Chapter One
Chapter One
1.1 Introduction
Until the end of the Dark Ages, especially until when commerce began to grow in the Mediterranean
regions, no important managerial tools of analysis were developed. Even administrative problems
received more attention than managerial problems.
In the Middle Ages, owing to the fact that the family was the basic production organization,
there was no need for paying a separate attention to managerial activities. It was the industrial
revolution and the inventions of the eighteenth century that triggered a paradigm shift in the way
people manage their business. During this time, the highly developing technology influenced the
production to move from homes to separate places of installations where machinery was concentrated
and labor employed. In the early stages of the Industrial Revolution, owners of factories did not
distinguish between ownership functions and management duties [1, 11].
In early nineteenth century, the need for higher capital to support plants resulted in increased
applications of a special legal form of organizing business. Large sum of money was raised by
corporations through sales of shares of stocks to many individuals. In cases where the family business
was insufficient for expansion, the newly emerging corporation system provided the means of
acquiring finance from other sources. This development made the distinction between ownership
functions and management duties very clear. And this distinction attracted the attention of scholars to
concentrate on industrial management as a distinct field of study. In the United States of America,
late in the nineteenth century, professional associations began to conduct symposiums that triggered
the presentation of technical papers with an emphasis to recognize management as a new sphere of
study.
Frederik Taylor, a pioneer in this field, noticed that managers were supposed to pick up their
management skill through trial and error. But he felt that it was necessary to set up methods and
standards of work and provide a proper wage incentive system for a better production. In his
philosophy the core of scientific management was to rest not on individual techniques but on the new
paradigm of managing an enterprise. Taylor outlined it in four general areas.
The first area was the discovery of basic elements of man's work through the use of scientific
methods. The second pays due attention to the preparation of work plan rather than allowing the
workers to choose their own way of doing things. The third area that Taylor indicated was the
selection and training of workers and the development of corporations. The final area of his concern
was the relations and placement of workers. The division of labor between management and the
workforce should be in such a way that each would perform its duty for which it was best fitted.
The development of management thought is the result of integrated ideas of various
disciplines. It is not the result of the development of a single discipline. Behavioral scientists
developed group dynamics, a new approach to the study of management. Group dynamics deals
with the advantage of group participation. Concurrent with the development of group dynamics,
new meanings of Accounting, Economics and the basic disciplines of business began to have
practical implications for managers. The developments in the field of Statistics proved to be of
great help in handling the problems of uncertainty, which have long caused management a serious
worry. Furthermore, the advancement in computer technology have enabled management to deal
with theoretical questions in a more definite and rigorous manner. During the developments, the
focus of attention has been shifting from one stream to another. In the first thirty years of the 20 th
century the major focus was on the physical factors as viewed from the engineering and economics
points of view. In the next thirty years, i.e., 1930 to 1960 the focus of attention shifted to
ergonomics (human factors) affecting productivity. Along with the development of ergonomics
due attention was given to managerial accounting and classical concepts of personnel and finance.
During the 1960s emphasis was placed on achieving precision through the use of quantitative
methods (mathematics and statistics) and the behavioral sciences (psychology, sociology and
anthropology). Moreover, computers and systems thinking developed rapidly during this decade
as new techniques of management. The trend in the 1970s and 80s has focused more on organiza-
tional behavior. The recent development in management thought highly focused on customer
satisfaction.
1
Detail treatment of industrial enterprises is given in Chapter 2.
machines, and so is involved in both trading and service-providing activities. Such enterprises are
called multi-purpose activity enterprises.
All categories of enterprises are dependent upon each other. For instance:
If there were no industrial enterprises’ there would be no raw materials available, and
there would be few, if any, goods for the trading businesses to buy and sell.
At the same time, most industrial enterprises depend on trading businesses to buy −
and sell to consumers − the raw materials, the components or the manufactured goods
which it produces.
Few industrial enterprises could operate services − particularly utilities − provided by
service enterprises.
Even most service enterprises require services provided by other service − and
particularly utility − enterprises.
And, of course, if there were no industrial enterprises or trading businesses’ there
would be few, if any, customers for the many services provided by the service
enterprises!
