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ASSIGNMENT JULY DECEMBER 2016

MS-05 (SAMPLE COPY)

Course Code
Course Title
Assignment Code
Assignment Coverage

MS - 05
Management of Machines and Materials

MS-05/TMA/SEM - II/2016
All Blocks

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1. There are many stages involved in bringing a new output to the market. Why cant the stages be
performed in smooth sequence.
Product selection as --------------------------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------. tomorrow. For example, jute has


been in use as a packing medium for a -----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------, its demand has reduced.
Product Selection Stages
The process of creating, ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------. Output possibilities are generated from many sources:
a) From the field itself through' market research. ---------------------------------------------------------------, opinion polls etc.
b) From research laboratories. This ----------------------------------------------------------------------------------------------research in developing new knowledge.
c) From conscious and --------------------------------------------------- products or services. These ideas can be generated by
using ------------------------------------------------------------------------------------------------ forecasting etc.

The output ideas thus as ----------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------. finally by design and testing.


No Smooth Sequence
Although Figure I depicts product selection as a sequential process where one stage follows another, in reality, the process
may not be so smooth as shown. --------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------the output selection


process and this may go on and on. The product selection process therefore ensures a continuous match between what is
demanded and what is produced.
In some cases, the production process has also to be designed along with the product or service. This has to be done, for
example, when the market --------------------------------------------------------------------------------------------------

-----------------------------------------------------------------------------------------------------------------------------

----------------------------------------------------------------------------------------------- with the product in such a


case.
New-Idea Mortality Curve
The previous section highlighted the fact ------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------. Figure II
assumes that after three years of research, fifty potential chemical product-ideas are available for consideration. Initial.
screening reduces this number to about half and after economic analysis, by the end of year four, the number of potential
products decreases to nine. -------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- has not been tested


empirically. Thus, the mortality curve should be treated as an indicative proposition in the Indian context.

The curve also shows that converting product ideas into marketable products is a slow process. For chemical products, on an
average it takes six years to commercialise a product after the initial research has been completed, as is shown by Figure II.
At the end of it all, a product commercially launched may not turn out to be successful and the mortality may extend to the
product as well.
The actual figures in --------------------------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- testing and would perhaps also waitit-out to see how some others have fared with similar products.

2. What do you understand by work study, method study and work measurement? Highlight the basis
steps involved.
Work study is indeed an important tool for achieving higher productive efficiency of an organisation in a scientific
manner. Work study is a ------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------ systematically to the investigations of all the facts which affect the
efficiency and economy of the situation being reviewed, in order to effect improvement.
Work study may be defined ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------.
Work
study,
therefore,
comprises of two areas of study: method study (motion study) and time study (work measurement).
Role of Work Study in Improving Productivity
In order to understand the role of work study, we need to understand the role of method study and that of time study. Method
study (also sometimes called Work Method Design) ------------------------------------------------------------------------

--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------manpower
so
that work is performed in well organized manner leading to increased resource utilization, better quality and lower costs. It
can therefore be stated that through method study we have a systematic way of developing human resource effectiveness,
providing high machine and equipment utilization, and making economical use of materials.
The work study and the ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------ work is less fatiguing and less time taking.
There are eight basic steps, some of which are common to both method study (MS) and work measurement (WM)
1 Select -----------------------------------2 ------------------------------------------3 ----------------------- (MS and WM)
4 Develop ---------------------5 ----------------------------------6 Define (WM)
7 Install (MS)
8 Maintain -----------------

Method study:
The systematic ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- more effective methods, and reducing costs.
Method study is basically ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- of resources. Method signifies how a
work is to be done i.e. description of how we consume resources in order to achieve our target?
Methods are integral part of work accomplishment and signify:
1. How well our --------------------------------------------------------------------------------------------------, materials and money.
2. How ------------------------------------------------------------------------------------------------------ of the unit.
3. The ---------------------------------------------------------------------------------------------- of our methods.
Thus methods can determine the amount of input materials, time power and money consumed. So methods may be
considered the core where one --------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- the cost and quality of output produced.
The following section deal with it in a definite and ordered sequence of deferent a definite and ordered sequence of
different stages as under:
i) Identification
As mentioned above, ----------------------------------------------------------------------------------- is primarily based on:

a) Economic --------------------------------b) Technical considerations


c) ------------------------------ considerations.
ii) Recording
When a job has been --------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- presented pictorially.


iii) Examination
After record comes -------------------------------------------------------------------------------------------------------

-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------examination may yield the futility


of the key activity and, in one stroke, many of the preceding and succeeding activities might just as well be `washed off'.
Key activities could preferably be coloured or shown hatched in the process charts after the `record' stage.
iv) Development
After developing the alternatives --------------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------productive' areas. The


proposals for improvement can now be submitted for approval.
v) Installation
And so now you have reached the final stages of method study. Installation can be divided into five phases:
1. Gain ------------------------------------------------------ supervision.
2. Gain approval of ------------------------------------------------------ management.
3. Gain -------------------------------------------------------------------------------------- their representatives.
4. Retain the workers to operate new methods.
5. Continual ------------------------------------------------------------------------------- is being used.

