POST-GRADUATE COURSE IN INDUSTRIAL ENGINEERING-SYLLABUS OF STUDIES APPROVED BY THE BOARD OF TECHNICAL STUDIES IN MANAGEMENT
Examination
Subject Study
Hours Duration Mark
PART-I
1. Structure & Economic Aspects of Industry
& Commerce 50 3 hours 100
2. Personnel Management and
Industrial Relations 100 3 " 100
3. Management Principles and Practice 100 3 " 100
4. Procurement & Inventory Control 25 2 " 50
PART-II
1. Work Study 50 3 " 100
2. Materials Handling 25 2 " 50
3. Statistical Methods and
Statistical Quality Control 75 3 " 100
4. Location of Industry & Plant Layout 50 3 " 100
PART-III
1. Production, Planning & Control 50 3 " 100
2. Cost Control503100
3. Quality Control & Metrology 50 3 " 100
4. Operational Research 25 2 " 50
5. Maintenance 25 2 " 50
6. Job Evaluation & Merit Rating 50 3 " 100
7. Project Work & Report (Instruction & Contact
hours) 50 3 " 100
Post-Institutional Project Work-Duration 3 months
Project 100
Viva 50
SYLLABUS
Part I
1. Structure and Economic Aspects of Commerce and Industry 1. Nature and significance of economic science-economics and technology-utility of economics in business management and industrial engineering.
2. The Economic Flow Chart-the various stages of conversion and changes in value in manufacturing, agriculture, mining, construction, transportation, utilities and trade.
3. Importance of concepts-analysis of demand and supply-law of diminishing utility-concept of elasticity of supply and demand- importance of marginal principle in economic action-laws of costs- importance of increasing returns in industrial activity-forces governing the supply of factors of production-land, labour and capital and ownership.
4. Theory of the firm under static and dynamic conditions-The problem of price fixation-The role of supply and demand-Concept of rent and quasi-rent-Equilibrium analysis, partial and general-Concept of normal profits-The representative firm-Price fixation under conditions of monopoly-Oligopoly and bilateral monopoly.
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5. Theory of distribution-The principle of substitution and marginal productivity theory-Effects of economic institutions on distribution-Trade unions and wage rates Distribution and economic progress.
6. Methods of obtaining finance-Internal and outside sources- Industrial Financing Institutions-The problem of working capital ; Relationship of the business units With banks.
7. The external influences affecting an enterprise ; national income: national output income distribution ; savings and capital ; money rates ; stock market prices ; long-term and short-term economic changes.
8. Size and location of industries.
9. Money-Present worth ; sinking fund deposits; Capital recovery equivalence interest as an item of cost.
10. Depreciation-causes, definitions and significance of depreciation in industrial production the straight-line method, the sinking fund method and the diminishing balance method of accounting for depreciation; book value of a depreciated asset; probable useful life of industrial property ; industrial property mortality curves and statistical means of determining lives of assets.
11. Unit cost characteristics-theory of units costs and total costs ; the cost to Possess, the cost of service and the hourly burden; the cost of operation and maintenance ; cost per unit of output in relation to the volume of production ; the, break-even chart, sales expense, relationships ; the profit and loss chart for companies and industries.
13. Relative worth of alternatives-determination of the relative worths of several competing propositions ; Kelvin's law and its application ; minimum cost formulae and their applications.
14. Quantitative assessment of the performance of companies and industries.
Part I
. Personnel Management and Industrial Relations Personnel management-background, need for an importance of formal personnel, administration ; basic functions and place in the organisation ; qualitative and quantitative aspects of manpower ; job analysis, job descriptions and job specifications; employment activities-sources of recruitment, interviewing tests and examinations, selection, placement, induction and follow-up ; personnel ; training and education ; training of operatives supervisors and executives ; T. W. L, statutory provision labour turnover promotions and transfers.