Whether an enterprise is classified as being industrial, trading or service- providing (or a
combination of two or more of them) a manager's job will still comprise the two aspects described
in section 1.6.1: the "technical" or "functional", requiring a knowledge of the work of the enterprise
or the department or the section of it in which he is employed; and the 'human' aspect concerned
with the people through whom the objectives of the enterprise or department or section will be
achieved.
Production
Industrial Commercial
Extraction Construction
Services
Trading
Warehouse
Transport
Home Foreign
Maintenance
Production
& Repair
Production
Banking and
Wholesale Retail Export Import Finance
Insurance
Accommodation
& Catering
1.13.
1.14.
reflecting
on plans
and objectives
Step 5 Step 2
Evaluating
results for Establishing
organizing major tasks
strategy
Step 3
Step 4
Top Level
Managers
es
iti
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Ac
s
tie
ial
Middle Level
vi
er
Managers
cti
ag
lA
an
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ca
ni
ch
Te
Supervisors
time
Figure 1.3: Time Spent for Managerial and Non Managerial Activities
With Respect to Managerial Hierarchy
1.21. 1.6.2 Personal Qualities Needed for Managerial Success
The character traits and personal behavioral qualities, which the "ideal" manager should possess
range from the ability to deal fairly and honestly with his or her staff in an amicable way without
constant resort to threats of dismissal; from being able to set good examples, to dealing calmly and
courteously with the most difficult or delicacies of problems. Very few people are likely to be
born with all the traits and abilities mentioned, but many if not all − can be developed if there is
will to succeed.
Basically it is a matter of the manager or supervisor taking a good, hard, and honest − look
at himself/herself and deciding what traits or abilities or qualities he/she is lacking; and then taking
positive steps to remedy the situation. Let us take two simple examples.
If a person has difficulty in arriving at work on time, it is merely a matter of setting an
alarm-clock 10 or 15 or more minutes earlier to provide the extra time.
If a person finds it difficult to become concerned with problem of other people, it is a matter
of trying to think what he or she would feel if placed in the other's "shoes" (known as empathy).
After all, the ability to analyze a situation, and then to plan and to carry out a course of
action to deal with that situation, is in itself a managerial quality.
In this section, we concentrate on the "mental" qualities or abilities which are desirable in
a manager if success in the profession is to be achieved. It is unlikely that they will all be found
in one person, or that they will necessarily be conspicuous in every person considered to have
managerial potential. Indeed, many, if not most, of the desirable attributes are likely to be "latent"
- that is, dormant, existing but not manifested when a career in supervision or management is first
embarked upon, and they will develop gradually as the result of training and experience. It is better
not to make all experiences yours. But learn from the mistakes other make.
Some of the more important personality traits of a successful manager are the following:
i) Ability to Think Clearly and Logically: A manager needs to be able, as the result of
training, to approach each situation and problem positively and objectively, without
prejudgment or being distracted by irrelevancies. This requires him to think in a clear,
orderly fashion and to marshal and arrange logically in his mind all the facts and
information available to him.
With training and experience such processes are occurring in the mind automatically
and reperformed unconsciously, so that a sensible decision is reached in a short time.
Naturally, complex or unusual problems may require more thorough consideration and
examination. It is important that a manager neither makes snap decisions' based on
inadequate thought or consideration, nor is hesitant in reaching a decision.
ii) The Abilities to Make Decisions and to Act Decisively: These follow on from the
foregoing, and also require a measure of self-confidence; a belief in one's own ability
to succeed in solving problems in the right way, and in one's own ability to deal
effectively with different situations and sets of circumstances. One of the basic reasons
why leaders − managers − are needed is to identify problems and to make the decisions
necessary in order to surmount or to solve them.