Work measurement refer to the -----------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------carry out a specified


manufacturing task at a defined level of performance. It is concerned with the length of time it takes to complete a work task
assigned to a specific job.
Attempts to measure work and to establish work standards have always resulted in reactions, promoted criticism and
generally have been the topic of considerable controversy among the managements and work force/workers.
It gives feeling to the workers that ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------- workers to work hard which may result in higher wage bills.
Application of techniques ------------------------------------------------------------------------------------------------------------------------------------------------ job at a defined level of performance is called the work measurement.

In other words, time study is the systematic study of work system with the purpose of:
(i) Developing the ---------------------------------------------------------------------------------- lowest cost.
(ii) ----------------------------------------------------------------- and method.
(iii) Determining the time -------------------------------------------------------------------- pace to do a specific operation.
The main objectives of work measurement are the followings:
(1) Target time for -------------------------------------------------------------------------------- requirements can be prepared.
(2) Sound ------------------------------------------------------------------------------------------------------- basic times.
(3) Useful wage ---------------------------------------------------------------------------- basis of target times.
(4) In can lead to proper balancing of the work distribution.
(5) It can help to ------------------------------------------------------------------------------------------------------------- or repetitive
operations so that human effort can be minimized.
(6) To standardise the ---------------------------------------------------- operations.
(7) ---------------------------------------------------------------- efficient performance.
(8) To determine man and ---------------------------------------------------------------- of both.
(9) To provide ------------------------------------------------------------- and scheduling activities.
Method study and Work ----------------------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------techniques like work-sampling in


order to determine where ineffective time is occurring and its extent so that management action can be taken to eliminate it
even before going in for method study. Equally, on the other hand, time study may be used to compare the effectiveness of
alternative methods.
Work Measurement Procedure
The basic steps to -------------------------------------------------- are:
1. Select the ----------------------------------------------------------- preliminary survey.
2. Record all the relevant data ------------------------------------------------- methods and the elements of activity in them.
3. Measure each element in ------------------------------------------------------------------------------- picture has been obtained.
4. Examine the recorded data and time ----------------------------------------------------------------------------------------------------------------------------------------------------- each element and determine a representative time for each.
5. Compile a time for the ---------------------------------------------------------------------------------------------------------------------------------------------------------- needs, contingencies etc.
6. Define precisely the series of activities and method of operation for which the time has been allowed and issue the
standard time for the activities and methods specified.

3. What is batch production? Under which circumstances it is used? Discuss some features of batch
production.

Batch Production
The manufacture of product in batches (small or large)or lots by a series of operations each operation being carried out onthe
whole batch before any ------------------------------------------------------------------------------------------------------ of identical
articles either to meet a specific order or to satisfy continuous demand.
Batch production can be useful for small businesses that dont have enough capital to run continuous production lines. It also
helps companies avoid large amounts of waste. A bakery business owner, for example, can ---------------------------------

--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------making big investments in new products that may not sell.


When a variety of products is to be made and the volumes of production are not large enough to justify a separate line for
each product, production in batches is often resorted to. ---------------------------------------------------------------------

--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------times are larger as compared. to those in mass production.


Batch production is distinguished from the Job ----------------------------------------------------------------------------------------------------------------------------------------------------------- of demand, there is a need to produce products in batches. The
scheduling problem here is concerned with determining the batch sizes for products and the order in which they should be
produced.
Manufacturers of anything from cakes to ------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------until the whole


batch is done.
For example, in -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------, then place it onto baking sheets, and then bake it. People are limited
as to how many cookies they can produce at one time by the number of baking sheets and ovens they possess, and by the size
of bowls available to mix each batch.
This is batch production, since ----------------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------the dough and actually


having completed baking all the cookies.
Sometimes, this type of production is necessary when a manufacturer is producing similar things, but with variants. For
instance, if a company manufactures two colors of the same shoe, -----------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------that can be manufactured and take longer in total production time.

Another example is found in thin ------------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------considerable time, and


may require several steps before the next batch can be placed in the machine.

Features of batch productionUnlike mass production -----------------------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------some of the advantages and


disadvantages of process layouts are summarised below:
Advantages:
i) Better ----------------------------------------------------------------- machines are required.
ii) A high degree of -------------------------------------------------------------------------- for specific tasks.
iii) Comparatively ---------------------------------------------------------- is needed.
iv) There is generally -------------------------------------------------------------------------------- of jobs handled.
v) Specialised supervision is possible.
Disadvantages:
i) Since longer -------------------------------------------------------------------- is more expensive.
ii) Production -------------------------------------------------------------------------------- involved.
iii) Total ----------------------------------------------------------------------- longer.
iv) ------------------------------------------------------------------------------ inventory result.
v) Space and -------------------------------------------------------------------- in process.
vi) Because of the ----------------------------------------------------------------------------------- of skill are required.
Batch production is the manufacture of a number of identical articles either to meet a specific order or to meet a continuous
demand. Batch can be manufactured eitherThe following are the important characteristics of batch type production system:

As final product is -------------------------------------------------------------------- can be availed to some extent.


