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Dept. of ME, JSSATE, Bengaluru 1
I Can't Keep Calm Because I Am An
Operations Management Trainee
- Camila Cooper
Service Vs. Manufacturing
3
Dept. of ME, JSSATE, Bengaluru
Manufacturing and Service Organizations differ chiefly because manufacturing
is goods-oriented and service is act-oriented.
Tangible Act-Oriented
Goods Services
(Stevenson, W. J (2018). Operations Management)
Service Vs. Manufacturing
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Dept. of ME, JSSATE, Bengaluru
(Stevenson, W. J (2018). Operations Management)
Service & Manufacturing - Similarities
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Dept. of ME, JSSATE, Bengaluru
• Both have customers, suppliers, scheduling and
staffing issues
• Both use technology
• Both have quality, productivity, & response
issues
• Both must forecast demand
• Both can have capacity, layout, and location
issues
Operations Management
• Course code: 18ME56
• Lecture hours/week: 3 (No. of credits = 3)
• CIE marks: 30 (blue book) + 10 (activity) = 40
• Number of CIEs: 3
• Final CIA marks: Average marks of three blue book
tests + Activity marks
• Minimum marks to be obtained: 16
• CIE duration: 1.5 hour
• SEE marks: 100 (5 questions, each 20 marks)
• SEE duration: 3 hours
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Dept. of ME, JSSATE, Bengaluru
Curriculum
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Dept. of ME, JSSATE, Bengaluru
Module – 1:
• Introduction: Functions within business
organizations, the operation management
function, classification of production systems,
Productivity, factors affecting productivity.
• Decision Making: The decision process,
characteristics of operations decisions, use of
models, decision making environments,
graphical linear programming, analysis and
trade-offs.
(8 hours)
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Dept. of ME, JSSATE, Bengaluru
Operations Management
Module – 2:
• Forecasting:
• Steps in forecasting process, approaches to
forecasting, forecasts based on judgment
and opinion, analysis of time series data,
accuracy and control of forecasts, choosing
a forecasting technique, elements of a
good forecast.
(8 hours)
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Dept. of ME, JSSATE, Bengaluru
Operations Management
Module – 3:
• Capacity & Location Planning:
• Importance of capacity decisions, defining and
measuring capacity, determinants of effective capacity,
determining capacity requirement, developing capacity
alternatives, evaluating alternatives.
• Need for location decisions, nature of locations
decisions, general procedure for making locations
decisions, evaluating locations decisions, facilities
layout – need for layout decisions, types of processing.
(8 hours)
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Dept. of ME, JSSATE, Bengaluru
Operations Management
Module – 4:
• Aggregate Planning
• Nature and scope of aggregate planning,
strategies of aggregate planning, techniques for
aggregate planning – graphical and charting
techniques, mathematical techniques.
• Master Scheduling
• The master production schedule, Master
scheduling process, Master scheduling methods.
(8 hours)
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Dept. of ME, JSSATE, Bengaluru
Operations Management
Module – 5:
• Material Requirement Planning (MRP):
• Dependent versus independent demand, an
overview of MRP – MRP inputs and outputs, MRP
processing, ERP capacity requirement planning,
benefits and limitations of MRP.
• Purchasing and Supply Chain Management (SCM):
• Introduction, Importance of purchasing and SCM,
the procurement process, Concept of tenders,
Approaches to SCM, Vendor development.
(8 hours)
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Dept. of ME, JSSATE, Bengaluru
Operations Management
Books Prescribed:
Text Books:
• Operations Management, William J Stevenson, Latest Ed., Tata McGraw Hill.
• Operations Management, David A Collier, James R Evans, Kunal Ganguly,
Cengage Learning India Pvt. Limited, 3rd Edition, 2016,
• Reference Books:
• Lee J Krajewski, Larry P Ritzman and Manoj Malhotra, Operations
Management – Processes and Supply Chain, Pearson Education Asia, 11th Edn,
2010
• R. Paneerselvam, Production and Operations Management, PHI, 2nd Edn, 2006
• B. Mahadevan, Operations Management – Theory and Practice, PHI, 2010, 2nd
Edn.
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Dept. of ME, JSSATE, Bengaluru
Operations Management
Course Outcomes:
At the end of this course, you will be able to:
CO# Course Outcome
Bloom’s
Level
1
Apply the necessary tools for decision making in operations
management.
3
2
Examine various approaches for forecasting the sales demand
for an organization.
4
3
List various capacity and location plans to determine the suitable
capacity required for meeting the forecast demand of an
organization.
4
4
Analyse the aggregate plan and master production schedule for
an organization, given its periodic demand.
4
5 Apply MRP, purchasing and SCM techniques into practice. 3
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Dept. of ME, JSSATE, Bengaluru
Operations Management
Bloom’s Learning Levels - Revised
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Dept. of ME, JSSATE, Bengaluru
Bloom’s Taxonomy- Revised
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Dept. of ME, JSSATE, Bengaluru
POs->
COs
PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12 PSO1 PSO2
CO1 3 3 2 - - - - 2 - 2 2 - - -
CO2 3 3 3 - - - - 2 - 2 2
CO3 3 3 3 - - - - 2 - 2 2
CO4 3 3 3 - - - - 2 - 2 2
CO5 3 3 3 - - - - 2 - 2 2
Avg. 3 3 2.80 2 2 2
Mapping of COs with POs & PSOs
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Dept. of ME, JSSATE, Bengaluru
Justification of COs with POs and PSOs
• CO1-PO1: Use of decision making tools such as break-even analysis,
linear programming, statistical analysis, simulation, etc. demands a
strong knowledge of mathematics, science and engineering
fundamentals.
• CO2-PO1: Forecasting models are basically mathematical equations.
Formulating these models and solving them requires skill and a strong
knowledge of mathematics, science, engineering & management
fundamentals.
• CO3-PO1: Facility location and Capacity planning can be made by the
use various mathematical models. Use of these models and solving
them subsequently for arriving at a decision demands skill and
knowledge on mathematics, science, engineering & management
fundamentals.
• CO4-PO1: Preparation of aggregate plans and master schedule in an
organization requires a strong background of mathematics, science,
engineering & management fundamentals.
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Dept. of ME, JSSATE, Bengaluru
Program Outcomes
• PO1. Engineering knowledge: Apply the knowledge of mathematics,
science, engineering fundamentals, and an engineering specialization to
the solution of complex engineering problems.
• PO2. Problem analysis: Identify, formulate, review research literature,
and analyze complex engineering problems reaching substantiated
conclusions using first principles of mathematics, natural sciences, and
engineering sciences.
• PO3. Design/development of solutions: Design solutions for complex
engineering problems and design system components or processes that
meet the specified needs with appropriate consideration for the public
health and safety, and the cultural, societal, and environmental
considerations.
• PO4. Conduct investigations of complex problems: Use research-based
knowledge and research me thods including design of experiments,
analysis and interpretation of data, and synthesis of the information to
provide valid conclusions.
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Dept. of ME, JSSATE, Bengaluru
Program Outcomes
• PO5. Modern tool usage: Create, select, and apply appropriate
techniques, resources, and modern engineering and IT tools
including prediction and modeling to complex engineering
activities with an understanding of the limitations.
• PO6. The engineer and society: Apply reasoning informed by the
contextual knowledge to assess societal, health, safety, legal and
cultural issues and the consequent responsibilities relevant to the
professional engineering practice.
• PO7. Environment and sustainability: Understand the impact of
the professional engineering solutions in societal and
environmental contexts, and demonstrate the knowledge of, and
need for sustainable development.
• PO8. Ethics: Apply ethical principles and commit to professional
ethics and responsibilities and norms of the engineering practice.
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Dept. of ME, JSSATE, Bengaluru
Program Outcomes
• PO9. Individual and team work: Function effectively as an
individual, and as a member or leader in diverse teams, and in
multidisciplinary settings.
• PO10. Communication: Communicate effectively on complex
engineering activities with the engineering community and with
society at large, such as, being able to comprehend and write
effective reports and design documentation, make effective
presentations, and give and receive clear instructions.
• PO11. Project management and finance: Demonstrate knowledge
and understanding of the engineering and management principles
and apply these to one’s own work, as a member and leader in a
team, to manage projects and in multidisciplinary environments.
• PO12. Life-long learning: Recognize the need for, and have the
preparation and ability to engage in independent and life-long
learning in the broadest context of technological change.
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Dept. of ME, JSSATE, Bengaluru
Program Specific Outcomes
• PSO1: Apply the acquired knowledge in design,
thermal, manufacturing and interdisciplinary areas
for solving industry related problems.
• PSO2: Solve complex Mechanical Engineering
problems using appropriate software tools.
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Dept. of ME, JSSATE, Bengaluru
• Operations
• A set of activities that serve a purpose (result).
• Processes that either provide services or create goods.
• Take place in businesses such as restaurants, retail
stores, supermarkets, factories, hospitals, and colleges
and universities.
• Are the core of what a business organization does.
• Operations Management
• The management of systems or processes that create
goods and/or provide services.