Many managers and supervisors try to shirk the responsibility for making decisions −
and give various reasons for doing so: insufficient facts or data, insufficient time for
proper consideration, and so on. But more often than not the real reason is the lack of
self-confidence or, indeed, courage. The process of decision-making can be analyzed
and seen in stages, although in practice the process will be continuous, automatic, and
− with experience − is often performed without conscious thought. The stages are:
a) Defining as accurately as possible the problem which needs to be solved.
b) Obtaining all relevant information about the problem or which may have a
bearing on it or on the solution to be found.
c) Breaking down the problem into parts − very often the solution to one part is
obvious and leads, logically, to the solving of other parts or the whole problem.
d) Comparing and judging the probability of success of any possible different
solutions to the same problem, and their possible consequences on other areas.
e) Selecting the most attractive solution − making the decision.
Of course, once a decision has been reached, it must be implemented. Hesitancy in this
respect shows lack of self-confidence in one's judgment, and uncertainty will quickly
be spotted by subordinates. If a manager does not have confidence in himself, how can
he really expect his subordinates to have confidence in him?
Once a course of action has been decided upon, the manager must act decisively and
with confidence. The more senior a manager becomes, the more complex and
important decisions he is likely to make.
iii) The Ability to Use Initiative: The majority of decisions which a manager will make
and actions which he takes, will be relatively routine, and will be based on past
experience of similar problems or situations and their solutions. However, from time
to time a manager is bound to come across problems or situations which are outside his
range of experience or outside the normal scope of his responsibly; the latter can,
perhaps, arise when a senior is away or is unavailable for some reason. In such
circumstances, particularly if action is urgently needed, the manager must not simply
leave the matter until his senior is available or wait to be told what to do, but must
initiate - that is, lead the action without waiting to be prompted. Using his knowledge
of the enterprise's policies in such matters, logical thought and common sense and any
advice or information available to him, he must decide what should best be done in the
circumstances - and then do it.
As soon as possible thereafter, he should report the matter to his superior, explaining
what the circumstances were, what action he took or decision he made and what reasons
he had for so doing. Such a report has two-fold importance:
Firstly, it allows the superior the opportunity of changing or modifying the
action initiated if necessary, and perhaps giving the manager the chance to learn
why.
Secondly, his superior has the chance to assess his ability to handle himself in a
difficult or unexpected situation.
Another often overlooked advantage of encouraging people to make use of their
initiative is that new ideas and thoughts are brought to bear on problems. In many ways
initiative is associated with creativity. This does not necessarily mean creativity as used
to describe the abilities of artists, poets, writers, inventors, architects, etc., but the
ability to innovate or to improvise an emergency, or to find better ways to perform a
job or to work out a new procedure.
iv) Ability to Handle Conflict: A good manager is calm, able to listen, is positively
responsive to criticism and is able to handle conflicts and differences in a constructive
manner. In order to handle conflicts well, a manager must be confident, self-assertive,
fair and dominant. He should be highly tolerant of stress, as conflicts generally lead to
stress and tension. This would require a sound mind in a sound body. A good physical
health generally introduces drive, energy, and stability leading to more balanced
outlook.
v) Ability to Adapt and be Flexible: No enterprise can ever remain static; certainly not if
it is to survive. Changes − some large and some small − take place continually;
personnel change, market and consumer demands change, the economy and associated
circumstances change, new machinery and/or new equipment is introduced,
technological developments take place, and so on.
Any manager must therefore be able to adapt to changes and, if necessary, to cope with
changed circumstances, and ensure that his subordinates also do so. Adaptability to
different situations and flexibility of mind are also necessary in the routine, day-to-day
running of a section, department or an entire enterprise. Many problems and situations
of a widely varying nature confront the manager every day, and he must be able to
adapt is approach and manner to every person with whom he comes into contact: is
subordinates, seniors, customers/clients, suppliers, etc.
A manager needs to be able to turn his attention and thoughts from dealing with one
task, problem or situation to another, without hesitation or loss of control. He must
also be prepared to deal with the unexpected as well as with normal, routine matters.