Industrial Psychology-individual difference ; definitions and terminology in testing mental ability ; mechanical comprehension dexterity, manipulation, achievement, personality, interest and aptitude tests ; training of employees and learning curves ; work, fatigue and efficiency; Hawthrone investigations ; incentives ; attitudes and moral; Employee development-mental, physical, moral, social, emotional, vocational and avocational.
Industrial Relations-determinants of industrial relations-unions, employers, Governments and managements-their functions and obligations ; organised labour in India-Principal unions, their history, growth and structure ; Labour management consultation ; a brief survey of the growth of trade unionism in the U.S.A., and in the U.K. ; typical labour agreements and their provisions-wages, hours and working conditions ; grievance procedure ; collective bargaining ; strikes and lockouts ; conciliation and arbitration of disputes ; tribunals and industrial courts.
Industrial health and safety-accident and health hazards in industry ; accident records severity and frequency of accidents ; Organisation for safety ; the Safety Committee ; safety education and accident prevention programmes ; workmen's compensation ; lighting, ventilation, humidity, air conditioning, noise, vibration, sanitation, disposal of industrial wastes and health services ; insurance plans and Statutory provisions ; the economic. technical and human aspects of industrial safety and health.
Industrial and labour laws and their administration.
Elementary discussions on the activities of the Ministry of Labour, the Central Labour institute, the I.L.O. and its covenants, problems of industrial labour, elderly workers, women workers, rationalisation and employment opportunities.
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Part I
3. Management Principles & Practice
A-Management Thoughts 1. Evolution of 'management' thought and of the principles and methods of scientific management-Impact of empirical studies on the development of management' thought-Contribution by leading authorities ; the current trends in 'management' thought.
2. Training for management : Value of theory and experience and interdependence of the two-Social purpose in history- Status of the individual and the human element Problem yet unsolved.
B-Nature and Functions of Management 3. Preliminary : The need for precision in terminology (e.g. the term 'management' to be confined to function rather than status). The art of directing human activities. Responsibilities of management to different social groups--Application of scientific methods to managerial problems--inductive thinking--The importance of standards Responsibilities of Management-to customers, to consumers, to the community, to employees, to the owners and to management itself as a profession ; growth of management as a profession as distinct from ownership; management as a Science, an Art and a profession. Managing the business, the managers, the work and workers. The objectives of management.
4. Elements of Management-Planning, Organising, Co-ordinating, Motivating and Controlling.
5. General principles of organization and management- functionalisation line and staff and lateral relationship ; authority and responsibility ; chain of command span of control ; the exception principle ; principles and duties of management.
6. Responsibilities of the various levels of management- the board of directors, the chief executive, the functional beads, senior and junior executives and supervisors ; determining, defining and directing executives ; supervisory responsibilities establishing the organisational structure ; Organisation charts and manuals.
7. Relation of functional and sectional policies to general policies issue of instructions and the means of communication ; ensuring co-ordination through committees and reports ; presentation ; control of information.
8. External relationships of an organisation-public relations ; trade associations, trade unions, Government agencies, civic and local authorities ; technical and professional associations, etc.
9. The Management Movement--growth of management associations in the U.S.A.. the U.K. and other countries ; situation in India ; education and training for management abroad and in India ; the international Organisation for management the qualities and attainments of a manager ; the specialist vs. the generalist as a manager executive development programmes.
Part I
4. Procurement and inventory control purchasing
The Purchasing Function The Purchasing Officer--Qualifications-Purchasing ; Its place in management-Purchasing and development and design-Purchasing and production-Purchasing and accounts-Purchasing and costing-Purchasing and sales-Management and purchasing-Purchasing department organisation-Centralisation and decentralisation-Location of de- partment-Department layout.
Basic Economic Principles Buying the right quality-Quality by brand-Quality by sample- Quality by market grade-Quality by standards-Quality by specification- The right quantity-Cost of placing
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an order-Cost of handling and holding stock--Quantity discounts- Stock levels and ordering quantities-How much to buy at a time-Open market purchases-Special purchases-Supply and demand-Buyer's and seller's markets-Market price and timing-Competitive buying-Sources of supply.