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Dept. of ME, JSSATE, Bengaluru
Operations Management
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Dept. of ME, JSSATE, Bengaluru
Operations Management
• OM Transforms inputs to outputs
– Inputs are resources such as
• People, Material, and Money
– Outputs are goods and services
(Source: OM by Reid & Sanders)
• Concerned with converting a set of resources
into goods and services as efficiently as possible
to maximize the profit of an organization.
Dept. of ME, JSSATE, Bengaluru 25
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Dept. of ME, JSSATE, Bengaluru
OM’s Transformation Process
(Source: OM by Reid & Sanders)
Value addition is the net increase between output product
value and input material value.
Efficient transformation is performing activities at the least
possible cost
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Dept. of ME, JSSATE, Bengaluru
OM’s Transformation Process – Ex. 1
Materials
Machines
Human resource
Money
Design & Draft
Cutting
Machining
Assembling
Painting
Quality assurance
Inputs Outputs
Transformation Process
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Dept. of ME, JSSATE, Bengaluru
OM’s Transformation Process – Ex. 2
Students with
raw but …
Teachers
Teaching aids
Classrooms &
other facilities
Teaching-Learning
Tests / Assignments
/ Seminars /
Projects
SEEs
Extracurricular
activities
Inputs Outputs
Transformation Process
Operations Management
https://www.youtube.com/watch?v=nG5-52a5lRo
https://www.youtube.com/watch?v=FbbGlVle3oU
https://www.youtube.com/watch?v=_VJkKZFuRvE
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Dept. of ME, JSSATE, Bengaluru
Operations Manager
• Operations managers are the improvement
people, the realistic, hard-nosed, make-it-work,
get-it-done people; the planners, coordinators,
and negotiators.
• They perform a variety of tasks in many different
types of businesses and organizations.
• Examples..
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Dept. of ME, JSSATE, Bengaluru
Operations Manager
• Operations managers plan and make decisions.
• Select the best possible alternatives that can have quite
different impacts on costs or profits.
• Some of the key decisions operations managers make:
• What: What resources will be needed, and in what amounts?
• When: When will each resource be needed? When should the
work be scheduled? When should materials and other supplies
be ordered? When is corrective action needed?
• Where: Where will the work be done?
• How: How will the product or service be designed? How will
the work be done (organization, methods, equipment)? How
will resources be allocated?
• Who: Who will do the work?
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Dept. of ME, JSSATE, Bengaluru
Costs
(budget),
Quality
and
Schedules
(time)
Source: OM by W J Stevenson
Operations Management
• The evolution of the name:
• Production Management
• Production and Operations Management
• Production/Operations Management
• Operations Management
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Dept. of ME, JSSATE, Bengaluru
Production Management Vs. Operations
Management
Dept. of ME, JSSATE, Bengaluru 33
Meaning
Managing production-related activities of an
organization
Managing routine business activities of an
organization related to creation of products
as well as to the delivery of services
Scope
Limited to the production of goods; taking
decisions on quality, quantity, design and
pricing of the product being developed
Wider scope; management of routine
business activities, such as product quality,
design, quantity, storage, workforce
requirement, etc.
Focus
Offering the right quality of products at the
right time, in the right quantity and at the
right price.
Efficient and effective use of organizational
resources
Organization where it is prevalent
Organizations where products are created All types of organizations, such as service-
oriented firms, banks, manufacturing
companies, hospitals, etc.
https://www.termscompared.com/difference-between-operations-
management-and-production-management/
Dept. of ME, JSSATE, Bengaluru 34
Operations Management - Evolution
Source: OM by Russel & Taylor
Dept. of ME, JSSATE, Bengaluru 35
Operations Management - Evolution
Source: OM by Russel & Taylor
Operations Management – Why study?
• Every aspect of business affects or is affected by operations.
• Many service jobs are closely related to operations
– Financial services
– Marketing services
– Accounting services
– Information services
• There is a significant amount of interaction and collaboration
amongst the functional areas.
• It provides an excellent vehicle for understanding the world
in which we live.
(Stevenson, W. J (2018). Operations Management)
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Dept. of ME, JSSATE, Bengaluru
Functions within business organizations
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Dept. of ME, JSSATE, Bengaluru
A retail store, a hospital, a manufacturing firm, a car wash, or some
other type of business.
Source: OM by Russel & Taylor
• Finance
• Responsible for securing financial resources at favorable prices
and allocating those resources throughout the organization;
• Budgeting, analyzing investment proposals;
• Providing funds for operations.
• Marketing
• Responsible for assessing consumer wants and needs;
• Selling and promoting the organization’s goods or services.
• Operations
• Responsible for producing the goods or providing the services
offered by the organization.
• Examples..
(Stevenson, W. J (2018). Operations Management)
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Dept. of ME, JSSATE, Bengaluru
Functions within business organizations
• A system is an arrangement or assembly of inter-dependent
processes (activities) that are based on some logic and
objectives.
• A system operates as a whole and is designed (built) with an
intention to achieve (fulfill) some objective or do some work.
• Manufacturing is a huge system consisting of many
subsystems and activities that turn out useful outputs.
• A production system is a subsystem of manufacturing system
that includes all functions required to design, produce,
distribute and service a manufactured product.
• Elements of a production system are: inputs, transformation
and outputs.
• A production system may be intermittent or continuous.
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Dept. of ME, JSSATE, Bengaluru
Production Systems
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Dept. of ME, JSSATE, Bengaluru
Classification of production systems
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Dept. of ME, JSSATE, Bengaluru
Classification of production systems
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Dept. of ME, JSSATE, Bengaluru
Classification of production systems
• Job-Shop Production System
• A high variety of products and low volume.
• Use of general-purpose machines and facilities.
• Highly skilled operators who can take up each job as a challenge because
of uniqueness.
• Large inventory of materials, tools, parts.
• Batch Production System
• Shorter production runs.
• Plant and machinery are flexible.
• Plant and machinery set up are used for the production of the item in a
batch and change of set up is required for processing the next batch.
• Manufacturing lead-time and cost are lower as compared to job order
production. 43
Dept. of ME, JSSATE, Bengaluru
Classification of production systems
Musical instruments, Body parts, Aircrafts
• Mass Production System
• Standardization of product and process sequence.
• Dedicated special purpose machines having higher production capacities
and output rates and hence a large volume of products.
• The shorter cycle time of production.
• Lower in process inventory.
• Perfectly balanced production lines.
• Continuous Production System
• Dedicated plant and equipment with zero flexibility.
• Material handling is fully automated.
• The process follows a predetermined sequence of operations.
• Component materials cannot be readily identified with the final product.
• Planning and scheduling is a routine action.
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Dept. of ME, JSSATE, Bengaluru
Classification of production systems
Food,
energy,
Fuel,
etc.
Automobiles, Footwear, Chocolates
• The state or quality of being productive
• The effectiveness of productive effort, especially
in industry, as measured in terms of the rate of
output per unit of input.
• The output of an industrial concern in relation to
the materials, labour, etc. it employs.
• Example … (land, crop, typist, etc.)
• Ratio of output to inputs
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Dept. of ME, JSSATE, Bengaluru
Productivity
One
acre
of
land
that
produces
10
pumpkins?
• A measure of the effective use of resources, usually expressed as
the ratio of output to input.
• An index that measures output (goods and services) relative to
the input (labor, materials, energy, and other resources) used to
produce it.
• Ratio of output to inputs,
• For a nation / organization, productivity growth is the relative
change in the productivity in the current period relative to
previous period.
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Dept. of ME, JSSATE, Bengaluru
Productivity
• Types (Computing Productivity)
• Total productivity
• Multifactor productivity
• Partial productivity
• The choice of productivity measure depends
primarily on the purpose of the measurement.
• For ex., If the purpose is to track improvements
in labor productivity, then labor becomes the
obvious input measure.
Dept. of ME, JSSATE, Bengaluru 47
Productivity
• Types (Computing Productivity)
Dept. of ME, JSSATE, Bengaluru 48
Productivity
Source: OM by W J Stevenson
• Determine the productivity for these cases:
a) Four workers installed 720 square yards of carpeting in
eight hours.
b) A machine produced 70 pieces in two hours. However,
two pieces were unusable.
Dept. of ME, JSSATE, Bengaluru 49
Computing Productivity
Source: OM by W J Stevenson
b) A machine produced 70 pieces in two hours. However,
two pieces were unusable.
Dept. of ME, JSSATE, Bengaluru 50
Computing Productivity
Source: OM by W J Stevenson
• Determine the multifactor productivity for the combined
input of labor and machine time using the following
data:
• Output: 7,040 units;
• Input: Labor: $1,000; Materials: $520; Overhead: $2,000
Dept. of ME, JSSATE, Bengaluru 51
Computing Productivity
Source: OM by W J Stevenson
• A bank through its five tellers served a total 1497
customers during the past week. The bank works 5
days/week and the business hours are 10:30 am – 02:30
pm. Compute the productivity measure of its tellers.