A manager must also be sufficiently flexible in mind and attitude to consider other
peoples' opinions, ideas and suggestions. If, on reflection, he finds merit in the ideas,
suggestions, advice, etc., of others, he must be sufficiently mature and confident to
adapt his own plans, decisions, etc., to incorporate or to build on other features of value
- that is, to innovate.
vi) Ability to Be Emotionally Stable: Hand in hand with adaptability and flexibility
of mind, go self-discipline and self-control. In dealing with different problems and
situations, some of which might be irritating, annoying, worrying or heated − or include
emotional displays (e.g. tearful women, angry voices, etc.) by others − a manager must
be sufficiently mature to keep calm and collected. He must be able to keep control over
his own emotions and his temper whatever may the provocation be, and be able to
concentrate his attention on the matter in hand, thinking clearly, logically, and avoiding
hasty reactions.
He also needs self-discipline in ensuring that he sets good examples for his subordinates
to follow and in working to his full capacity no matter what worries or problems
confront him or the pressures, which he may be under.
Although a manager cannot simply leave problems behind in his office when he departs
at the end of a working day, he still needs the capacity to relax and to relegate those
problems to his subconscious mind at times.
vii) Stamina and Concentration: Although stamina − required to enable a manager to
work long and hard without undue stress or strain − may be looked upon as a physical
rather than a mental ability, it is not necessarily physical fitness which is essential, but
mental fitness (although the first may lead to the second). Besides mental alertness, a
manager needs to be able to concentrate his mind on the matter in hand even under the
most trying circumstances and/or when he is under pressure; to focus or keep one's
mind intently fixed over a long period can be tiring, particularly as there will be many
different matters requiring attention and concentration during a manager's working day.
ix) Drive and Determination: A manager needs the urge and enthusiasm to stimulate
action, not only by himself, but by other people as well. He also needs the determination
to keep going whatever the difficulties, adapting his actions and decisions to overcome
problems encountered, and pressing on to a successful conclusion.
Of course, determination must be tempered by a willingness to listen to the advice,
suggestions, etc., of other people and by consideration for feelings, welfare, views and
positions of others; determination does not mean ruthlessness!
x) Leadership: Leadership is the ability of a person to exert a positive influence over the
thoughts, behavior and actions of others, and then to direct their thoughts, behavior and
actions towards a common goal or objective.
The ability to lead others does not necessarily manifest itself in any specific physical
characteristics, e.g. age or size − height or weight − or strength or looks, etc., and the
ability appears in both men and women (although, perhaps, the latter's abilities have
frequently been ignored, and are still unrecognized, in some countries). Many leaders,
say, in the field of politics, tend to be older because people, e.g. voters, tend to respect
the knowledge and experience they have gained, which give them authority. Other
people may be influenced by the looks of, or by the ideals or ideologies propounded
by, those seeking political leadership positions.
Generally, leaders are good communicators, but not necessarily orally. There are,
however, many characteristics of some leaders which are not found in other, equally
successful, leaders. A manager must, by definition, be a leader; his managerial
functions are concerned with planning, organizing, coordinating, controlling and
directing the activities of people towards the achievement of an objective. The different
attributes needed by a successful leader, in managerial terms, are many and varied, and
to a large extent will be demanded by the circumstances under which the leadership has
to be exercised.
Perhaps, more accurately, it is those attributes which are - or can be displayed when
the situation demands, which really count towards successful management; different
situations require the display of different attributes from managers. It is evident that at
various times, and in various circumstances, managers will have to display a "mix" of
some or all of the various qualities, abilities and attributes.
1.7 Organizational Structure
1.22.
Vice President
Plant Manager
ii) Functional Organization: This is the type of organization in which it is the function
(the type of activity), which determines the areas of authority and responsibility (Figure
1.5). An expert or specialist is placed in charge of each function, and will have direct
control of that function wherever it is undertaken within the enterprise. For example,
the personnel manager will have authority over employees in whichever department
they may work, or the office manager may have authority over clerical and secretarial
staff working in any department. This means that ‘line’ managers, in whose
departments the relevant function is being carried out (and who are responsible for all
matters authority relating to their staff) find their authority reduced with regard to
functional activity, to discipline and to staff relationships.
