module before entering the
lesson.

 Tutorial Assignment, discussion and problem - In this segment of the report, each
team should focus on question given. When identifying a problem, be specific, and
also make sure the problem relates to the activities that you are to study. Further,
when developing a solution(s), do not be open-ended. If you are recommending
changes in the current method(s), you need to estimate the costs, if any, of such
changes. As before, be thorough about solutions that are proposed; that is, make sure
that you consider all aspects of the problem.

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Information about assessment
Coursework (60%)

This is the work that you are required to complete before the examination.

Satisfactory completion of the coursework listed below is compulsory:

1. Pre-lecture assignment (10%) – individual work. Summary for each Module.

2. Attendance and participation (5%)
3. Practical: Tutorial / Assignment (30%) – teamwork
4. Tests (15%)- individual work

Any late submission will be a penalty and will deduct from your marks. Any plagiarism
between groups are consider cheating and students should be aware of their University’s
policy on plagiarism. The following definition and policy regarding penalties are taken from
the University Kuala Lumpur policy on academic misconduct.

See Appendix 1 for details regarding the work.

Examination (40%)

It is a three-hour examination. See Appendix 2 for a sample of previous year examination.

Grading

Grade Notation Mark range

Excellent A 80-100
A- 75-79
Pass with honours B+ 70-74
B 65-69
B- 60-44
Pass C+ 55-59
C 50-54
C- 45-49
D 40-44
Fail F 0-39

Staff Responsible for Subject

Mohd Kamarul Nizam

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 STUDY PROGRAM PLAN

WEEK HOURS STUDY ACTIVITIES

1 2 Induction and Registration Week

2 2 Introduction to the course. Recommended textbook required for the subject.

Coursework marking system. Selection of team group, less than 5 students are
acceptable for each group. Preparation of contact session in week 2.
Activity 1: Individual submission of summary is required for Module 1 and to
submit in the next contact.
3 2 Submission 1: To submit activity 1 of Module 1 for assessment
Class discussion and tutorial work for Module 1 including all activities.
Activity 2: Individual submission of summary is required for Module 2 and to
submit in the next contact
4 2 Submission 2: To submit activity 2 of Module 2 for assessment
Class discussion and tutorial work for Module 2 including all activities.
Activity 3: Completion of discussion question 1, 3,
Activity 4: Completion of problems question 7.1(a), 7.2, 7.3
Submission 3: To submit activity 3 and 4 for assessment
5 2 Class discussion and tutorial work for Module 2 including all activities.
Activity 5: Completion of discussion question 4, 5
Activity 6: Completion of problems question 7.4, 7.5, 7.6
Submission 4: To submit activity 5 and 6 for assessment
6 2 Class discussion and tutorial work for Module 2 including all activities.
Activity 7: Completion of discussion question 6, 7,
Activity 8: Completion of problems question, 7.7, 7.8, 7.9,
Submission 5: To submit activity 7 and 8 for assessment
7 2 Class discussion and tutorial work for Module 2 including all activities.
Activity 9: Completion of discussion question 10, 13,
Activity 10: Completion of problems question 7.10, 7.11, 712
Activity 11: Individual submission of summary is required for Module 3 and
to submit in the next contact
Submission 6: To submit activity 9 and 10 for assessment
8 2 Revision activity for Module 2

9 2 Test

10 2 Semester Break

11 2 Submission 7: To submit activity 11 of Module 3 for assessment

Class discussion and tutorial work for Module 3 including all activities.
Activity 12: Completion of discussion question 2, 4
Activity 13: Completion of problems question 10.1, 10.2,
Submission 8: To submit activity 12 and 13 for assessment
12 2 Class discussion and tutorial work for Module 3 including all activities.

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 Activity 14: Completion of discussion question 6, 7
Activity 15: Completion of problems question 10.4, 10.5
Submission 9: To submit activity 14 and 15 for assessment
13 2 Class discussion and tutorial work for Module 3 including all activities.
Activity 16: Completion of discussion question 8, 9
Activity 17: Completion of problems question 10.6, 10.7
Submission 10: To submit activity 16 and 17 for assessment
14 2 Class discussion and tutorial work for Module 3 including all activities.
Activity 18: Completion of discussion question 10, 11
Activity 19: Completion of problems question 10.9, 10.10
Submission11: To submit activity 18 and 19 for assessment
15 2 Class discussion and tutorial work for Module 3 including all activities.
Activity 20: Completion of problems question 10.11, 10.12
Submission 12: To submit activity 20 for assessment
16 2 Class discussion and tutorial work for Module 3 including all activities.
Activity 21: Completion of problems question 10.13
Submission 13: To submit activity 21 for assessment
17 2 Revision activity for Module 3

18 2 Test 3

19 - Preparation for the Final Examination (Revision Week)

20 - Final exam

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Module 1: OPERATION AND PRODUCTIVITY
Aim:
This Module is meant to provide an overview of organization such as chart and design stages.
Concepts will be introduced here and their discussion will be expanded in later modules.