Purchasing Policies Budgetary control-Unit production cost-Finance and purchasing policy--inventory investment-Purchasing and price trends-Specific buying policies-Speculative purchasing-Buying policy for various types of commodity-Make or buy-Determination of policy-Scope of self- manufacture-Purchase through dealers-Personal purchase for employees- Policy and purchasing ethics-Dealing with suppliers-Principles and standards.
Purchasing Procedure Outline-Purchase requisition-Selecting the supplier-The enquiry form-comparing the quotations-The quotation record-The purchase order- Acceptance of the order. The contract note-Alteration or cancellation- Progressing delivery-The delivery date-Progressing methods-The delivery follow-up department-Importance of efficient progressing-The advice note-Notice to goods-receiving department-Receiving goods-The tools received note-Goods-receiving procedure-Rejection of goods- Notification to carrier-Divergence of receiving practice-Inspection for quality-Containers-Payment-Certification of invoices-Handling invoices-Cash discounts-Trade discounts--Quantity discounts-Cumulative discounts and rebates--Loyalty rebates, Summary-Conclusion.
Forms and Records Introduction-Designing a form-Purchase forms-Purchase requisition-Enquiry form-Purchase order-Amendment to purchase order- Specification sheets-Conditions of purchase-Goods received note- Purchasing records-Catalogues ; Filing-Catallogues Indexing-Charts- Contract record-Delivery record-Departmental code-Drawing register- Follow-up record-Inspection reports-Material classification code- Material specification record-Order register-Purchasing record-Price record-Quotation analysis; record-Foreign Import Licence and Customs Formalities.
Construction Schemes Scope-Basis of contracts, price or lump sum, schedules of prices, reimbursement of actual cost plus a fee-Standard forms of agreements- Professional relationships, architects, quantity surveyor, engineer- Subcontractors-specialist Sub-contractor-Price variation-Variations in requirements-Delays-Injury and damage-Labour-Payment-Demolition utility supplies, etc.
Purchasing Reasearch Definition-Purchasing research activities, spending less on materials, reducing product cost, cost of the supply operation, meeting production or service needs, planning for the future-value analysis, standardisation, substitution, assessing relative value- sphere of influence-Obvious advantages-Unstable commodity prices- Practical problems in securing safety of supply.
Inventory Control Methods of control, Maxima and Minima, order Levels, Inventory Theories.
Storekeeping as a security and service function. Kinds of stores ; raw materials ; component parts (and work-in-progress) general supplies ; finished products ; tools and plant Arrangement and equipment of storage accommodation to suit each. Safeguarding against theft, misplacement, damage by fire or water, depredations by pests, deterioration through atmospheric conditions. The layout of stores in relation to easy location and access to articles ; systems of designing bins and storage space. Controls and checks over receipts and issues ; the importance of written authorisation. Forms and procedures. Receiving goods from outside ; check of quality of description ; arrangements for inspection of quality ; deviations from specification. Receiving articles produced in works ; returns of surplus materials. Issue of materials and components ; ensuring promptness and accuracy. Maintaining records of all transactions. Periodical stock check of every item ; perpetual inventory or annual stock-taking. Relationship with Stock control and Accounting function
Ware-housing finished goods. Packing ; types of packages and containers ; suitability or different products and modes of despatch.
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Part II
1. Work Study Work study-definitions and terminology ; field of work study.
Methods Improvement--purpose and objectives ; brief history and growth of tools and techniques ; procedure in a methods improvement programme ; principles of motion ,economy pertaining to the movements of human body and its parts, work place layout and design of tools and equipment ; tools and techniques used in methods improvement-process chart symbols, process charts for operator of material, process charts for units with more than one component, flow diagram, two-handled charts and multiple activity charts ; operation analysis questionnaires for materials, materials handling, tools, jigs and fixtures, machine set-up and operation, the operator, working conditions and inspection requirements ; use of motion picture films in motion analysis ; SIMO charts ; chronocyclegraphy ; developing improved methods ; presentation, installation and maintenance of the improved method.