As the functional specialists are not involved in the day-to-day running of the enterprise
(which is the domain of the line managers) they are free to the concentrate on their
particular functions that produce many benefits for the enterprise. However, this form
of organization makes control difficult as there are no clear lines of authority and it is
similarly difficult to establish responsibility when things do not go right. Furthermore,
staff as well as supervisors and junior managers become confused at being subject to
the authority of more than one superior.
BOSSES
I J K L
A B C D E F G H
OPERATORS
Figure1.5: Functional Organization
iii) Line and Staff Organization: This is a combination of line and functional organizations
and is an organizational structure commonly used successfully. It is important to note
that the word 'staff’ in this case refers not to the workforce of an enterprise or section of
it, but to specialists who act mainly as advisers and who have no executive authority
outside their own departments. In such a structure, the line managers control the primary
functions, such as marketing and production, which are directly concerned with
achieving the objectives of the business; whilst the staff managers are generally involved
with secondary functions which assist the smooth and efficient running of the primary
functions.
You can see that the personnel manager is directly responsible for his own department
and has full authority over its staff. However, although he provides services for the line
managers and supervisors with regard to recruitment of staff, staff records, and staff
welfare; he has no authority over the staff in those other departments. For example, the
sales manager will inform the personnel manager of his need to recruit, say, two new
salesmen and job descriptions and some idea of the type of people he requires. The
personnel manager will advertise for or otherwise seek suitable candidates for the post,
undertake preliminary screening and/or testing, and arrange interviews. However, the
sales manager will attend the interviews and, in consultation with the personnel manager,
will make the final selections. The line manager, the sales manager in this case, is thus
free to concentrate on pursuing the (primary) function of his department.
MANAGING DIRECTOR
DIRECTOR
L L
L SECTION MANAGERS SECTION MANAGERS SECTION MANAGERS
SUPERVISORS & SUPERVISORS & SUPERVISORS &
OPERATORS SALESMEN CLERKS
Figure1.6: Line and Staff Organization
This composite form of organization ensures that the lines of responsibility and
authority are still clear for all (managers, supervisors and staff alike) to see, and
understand, and that the line managers keep full control of their respective departments
or sections, whilst having expert advice and assistance available in many subsidiary
areas. The relationships between the line managers and the staff managers must be
clearly defined, and cooperation between them must be encouraged. There is no value,
for instance, in a line manager continually rejecting or refusing to consider or accept
the advice or assistance of the personnel manager, whilst the personnel manager must
not be permitted to usurp the authority of line managers.
One other advantage of line and staff organization is that 'staff departments’ can be
introduced fairly easily into an existing enterprise, whose organization may have
evolved (as in the example of the retail business) on the line system as the enterprise
has expanded. Many but not all, line managers are only too happy to delegate
responsibility to specialists for certain routine activities not directly involved in
achieving the objectives of their departments; provided they, the line managers, still
have the 'final say'.
iv) Matrix Organization (Project Organization): These are temporary organizational
structures formed for specific projects for a specific period of time and are dismantled,
once the required goal is achieved. A typical example for this kind of organizational
structure can be the goal to design and build a new airport. For this project, the
specialists from different functional departments will be drawn to work together. These
functional departments are production, engineering, quality control, safety, marketing
research, etc. When the project is completed; these specialists go back to their
respective duties. The specialists are selected primarily on the basis of task-related
skills and expertise rather than decision making experience or planning ability.
These structures are very useful when:
The project is clearly defined in terms of objectives to be achieved and the target
date for completion of the project.
The project must be separate and unique and not be a part of daily work routine
of the organization.
There must be different types of activities which require skills and specialization
and must be coordinated to achieve the desired goal.
The project must be temporary in nature and not extended into other related
projects.
This kind of organization occurs frequently in:
Construction ( e.g. building a bridge)
Aerospace engineering ( i.e. designing and launching weather satellite)
Marketing( e.g. advertising company for new product)
Installation of an electronic data processing system, etc.
Figure 1.7 presents an example of how a matrix organization (team) is formed in a
traditional organization. The agency depicted uses functional design during normal
periods, but during an emergency, the functional departments are regarded as pools of
personnel from which teams are formed for the purpose of carrying out a specific
operation.
