| 1. | (a) | Match each item in the left hand Column A with an appropriate item in the right hand Column B. | Column A | Column B | (i)
(ii)
(iii)
(iv)
(v) | Henry Ford
Gilbreth
Herbert Simons
W.A.Shewart
Henry Gantt | A.
B.
C.
D.
E. | Scheduling
Decision–making process
Assembly Line Concept
Fractionalisation of work
Statistical Control Technique |
| 1x5 | (0) |
| | (b) | State whether the following statements are ‘True’ or ‘False’. If ‘False’, put up the corrected statement. | 1x5 | |
| | | (i) | Photonics is the most exciting information technology for transmitting large amounts of digital information. | | (0) |
| | | (ii) | Quality Circle is a useful technique for motivating employees through enrichment of their jobs. | | (0) |
| | | (iii) | ‘Therbligs’ stands for a set of elementary motions which are commonly found in Human motions. | | (0) |
| | | (iv) | Pure Metals offer no scope of improvement in strength by heat treatment. | | (0) |
| | | (v) | Tumbling is a surface treating process. | | (0) |
| | (c) | Choose the most appropriate one from the stated options and write it down | 1x5 | |
| | | (i) | Normal time means………… | A. | Time to do a job normally | | B. | Time required by any person to do a job | | C. | Time required by a qualified worker to do a job under normal circumstances | | D. | How much time should be taken to get incentive |
| | (0) |
| | | (ii) | In value Engineering, the focus is on | A. | Cost value | | B. | Functional value | | C. | Exchange value | | D. | Esteem value |
| | (0) |
| | | (iii) | In an Engineering Industry, the major component of Production cost is | A. | Labour | | B. | Materials | | C. | Overheads | | D. | None of the above |
| | (0) |
| | | (iv) | Information on the concept of material for costing is available from | A. | Job Card | | B. | Material Requisition | | C. | Inventory Cards | | D. | None of the above |
| | (0) |
| | | (v) | Work study means | A. | To fine out the work of a job | | B. | Another way of exploiting labour | | C. | To determine scientifically the methods and contents of a job | | D. | To study the work. |
| | (0) |
| | (d) | Define the following terms in not more than a sentence or two: | 1x5 | |
| | | (i) | Rotable Spares | | (0) |
| | | (ii) | Activity Sampling | | (0) |
| | | (iii) | Milestone Chart | | (0) |
| | | (iv) | Facilities Planning | | (0) |
| | | (v) | Tele–commuting | | (0) |
| 2. | (a) | XYZ Ltd. makes four components P,Q,R and S for which costs in the forthcoming year are expected to be as follows: | P | Q | R | S | | Production (unit) | 1,000 | 2,000 | 3,000 | 4,000 | | Unit marginal costs | | | Figures are in Rs. | Direct material
Direct labour
Variable production overheads | 4
8
2 | 5
9
3 | 2
4
1 | 4
6
2 | | Total | 14 | 17 | 7 | 12 |
Directly attributable fixed cost/annum and committed fixed costs are as follows: | Rs. | Incurred as a direct consequence of making P
Incurred as a direct consequence of making Q
Incurred as a direct consequence of making R
Incurred as a direct consequence of making S
Other fixed cost committed | 1,000
5,000
6,000
8,000
30,000 | | 50,000 |
A sub contractor has offered to supply units of P,Q,R and S for Rs. 12, Rs. 21, Rs. 10 and Rs. 14 respectively. Decide whether to make or buy components. | 8 | (0) |
| | (b) | M/s. Pioneers Ltd. manufactures three components X, Y and Z using the same machine for each. The budget for the next year calls for the production and assembly of 4,000 of each components. The variable production cost/unit of the final product is: | Machine hours | Variable Costs (Rs.) | 1 unit of X
1 unit of Y
1 unit of Z
Assembly | 3
2
4 | 20
36
24
20
100 |
Only 24,000 hours of machine time will be available during the year and a subcontractor has quoted the following unit prices for supplying components. X–Rs.29; Y–Rs. 40; Z–Rs. 34.
Advise M/s. Pioneers Ltd. | 7 | (0) |
| 3. | (a) | State briefly what do you mean by ‘Integrated Planning and Control System’. | 5 | (0) |
| | (b) | Ram and Shyam are workers on a two–station assembly line. The distribution of activity times at their stations are as follows: | Time | Time frequency for Ram | Time frequency for Shyam | | 10 | 4 | 4 | | 20 | 6 | 5 | | 30 | 10 | 6 | | 40 | 20 | 7 | | 50 | 40 | 10 | | 60 | 11 | 8 | | 70 | 5 | 6 | | 80 | 4 | 4 |
| (i) | Simulate operation of the line for 8 times, use the following Random numbers given below:
Operation — 1
14, 01, 14, 44, 61, 82, 00 and 03.
Operation — 2
36, 76, 55, 25, 97, 41, 16 and 34. |
| (ii) | Assuming Shyam must wait until Ram complete the first item before starting work, will he have to wait to process any of the other 7 items. Explain your answer, based upon your simulation. |
| 5+5 | (0) |
| 4. | (a) | There operations are to be performed on three work stations on six jobs with timing as follows: | Job | Time required in work stations (Hrs) | | (1) | (2) | (3) | A
B
C
D
E
F | 5
7
10
9
8
12 | 7
6
4
8
7
6 | 8
11
8
10
13
9 |
Note: The minimum time in work station 3 is equal to the maximum in work station 2.
Schedule the jobs, using Johnson’s Algorithm. | 7 | (0) |
| | (b) | Both direct and indirect labourers of a department in a factory are entitled to get production bonus, in accordance with a group incentive scheme, the outline of which are as follows: | (i) | For any production, in excess of standard rate fixed at 10000 tonnes/month of 25 days, a general incentive of Rs. 10 per tonne is paid in aggregate. The total amount payable to each separate group is determined on the basis of an assumed percentage of such excess production being contributed by it, namely @ 70% by direct labour, @ 10% by inspection staff, @ 12% by maintenance staff and 8% by the supervisory staff. | | (ii) | Moreover, if the excess production is more than 20% above standard, direct labourers also get a special bonus @ Rs. 5 per tonne for all good production in excess of 120% of standard. | | (iii) | Inspection staff are penalized @ Rs. 20 per tonnes for rejection by customer in excess of 1% of production. | | (iv) | Maintenance staff are also penalized @ Rs. 0.20 per hour of machine breakdown. |
From the following particulars for a month, work out the production bonus by each group. | • | Actual working days = 20 | | • | Production = 11000 tonnes | | • | Rejection by customers = 200 tonnes | | • | Machine breakdown = 40 hours. |
| 8 | (0) |
| 5. | Write short notes on: | 3x5 | |
| | (a) | Payment by Results | | (0) |
| | (b) | Reasons for failure of Incentive plans | | (0) |
| | (c) | Flexible Manufacturing System. | | (0) |