Predetermined Motion Time Standards ; Works Measurement (Time study) aims and Objectives ; uses of time study data ; origin and development ; time study terminology and tools ; use of the stopwatch; the procedure in making a time study ; breaking up the operation into elements ; selection of operators ; measuring and recording time study date ; forms used ; handling foreign elements ; objective and subjective rating and levelling ; allowances,personal, delays. fatigue and others ; analysis and calculations, shortcut timing methods ; ,production ratio delay and other special purpose Studies ; synthetic and standard data methods handling and setting times, idle times, process allowance, etc., timing group operations use of time study data for wage incentives ; special timing devices and equipment ; application of time study to typical production operations ; role of incentives and their limiin increasing productivity, financial and non-financial incentives ; human factors involved ; types of incentive plans ; group plans ; plans for indirect workers.
Discussion on introducing work study and wage incentives into an Organisation ; criticisms on time study and incentives ; training of personnel in work study and incentive applications ; the time study engineer, present-day problems in India in increasing productivity through work study and wage incentives.
Part II
2. Materials Handling Materials handling, its importance in increasing productivity and effecting savings Selection of materials-handling equipment, annual cost analysis ; its application, co-ordination ; Effect of materials handling on plant layout in industrial situations, to the processes and operations of the factory in Saving working area, and in reducing the unit cost of production. Consideration of the simpler non- mechanised handling methods ; Pallets and stillages, hand trucks, hand traversing mono-rail conveyors, belt conveyors, roller conveyor, moving platforms, overhead runway conveyors, Scraper conveyors, bucket elevators, pneumatic conveyors, fork lift truck, Straddle Trucks, mobile cranes, overhead cranes, electric cranes. Handling bulk materials in tipping trucks & shovels, filling wagons and lorries from elevated hoppers by portable elevators and dumpers, wagon tipplers, removable bulk containers. A few case problems will be highly desirable.
Part II
3. Statistical methods and Statistical Quality Control 1. Importance of use of statistical techniques in business administration.
2. Collection and presentation of data--Sources of economic statistics in India-Their methods of collection, accuracy and coverage Statistical organization as set up at the Centre and in the States.
3. Permutations, combinations, elementary theory of probability, mathematical expectation law of large numbers, central limit theorem.
(Without proof-applications and importance only).
4.The design and preparation of a statistical report.
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5. Standard statistical techniques for analysis and interpretation of data. Standard' Distributions-Binomial, Poisson, Normal anti Hypergeometric, large sample tests-Exact sample tests- Students' t, F, Chi Square, Correlation, Regression, Association an & Contingency.
6. Methods of forecasting-Analysis of time-series.
7. Use of Sample surveys and design of experiments.
Statistical Quality Control Importance of Statistical Methods in Quality Control-Frequency Distributions and Applications--Probability--Normal Distribution.
Control Charts for Variables, for fraction defective and for defects-Theory of Runs.
Sampling Inspection-Acceptance Procedures-Single, Double, Multiple and Sequential Sampling Inspection Plants-Use of Dodge Roming and other statistical sampling Inspection Tables.
Special Statistical Methods-Tests of Significance-Analysis of variance- Design of Experiments-Correlation Theory of Goodness of Fit.
Quality audit--Measuring and controlling effectiveness of quality control.
Part II
4. Location of Industry & Plant Layout Plant location- major factors influencing the location of an industry and choice of site the big city and small town plant location ; localisation of industries ; social and governmental factors in plant location; decentralization of industries and regional self- sufficiency industrial housing ; discussion on the location of some major new plants in India.