General
Manager
Project A Manager
Project B Manager
Project C Manager
Figure1.7: Matrix Organization
A manager is appointed to head the project. The manger has authority over the personnel
assigned to the team and is accountable for the performance of the personnel. When the
project is completed, the personnel return to their respective functional units.
In matrix organization, it is possible for the individual employee to have two managers.
However, proponents of matrix organization believe that it provides an agency with the
flexibility to work on critical projects. Matrix organization also brings together the
specialized talent that is often necessary to complete a project. It preserves the strength
of the vertical structure while adding the strengths of a horizontal cross functional
structure.
Like any other organizational structure, matrix has both strengths and weaknesses. The
major potential advantage is a higher degree of flexibility and adaptability.
Other advantages of matrix organization:
Decision making is decentralized to a level where information is processed
properly and relevant knowledge is applied.
Extensive communications networks help to process large amount of
information.
With decisions delegated to appropriate levels, higher management levels are
not over loaded with operational decisions.
Resource utilization is efficient, because key resources are shared across several
important programs or products at the same time.
Employee learns the collaborative skills needed to function in an environment
characterized by frequent meeting and more informal interactions.
Dual career ladders are elaborated as more career options become available on
both sides of the organization.
Many of the disadvantage stem from the matrix organization inherent violation of the
unity of command principle, which states that a person should have only one boss.
Reporting to two supervisors can create confusion and a difficult inter personnel
situation.
Other disadvantages include:
The design encourages managers who share subordinate to jockey for power.
The mistaken belief can arise that matrix management is the same thing as group
decision making − in other words every one must be consulted for every
decision.
Too much democracy can lead to not enough action.
1.26.1.27.
B C
D E
F G
H I
Figure1.8: Example of Organizational Chart Showing that Always Adhering to the Chain of
Command is not Advisable
ii) Types of Simulation: Simulation models vary along from physical models to
mathematical models.
a) Physical (iconic) models: Look alike models such as architectural models, plant
layout models, full scales mockups or reduced scale mockups are grouped under
this category.
b) Scaled models: These types of models are used when a look alike model
building is not possible or sufficient to study the system. Training mockups like
the solar system (scaled down) or model of an atom (scaled up) are examples of
this group.
c) Analogue models: These are models in which a property of a real object is
represented by a substitute property that often balances in a similar manner. An
analogue computer in which the voltage through a network might represent the
flow of goods through a system is a good example. A slide rule in which the
measured property is represented by a logarithmic length along the scale and a
graph are also examples of analogue models.
d) Management games: Humans interact with the computer output and make
decisions on information received. These decisions are then fed back into the
computer as inputs to the system.
e) Computer simulation: It is an extension of management games where the
human interaction is minimum and the computer operates using the engineering
and manufacturing database, artificial intelligence and an inference engine (the
capability) to apply the intelligence to the database). Here the interaction of a
human operator is minimal.
f) Mathematical model: The least one in the spectrum is mathematical model
where symbols rather than physical device are used to represent an activity.
Representing discrete or continuous conditions by mathematical equations is an
example. Since these models are the most abstract and the most general models,
symbols or mathematical models are widely used in system studies.
g) Geometric modeling in CAD: The use of CAD (computer aided design) helps to
develop a mathematical description of the geometry of an object, it is then stored
in the memory. The mathematical description is called the model; it permits the
user to display an image of the model on a graphic terminal and perform certain
operation on the model. The designer can adapt, modify or generate another
design using the model. There are different types of geometric models:
Two dimensional models: flat object and layout of buildings;
Three dimensional models: wire framed (i.e. interconnected lines to
depict an object) and solid models (an object is modeled in solid three
dimension.
Two other futures are color and animation. The use of color enhances the ability
of the user to visualize the object on a graphic screen. Animation capability
permits the operation of mechanisms and other moving objects to be displayed
on graphics monitor.
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Exactness Abstraction
Figure 1.9: Types of Simulation
iii) Elements of Simulation: Several terms will recur throughout any work on simulation.
The following are elements of simulation:
a) Entities: A system is defined as a group or a set of entities limited by some form
of regular interaction or interdependence to perform a certain specified function.