• Soln.:
• No. of business hours / day / teller = 4
• Total no. of business hours / day = 5 x 4 = 20
• Total no. of business hours / week = 5 x 20 = 100
• Productivity = (No. of customers served / week) / (No. of
hours tellers worked/week)
= 1497 / 100 = 14.97 or 15 customers / hour
Dept. of ME, JSSATE, Bengaluru 52
Computing Productivity
• An organization can use productivity
measures to
• compare its performance with that of
competitors,
• assess the relative performance of its
individual departments,
• compare the relative benefits of various
inputs,
• plan the most effective use of resources.
Dept. of ME, JSSATE, Bengaluru 53
Why Productivity is Measured?
• Generally, methods, capital, quality, technology and management
affect productivity.
• A misconception is that workers are the main determinant of
productivity. Hence, organizations insist their employees to work
harder.
• The fact is that many productivity gains in the past have come
from technological improvements.
• However, technology alone won’t guarantee productivity gains; it
must be used wisely and thoughtfully.
• Current productivity pitfall results from employees’ use of
computers or smartphones for nonwork-related activities (playing
games or checking stock prices or sports scores on the Internet or
smartphones, and texting friends and relatives).
Dept. of ME, JSSATE, Bengaluru 54
Factors Affecting Productivity
Source: OM by W J Stevenson
• Capital/Labour Ratio: is a measure of whether enough investment
is made in plant, machinery, tools, etc. to make effective use of
labour hours.
• Scarcity of some resources: such as energy, water, materials,
skilled labours, etc.
• Work-force changes is steady shift of from blue-collar occupations
to….
• Innovation and technology: will be developed if enough
investment is made in R & D; Strong patenting rules are required.
• Regulatory effects: sometimes, impose substantial constraints
(pollution, health, safety, labour benefits, etc.).
• Bargaining power: of organized labour to command wage increase.
• Quality of work life describes the organizational culture -
motivation to employees for teamwork, commitment, loyalty, etc.
Dept. of ME, JSSATE, Bengaluru 55
Factors Affecting Productivity
Source: Joseph Monks, OM, 1987
• (Personal)
• Do Your Heavy Lifting When You're at Your Best. ...
• Stop Multitasking. ...
• Prepare a To-Do List Each Night. ...
• Cut Down Your To-Do List. ...
• Delegate Properly. ...
• Eliminate Distractions. ...
• Plan Phone Calls. ...
• Break up Work Periods.
Dept. of ME, JSSATE, Bengaluru 56
Methods to Increase Productivity
• Strategies
• Increased output for the same input.
• Decreased input for the same output.
• Proportionate increase in the output is more than the
proportionate increase in the input.
• Proportionate decrease in the input is more than the
proportionate decrease in the output.
• Simultaneous increase in the output with decrease in the
input.
Dept. of ME, JSSATE, Bengaluru 57
Methods to Increase Productivity
Source: R. Panneerselvam, POM, 2012
Part – 2:
Decision Making
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Dept. of ME, JSSATE, Bengaluru
• He who has a choice has trouble.
• Every decision ever taken is born out of choices.
• A process of consciously choosing an alternative among
the several available.
• Decision making is one of the most important basic
management skills for all of us. It is a cognitive ability. It
can differ from person to person.
• Decisions should neither be taken in haste nor be
procrastinated indefinitely.
• Making a decision which is timely and which is based on
careful analysis of various information is critical for an
operations manager.
Dept. of ME, JSSATE, Bengaluru 59
Decision Making
Dept. of ME, JSSATE, Bengaluru 60
Decision Making Process
https://www.umassd.edu/fycm/decision-making/process/
• 1. Identify the decision to be made
• What is the problem on hand?
• What is the objective to be achieved?
• How will the decision impact people or the organization?
• Urgency and criticality of the decision
• 2. Gather relevant information
• What information is needed?
• The best sources of information
• How to get it?
• Involves both internal and external “work.”
• Internal: a process of self-assessment.
• External: obtained online, in books, from other people, and from
other sources.
Dept. of ME, JSSATE, Bengaluru 61
Decision Making Process
• 3. Identify the options
• Information collected helps identifying several possible paths of
action or alternatives.
• Imagination and additional information to construct new
alternatives may also be used.
• All possible and desirable alternatives are to be listed.
• 4. Weigh or Evaluate the evidence of each alternative
• Evaluate whether the need identified in Step 1 would be met or
resolved through the use of each alternative.
• Certain options seem favorable, have a higher potential for
reaching the goal.
• Place the alternatives in a priority order, based upon your own
value system.
Dept. of ME, JSSATE, Bengaluru 62
Decision Making Process
• 5. Choose among alternatives
• After weighing the evidences, select the alternative that seems to
be best one for you.
• A combination of alternatives may also be chosen.
• The selected alternative may very likely be the same or similar to
the alternative that is placed at the top of the list at the end of
Step 4.
• 6. Implement the chosen alternative (Take action)
• Implement the actions associated with the alternative or option
being selected.
• 7. Analyse the results
• Evaluate whether or not the chosen option has resolved the need
identified in Step 1. If not, certain steps may be repeated.
Dept. of ME, JSSATE, Bengaluru 63
Decision Making Process
• Operations decisions range from simple judgments to
complex analyses (these may also involve judgments).
• Judgmental decisions are made by basic knowledge,
experience and common sense.
• Both subjective and objective data is used to arrive at a
choice.
• The decisions are characterized by
– The significance of the decision being made
– The time and cost involved (limitations)
– The degree of complexity of the decision being made
Dept. of ME, JSSATE, Bengaluru 64
Characteristics of Operations Decisions
• Significant (or long-lasting) decisions deserve more
consideration than trivial or routine one. Ex., medical
products, investment in new plant, etc.
• Time availability and cost analysis
• Decision complexity increases when a) many variables
are involved, b) the variables are highly interdependent
or sequentially related, and c) the data describing the
variables are incomplete or uncertain.
• Example: new factory location decisions (involve
economical, social, and environmental concerns; cost on
technology and amount of automation).
Dept. of ME, JSSATE, Bengaluru 65
Characteristics of Operations Decisions
• Degree of certainty that exist with respect to the decision
variables and possible outcomes.
Dept. of ME, JSSATE, Bengaluru 66
Decision Making Environment
Complete
Certainty
Complete
Uncertainty
Risk &
Uncertainty
How much
certainty exists?
All information Some information No information
• Degree of certainty – a) complete certainty, b) risk and
certainty, and c) extreme uncertainty
• Complete certainty: All the information to make decision
is available (or assumed to be available). Outcomes are
probably known.
• Decision making may not be easy since the problem may
be ill defined, the decision criteria may be unclear, there
may be too many variables to handle, etc.
– Some of the methods (tools) used are:
– Break-even analysis, Benefit/cost analysis, linear, non-
linear, integer, goal and dynamic programming
Dept. of ME, JSSATE, Bengaluru 67
Decision Making Environment
• Risk and uncertainty: Information about the decision
variables or the outcomes is usually probabilistic.
• Objective data from large samples may give more
certainty than subjective data.
– Some of the methods (tools) used are:
– Statistical analysis for setting labour standards, forecasting,
inventory and quality control, etc.
– Queuing theory for waiting line, maintenance activities,
shop floor control activities.
– Network analysis techniques such as PERT, CPM, Decision
trees, etc.
– Simulation for duplicating the essence of an activity
without actually doing it.
Dept. of ME, JSSATE, Bengaluru 68
Decision Making Environment
• Complete Uncertainty: No information about the
decision variables or the outcomes is available.
– Some of the methods (tools) used are:
– Game theory
– Coin flip
Dept. of ME, JSSATE, Bengaluru 69
Decision Making Environment
• Linear Programming
• A firm manufactures two types of products A and B and
sells them at a profit of Rs. 2 on type A and Rs. 3 on type
B. Each product is processed on two machines G and H.
Type A requires one minute of processing time on G and
2 minutes on H, type B requires one minute on G and
one minute on H. The machine G is available for not
more than 6 hours and 40 minutes while machine H is
available for 10 hours during one working day.
Formulate the problem as a linear programming
problem.
Dept. of ME, JSSATE, Bengaluru 70
Decision Making - Certainty
• Let x1 be the number of products of type A and x2 be the
number of products of type B.
Dept. of ME, JSSATE, Bengaluru 71
Decision Making - Certainty
• Let, Z – the objective function = Total profit
• Z = 2 x1 + 3 x2 (objective function)
• The total time (in minutes) required on machine G is
given by
= x1 + x2
• But the machine G is not available for more than 6 hours
and 40 minutes (i.e., 400 minutes). Therefore,
• x1 + x2 ≤ 400
• Similarly, the total time (minutes) required on machine
H is 2x1 + x2. Since machine H is available for 600 min.,
• 2x1 + x2 ≤ 600
Dept. of ME, JSSATE, Bengaluru 72
Decision Making - Certainty
The Linear Programming Model (equations)
Maximize Z = 2 x1 + 3 x2 (objective function)
Subject to constraints
x1 + x2 ≤ 400 --- Machine G time constraint
2x1 + x2 ≤ 600 --- Machine H time constraint
x1 ≥ 0 & x2 ≥ 0 --- non negative constraints.
