ABM (ist Sin)-Production S& Operation-14 2010 PRODUCTION AND OPERATION MANAGEMENT | Fourteenth Paper : Full Marks - 86 The figures in the margin indicate fill marks Candidates are required to give their answers in their own words as far as practicable Answer anp five questions 1. (a) What is flexible layout 2 6 j (b) Draw flow diagram of Group layout. 6 | © t advantages and disadvantages of Flexible and Group ! layout. 4 or From following matrix s Re-design the New lay-out of No. of trips between th shop where ariments are given } [ BC | y TE TE i} ; Die TF ' | 2. (a) Prepare Total Cost and inventory Maximum (") model when d= Average daily consumption | p= Daily production rate D = Annual Demand | Q= Economic Production Quantity, Set-up Cost / set-up | H1® Inventory Holding Cost 6 : ! [Tum Over} |(0) Annual Demnand = 2,000 kiz (2) What are ihe main factors to considered for locating manufacturing industey ? Ordering cost/order = R's, 100 Carrying Cost + Holding Cost= Rs. 3/kg be the No. of orders / year Or (bY What fetors will you consider for setting up of the following © Wnterational Air-Poxt Gi) Factory manufacturing engineering items (ii) Oil Refinery, (iv) Retail Cen 8Hx 2} (a) What is Quality Fmetion Deployment (QED) ? 6 (2) A QC Inspector has taken 3 samples with 4 observations, If ion of operation is 0,2 ; develop limits of 6 (6 operations from following data 10 ] Observations (®) What is the difference henwees Mass Production and Bateb (>) Explain Exponential Smoothing model of Forecasls. 10 Months | Actnat Sale ry Sa Catoulaie Fores: Pel month 4,5,6,7 5 assumii 3 | 56 : 3 forecast for month 3 is 61 4) 6 caeosy i “a 5 155. (a) Explain clastic zone of Manning. 4 (>) Explain Zurar's Quality Triotogy. 4 (©) The demand for a material is probabilistic ; following distbution I/(b—a) when b ~ 3,000 kg, a 1,200 kg. If shortage cost is Rs30/ky imd holding cost Rs.2/ee per annem, determine optimal oxdering quantity, 8 Or Write short notes on any three of the following > ) Time Study and Method Study, (8) Quatity Control methods Gil) Gant ¢ (iv) Heonomic Order Quantity () Bateh Process and Continuous Process, (i) Line Balaneing, 6. Write shovt notes (any four) @ QL 0b) Kaizen (©) QED @ ‘TPM (e) JIT @ MRP TL (e) Work-Coment 7A mannfacturing: wait passes through four clements of operation of Nornal Time (ND) of operations are 0,6 , 0,6 ; 0,72 ; 0,90 , if velasation time aliowed is 13% of NY and the no. of resous employed are 2,4,5,3 of 100 Nox are all 7.5 His : find out 85%). 16 respectively and setting time for the ba total operation hours, (considering work effst Sin)~Produetion & Oper jon: Mangl 14 2011 PRODUCTION AND OPERATION MANAGEMENT Bourteenth Paper Full Marks ~ 86 The figures in the margin inticaie full marks Candidates are required to give their answors in their own words as far as practicable Answer any five questions: Lf) What are the different types of Production. generally classified How ‘Batch type Production’ differs from ‘Project type Production’ ? 6 th) A mie operator bas ia perform wo operttions “Turing” and g' on maniber of different jobs. Thiwe requived to perform these operations (én Minutes) for each job is known, Determine the order in whieh the job is processed in order to minimise the toval fitne required to Finish all the jobs. "Vareadi 10 Job | Time for Turning | i ae 3 ' | 2 | i 3 | 5 9 7 | | I Hecate] 9 3 6 | i i (a) Explain. Exponential Smoothing Model! of For How t@ duvide the value of 'o! ; (mention the steps of L.S, Method} ? 6 fb) Sales figure for four months of an organisation are given below Find ovt Sale figure for the month of Five! using regression equation. 