## GUJARAT TECHNOLOGICAL UNIVERSITY Program Name: Diploma Engineering ## Level: Diploma Branch: Mechanical Engineering / Mechanical Engineering (CAD/CAM) Subject Code: DI04000271 Subject Name: Operations Management w.e.f. Academic Year: 2025-26 Semester: 4 th Category of the Course: Professional Elective - I | Prerequisite: | Basic understanding of mathematics, statistics, and engineering fundamentals . Prior exposure to engineering economics or manufacturing processes is helpful . | |-----------------|-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------| | Rationale: | This course equips engineering students with the skills to design, manage, and optimize production and service operations for improved efficiency and quality. It builds a foundation for effective decision-making in real-world industrial and technological environments. | ## Course Outcome: After Completion of the Course, Student will able to: | No | Course Outcomes | |------|------------------------------------------------------------------------------------------------------------------------------| | 01 | Define key concepts in operations management. Understand the role of operations in manufacturing and service organizations. | | 02 | Apply operations management tools to design, analyze, and improve production systems. | | 03 | Use forecasting, planning, scheduling, and inventory management techniques. Design and manage inventory systems. | | 04 | Apply quality management and continuous improvement tools. Understand supply chain structures and logistics. | ## Teaching and Examination Scheme: | Teaching Scheme (in Hours) | Teaching Scheme (in Hours) | Teaching Scheme (in Hours) | Total Credits L+T+(PR/2) | Total Credits L+T+(PR/2) | Assessment Pattern and Marks | Assessment Pattern and Marks | Assessment Pattern and Marks | Total | |-------------------------------|-------------------------------|-------------------------------|-----------------------------|-----------------------------|--------------------------------|--------------------------------|--------------------------------|---------| | L | T | PR | C | Theory | Theory | Tutorial/ Practical | Tutorial/ Practical | Marks | | L | T | PR | C | ESE(E) | PA(M) | PA(I) | ESE(V) | Marks | | 3 | 0 | 2 | 4 | 70 | 30 | 20 | 30 | 150 | ## GUJARAT TECHNOLOGICAL UNIVERSITY Program Name: Diploma Engineering Level: Diploma Branch: Mechanical Engineering / Mechanical Engineering (CAD/CAM) Subject Code: DI04000271 Subject Name: Operations Management ## Course Content: | Unit No. | Content | No. of Hours | %of Weightage | |-------------|--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------|-----------------|------------------| | 1 | Introduction to Operations Management  Definition, scope, and objectives of Operations Management.  Role of operations in manufacturing & service sectors.  Productivity: definition, factors affecting productivity, productivity improvement.  Operations strategy and decision-making.  Types of production systems: job, batch, mass, continuous, cellular, lean. | 5 | 10 | | 2 | Product & Process Design  Product development process and engineering involvement.  Value engineering & value analysis.  Product lifecycle and standardization.  Process design: process planning, process charts, flow diagrams.  Process selection: make-or-buy decisions.  Facility location: factors, location analysis techniques (qualitative & quantitative).Facility layout: types-process, product, fixed, cellular; layout planning tools. | 10 | 20 | | 3 | Production Planning & Control (PPC), Forecasting & Capacity Planning  Role of PPC in manufacturing.  Aggregate planning: strategies & methods.  Master Production Schedule (MPS).  Material Requirements Planning (MRP) & MRP-II.  Enterprise Resource Planning (ERP).  Scheduling: job scheduling (Gantt charts, priority rules), machine loading, sequencing (Johnson's rule).  Dispatching & follow-up. | 10 | 25 | | 4 | Inventory Management  Role of inventory, types of inventory, inventory costs.  Deterministic models: EOQ, EPQ, quantity discount models.  