Dept. of ME, JSSATE, Bengaluru 73
Decision Making - Certainty
The Three basic elements of an LP model are:
• The objective function
• Decision variables
• A set of constraints
The Linear Programming Model (equations)
Soln.:
x1 + x2 = 400 --- 1
2x1 + x2 = 600 --- 2
Eqn. 2 – Eqn. 1 gives us,
x1 = 200 and x2 = 200
Hence, Profit maximized, Z = 2 (200) + 3 (200) =
Rs. 1000
Dept. of ME, JSSATE, Bengaluru 74
Decision Making - Certainty
Graphical Soln.:
•OABC is the area
bound by the two
constraint lines.
It is called Solution
Space.
Optimum value Z at
each point:
O = Zero
A = Rs. 4000
B = Rs. 1000
C = Rs. 600 Dept. of ME, JSSATE, Bengaluru 75
Decision Making - Certainty
• Break-even analysis (Cost-Volume-Profit)
• Revenue = Unit Selling Price, SP x Sales quantity, Q
• Total Cost = Total Fixed Cost (FC) + Total Variable Cost (VC)
• Total profit, P = Total revenue – Total cost
• P = (Q x SP) – (FC + v x Q)
• P = Q (SP -v) – FC
Dept. of ME, JSSATE, Bengaluru 76
Where, SP – Selling Price / unit; VC – Variable Cost/unit
Decision Making - Certainty
Dept. of ME, JSSATE, Bengaluru 77
Decision Making - Certainty: BEA
• Break-even analysis (Cost-Volume-Profit)
• If fixed costs are Rs. 40000 per week and variable costs
are estimated at 50% of the unit selling price of Rs.160,
what is the BEP?
• = (40000)/(160-80) = 500 units
Dept. of ME, JSSATE, Bengaluru 78
Decision Making - Certainty: BEA
• Break-even analysis (Cost-Volume-Profit)
• The owner of a bakery is planning to produce a new
cake, which will require leasing new equipment for a
monthly payment of $6,000. Variable costs would be $2
per cake, and cakes would retail for $7 each.
• How many cakes must be sold in order to break even?
• What would the profit (loss) be if 1,000 cakes are made
and sold in a month?
• How many cakes must be sold to realize a profit of
$4,000?
• If 2,000 cakes can be sold, and a profit target is $5,000,
what price should be charged per cake?
Dept. of ME, JSSATE, Bengaluru 79
Source: OM by W J Stevenson
Decision Making - Certainty: BEA
• FC = $6,000, VC = $2 per cake, SP = $7 per cake
• a.
• b. For Q = 1,000, P = Q ( SP − VC )  − FC
• = 1,000 ($7 − $2)− $6,000 = − $1,000
• c. Profit, P = $4,000; Solve for Q using Q = (P+FC)/(SP-VC)
• d. P = $5000, Q = 2000 cakes; We know, P = Q (SP -v) – FC
• $5,00 0 = 2,000 (SP − $2) − $6, 000
• Therefore, SP = $7.50
Dept. of ME, JSSATE, Bengaluru 80
Source: OM by W J Stevenson
Decision Making - Certainty: BEA
Risk & Uncertainty:
• When probabilities can be assigned to the occurrence of
states of nature (events that may occur in future), the
situation is referred to as decision making under risk.
• When probabilities cannot be assigned to the
occurrence of future events, the situation is called
decision making under uncertainty.
• Decision Criteria used:
– Maximax
– Maximin
– Minimax regret
– Hurwicz
– Equal likelihood (LaPlace)
Dept. of ME, JSSATE, Bengaluru 81
Decision Making Situations
Source: OM by Russel & Taylor
• A Textile MNC is contemplating the future of one of its
plants located in Mumbai. Three alternative decisions are
being considered: (1) Expand the plant and produce
lightweight, durable materials for possible sale to the
military, a market with little foreign competition; (2)
maintain the status quo at the plant, continuing
production of textile goods that are subject to heavy
foreign competition; or (3) sell the plant now. If one of the
first two alternatives is chosen, the plant will still be sold
at the end of the year. The amount of profit that could be
earned by selling the plant in a year depends on market
conditions. The following payoff table is prepared by the
top management of the company:
Dept. of ME, JSSATE, Bengaluru 82
Decision Making – Risk & Uncertainty
Source: OM by Russel & Taylor
• Determine the best decision using each of the decision
criteria,
1. Maximax, 2. Maximin, 3. Minimax regret
4. Hurwicz (Take α = 0.3), 5. Equal likelihood
Dept. of ME, JSSATE, Bengaluru
83
Source: OM by Russel & Taylor
Decision Making – Risk & Uncertainty
• Maximax (Optimistic) criterion
• The decision maker optimistically assumes that ‘good
competitive conditions’ will prevail in the future.
• The decision selected will result in the maximum of the
maximum payoffs.
• Hence,
• Expand: $800,000
• Status quo: $1,300,000 ← Maximum
• Sell: $320,000
• Decision: Maintain status quo
Dept. of ME, JSSATE, Bengaluru 84
Source: OM by Russel & Taylor
Decision Making – Risk & Uncertainty
• Maximin (Pessimistic) criterion
• The decision maker is pessimistic and assumes that
‘minimum payoffs’ will occur in the future.
• The decision maker selects the decision that will reflect
the maximum of the minimum payoffs.
• Hence,
• Expand: $500,000 ← Maximum
• Status quo: - $150,000
• Sell: $320,000
• Decision: Expand
Dept. of ME, JSSATE, Bengaluru 85
Source: OM by Russel & Taylor
Decision Making – Risk & Uncertainty
• Minimax regret criterion
• The decision maker attempts to avoid regret by selecting the
decision alternative that minimizes the maximum regret.
• First, select the maximum payoff under each state of nature; then
all other payoffs under the respective states of nature are
subtracted from these amounts.
• The maximum regret for each decision must be determined, and
the decision corresponding to the minimum of these regret values
is selected.
Dept. of ME, JSSATE, Bengaluru 86
Source: OM by Russel & Taylor
Decision Making – Risk & Uncertainty
• Minimax regret criterion
• Expand: $500,000 ← Minimum
• Status quo: $650,000
• Sell: $980,000
• Decision: Expand
Dept. of ME, JSSATE, Bengaluru 87
Source: OM by Russel & Taylor
Decision Making – Risk & Uncertainty
• Hurwicz criterion
• The decision maker is neither totally optimistic (maximax
criterion) nor totally pessimistic (maximin criterion).
• The decision payoffs are weighted by a coefficient of
optimism, α, a measure of the decision maker’s
optimism.
• If α =1, the decision maker is completely optimistic; if α =
0, the decision maker is completely pessimistic. (Given
this definition, (1 - α) is the coefficient of pessimism.)
Dept. of ME, JSSATE, Bengaluru 88
Source: OM by Russel & Taylor
Decision Making – Risk & Uncertainty
• Hurwicz criterion
• For each decision alternative, the maximum payoff is
multiplied by α, and the minimum payoff is multiplied by
(1 - α).
• In the given example, if α equals 0.3 (i.e., the company is
slightly optimistic) and (1 - α)=0.7, the following decision
will result:
• Expand: $800,000(0.3) + 500,000(0.7) = $590,000 ← Maximum
• Status quo: $1,300,000(0.3) - 150,000(0.7) = $ 285,000
• Sell: $320,000(0.3) + $320,000(0.7) = $320,000
• Decision: Expand
Dept. of ME, JSSATE, Bengaluru 89
Source: OM by Russel & Taylor
Decision Making – Risk & Uncertainty
• Equal Likelihood:
• Each state of nature is weighted equally. That is, it is assumed
that the states of nature are equally likely to occur (weight of
0.5 each since there are two).
• Multiply the weights by each payoff for each decision.
• Select the alternative with the maximum of these weighted
values.
• Expand: $800,000(0.50) + $500,000(0.50) = $650,000 ←
Maximum
• Status quo: $1,300,000(0.50) +$150,000(0.50) = $575,000
• Sell: $320,000(0.50) + $320,000(0.50) = $320,000
• Decision is Expand
Dept. of ME, JSSATE, Bengaluru 90
Source: OM by Russel & Taylor
Decision Making – Risk & Uncertainty
• Consider the following payoff table for three product
decisions (A, B, and C) and three future market
conditions (payoffs in $ millions).
• Determine the best decision using the following decision
criteria.
1. Maximax, 2. Maximin
Dept. of ME, JSSATE, Bengaluru 91
Source: OM by Russel & Taylor
Decision Making – Risk & Uncertainty
• Decision Tree: A schematic representation of the alternatives
available to a decision maker and their possible consequences.