Study Methodology:
It is recommended that you quickly read the sections listed below. You do not need to write
notes to summarize the information at this stage. After you have finished the readings from
the textbook, work through the notes included in this module and complete the recommended
activities. This activity will draw out the key points from the chapter.

Reading:
Lecturer handouts

Outline

1. ORGANIZATION CHART
 Organization Design
 Division of work
 Basic element of organization

2. PROJECT AND COMPANY ORGANIZATION STRUCTURE

 Hierarchy structure
 Project structure
 Advantage and Disadvantages
 Steps to design an organization

3. MANUFACTURING ORGANIZATION

 The major department

 The objective of manufacturing department
 Structure of manufacturing engineering

4. DESIGN PROCESS
 Structure of design process
 Design decision

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Module 2: PROCESS STRATEGY
Aim:
This Module is meant to provide an overview of process strategy. A process strategy is an
organization’s approach to transform resources into goods and services. The objective of a
process strategy is to find a way to produce goods and services that meet customer
requirements and product specification within costs and other managerial constraints. The
process selected will have a long term effect on efficiency and production, as well as the
flexibility, cost, and quality of the goods produced. Therefore, much of a firm’s strategy is
determined at the time of this process decision.

Study Methodology:
It is recommended that you quickly read the sections listed below. You do not need to write
notes to summarize the information at this stage. After you have finished the readings from
the textbook, work through the notes included in this module and complete the recommended
activities. This activity will draw out the key points from the chapter.

Reading:
Title: Priciples of Operation Management, 5th edition, Author Jay Heizer, Barry Render,
Publisher Pearson Prentice Hall, Chapter 7 Process Strategy

Outline

1. PROCESS STRATEGIES

 Process focus

 Repetitive focus

 Product focus

 Mass customization focus

2. PROCESS ANALYSIS AND DESIGN

 Flow diagrams
 Time function mapping
 Process chart
 Service blueprinting

3. PRODUCTION TECHNOLOGY

 Machine technology
 Automatic Identification System (AIS)

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  Process Control
 Vision System
 Robots
 Automated Storage and Retrieval System (ASRS)
 Automated Guided Vehicle (AGV)
 Flexible Manufacturing System (FMS)
 Computer Integrated Manufacturing (CIM)

Review of Problem Solving

7.1 The question asked about the consideration of equal quality and reliability

Tutorial

1 Discussion Question 1, 3, 4, 5, 6, 7, 8, 9, 10, 13, 15, 16, 17 P 271

2 Problems 7.1 (a), 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, P 272
7.9, 7.10, 7.11, 7.12

3 Case study Rochester Manufacturing Corporation P 273

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Module 3: JOB DESIGN
Aim:
This Module is meant to provide an overview of human resources and job design. This
chapter will examine a variety of human resources issues because organization do not
function without people. They do not function well without competent, motivated people.

Study Methodology:
It is recommended that you quickly read the sections listed below. You do not need to write
notes to summarize the information at this stage. After you have finished the readings from
the textbook, work through the notes included in this module and complete the recommended
activities. This activity will draw out the key points from the chapter.

Reading:
Title: Priciples of Operation Management, 5th edition, Author Jay Heizer, Barry Render,
Publisher Pearson Prentice Hall, Chapter 10 Human Resources and Job Design

Outline

1. JOB DESIGN

 Labor specialization

 Job expansion

 Component in job design

 Self direct team

2. ERGONOMICS AND WORK METHOD

 Ergonomics
 Working environment
 Methods analysis
 Flow Diagram
 Activity Chart
 Operation Chart

Review of Problem Solving

10.1 The question asked about time study and activity chart

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Tutorial

1 Discussion Question 2, 4, 6, 7, 8, 9, 10, 11 P 386

2 Problems 10.1, 10.2, 10.4, 10.5, 10.6, 10.7, P 387

10.9, 10.10, 10.11, 10.12, 10.13

3 Case study -

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 APPENDIX 1

DETAILS OF COURSEWORK REQUIREMENTS

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 COURSEWORK REQUIREMENTS

As indicated on Page 5 of the Study Guide, the overall assessment for this course is allocated
as follows:
Final Examination 40%
Coursework 60%

The Final examination will be a two-hour. The sample examination is indicative only as it
does not cover the full scope of material covered in the course. Questions for the final
examination may include material from any of the 4 Modules.