Plant layout-factors influencing plant layout ; balance in departments and operations production or work centres and the work- place layout ; product or line layout ; layout by process of functions ; work in process banks; service centres, tools and techniques used in making layouts-flow diagrams, process charts, machine layout data cards, visual aids such as templets and th dimensional models, layout drawings and plot plan or model plant ; illustrative examples of representative plants in selected industries ; factors indicating poor layout ; means of securing more floor space.
Plant building and Services-sizes and types of factory buildings and their construction ; latest trends in factory buildings and industrial architecture building costs of alternative types ; scope for expansion ; lighting power ventilation air-conditioning ; dust removal ; water ; steam ; compressed air ; gas industrial waste disposal.
Part II
5. Product Design & Development Research and its relation to development and design. Types of research ; Fundamental, applied and development their relative nearness to the objectives of industry and commerce. Subjects of research raw materials ; processes and machines ; products ; labour ; and markets. Research within the enterprise ; its Organisation and personnel. Outside agencies and their use ; Trade Associations ; Department of Scientific Research; Technological Research Institutions; The Government Test House, Physical and Chemical Laboratories ; University and Technical Institution Laboratories. Co- operation and coordination between industrial enterprises and those bodies. The financing of research.
Development and the application of research. Importance of utilising the results of research for the benefit of the community. The impact of new materials and new processes on established products and on the industries producing them. The need to keep "up with the times" as alternative to regression. Encouraging initiative and new ideas throughout the enterprise. Inventions. Patents ; as a reward to the inventor ; their nature and legal implications. Stages in the development of products and of processes. By-products;. investigation of their commercial potentialities and possible value.
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The design function. Organisation and personnel of a design department. The equivalent function in Textile, Chemical and extractive industries. Considerations of utility, serviceability, appearance and style. Consumer preference. Design for production ; considerations of quantity and costs in relation to alternative materials and processes of manufacture ; case of adjustment and repair ; Use of standard parts and standardised manufacturing operations. Interchangeability of parts ; the specification of quality, the economic balance against costs. Quality control in relation to design.
Part III
1. Production, Planning and Control Introduction-definitions and terminology in production forecasting planning and control ; basic functions ; design installation and operation of a system benefits from production planning and control ; types of production and their basic characteristics.
Elements of Planning function-materials and their availability, quality standards machine and equipment capacity tolling, operation analysis, time standards, lot sizes and assignment of due dates ; preplanning activities ; routing and scheduling activities.
Part III
2. Cost Control Importance of costing and cost control. Sources of cost data.
A brief review of principles of cost accounting, concept of marginal costs, standards and standards costs. (Students must have studied all these while studying Elements of Financial and cost accounting in Part I. (At this stage only recapitulation will be necessary).
2. Control of material costs : responsibility for control ; materials specifications, purchasing, receiving and storage, physical loss, current control technique; performance against perfection standards ; salvage.
3. Control of labour costs ; desirability of standards for direct and indirect labour; planning the labour force ; performance reports ; variance reports ; productivity indices and control through incentive plans.
4. Control of factory expenses : budgets based on judgements and standards; fixed and flexible budgets : monthly budget reports and other reports.
5. Costing bye-products and joint products.
6. Distribution expenses : recording of distribution expense ; responsibility for distribution expense ; budgetary control of distribution expense ; control of selling expense; evaluation based on results.
7. Administrative Expense : recording administrative expenses, administrative expense budgets, research project costs and allocation to product lines.
8. Break-even Analysis :
9. The operating budget and measurement and' control of project.
10. Reporting to top management : integrated periodic reports to the chief executive and to board of directors.
11. Measuring the effectiveness of a cost control programme.
Part III
3. Quality control and Metrology Definition of quality-Meaning of control in Industry-History of quality control-Cost and Benefits of Quality Control.
Organisation for Quality Control-Introduction of Quality Control in the Plant-Benefits to be derived from Quality Control-Relation to other departments, single plant'. versus multiplant organisations.