Dept. of ME, JSSATE, Bengaluru 92
Decision Tree
Source: OM by Russel & Taylor
• Using the information in the payoff table given and a
probability of 0.6 for new bridge and 0.4 for No New
Bridge, construct a decision tree and select the best
alternative:
Dept. of ME, JSSATE, Bengaluru 93
Decision Making Situations
Source: OM by W J Stevenson
Decision
Alternative
Expected Payoff ($) under State of Nature
New Bridge No New Bridge
A 1 14
B 2 10
C 4 6
Dept. of ME, JSSATE, Bengaluru 94
Decision Tree
Source: OM by W J Stevenson
Dept. of ME, JSSATE, Bengaluru 95
Decision Tree
Source: OM by W J Stevenson
Dept. of ME, JSSATE, Bengaluru 96
Decision Tree
Source: OM by W J Stevenson
Dept. of ME, JSSATE, Bengaluru 97
Decision Tree
Source: OM by W J Stevenson

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18ME56-OM_ Module 1-Curriculum COs Mapping.pdf

  • 1. Dept. of ME, JSSATE, Bengaluru 1
  • 2. I Can't Keep Calm Because I Am An Operations Management Trainee - Camila Cooper
  • 3. Service Vs. Manufacturing 3 Dept. of ME, JSSATE, Bengaluru Manufacturing and Service Organizations differ chiefly because manufacturing is goods-oriented and service is act-oriented. Tangible Act-Oriented Goods Services (Stevenson, W. J (2018). Operations Management)
  • 4. Service Vs. Manufacturing 4 Dept. of ME, JSSATE, Bengaluru (Stevenson, W. J (2018). Operations Management)
  • 5. Service & Manufacturing - Similarities 5 Dept. of ME, JSSATE, Bengaluru • Both have customers, suppliers, scheduling and staffing issues • Both use technology • Both have quality, productivity, & response issues • Both must forecast demand • Both can have capacity, layout, and location issues
  • 6. Operations Management • Course code: 18ME56 • Lecture hours/week: 3 (No. of credits = 3) • CIE marks: 30 (blue book) + 10 (activity) = 40 • Number of CIEs: 3 • Final CIA marks: Average marks of three blue book tests + Activity marks • Minimum marks to be obtained: 16 • CIE duration: 1.5 hour • SEE marks: 100 (5 questions, each 20 marks) • SEE duration: 3 hours 6 Dept. of ME, JSSATE, Bengaluru
  • 7. Curriculum 7 Dept. of ME, JSSATE, Bengaluru
  • 8. Module – 1: • Introduction: Functions within business organizations, the operation management function, classification of production systems, Productivity, factors affecting productivity. • Decision Making: The decision process, characteristics of operations decisions, use of models, decision making environments, graphical linear programming, analysis and trade-offs. (8 hours) 8 Dept. of ME, JSSATE, Bengaluru Operations Management
  • 9. Module – 2: • Forecasting: • Steps in forecasting process, approaches to forecasting, forecasts based on judgment and opinion, analysis of time series data, accuracy and control of forecasts, choosing a forecasting technique, elements of a good forecast. (8 hours) 9 Dept. of ME, JSSATE, Bengaluru Operations Management
  • 10. Module – 3: • Capacity & Location Planning: • Importance of capacity decisions, defining and measuring capacity, determinants of effective capacity, determining capacity requirement, developing capacity alternatives, evaluating alternatives. • Need for location decisions, nature of locations decisions, general procedure for making locations decisions, evaluating locations decisions, facilities layout – need for layout decisions, types of processing. (8 hours) 10 Dept. of ME, JSSATE, Bengaluru Operations Management
  • 11. Module – 4: • Aggregate Planning • Nature and scope of aggregate planning, strategies of aggregate planning, techniques for aggregate planning – graphical and charting techniques, mathematical techniques. • Master Scheduling • The master production schedule, Master scheduling process, Master scheduling methods. (8 hours) 11 Dept. of ME, JSSATE, Bengaluru Operations Management
  • 12. Module – 5: • Material Requirement Planning (MRP): • Dependent versus independent demand, an overview of MRP – MRP inputs and outputs, MRP processing, ERP capacity requirement planning, benefits and limitations of MRP. • Purchasing and Supply Chain Management (SCM): • Introduction, Importance of purchasing and SCM, the procurement process, Concept of tenders, Approaches to SCM, Vendor development. (8 hours) 12 Dept. of ME, JSSATE, Bengaluru Operations Management
  • 13. Books Prescribed: Text Books: • Operations Management, William J Stevenson, Latest Ed., Tata McGraw Hill. • Operations Management, David A Collier, James R Evans, Kunal Ganguly, Cengage Learning India Pvt. Limited, 3rd Edition, 2016, • Reference Books: • Lee J Krajewski, Larry P Ritzman and Manoj Malhotra, Operations Management – Processes and Supply Chain, Pearson Education Asia, 11th Edn, 2010 • R. Paneerselvam, Production and Operations Management, PHI, 2nd Edn, 2006 • B. Mahadevan, Operations Management – Theory and Practice, PHI, 2010, 2nd Edn. 13 Dept. of ME, JSSATE, Bengaluru Operations Management
  • 14. Course Outcomes: At the end of this course, you will be able to: CO# Course Outcome Bloom’s Level 1 Apply the necessary tools for decision making in operations management. 3 2 Examine various approaches for forecasting the sales demand for an organization. 4 3 List various capacity and location plans to determine the suitable capacity required for meeting the forecast demand of an organization. 4 4 Analyse the aggregate plan and master production schedule for an organization, given its periodic demand. 4 5 Apply MRP, purchasing and SCM techniques into practice. 3 14 Dept. of ME, JSSATE, Bengaluru Operations Management
  • 15. Bloom’s Learning Levels - Revised 15 Dept. of ME, JSSATE, Bengaluru
  • 16. Bloom’s Taxonomy- Revised 16 Dept. of ME, JSSATE, Bengaluru
  • 17. POs-> COs PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12 PSO1 PSO2 CO1 3 3 2 - - - - 2 - 2 2 - - - CO2 3 3 3 - - - - 2 - 2 2 CO3 3 3 3 - - - - 2 - 2 2 CO4 3 3 3 - - - - 2 - 2 2 CO5 3 3 3 - - - - 2 - 2 2 Avg. 3 3 2.80 2 2 2 Mapping of COs with POs & PSOs 17 Dept. of ME, JSSATE, Bengaluru
  • 18. Justification of COs with POs and PSOs • CO1-PO1: Use of decision making tools such as break-even analysis, linear programming, statistical analysis, simulation, etc. demands a strong knowledge of mathematics, science and engineering fundamentals. • CO2-PO1: Forecasting models are basically mathematical equations. Formulating these models and solving them requires skill and a strong knowledge of mathematics, science, engineering & management fundamentals. • CO3-PO1: Facility location and Capacity planning can be made by the use various mathematical models. Use of these models and solving them subsequently for arriving at a decision demands skill and knowledge on mathematics, science, engineering & management fundamentals. • CO4-PO1: Preparation of aggregate plans and master schedule in an organization requires a strong background of mathematics, science, engineering & management fundamentals. 18 Dept. of ME, JSSATE, Bengaluru
  • 19. Program Outcomes • PO1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering fundamentals, and an engineering specialization to the solution of complex engineering problems. • PO2. Problem analysis: Identify, formulate, review research literature, and analyze complex engineering problems reaching substantiated conclusions using first principles of mathematics, natural sciences, and engineering sciences. • PO3. Design/development of solutions: Design solutions for complex engineering problems and design system components or processes that meet the specified needs with appropriate consideration for the public health and safety, and the cultural, societal, and environmental considerations. • PO4. Conduct investigations of complex problems: Use research-based knowledge and research me thods including design of experiments, analysis and interpretation of data, and synthesis of the information to provide valid conclusions. 19 Dept. of ME, JSSATE, Bengaluru
  • 20. Program Outcomes • PO5. Modern tool usage: Create, select, and apply appropriate techniques, resources, and modern engineering and IT tools including prediction and modeling to complex engineering activities with an understanding of the limitations. • PO6. The engineer and society: Apply reasoning informed by the contextual knowledge to assess societal, health, safety, legal and cultural issues and the consequent responsibilities relevant to the professional engineering practice. • PO7. Environment and sustainability: Understand the impact of the professional engineering solutions in societal and environmental contexts, and demonstrate the knowledge of, and need for sustainable development. • PO8. Ethics: Apply ethical principles and commit to professional ethics and responsibilities and norms of the engineering practice. 20 Dept. of ME, JSSATE, Bengaluru
  • 21. Program Outcomes • PO9. Individual and team work: Function effectively as an individual, and as a member or leader in diverse teams, and in multidisciplinary settings. • PO10. Communication: Communicate effectively on complex engineering activities with the engineering community and with society at large, such as, being able to comprehend and write effective reports and design documentation, make effective presentations, and give and receive clear instructions. • PO11. Project management and finance: Demonstrate knowledge and understanding of the engineering and management principles and apply these to one’s own work, as a member and leader in a team, to manage projects and in multidisciplinary environments. • PO12. Life-long learning: Recognize the need for, and have the preparation and ability to engage in independent and life-long learning in the broadest context of technological change. 21 Dept. of ME, JSSATE, Bengaluru
  • 22. Program Specific Outcomes • PSO1: Apply the acquired knowledge in design, thermal, manufacturing and interdisciplinary areas for solving industry related problems. • PSO2: Solve complex Mechanical Engineering problems using appropriate software tools. 22 Dept. of ME, JSSATE, Bengaluru
  • 23. • Operations • A set of activities that serve a purpose (result). • Processes that either provide services or create goods. • Take place in businesses such as restaurants, retail stores, supermarkets, factories, hospitals, and colleges and universities. • Are the core of what a business organization does. • Operations Management • The management of systems or processes that create goods and/or provide services. 23 Dept. of ME, JSSATE, Bengaluru Operations Management
  • 24. 24 Dept. of ME, JSSATE, Bengaluru Operations Management • OM Transforms inputs to outputs – Inputs are resources such as • People, Material, and Money – Outputs are goods and services (Source: OM by Reid & Sanders) • Concerned with converting a set of resources into goods and services as efficiently as possible to maximize the profit of an organization.