As all of the coursework will be submitted as a group, it is necessary to set a minimum

acceptable mark for the examination. If a student scores less than 40 percent in the
final examination, the student will fail the subject overall. Where a student has
performed well in coursework, but has achieved a mark less than 40 percent in the
examination, the student will be eligible for a supplementary assessment.

COURSEWORK:

The marks allocated for the coursework component of the assessment will be divided up as
follows:
Attendance and participation in class contact sessions 5%

Submission of answers to tutorial questions (This is to be done on a group basis):-

Summary (3 Modules) 10%
Modules 2, 10%
Modules 2, 10%
Modules 3, 10%

Tests (3 x 5%) 15%

Total 55%

Attendance and participation:

Students will be awarded up to 2% for each of the 5, class contact sessions that they attend
and actively participate in. Active participation will be indicated by the asking and answering
of questions, contribution to discussions and involvement in group tasks.

It is recommended that students keep a photocopy of all tutorial solutions that are submitted.
This is to guard against loss of the information during postal transmission.

The intention of assessing the tutorial questions is to strongly encourage you to attempt all
questions. This effort will help to cement an understanding of the course content. When
assessing your submissions, you will not be heavily penalised for making minor mistakes.

Your tutorial solutions do not need to be typed. Neat hand-written solutions will be
quite acceptable.

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Some guidance on the preparation of your answers

Discussion Questions

Some students may find it difficult to tackle concept questions (or descriptive questions).
The following hints may be useful.
Read the question carefully, and identify the key words in the question. This will help you to
understand clearly what is being asked and what the expected answers are.
Prepare a framework for your answer before you start writing. This can be done by preparing
a list of dot points for each key word that you have identified.
Remember to use headings, sub-headings and paragraphs in your answer. The list of dot
points may be used as headings/ sub-headings.

Problem Solving Questions

Although problem-solving questions may seem easy to some engineering students, it is

important that you present your work clearly.
Remember to present your work in a logical sequence with explanation, not just a list of
equations and numbers.

You may find it useful to understand clearly what is being asked, and work backward from
there to identify the necessary equations and data needed.

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Group Assignment

Assignment questions will be provided by the lecturer at the contact session

Some guidance on the preparation of your report

Writing Technical Reports and Assignments

It is important that you follow the correct format for your assignments and reports.
Your report should have an Abstract. The body of the report should include headings and
sub-headings, e.g. Introduction, Other headings, Conclusions. You should also have a list of
references with appropriate cross-referencing in the body of the report. All tables and figures
should be numbered and have table headings or figure captions. Figures and tables should
also be referred to in the text.

Assessment criteria

Assessment of your work will take into account:

 Relevance of your answer to the question or task set
 Clarity of expression
 Logical planning and sequence
 Overall presentation of the work and grammar.

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 APPENDIX 2

PEER ASSESSMENT

As the assignment and the tutorial question submissions are to be completed in a group, there
is a need for students to assess the relative contribution of the members in their group. The
peer assessment form is shown overleaf. Students should photocopy and complete the form
when submitting each of the assignments and tutorial submissions. The peer assessment
should be confidential and the form should be submitted in a sealed envelope along with the
assessment component. Marks will be apportioned amongst the group on the basis of the
average of these peer assessment percentages. A group that has functioned well will always
show that each member contributed equally to the completion of the assignment.

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 UNIVERSITY KUALA LUMPUR MFI
SECTION OF FABRICATION AND JOINING
CONCEPT AND STAGES IN PRODUCTION ORGANIZATION

PEER ASSESSMENT FORM

ASSESSMENT COMPONENT:
(eg Tutorial Submission Modules 1-3, Assignment 1 etc.)

…………………………………………………………………………………………………..

GROUP NUMBER: ……………..

In the table below, list the members of your Group (including yourself as the first name). For
each member, assess the contribution that the member made to the submitted work. The
areas assessed are:
Attendance and participation at Group meetings (Attendance)
Willingness to work and share with the Group (Teamwork)
Contribution made to the assessment component (Contribution)

Please give a score out of ten in each category in the table below.

Name Attendance Teamwork Contribution Average

Comment on the performance of Group members to justify the scores given above:

…………………………………………………………………………………………………

…………………………………………………………………………………………………

…………………………………………………………………………………………………

…………………………………………………………………………………………………

…………………………………………………………………………………………………

PLEASE HAND UP IN A SEALED ENVELOPE WITH THE ASSESSMENT

COMPONENT.

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