Entities are components of the system such as machines, work-piece, handling
equipment and so on. There are permanent entities (which last the entire duration
of simulation experiment) and temporary entities (which enter the model at some
time and pass through it and leave at some other time.) Machines are permanent
entities and jobs are temporary entities.
b) Activities: These are the things that the entities do or have done to them. In other
words, when two entities meet (a permanent and temporary entities usually) for
a period of time an activity is performed. Processing of a job by a machine is the
coming together of two activities together.
c) Events: Events are instant in time when some changes take place in the model;
when one or more activities begin or end.
d) Queues: These are passive states of an entity that waits for condition to change
so that another activity can. Jobs waiting begin for machines to finish operation
on other parts are said to be in queue.
e) Attributes: These are characteristics of entities such as types of machines, or
number of operations required on a job. Attributes are used to distinguish one
entity from another. The selection of an entity from queue frequently depends
on the attributes of entities in the queue.
f) Set: It is a general concept in simulation to describe queue in the model or a list
of needed and/or available tools or materials in the plant.
g) State: This is the condition of the model or its entities. It refers to entities being
in an active state or passive state depending on whether they are engaged in an
activity or are waiting in a queue.
The following example of Figure 1:10 illustrates an activity cycle for a simple machine shop. Jobs
from (customer) outside arrive to be processed and wait in the queen until a processing machine
is free and then the required operation is performed on the parts before they are released to the
customer.
Jobs coming from outside (entities)
Arrive (activity of zero time)
Wait (queue)(temporary entities)
Process (Activity- a permanent entity meets a temporary entity i.e., a machine operates on
a part)
Leave (activity of zero time)
Idle (queue of permanent entities)
Outside world (queue) unfinished and finished temporary entities.
OUT SIDE WORLD
Key
PROCESS
Activities
Queues
Temporary Entities
IDLE Permanent Entities
Problem
Formulation
System
Defination
No
Simulation Stop
Yes
No
Model Building
No
Data Collection
Translation
Bad
Validation
Good
Figure 1.11: Flow Diagram of Building a Simulation Model
1. Convenience of service U U U U
10 0 20 20 20
2. Ease of supervision 6 0 A E E
6 24 15 15
4. Flexibility 12 0 E I E
12 36 24 30
.
n. Investment cost (building alterations)
Notes: A- Almost perfect (4), E- Especially Good (3), I- Important Results Obtained (2),
O - Ok, Ordinary Results (1), U - Unimportant Results Obtained (0)
ii) Choosing the Solution: Whenever possible, tests should be applied to various alternative
approaches. In some cases, alternative schemes might be tested with simulation models
(section 1.8.3) or other quantitative techniques. In other cases, particularly those involving
bulk solids, laboratory or pilot-plant runs may provide required data. The various proposed
solutions should also be tested against economic criteria. Factors such as cash flow,
investment, tax, credit, and income tax must always be taken into account. After technical
and economic factors have been considered, however, another set of factors that must be
dealt with are the intangibles. Often, these items can tip the scales in one direction or another.
Typical intangibles include the following:
- Increase in morale
- Job enrichment
- Improved customer service
- Compatibility with company philosophy
- Operating feasibility (considering availability of labor and
skills)
- Operator comfort
- Ability to cope with changing conditions
- Adaptability to future changes in technology
- Adaptability for expansion (or reduction)
- Quality of service
- Reputation with customers and vendors
- Durability of equipment
iii) Applying the Solution: Once a preferred solution has been identified, the major challenge
is developing the implementation plan. Obviously a different degree of effort and expertise
is required to obtain machine or equipment. Depending on the complexity of the job,
assistance may be required from equipment manufacturer’s, distributor’s, consultant’s, and
systems contractor’s.
Generally, the following steps are involved in implementing the solution:
Develop specifications
Evaluate suppliers
Evaluate bids
Select suppliers
Award contracts
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iv) Develop specifications: It is very important that the bid specification be written and well
organized, and spell out clearly and precisely what various vendors will be bidding against.