  • 25. Dept. of ME, JSSATE, Bengaluru 25
  • 26. 26 Dept. of ME, JSSATE, Bengaluru OM’s Transformation Process (Source: OM by Reid & Sanders) Value addition is the net increase between output product value and input material value. Efficient transformation is performing activities at the least possible cost
  • 27. 27 Dept. of ME, JSSATE, Bengaluru OM’s Transformation Process – Ex. 1 Materials Machines Human resource Money Design & Draft Cutting Machining Assembling Painting Quality assurance Inputs Outputs Transformation Process
  • 28. 28 Dept. of ME, JSSATE, Bengaluru OM’s Transformation Process – Ex. 2 Students with raw but … Teachers Teaching aids Classrooms & other facilities Teaching-Learning Tests / Assignments / Seminars / Projects SEEs Extracurricular activities Inputs Outputs Transformation Process
  • 30. Operations Manager • Operations managers are the improvement people, the realistic, hard-nosed, make-it-work, get-it-done people; the planners, coordinators, and negotiators. • They perform a variety of tasks in many different types of businesses and organizations. • Examples.. 30 Dept. of ME, JSSATE, Bengaluru
  • 31. Operations Manager • Operations managers plan and make decisions. • Select the best possible alternatives that can have quite different impacts on costs or profits. • Some of the key decisions operations managers make: • What: What resources will be needed, and in what amounts? • When: When will each resource be needed? When should the work be scheduled? When should materials and other supplies be ordered? When is corrective action needed? • Where: Where will the work be done? • How: How will the product or service be designed? How will the work be done (organization, methods, equipment)? How will resources be allocated? • Who: Who will do the work? 31 Dept. of ME, JSSATE, Bengaluru Costs (budget), Quality and Schedules (time) Source: OM by W J Stevenson
  • 32. Operations Management • The evolution of the name: • Production Management • Production and Operations Management • Production/Operations Management • Operations Management 32 Dept. of ME, JSSATE, Bengaluru
  • 33. Production Management Vs. Operations Management Dept. of ME, JSSATE, Bengaluru 33 Meaning Managing production-related activities of an organization Managing routine business activities of an organization related to creation of products as well as to the delivery of services Scope Limited to the production of goods; taking decisions on quality, quantity, design and pricing of the product being developed Wider scope; management of routine business activities, such as product quality, design, quantity, storage, workforce requirement, etc. Focus Offering the right quality of products at the right time, in the right quantity and at the right price. Efficient and effective use of organizational resources Organization where it is prevalent Organizations where products are created All types of organizations, such as service- oriented firms, banks, manufacturing companies, hospitals, etc. https://www.termscompared.com/difference-between-operations- management-and-production-management/
  • 34. Dept. of ME, JSSATE, Bengaluru 34 Operations Management - Evolution Source: OM by Russel & Taylor
  • 35. Dept. of ME, JSSATE, Bengaluru 35 Operations Management - Evolution Source: OM by Russel & Taylor
  • 36. Operations Management – Why study? • Every aspect of business affects or is affected by operations. • Many service jobs are closely related to operations – Financial services – Marketing services – Accounting services – Information services • There is a significant amount of interaction and collaboration amongst the functional areas. • It provides an excellent vehicle for understanding the world in which we live. (Stevenson, W. J (2018). Operations Management) 36 Dept. of ME, JSSATE, Bengaluru
  • 37. Functions within business organizations 37 Dept. of ME, JSSATE, Bengaluru A retail store, a hospital, a manufacturing firm, a car wash, or some other type of business. Source: OM by Russel & Taylor
  • 38. • Finance • Responsible for securing financial resources at favorable prices and allocating those resources throughout the organization; • Budgeting, analyzing investment proposals; • Providing funds for operations. • Marketing • Responsible for assessing consumer wants and needs; • Selling and promoting the organization’s goods or services. • Operations • Responsible for producing the goods or providing the services offered by the organization. • Examples.. (Stevenson, W. J (2018). Operations Management) 38 Dept. of ME, JSSATE, Bengaluru Functions within business organizations
  • 39. • A system is an arrangement or assembly of inter-dependent processes (activities) that are based on some logic and objectives. • A system operates as a whole and is designed (built) with an intention to achieve (fulfill) some objective or do some work. • Manufacturing is a huge system consisting of many subsystems and activities that turn out useful outputs. • A production system is a subsystem of manufacturing system that includes all functions required to design, produce, distribute and service a manufactured product. • Elements of a production system are: inputs, transformation and outputs. • A production system may be intermittent or continuous. 39 Dept. of ME, JSSATE, Bengaluru Production Systems
  • 40. 40 Dept. of ME, JSSATE, Bengaluru Classification of production systems
  • 41. 41 Dept. of ME, JSSATE, Bengaluru Classification of production systems
  • 42. 42 Dept. of ME, JSSATE, Bengaluru Classification of production systems
  • 43. • Job-Shop Production System • A high variety of products and low volume. • Use of general-purpose machines and facilities. • Highly skilled operators who can take up each job as a challenge because of uniqueness. • Large inventory of materials, tools, parts. • Batch Production System • Shorter production runs. • Plant and machinery are flexible. • Plant and machinery set up are used for the production of the item in a batch and change of set up is required for processing the next batch. • Manufacturing lead-time and cost are lower as compared to job order production. 43 Dept. of ME, JSSATE, Bengaluru Classification of production systems Musical instruments, Body parts, Aircrafts
  • 44. • Mass Production System • Standardization of product and process sequence. • Dedicated special purpose machines having higher production capacities and output rates and hence a large volume of products. • The shorter cycle time of production. • Lower in process inventory. • Perfectly balanced production lines. • Continuous Production System • Dedicated plant and equipment with zero flexibility. • Material handling is fully automated. • The process follows a predetermined sequence of operations. • Component materials cannot be readily identified with the final product. • Planning and scheduling is a routine action. 44 Dept. of ME, JSSATE, Bengaluru Classification of production systems Food, energy, Fuel, etc. Automobiles, Footwear, Chocolates
  • 45. • The state or quality of being productive • The effectiveness of productive effort, especially in industry, as measured in terms of the rate of output per unit of input. • The output of an industrial concern in relation to the materials, labour, etc. it employs. • Example … (land, crop, typist, etc.) • Ratio of output to inputs 45 Dept. of ME, JSSATE, Bengaluru Productivity One acre of land that produces 10 pumpkins?
  • 46. • A measure of the effective use of resources, usually expressed as the ratio of output to input. • An index that measures output (goods and services) relative to the input (labor, materials, energy, and other resources) used to produce it. • Ratio of output to inputs, • For a nation / organization, productivity growth is the relative change in the productivity in the current period relative to previous period. 46 Dept. of ME, JSSATE, Bengaluru Productivity
  • 47. • Types (Computing Productivity) • Total productivity • Multifactor productivity • Partial productivity • The choice of productivity measure depends primarily on the purpose of the measurement. • For ex., If the purpose is to track improvements in labor productivity, then labor becomes the obvious input measure. Dept. of ME, JSSATE, Bengaluru 47 Productivity
  • 48. • Types (Computing Productivity) Dept. of ME, JSSATE, Bengaluru 48 Productivity Source: OM by W J Stevenson
  • 49. • Determine the productivity for these cases: a) Four workers installed 720 square yards of carpeting in eight hours. b) A machine produced 70 pieces in two hours. However, two pieces were unusable. Dept. of ME, JSSATE, Bengaluru 49 Computing Productivity Source: OM by W J Stevenson
  • 50. b) A machine produced 70 pieces in two hours. However, two pieces were unusable. Dept. of ME, JSSATE, Bengaluru 50 Computing Productivity Source: OM by W J Stevenson
  • 51. • Determine the multifactor productivity for the combined input of labor and machine time using the following data: • Output: 7,040 units; • Input: Labor: $1,000; Materials: $520; Overhead: $2,000 Dept. of ME, JSSATE, Bengaluru 51 Computing Productivity Source: OM by W J Stevenson
  • 52. • A bank through its five tellers served a total 1497 customers during the past week. The bank works 5 days/week and the business hours are 10:30 am – 02:30 pm. Compute the productivity measure of its tellers. • Soln.: • No. of business hours / day / teller = 4 • Total no. of business hours / day = 5 x 4 = 20 • Total no. of business hours / week = 5 x 20 = 100 • Productivity = (No. of customers served / week) / (No. of hours tellers worked/week) = 1497 / 100 = 14.97 or 15 customers / hour Dept. of ME, JSSATE, Bengaluru 52 Computing Productivity
  • 53. • An organization can use productivity measures to • compare its performance with that of competitors, • assess the relative performance of its individual departments, • compare the relative benefits of various inputs, • plan the most effective use of resources. Dept. of ME, JSSATE, Bengaluru 53 Why Productivity is Measured?