10 Month (X) Sales {¥) i 100 2 420 3 us 4 12s [Turn Over}[Durarion | | ' Activity Interitepences poe Ltd 4 {A \ : Ieee EEE \ 8 \ cut 6. | A 1 yb st N LE 5} B pL c ye} le i 1 es ! FG 1 ESL From above dat fay draw Novwouk and Mack Critical Path {b) find ous Project duration time fey AF project schedule i given 20 wks ane Rebate allowed Rs, 10,000/¥K caving end Project cost estimated RS. {50,600 « Inuirogt Cost esairmaged Bs 3.g00'wk sige Peige = RS. L302,000, what tl Be the cerisnated profit ? Iacciviy ‘and sue crashed by § 07k, wher will Be BeW project duration ? 4. fa) Explain TOM tool ‘53° Five 'S. «hy fixplain tre concept of ‘Qusity Loss Function (QL) of Taguettl ret Explain howe Conkinuonss Draven of Quality is possibte wiht uran’s ed Goods: ongepl of F acing, Percent detect in Fin 5. tai W with Flew Diagram) ss Line tayout Mow ts it fos wth exible yest cExpiain Jp) From the table below + find ear proposes ayou existin cout i ips benween the Depts > pe hospital: the 0Deph. ~ Closeness Rating between Depa A BoC op Rating : A = Absolute Necessary 1 Patient Convenience B= Especially Important 2 Sharing of Medical sta L= Important 3 Access to Equipment O= Ordinary 4 Patient Privacy Us Un-Important X = Undesirable &. (a) What are the factors which are to be considered for location of a Factory ? (6) A choice has to be made between three alternative locations Ll, L2 ato oleate the optimal region for seting up of the facility, The table given below considers the multi-criteria decision variables and their corresponding weighiages : focation Fixed Cost Working Transponn Expos: LA (Rs Ce) Capital’ network — potential Hub Index yr(Rs. Cr} index index availability index 200 150 3 3 3 320 200 3 2 215, 2 2 Factor 7 Wei 3 2 Use appropriate multiplicative-ctiteria model and create a prefevence ranking for the locations. 8 (6) Application of Price Discounting in EOQ decisions. 4 Answer any three ofthe following alongwith illustrative examples SSH (a) Use of Index Method for Job-Machine Loading Problem and estimation of machine idle times for optimal loading schedule | (6) Estimation of Buifer-Siock and Safety-stock Levels and Re-order | levels for an inventory control management system, i {ch Estimation of activity standard time based on normal time, rating and Percentage allowance for personal needs, delays and fatigue. (4) Estimation of systems reliability for production unit with series and Tm redundancy configuration, Er . {c) Sequential production plan for a 3-machine 5-job problem and fy) a Fare nation of total minimum process time, average job waiting time and machine \e( USRARY ep idle times a, Oa {) KANBAN, KAIZEN and JIT — Concepts and application, a (g) TPM and MRP-I and their uses. (1) Derivation of Economic Order Quantity Model with assumptions t@ 2012 BUSINESS ADMINISTRATION Fourteenth Paper (Production and ‘Operations Management) ‘Fall Marks ~ 80 ‘Phe: figures in the margin indicate full mares Candidases are required to give thelr answers in their own words as far as practicable Answer any fire questions 1. fa} Determine the total completion time of the following jobs in oplimal sequence anid the il time of toial wosk centres i Yeoh Too! Lt, ft seeds to prooe “EDM Cepite’ and thereof in *Miling Machine’, Tae proces 3s follows 18 Processing ‘ime for Jobs (in hours) Job EDM Centre Milling Machine A 8 3 R 3 9 12 6 D is n 10 B® (2) Describe the “Sequencing” process and its mnportance in production planning, 4 2. fal othe production process toca particular bearing at Goliath Hagineering Company, 19 samples, for ihe diameter over a 10-dty period, of 5 bearings in exch ‘stmple were taken, The individual observations from each sataple ae prosented below, Draw the meab and mange chact and comment on the process. Consider the vals comespanding 1 semple of five ts ;D,=07,= 2.11 and A, = 058. 