Even in a small job, involving only a few pieces of equipment, competitive bids can vary
widely in price if vendors do not understand clearly what the specifications are to which they
must bid. As a minimum, requests for bids should be accompanied by scaled drawings
whenever appropriate. If larger systems are involved, consultants are often brought in to
assist with bid preparation.
v) Evaluating Suppliers: For a system of any significant size, qualifying those suppliers that
will be invited to submit bids is an important part of the bid preparation process. Evaluation
of supplier capabilities is also a factor when subsequent bids are being evaluated. Depending
on the scope of the project, it might be a good idea to tour the prospective supplier's facilities,
with the following questions in mind.
- What is the condition of the supplier's plant?
- How well organized are plant operations?
- What is the condition and age of equipment?
- How good is the quality control?
- How busy is the supplier?
- Will his workload permit him to give proper attention to my project?
- What full-time skills are available in mechanical, electrical, and structure
crafts?
- How about data processing capabilities?
If possible, customers of the supplier also should be visited to see how their systems are
working out. If possible, operators and mechanics should be interviewed, as well as
supervisory and managerial personnel, in order to get a balanced viewpoint. Information
about the following matters should be sought:
- How smooth was the system installation and start-up?
- Did the supplier assist in setting up a training program for the user's
personnel?
- How helpful was the supplier in setting up a maintenance program and spare
parts inventory?
- Was the supplier effective in solving problems that surfaced during
installation and start-up?
- Did supplier personnel have adequate skills, and were the same people
available throughout the duration of the project?
- Is the system delivering what was promised in terms of performance and
uptime?
iii) Evaluating the Bid: An important part of evaluating competitive bidders is making sure that
all vendors are bidding to the same specifications. This job is made easier when well-written,
precise specifications are prepared in advance. Otherwise, prices quoted may have no relation
to duty classification or construction grade of equipment quoted.
In the case of a large system or facility, a performance specification may be the basis on
which prospective suppliers bid. This type of specification spells out the type of performance
required, but does not necessarily restrict the supplier to the type of approach to be used.
Rather, the burden is on the bidder to suggest the approach to be taken.
iv) Selecting the Supplier: When such a performance specification is evaluated, a meticulous
cost analysis is an important if not the major part of the evaluation. Operating costs as well
as initial costs must be evaluated carefully for every alternative approach. Anticipated
maintenance costs and spare parts inventory costs are among the items to be included in the
operating cost category. In a surprisingly large number of cases, the initial cost of a system
does not represent the overriding consideration when compared against total life-cycle costs.
Obviously, absolute cost figures should be balanced against perceptions of overall supplier
capabilities. A supplier presenting the lowest overall cost bid may also carry the lowest
overall confidence level. Qualitative judgments must be made at this point. In some cases,
numerical point rating systems might be applied to help factor such issues into the evaluation.
v) Awarding the Contract: Once the supplier has been selected and the winning bid chosen,
the contract must be awarded. Often the success of the system fails down at this point.
Practicality must be kept in mind when the contract is drawn up. The important thing is that
the system meets performance specifications, on time, and within budget. The supplier
should not be bogged down with an overly restrictive contract that limits his abilities to
perform. On the other hand, the needs of the customer, as identified and approved by top
management, must not be compromised. Basically, the contract should be viewed as a tool
for helping both parties-the customer and the supplier-in managing the project. A good
materials handling contract generally contains the following elements.
Review Questions
1. What are the various skills that an effective manager must possess? Are all these skills
equally important?
2. What are the five major functions of management? Is planning the most important function?
If so, why?
3. Discuss the three main characteristics of MBO.
4. What are the advantages and the limitations posed by MBO which brings to the organization?
5. What are the three types of business organization?
6. What are the general five elements in which planning is composed?
7. What are the main steps of organizing process?
8. Discuss the types of organizational structures, what are the merit and the demerits of each
type?
9. List out the principles of controlling.
10. What personal qualities needed for managerial success?
11. What are the steps needed in systematic approaches of problem solving?
12. Define simulation and discuss the different steps used in simulations.
13. What are various criteria needed for supplier selection?
Reference