  • 54. • Generally, methods, capital, quality, technology and management affect productivity. • A misconception is that workers are the main determinant of productivity. Hence, organizations insist their employees to work harder. • The fact is that many productivity gains in the past have come from technological improvements. • However, technology alone won’t guarantee productivity gains; it must be used wisely and thoughtfully. • Current productivity pitfall results from employees’ use of computers or smartphones for nonwork-related activities (playing games or checking stock prices or sports scores on the Internet or smartphones, and texting friends and relatives). Dept. of ME, JSSATE, Bengaluru 54 Factors Affecting Productivity Source: OM by W J Stevenson
  • 55. • Capital/Labour Ratio: is a measure of whether enough investment is made in plant, machinery, tools, etc. to make effective use of labour hours. • Scarcity of some resources: such as energy, water, materials, skilled labours, etc. • Work-force changes is steady shift of from blue-collar occupations to…. • Innovation and technology: will be developed if enough investment is made in R & D; Strong patenting rules are required. • Regulatory effects: sometimes, impose substantial constraints (pollution, health, safety, labour benefits, etc.). • Bargaining power: of organized labour to command wage increase. • Quality of work life describes the organizational culture - motivation to employees for teamwork, commitment, loyalty, etc. Dept. of ME, JSSATE, Bengaluru 55 Factors Affecting Productivity Source: Joseph Monks, OM, 1987
  • 56. • (Personal) • Do Your Heavy Lifting When You're at Your Best. ... • Stop Multitasking. ... • Prepare a To-Do List Each Night. ... • Cut Down Your To-Do List. ... • Delegate Properly. ... • Eliminate Distractions. ... • Plan Phone Calls. ... • Break up Work Periods. Dept. of ME, JSSATE, Bengaluru 56 Methods to Increase Productivity
  • 57. • Strategies • Increased output for the same input. • Decreased input for the same output. • Proportionate increase in the output is more than the proportionate increase in the input. • Proportionate decrease in the input is more than the proportionate decrease in the output. • Simultaneous increase in the output with decrease in the input. Dept. of ME, JSSATE, Bengaluru 57 Methods to Increase Productivity Source: R. Panneerselvam, POM, 2012
  • 58. Part – 2: Decision Making 58 Dept. of ME, JSSATE, Bengaluru • He who has a choice has trouble. • Every decision ever taken is born out of choices.
  • 59. • A process of consciously choosing an alternative among the several available. • Decision making is one of the most important basic management skills for all of us. It is a cognitive ability. It can differ from person to person. • Decisions should neither be taken in haste nor be procrastinated indefinitely. • Making a decision which is timely and which is based on careful analysis of various information is critical for an operations manager. Dept. of ME, JSSATE, Bengaluru 59 Decision Making
  • 60. Dept. of ME, JSSATE, Bengaluru 60 Decision Making Process https://www.umassd.edu/fycm/decision-making/process/
  • 61. • 1. Identify the decision to be made • What is the problem on hand? • What is the objective to be achieved? • How will the decision impact people or the organization? • Urgency and criticality of the decision • 2. Gather relevant information • What information is needed? • The best sources of information • How to get it? • Involves both internal and external “work.” • Internal: a process of self-assessment. • External: obtained online, in books, from other people, and from other sources. Dept. of ME, JSSATE, Bengaluru 61 Decision Making Process
  • 62. • 3. Identify the options • Information collected helps identifying several possible paths of action or alternatives. • Imagination and additional information to construct new alternatives may also be used. • All possible and desirable alternatives are to be listed. • 4. Weigh or Evaluate the evidence of each alternative • Evaluate whether the need identified in Step 1 would be met or resolved through the use of each alternative. • Certain options seem favorable, have a higher potential for reaching the goal. • Place the alternatives in a priority order, based upon your own value system. Dept. of ME, JSSATE, Bengaluru 62 Decision Making Process
  • 63. • 5. Choose among alternatives • After weighing the evidences, select the alternative that seems to be best one for you. • A combination of alternatives may also be chosen. • The selected alternative may very likely be the same or similar to the alternative that is placed at the top of the list at the end of Step 4. • 6. Implement the chosen alternative (Take action) • Implement the actions associated with the alternative or option being selected. • 7. Analyse the results • Evaluate whether or not the chosen option has resolved the need identified in Step 1. If not, certain steps may be repeated. Dept. of ME, JSSATE, Bengaluru 63 Decision Making Process
  • 64. • Operations decisions range from simple judgments to complex analyses (these may also involve judgments). • Judgmental decisions are made by basic knowledge, experience and common sense. • Both subjective and objective data is used to arrive at a choice. • The decisions are characterized by – The significance of the decision being made – The time and cost involved (limitations) – The degree of complexity of the decision being made Dept. of ME, JSSATE, Bengaluru 64 Characteristics of Operations Decisions
  • 65. • Significant (or long-lasting) decisions deserve more consideration than trivial or routine one. Ex., medical products, investment in new plant, etc. • Time availability and cost analysis • Decision complexity increases when a) many variables are involved, b) the variables are highly interdependent or sequentially related, and c) the data describing the variables are incomplete or uncertain. • Example: new factory location decisions (involve economical, social, and environmental concerns; cost on technology and amount of automation). Dept. of ME, JSSATE, Bengaluru 65 Characteristics of Operations Decisions
  • 66. • Degree of certainty that exist with respect to the decision variables and possible outcomes. Dept. of ME, JSSATE, Bengaluru 66 Decision Making Environment Complete Certainty Complete Uncertainty Risk & Uncertainty How much certainty exists? All information Some information No information
  • 67. • Degree of certainty – a) complete certainty, b) risk and certainty, and c) extreme uncertainty • Complete certainty: All the information to make decision is available (or assumed to be available). Outcomes are probably known. • Decision making may not be easy since the problem may be ill defined, the decision criteria may be unclear, there may be too many variables to handle, etc. – Some of the methods (tools) used are: – Break-even analysis, Benefit/cost analysis, linear, non- linear, integer, goal and dynamic programming Dept. of ME, JSSATE, Bengaluru 67 Decision Making Environment
  • 68. • Risk and uncertainty: Information about the decision variables or the outcomes is usually probabilistic. • Objective data from large samples may give more certainty than subjective data. – Some of the methods (tools) used are: – Statistical analysis for setting labour standards, forecasting, inventory and quality control, etc. – Queuing theory for waiting line, maintenance activities, shop floor control activities. – Network analysis techniques such as PERT, CPM, Decision trees, etc. – Simulation for duplicating the essence of an activity without actually doing it. Dept. of ME, JSSATE, Bengaluru 68 Decision Making Environment
  • 69. • Complete Uncertainty: No information about the decision variables or the outcomes is available. – Some of the methods (tools) used are: – Game theory – Coin flip Dept. of ME, JSSATE, Bengaluru 69 Decision Making Environment
  • 70. • Linear Programming • A firm manufactures two types of products A and B and sells them at a profit of Rs. 2 on type A and Rs. 3 on type B. Each product is processed on two machines G and H. Type A requires one minute of processing time on G and 2 minutes on H, type B requires one minute on G and one minute on H. The machine G is available for not more than 6 hours and 40 minutes while machine H is available for 10 hours during one working day. Formulate the problem as a linear programming problem. Dept. of ME, JSSATE, Bengaluru 70 Decision Making - Certainty
  • 71. • Let x1 be the number of products of type A and x2 be the number of products of type B. Dept. of ME, JSSATE, Bengaluru 71 Decision Making - Certainty
  • 72. • Let, Z – the objective function = Total profit • Z = 2 x1 + 3 x2 (objective function) • The total time (in minutes) required on machine G is given by = x1 + x2 • But the machine G is not available for more than 6 hours and 40 minutes (i.e., 400 minutes). Therefore, • x1 + x2 ≤ 400 • Similarly, the total time (minutes) required on machine H is 2x1 + x2. Since machine H is available for 600 min., • 2x1 + x2 ≤ 600 Dept. of ME, JSSATE, Bengaluru 72 Decision Making - Certainty