Probabilistic models: safety stock, service levels. | 10 | 20 | ## GUJARAT TECHNOLOGICAL UNIVERSITY ## Program Name: Diploma Engineering ## Level: Diploma Branch: Mechanical Engineering / Mechanical Engineering (CAD/CAM) Subject Code: DI04000271 Subject Name: Operations Management | |  Inventory control systems: P-system, Q-system.  Selective control techniques: ABC, VED, FSN, HML, SDE analysis.  Just-In-Time (JIT) inventory systems and Kanban. | | | |----|----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------|----|-----| | 5. | Quality Management, Lean Operations & Supply Chain Management  Basic concepts of quality, dimensions of quality.  Quality control tools: 7QC tools (Check sheet, Histogram, Pareto, Cause-effect, Control chart, Scatter diagram, Flowchart).  Statistical Process Control (SPC) basics.  Acceptance sampling plans.  Total Quality Management (TQM), Kaizen, 5S, Poka-Yoke.  Six Sigma: DMAIC process. | 10 | 25 | | | Total | 45 | 100 | ## Suggested Specification Table with Marks (Theory): ## Distribution of Theory Marks (in %) | R Level | U Level | A Level | N Level | E Level | C Level | |-----------|-----------|-----------|-----------|-----------|-----------| | 26 | 43 | 31 | | | | WhereR:Remember;U:Understanding;A:Application,N:AnalyzeandE:EvaluateC:Create(asper Revised Bloom's Taxonomy) ## References/Suggested Learning Resources: ## (a) Books: | Sr. No. | Book Title | Author(s) | Publisher | ISBN | |-----------|-----------------------------------------|-------------------------------------------------------|-------------------------------------------|-------------------------------------| | 1 | Operations Management | William J. Stevenson | McGraw- Hill Education | 978-9355322647 (mheducation.co.in) | | 2 | Operations Management (International) | Nigel Slack, Alistair Brandon-Jones, Nicola Burgess | Pearson Education | 978-1292408248 (Pearson) | | 3 | Operations Management | William J. Stevenson | McGraw- Hill Education (13th/14th ed.) | 978-1259667473 (Google Books) | w.e.f. 2025-26 ## GUJARAT TECHNOLOGICAL UNIVERSITY Program Name: Diploma Engineering Level: Diploma Branch: Mechanical Engineering / Mechanical Engineering (CAD/CAM) Subject Code: DI04000271 Subject Name: Operations Management | 4 | Production and Operations Management | S. N. Chary | McGraw- Hill Education | 978-9353164812 (mheducation.co.in) | |-----|-------------------------------------------------------------|-----------------------------------------------------|-------------------------------------------|---------------------------------------------------| | 5 | Production and Operations Management | R. Panneerselvam | PHI Learning / Prentice Hall of India | 978-8120345553 (Scribd) | | 6 | Operations Management | Rajesh Kumar R | Jyothis Publishers | 978-9356803787 (Google Books) | | 7 | Production and Operations Management | Chanchal Dey, Debasish Biswas, Nirmal Chandra Roy | Himalaya Publishing | 978-93-5840-606-1 (Himalaya Publishing House) | | 8 | Production and Operations Management | Everette E. Adam, Jr. & Ronald J. Ebert | Prentice Hall of India | (commonly cited classic title) (sanfoundry.com) | | 9 | Factory Physics: Foundations of Manufacturing Management | Wallace J. Hopp & Mark L. Spearman | McGraw- Hill | 0-256-15464-3 (en.wikipedia.org) | ## (b)Open source software and website: | Sr. No. | Resource Name | What It Covers | Free Web Link | |------------|--------------------------------------------------------|-------------------------------------------------|-----------------------------------------------------------------------| | 1 | NPTEL - Operations Management | PPC, forecasting, inventory, quality, SCM | https://nptel.ac.in/courses/110/106/110106062 | | 2 | MIT OpenCourseW are - Operations Management | Operations strategy, capacity, flow management | https://ocw.mit.edu/courses/15-761-operations- management-summer-2002 | | 3 | OpenStax - Management Principles | Inventory, forecasting, quality, productivity | https://openstax.org/details/books/principles- management | | 4 | TutorialsPoint - Production & Operations Management | Production systems, layouts, PPC, JIT | https://www.tutorialspoint.com/production_and _operations_management | | 5 | Khan | Regression, probability, | https://www.khanacademy.org/math/statistics- | w.e.f. 2025-26 ## GUJARAT TECHNOLOGICAL