Factors in controlling Quality-Jobs of Quality Control-New Design Control Incoming Material Control-Product Control-and special Process Studies.
Metrology.
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Part III
4. Operational Research Operational Research-Current operation analysis techniques ; use of Mathematical Models, application of methods and cost studies to advanced problems, e.g. Linear programming, Theory of Queues, Theory of Games, etc.
Part III
5. Maintenance Maintenance & Repairs, its importance in increasing productivity, and ensuring the fullest utilisation of the capital invested in respect of buildings, equipment and plants. Break down schedule, planned and Preventive Maintenance. The organisation of a maintenance ;and repair department, how it fits in the overall organisation, planning and control of maintenance work, maintenance of log sheet and design of other forms for collecting various information.
Part III
6. Job Evaluation & Merit Rating Introduction-deficiencies commonly seen in current wage administration plans; field of job evaluation, definitions and terminology ; basis for wages-national minimum rates, industry minimum rates, jot) minimum rates, wage rates and cost of living, base rates and auxiliaries, special rates, overtime rates and incentives.
Job analysis ; types of job evaluation plans and their relative merits ; the ranking method the factor-comparison method ; the point system organisation for job evaluation ; job evaluation committee selection of the right plan step-by-step procedure in evaluation job grades. the Job evaluation manual wage surveys ; relating points to wage structure operation and maintenance of the plan appeal procedure ; training for job evaluation.
Merit Rating : Objectives and purposes ; procedure and technique ; methods of rating the rating scale and sheet ; weighing individual traits and assigning values ; training of raters; putting a rating programme into effect.
Part III
7. Project Work and Report (Instruction and Contact hours) Each student will be required to prepare a comprehensive report covering one or more .aspects of a manufacturing unit of his choice in the following lines:
Summary-To be presented in the form of a chart/table indicating all the important features of the proposed project at a glance.
Introduction-Reasons for choosing the project-a brief survey of the working of similar units in the country and elsewhere in the world, present demand, future demand, government policy, foreign exchange savings, employment potentialities etc ; availability of raw materials ; skilled labour and other facilities ; choice of an economic unit, capital requirements, expected return on the capital investment ; any difficulty envisaged and how it is to be overcome.
Product Engineering-Detailed engineering specifications of the product, detailed processes to be explained by flow diagram and process chart ; time values allotted for each process if possible by operation ; bill of materials-indicating parts to be imported, parts to be .obtained through vendors, and parts to be made at the proposed unit.
Production, Planning and Control: Scheduling, material handling programme, inventory control, quality control, manning programme, etc.
Plant Layout-Specification of the various requirements of a suitable site, selection of equipment, layout, buildings and services, a floor plan indicating the important dimensions. The same floor plan may be used to show the flow of materials.
Sales and Sales Policy-Detailed plan after due consideration of various known sales techniques.
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Finance and Financial Control-Discussions on various patterns of company financing and capital formation in the light of the existing income-tax policy and the various financial incentives given by the government and the most advantageous one should be recommended for the new unit.
Presentation of a balance sheet as it is expected to be after the operation of the proposed unit for one year
Costing and Cost Control: Choice of a suitable costing system ; presentation of the detailed costing indicating all cost items ; detailed plan for an effective cost control system specially suited for the proposed industry.
Organisation-Presentation of an effective organisation chart, job description, salary recommended, training scheme for employees, line of communication etc.
Master Schedule-Presentation in the form of a chart, with explanatory notes where needed, indicating the target dates for all important activities.
Recommendation-Anything a student likes to make.
Note :-It is important for each student to adhere to a standard form to be prescribed by the institute, Each report should in addition to the above, have a table of contents, list of tables/charts, list of exhibits, an acknowledgement and a bibliography.
It is not advisable to present too much details in the main body of the report. They should be shown in the Appendix.
It will be extremely helpful for a student to put himself as an expert working on the request of an interested financier. No financier will pay for superfluous material nor will he pay for a report which does not give vital information.