Machines are -------------------------------------------------------------------------------------- manufacturing.
Semi automatic, special purpose ------------------------------------------------------------------------------------------------------------------------------------- among the products.
Labor should be skilled ------------------------------------------------------- product batches.
In process inventory is usually --------------------------------------------------------------------- policies adopted.
Semi automatic material handling systems are most appropriate in conjunction with the semi automatic machines.
Normally ---------------------------------------------------------------------- repetitive nature of order.

ExampleWhen a bakery bakes loaves of whole meal bread, a large ball of whole meal dough will be split into several loaves which
will be spread out together on a large baking tray. The loaves on the tray will then together be cooked, wrapped and
dispatched to shelves, before the bakery starts on a separate batch of, for example, crusty white bread. Note that each loaf is
identical within a batch but that loaves can vary from batch to batch. Batch production is a very common method of
organizing manufacture. Good examples include:

------------------------------------------------------------------------------------Paint and wallpaper manufacturers


----------------------------------------------

4. Briefly discuss the terms:1) Acceptance Sampling


Acceptance sampling uses -------------------------------------------------------------------------------------------------

-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------ber of defects falls below


where the acceptance number or otherwise the lot is rejected.
Acceptance sampling procedures became common during WWII. Sampling plans, such as MIL-STD-105, were developed
by Harold F. Dodge and others and became frequently used as standards.
More recently, quality assurance ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- such as statistical process control, HACCP, six sigma,
and ISO 9000. Some use of acceptance sampling still remains.
Sampling provides one rational means of -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- and costly. Rather than evaluating all items, a specified
sample is taken, inspected or tested, and a decision is made about accepting or rejecting the entire production lot.
Plans have known risks: an ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- a known average outgoing quality limit (AOQL).

A single sampling plan for attributes is a statistical method by which the lot is accepted or rejected on the basis of one
sample. Suppose that we have a lot of size
; a random sample of size
is selected from the lot; and an
acceptance number
is determined. If it is found the number of nonconforming is less than or equal to , the lot is
accepted; and if the number of nonconforming is greater than , the lot is not accepted. The design of a single sampling plan
requires the selection of the sample size
and the acceptance number .
MIL-STD-105 was a United ------------------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------are widely held. Acceptance


sampling does not have to be complicated. Any company can optimize its procedures by remembering this list of
principles:

The protection level ----------------------------------------------- -- its AQL--and what it rejects-- its LTPD.

Selecting a statistically valid ------------------------------------------------------------------------------------------------------------------------------------------- a sampling plan that provides the desired protection.

Companies must know the ------------------------------------------------------------------------------------------------------------------------------------------------------ other source, and the protection provided by a plan does
not depend on the lot size; it's the AQL and LTPD that reveal what protection the sampling plan
provides.

PCC cannot serve as a replacement for acceptance sampling. Instead, these two techniques should be
combined by using the same data to control the process and to make product disposition decisions.

Sampling plans with the ------------------------------------------------------------------------------------- be reduced by


using equivalent double, multiple, or variables sampling plans as alternatives to single sampling plans
2) Process Control Charts
Process Control Charts-In order to provide --------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------process
incorporating carefully derived limits to indicate unusual behaviour. A control chart can be based on categorical information
or actual measurement. Accordingly, they are called control chart for variables and control chart for attributes.
Much has been written about the greater benefits to be achieved by using PCC (Process Control Charts) as opposed to
acceptance sampling. But although preventing defects is certainly more desirable than detecting them through inspection,
PCC does not eliminate the need for acceptance -----------------------------------------------------------------------------

----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------unnecessary:
in practice, however, all processes have some risk of failure, and thus some procedure for accepting and rejecting product is
generally required.

To reiterate the difference in these two approaches: acceptance sampling plans are one-shot deals, which essentially test
short-run effects. Quality control is of the long-run variety, and is part of a well-designed system for lot acceptance.
An observation by Ed Schilling Schilling (1989) said:"An individual sampling plan has much the effect of a lone sniper,
while the sampling plan scheme can provide a fusillade in the battle for quality improvement."
Control of product quality --------------------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------on process acceptability rather


than on product disposition decisions.

A statistical measure used --------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------is generally measured by a tstatistic.


Probability is a key factor in acceptance ------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------test and averaging


the results. When done correctly, acceptance sampling is a very effective tool in quality control.
The data from measurements of --------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- from "common" sources. "Common" sources, because they are an
expected part of the process, are of much less concern to the manufacturer than "assignable" sources. Using control charts is
a continuous activity, ongoing over time.
When the process does not trigger any of the control chart" detection rules" for the control chart, it is said to be "stable". A
process capability analysis may be performed on a stable process to predict the ability of the process to produce "conforming
product" in the future.

5. Discuss some of the important and frequently used systems for Stores Accounting.

Store Accounting:STORE ACCOUNTING STORE FUNCTIONS PRICING OF PURCHASED MATERIAL. PRICING OF STORE
RETURNED MATERIAL. MATERIAL RECEIVED ACCOUNT. ISSUE OF MATERIAL FROM STORE. PHYSICL
VERIFICATION OF STORE STOCK.

-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

Methods of Store Accounting:---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

Verification System:-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

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