  • 73. The Linear Programming Model (equations) Maximize Z = 2 x1 + 3 x2 (objective function) Subject to constraints x1 + x2 ≤ 400 --- Machine G time constraint 2x1 + x2 ≤ 600 --- Machine H time constraint x1 ≥ 0 & x2 ≥ 0 --- non negative constraints. Dept. of ME, JSSATE, Bengaluru 73 Decision Making - Certainty The Three basic elements of an LP model are: • The objective function • Decision variables • A set of constraints
  • 74. The Linear Programming Model (equations) Soln.: x1 + x2 = 400 --- 1 2x1 + x2 = 600 --- 2 Eqn. 2 – Eqn. 1 gives us, x1 = 200 and x2 = 200 Hence, Profit maximized, Z = 2 (200) + 3 (200) = Rs. 1000 Dept. of ME, JSSATE, Bengaluru 74 Decision Making - Certainty
  • 75. Graphical Soln.: •OABC is the area bound by the two constraint lines. It is called Solution Space. Optimum value Z at each point: O = Zero A = Rs. 4000 B = Rs. 1000 C = Rs. 600 Dept. of ME, JSSATE, Bengaluru 75 Decision Making - Certainty
  • 76. • Break-even analysis (Cost-Volume-Profit) • Revenue = Unit Selling Price, SP x Sales quantity, Q • Total Cost = Total Fixed Cost (FC) + Total Variable Cost (VC) • Total profit, P = Total revenue – Total cost • P = (Q x SP) – (FC + v x Q) • P = Q (SP -v) – FC Dept. of ME, JSSATE, Bengaluru 76 Where, SP – Selling Price / unit; VC – Variable Cost/unit Decision Making - Certainty
  • 77. Dept. of ME, JSSATE, Bengaluru 77 Decision Making - Certainty: BEA
  • 78. • Break-even analysis (Cost-Volume-Profit) • If fixed costs are Rs. 40000 per week and variable costs are estimated at 50% of the unit selling price of Rs.160, what is the BEP? • = (40000)/(160-80) = 500 units Dept. of ME, JSSATE, Bengaluru 78 Decision Making - Certainty: BEA
  • 79. • Break-even analysis (Cost-Volume-Profit) • The owner of a bakery is planning to produce a new cake, which will require leasing new equipment for a monthly payment of $6,000. Variable costs would be $2 per cake, and cakes would retail for $7 each. • How many cakes must be sold in order to break even? • What would the profit (loss) be if 1,000 cakes are made and sold in a month? • How many cakes must be sold to realize a profit of $4,000? • If 2,000 cakes can be sold, and a profit target is $5,000, what price should be charged per cake? Dept. of ME, JSSATE, Bengaluru 79 Source: OM by W J Stevenson Decision Making - Certainty: BEA
  • 80. • FC = $6,000, VC = $2 per cake, SP = $7 per cake • a. • b. For Q = 1,000, P = Q ( SP − VC )  − FC • = 1,000 ($7 − $2)− $6,000 = − $1,000 • c. Profit, P = $4,000; Solve for Q using Q = (P+FC)/(SP-VC) • d. P = $5000, Q = 2000 cakes; We know, P = Q (SP -v) – FC • $5,00 0 = 2,000 (SP − $2) − $6, 000 • Therefore, SP = $7.50 Dept. of ME, JSSATE, Bengaluru 80 Source: OM by W J Stevenson Decision Making - Certainty: BEA
  • 81. Risk & Uncertainty: • When probabilities can be assigned to the occurrence of states of nature (events that may occur in future), the situation is referred to as decision making under risk. • When probabilities cannot be assigned to the occurrence of future events, the situation is called decision making under uncertainty. • Decision Criteria used: – Maximax – Maximin – Minimax regret – Hurwicz – Equal likelihood (LaPlace) Dept. of ME, JSSATE, Bengaluru 81 Decision Making Situations Source: OM by Russel & Taylor
  • 82. • A Textile MNC is contemplating the future of one of its plants located in Mumbai. Three alternative decisions are being considered: (1) Expand the plant and produce lightweight, durable materials for possible sale to the military, a market with little foreign competition; (2) maintain the status quo at the plant, continuing production of textile goods that are subject to heavy foreign competition; or (3) sell the plant now. If one of the first two alternatives is chosen, the plant will still be sold at the end of the year. The amount of profit that could be earned by selling the plant in a year depends on market conditions. The following payoff table is prepared by the top management of the company: Dept. of ME, JSSATE, Bengaluru 82 Decision Making – Risk & Uncertainty Source: OM by Russel & Taylor
  • 83. • Determine the best decision using each of the decision criteria, 1. Maximax, 2. Maximin, 3. Minimax regret 4. Hurwicz (Take α = 0.3), 5. Equal likelihood Dept. of ME, JSSATE, Bengaluru 83 Source: OM by Russel & Taylor Decision Making – Risk & Uncertainty
  • 84. • Maximax (Optimistic) criterion • The decision maker optimistically assumes that ‘good competitive conditions’ will prevail in the future. • The decision selected will result in the maximum of the maximum payoffs. • Hence, • Expand: $800,000 • Status quo: $1,300,000 ← Maximum • Sell: $320,000 • Decision: Maintain status quo Dept. of ME, JSSATE, Bengaluru 84 Source: OM by Russel & Taylor Decision Making – Risk & Uncertainty
  • 85. • Maximin (Pessimistic) criterion • The decision maker is pessimistic and assumes that ‘minimum payoffs’ will occur in the future. • The decision maker selects the decision that will reflect the maximum of the minimum payoffs. • Hence, • Expand: $500,000 ← Maximum • Status quo: - $150,000 • Sell: $320,000 • Decision: Expand Dept. of ME, JSSATE, Bengaluru 85 Source: OM by Russel & Taylor Decision Making – Risk & Uncertainty
  • 86. • Minimax regret criterion • The decision maker attempts to avoid regret by selecting the decision alternative that minimizes the maximum regret. • First, select the maximum payoff under each state of nature; then all other payoffs under the respective states of nature are subtracted from these amounts. • The maximum regret for each decision must be determined, and the decision corresponding to the minimum of these regret values is selected. Dept. of ME, JSSATE, Bengaluru 86 Source: OM by Russel & Taylor Decision Making – Risk & Uncertainty
  • 87. • Minimax regret criterion • Expand: $500,000 ← Minimum • Status quo: $650,000 • Sell: $980,000 • Decision: Expand Dept. of ME, JSSATE, Bengaluru 87 Source: OM by Russel & Taylor Decision Making – Risk & Uncertainty
  • 88. • Hurwicz criterion • The decision maker is neither totally optimistic (maximax criterion) nor totally pessimistic (maximin criterion). • The decision payoffs are weighted by a coefficient of optimism, α, a measure of the decision maker’s optimism. • If α =1, the decision maker is completely optimistic; if α = 0, the decision maker is completely pessimistic. (Given this definition, (1 - α) is the coefficient of pessimism.) Dept. of ME, JSSATE, Bengaluru 88 Source: OM by Russel & Taylor Decision Making – Risk & Uncertainty
  • 89. • Hurwicz criterion • For each decision alternative, the maximum payoff is multiplied by α, and the minimum payoff is multiplied by (1 - α). • In the given example, if α equals 0.3 (i.e., the company is slightly optimistic) and (1 - α)=0.7, the following decision will result: • Expand: $800,000(0.3) + 500,000(0.7) = $590,000 ← Maximum • Status quo: $1,300,000(0.3) - 150,000(0.7) = $ 285,000 • Sell: $320,000(0.3) + $320,000(0.7) = $320,000 • Decision: Expand Dept. of ME, JSSATE, Bengaluru 89 Source: OM by Russel & Taylor Decision Making – Risk & Uncertainty
  • 90. • Equal Likelihood: • Each state of nature is weighted equally. That is, it is assumed that the states of nature are equally likely to occur (weight of 0.5 each since there are two). • Multiply the weights by each payoff for each decision. • Select the alternative with the maximum of these weighted values. • Expand: $800,000(0.50) + $500,000(0.50) = $650,000 ← Maximum • Status quo: $1,300,000(0.50) +$150,000(0.50) = $575,000 • Sell: $320,000(0.50) + $320,000(0.50) = $320,000 • Decision is Expand Dept. of ME, JSSATE, Bengaluru 90 Source: OM by Russel & Taylor Decision Making – Risk & Uncertainty
  • 91. • Consider the following payoff table for three product decisions (A, B, and C) and three future market conditions (payoffs in $ millions). • Determine the best decision using the following decision criteria. 1. Maximax, 2. Maximin Dept. of ME, JSSATE, Bengaluru 91 Source: OM by Russel & Taylor Decision Making – Risk & Uncertainty
  • 92. • Decision Tree: A schematic representation of the alternatives available to a decision maker and their possible consequences. Dept. of ME, JSSATE, Bengaluru 92 Decision Tree Source: OM by Russel & Taylor
  • 93. • Using the information in the payoff table given and a probability of 0.6 for new bridge and 0.4 for No New Bridge, construct a decision tree and select the best alternative: Dept. of ME, JSSATE, Bengaluru 93 Decision Making Situations Source: OM by W J Stevenson Decision Alternative Expected Payoff ($) under State of Nature New Bridge No New Bridge A 1 14 B 2 10 C 4 6
  • 94. Dept. of ME, JSSATE, Bengaluru 94 Decision Tree Source: OM by W J Stevenson
  • 95. Dept. of ME, JSSATE, Bengaluru 95 Decision Tree Source: OM by W J Stevenson
  • 96. Dept. of ME, JSSATE, Bengaluru 96 Decision Tree Source: OM by W J Stevenson
  • 97. Dept. of ME, JSSATE, Bengaluru 97 Decision Tree Source: OM by W J Stevenson