1. | (a) | Put an appropriate word in blank position: | 1x5 | |
| | (i) | ____________is the process of polishing a work, after grinding, by means of abrasive materials to give fine finish. | | (0) |
| | (ii) | _____________is a type of surface treatment by an electro–chemical process which gives a slight anticorrosion protection and improves the appearance of the product. | | (0) |
| | (iii) | In formulating the linear programming problem, the basic step is to set up some ______________ model. | | (0) |
| | (iv) | Under CPM, the project is analysed into different operations or activities and their relationships are determined and shown on the _______________ diagram. | | (0) |
| | (v) | Wear and ______________ are the two main causes for replacement of machinery. | | (0) |
| (b) | Match the terms in Column I with the relevant terms in Column II: Column I | Column II | (A) | Inventory Control | (i) | Turbo–Alternator | (B) | Network Analysis | (ii) | Milling Machine | (C) | Aviation Fuel | (iii) | Shaping Machine | (D) | Hydro–electricity | (iv) | Crashing | (E) | Helical groove on shaft | (v) | Value Analysis | (F) | Improvement in productivity | (vi) | Stock Level | (G) | ‘V’ groove in a Vee–block | (vii) | Honing | (H) | Very fine finishing of the inside diameter of a cylinder liner | (viii) | Refinery | | 0.5x8 | (0) |
| (c) | For each part below, choose the most appropriate answer out of the four options given against each part: | 1x5 | |
| | (i) | Cutting tools are produced from: (A) | High Speed Steel, | (B) | Nickel, | (C) | Cobalt, | (D) | Silica. | | | (0) |
| | (ii) | The following establishes time sequence of operations: (A) | Routing, | (B) | Sequencing, | (C) | Scheduling, | (D) | Dispatching. | | | (0) |
| | (iii) | Arrangement of machines depending on sequence of operations happens in: (A) | Process Layout, | (B) | Product Layout, | (C) | Hybrid Layout, | (D) | Group Technology Layout. | | | (0) |
| | (iv) | Buffer stock is built to cater for: (A) | Fluctuating load, | (B) | Machine breakdown, | (C) | Import substitution, | (D) | Diversification. | | | (0) |
| | (v) | Linear Programming is a technique used for determining: (A) | Production Programme, | (B) | Plant Layout, | (C) | Product Mix, | (D) | Manufacturing sequence. | | | (0) |
2. | (a) | A department of a company has to process a large number of components/month. The process equipment time required is 36 minutes/component, whereas the requirement of an imported process chemical is 1.2 litres/ component. The manual skilled manpower required is 12 minutes/component for polishing and cleaning. The following additional data are available: | Availability/month | Efficiency of utilisation | Equipment–hours | 500 | 85% | Imported Chemicals–Litres | 1,000 | 95% | Skilled manpower–hours | 250 | 65% | (1) | What is the maximum possible production under the current conditions? | (2) | If skilled manpower availability is increased by overtime by 20%, what will be the impact on production increase? |
| 4+1 | (0) |
| (b) | "The term ‘Quality Control’ consists of two words ‘quality’ and ‘control’". (i) | What are implied by the terms ‘quality’ and ‘control’? | (ii) | From the discussions under (i), please arrive at a definition of ‘Quality Control’. | (iii) | Mention six major objectives of ‘Quality Control’. |
| 3+2+3 | (0) |
| (c) | Draw the schematic diagram from the following table showing tasks to be performed on an assembly line in the sequence and time specified: Task | Time (Seconds) | Tasks that must precede | A | 50 | – | B | 40 | – | C | 20 | A | D | 45 | C | E | 20 | C | F | 25 | D | G | 10 | E | H | 35 | B,F,G | | 3 | (0) |
| (d) | Replace the ‘missing words’ with appropriate terms in the formula contained in the following paragraph: "The analytical approach to evaluate the work done by preventive maintenance is (i) | (Inspections incomplete)/(‘missing words’) x 100 should be less than 10%. | (ii) | (Hours worked for maintenance)/(‘missing words’)x 100 = Performance of the department." |
| 1+1 | (0) |
3. | (a) | A lathe machine is used for turning operation and it takes 40 minutes to process the component. Efficiency of the lathe is 90 per cent and scrap is 20 per cent. The desired output is 600 pieces per week. Consider 48 hours per week and 50 weeks in a year. Determine the number of lathes required. | 6 | (0) |
| (b) | Expand the following: | 1x5 | |
| | (i) | EMQ | | (0) |
| | (ii) | ABFS | | (0) |
| | (iii) | TCM | | (0) |
| | (iv) | MBO | | (0) |
| | (v) | SPM | | (0) |
| (c) | Please describe the situation where ‘Assembly Line Balancing’ is required. What are the factors that cause problems in Line Balancing? Suggest the steps in solving the issue | 2+2+3 | (0) |
4. | (a) | The probabilities of failure Pn of an equipment in the nth period after maintenance have been estimated as follows: n | 1 | 2 | 3 | 4 | Pn | 0.1 | 0.2 | 0.4 | 0.3 |
Cost of preventive maintenance: Rs.150; Cost of breakdown maintenance: Rs. 1,000; Determine the optimum frequency of preventive maintenance. | 4 | (0) |
| (b) | (i) | Explain what is a Slack Variable under Simplex Method of Linear Programming. | 2 | (0) |
| | (ii) | A small manufacturing firm produces two types of gadgets, A and B, which are first processed in the foundry, then sent to the machine for finishing. The number of man-hours of labour required in each shop for the production of each unit of A and B and the number of man-hours the firm has available per week are as follows: | Foundry | Machine Shop | Product A: Man–hours/unit" | 10 | 5 | Product B: Man–hours/unit | 6 | 4 | Firm’s capacity per week (in hours | 1,000 | 600 |
Construct the objective function and the corresponding equations for calculating how many units should be produced per week so that the profit is maximum. The profit on the sale of A is Rs. 30 per unit as compared to B’s Rs. 20 per unit. | 3 | (0) |
| (c) | Examine each statement and indicate whether it is ‘True’ or ‘False’: | 1x5 | |
| | (i) | Industrial Engineering is not a line function. | | (0) |
| | (ii) | Ranking is one of the Job Evaluation Techniques. | | (0) |
| | (iii) | Results available from work sampling study is 100% accurate. | | (0) |
| | (iv) | Standard time does not allow for relaxation of the operators. | | (0) |
| | (v) | Incentives are substitutes for lower wages. | | (0) |
| (d) | A company which is planning to undertake the production of medical testing equipments has to decide on the location of the plant. Three locations are being considered, namely, A, B and C. The fixed costs of three locations are estimated to be Rs. 300 lakhs, Rs. 500 lakhs and Rs. 250 lakhs respectively. The variable costs are Rs. 3,000, Rs. 2,000 and Rs. 3,500 per unit respectively. The average sales price of the equipment is Rs. 7,000 per unit. Find: (i) | The range of annual production/sales volume for which each location is most suitable. | (ii) | Select the best location, if the sales volume is of 18,000 units. |
| 2+2 | (0) |