UNIVERSITY ## Program Name: Diploma Engineering ## Level: Diploma Branch: Mechanical Engineering / Mechanical Engineering (CAD/CAM) Subject Code: DI04000271 Subject Name: Operations Management | | Academy - Statistics & Forecasting | forecasting tools | probability | |----|----------------------------------------|--------------------------------------------|-----------------------------------| | 6 | SAP Learning Hub | Basics of ERP, MRP, planning systems | https://learning.sap.com | | 7 | ASQ - Quality Resources | 7 QC tools, SPC, TQM, quality improvement | https://asq.org/quality-resources | ## Suggested Course Practical List: | Sr. No. | Title of Practical | Objective / Aim | Related Unit | |------------|---------------------------------------------------|----------------------------------------------------------------------------------------------------------------------|-----------------| | 1 | Study of Types of Production Systems | To study job, batch, mass, continuous & cellular production systems with real industry examples. | Unit 1 | | 2 | Preparation of Process Chart & Flow Diagram | To develop Operation Process Chart (OPC) and Flow Process Chart (FPC) for a simple manufacturing/service activity. | Unit 2 | | 3 | Product Design & Value Engineering Exercise | To analyze a selected product and identify opportunities for value improvement and cost reduction. | Unit 2 | | 4 | Aggregate Planning & MPS Preparation | To prepare aggregate production plan and Master Production Schedule using given demand data. | Unit 3 | | 5 | MRP (Material Requirement Planning) Calculation | To prepare BOM, and calculate gross & net requirements and planned order releases. | Unit 3 | | 6 | Inventory Control using EOQ & ABC Analysis | To calculate EOQ and perform ABC classification using sample inventory data. | Unit 4 | | 7 | Application of 7 QC Tools | To collect sample data and prepare Histogram, Pareto Chart, Cause-Effect Diagram, Scatter Diagram, etc. | Unit 5 | | 8 | Study of Lean Tools - 5S, Kaizen & Kanban | To understand implementation of 5S, Kaizen and develop a simple Kanban card system. | Unit 5 | ## GUJARAT TECHNOLOGICAL UNIVERSITY ## Program Name: Diploma Engineering Level: Diploma Branch: Mechanical Engineering / Mechanical Engineering (CAD/CAM) Subject Code: DI04000271 Subject Name: Operations Management ## List of Laboratory/Learning Resources Required: | Sr. No. | Practical Title | Laboratory / Learning Resources Required | Remarks (Combined Content) | |------------|--------------------------------------------------|---------------------------------------------|-------------------------------------------------------------| | 1 | Study of Types of Production Systems | • Case study documents |  List of industries  Charts showing types of production | | 2 | Preparation of Process Chart & Flow Diagram | • Graph / A4 sheets | • Process chart symbols sheet • Stopwatch (optional) | | 3 | Product Design & Value Engineering Exercise | • Sample product (bottle, chair, etc.) | • Value engineering worksheets • Measuring tools | | 4 | Aggregate Planning & MPS Preparation | • Demand data sheets | • Calculator / spreadsheet software | | 5 | MRP (Material Requirement Planning) Calculation | • BOM sheets | • Product structure diagrams | | 6 | Inventory Control using EOQ & ABC Analysis | • Inventory data sheets | • EOQ formula sheets • ABC analysis templates | | 7 | Application of 7 QC Tools | • Check sheet | • Graph sheets | | 8 | Study of Lean Tools - 5S, Kaizen & Kanban | • 5S audit checklist | • Kanban card templates | ## Suggested ProjectList: | Sr. No. | Project Title | Brief Description | Related Syllabus Unit | |------------|--------------------------------------------------------------------------|----------------------------------------------------------------------------------------------------------------|----------------------------| | 1 | Design & Analysis of an Optimized Facility Layout for a Small Workshop | Students redesign a workshop layout using process/product/cellular layout and improve material flow. | Unit 2 - Facility Layout | | 2 | Development of a Production Planning & Control (PPC) System | Prepare MPS, Aggregate Plan, Scheduling (Gantt Chart), and Dispatching Sheets for a mini manufacturing unit. | Unit 3 - PPC & Scheduling | | 3 | Inventory Optimization Using EOQ, ABC & VED Analysis | Conduct inventory survey and apply EOQ and selective inventory techniques to optimize | Unit 4 - Inventory | w.e.f. 2025-26 Page 6 of 8 ## GUJARAT TECHNOLOGICAL UNIVERSITY ## Program Name: Diploma Engineering ## Level: Diploma Branch: Mechanical Engineering / Mechanical Engineering (CAD/CAM) Subject Code: DI04000271 Subject Name: Operations Management | | | stock. | Management | |----|----------------------------------------------------------------|-------------------------------------------------------------------------------------------------------------|-------------------------------| | 4 | Quality Improvement Using 7 QC Tools | Identify defects in a process and apply Pareto, Histogram, Fishbone Diagram, Control Charts, etc. | Unit 5 - Quality Management | | 5 | 5S Implementation Project in Workshop / Laboratory | Implement Sort, Set-in-order, Shine, Standardize & Sustain in a real workspace with before-after results. | Unit 5 - Lean Operations | | 6 | Value Engineering Study of an Everyday Product | Perform function analysis, cost analysis, and propose design or cost improvements. | Unit 2 - Value Engineering | | 7 | Design of a Simple Kanban System for Material Movement | Create Kanban cards, reorder levels, and implement a pull-based system in workshop/lab. | Unit 4 & 5 - JIT / Lean | | 8 | Forecasting & Demand Analysis for a Small Business | Use moving average, exponential smoothing, and trend analysis to predict future demand. | Unit 3 - Forecasting | | 9 | Development of a Mini MRP System Using Spreadsheet | Create BOM, Product Structure Tree, and MRP Table (GR, NR, POR) in Excel. | Unit 3 - MRP, MRP-II | | 10 | Study & Comparison of Production Systems in Local Industries | Prepare case studies of Job, Batch, Mass, Continuous, and Cellular production systems. | Unit 1 - Production Systems | ## Suggested Activities for Students: | Sr. No. | Suggested Activity | Description / Purpose | Related Syllabus Unit | |------------|--------------------------------|--------------------------------------------------------------------------------------------------------------------|------------------------------| | 1 | Industrial Visit Report | Students visit a manufacturing/service industry and prepare a report on production system, layout, and workflow. | Unit 1 - Production Systems | | 2 | Preparation of Process Charts | Students prepare Operation Process Chart (OPC) and Flow Process Chart (FPC) based on a chosen activity. | Unit 2 - Process Design | | 3 | Value Engineering Case Study | Select a product and identify unnecessary costs, propose value-improving alternatives. | Unit 2 - Value Engineering | | 4 | Mini Project on Scheduling | Prepare Gantt charts or scheduling sheets based on provided job data. | Unit 3 - Scheduling | ## GUJARAT TECHNOLOGICAL UNIVERSITY ## Program Name: Diploma Engineering Level: Diploma Branch: Mechanical Engineering / Mechanical Engineering (CAD/CAM) Subject Code: DI04000271 Subject Name: Operations Management | 5 | Inventory Data Collection | Collect inventory data from workshop or nearby shop and perform ABC/EOQ analysis. | Unit 4 - Inventory Management | |-----|----------------------------------|----------------------------------------------------------------------------------------------|-----------------------------------| | 6 | 7 QC Tools Practice Assignment | Students collect sample data and prepare Pareto, Histogram, Fishbone, Scatter diagram, etc. | Unit 5 - Quality Tools | | 7 | 5S Audit of Workshop | Conduct a 5S survey, identify problems, and recommend improvements. | Unit 5 - Lean Management | | 8 | Create a Mini Kanban System | Prepare Kanban cards for tools/materials used in workshop and demonstrate pull system. | Unit 5 - JIT & Lean | | 9 | BOM & MRP Preparation Exercise | Students prepare a simple Bill of Materials and perform MRP calculations using Excel. | Unit 3 - MRP | | 10 | Case Study on Supply Chain | Identify supply chain of a common product (mobile, pen, car part) and map all stages. | Unit 5 - Supply Chain Management | * * * * * **