10 Observations (easing diameter in cra) Sample : 2 3 4 5 1 502 SOL 454 4994.96, 2 SOL 303 5.074, 499 500-493 492.99 (are Over!4 503 A9T SO 9.9 5 495 4955.03, 505 s.at 6 491 3.08506 4.96 5.03 7 S05 5.015.204.9699 8 509 510 5.00499 5.08, 9 514" 510 49950859 0 501 4.98 = 5.085.078 (6) Establish and comment on the p-chart with 3-sigma Timits for process ‘onrrol from the following data for defectives in’20 samples each of 100 units, Number OF defecives in the samples are 6,0, 4, 10, 6,4, 12, 10,8, 10, 2, 10, 14,8 6,16, 12, 14, 20 and 28 respectively. 3 (@) Describe Product and Process layout with their advantages ant disad vantages. {2) State the factors involved in facility location decision and ilfusesate ‘with an example as w how to select the lovation outof four possible cation alternatives (A,B, C and D) using ranking method, or Aclars for selecting the location of a power plant and fa) G) State the itlesuete fe with exemp! 4) Suggest some weightexes giv YoU, giving brie’ reasoas for cack, (ii) “Take 3 hypomesical candidates for the location and assiva them ‘elves based on your judgment. Now rank the carudidates based on total marks scoted ang recommend the best alternative, g che various factors Fisted by (0) What ate the types of process in an operations? (Wh five the pras and cons of puocess andl product layout? fo) Novel Products Lad. has the demand data for its product feo January through December and these ate : 37, 40, 41, 37, 45, 30, 43, 47, 56, 52, 55 and 54 Units respectively, Find the forecast in nest Janbary with» 3-monthsieighted moving average wit « weight of 50% for December data, 33% for the November data and 2 ‘weight of 17% for October data. (6) Using theabove data, ind aor the forecast for Nevernbet next Jantiary considering a smogihing constant method, - Decentbor aad “2 in Exponential Smocihing. £6) Discuss oa ‘Delphi Method” and “Jury of Executive Opinion" for forecsssting, éene) 5. {@) A inannfacturer sells special purpose welding gloves to workshops. The ‘Aosiuat deonand is approximately 1,200 gloves. The compeny pays Rs, 28 for each sloves and estimates tat the anual folding cost is 30 per cent of ils value, {costs ‘pproximately Rs. 20 to place an order (avinagerial and clerical costs). The company cunently orders 100 gloves per month. 4) Determine the economie order quantity (OQ). 2 (i) How mnany orders will be placed por year using the BOQ? 2 (b) What is selective inventory contol? 2 (oj Briefly describe features of VED analysis and PSN analysis. 4 {d) Describe the ordering, holding and total inventory costs for the EOQ. 6 6. (a) What ave the inputs © aud outpuis from a MRP system? 4 (5) Whee is a master produetion schedate? 2 (© Ins manufhetaring company the relations for product PI and P2, sub assembly $1, $2, $3, $4 components CL. C2, C4, C3, C5, C6, CT and C8 and Raw ‘Material M4 aze as below : @ Progact Pi peels 1 S1 and 282 GH Product P2 needs £83 ax! t $4 end 2.07 Sub assembly St needs | C1, 4.02 and 1.3 G0) Sub assembly 82 needs 2.C4, 2 C5 ant 1 C6 ) Sub assembly $3 needs 1 64,4 C6 and 2 C7 (vi) Sub assembly $4 needs 2C2, and 1 C8 (4) Componem C4 ia sub asseatbly $$ needs | M4. TER schedule for PL and P2 for week 6 10 10 is given Betow At week 3, 40 units of raw malezial M4 is soliduled to be received, ‘Tee om hand quantity st beginning of week 3 for MA is 30 units, The lead times are as below ‘Lend tinte of assembling PI, P2, $2 end $3 ape | week ‘Lead time of mansiacturing component CA is 2 weeks Lead time fe procuring Mi is 3 weeks. (¢) | Caleutate planned onder release schedule and quantity far raw material MAL or weok 3. 6 (Turn Overy4 7. fa) What ore the principles of time study aud method! study? (b} Define normal time and stondant thine, fo} “The data given in dhe table telow ane the time ciudy of an operstion consisting of two elements, ‘The time study data in aninvtes is given below for the 2 elemenis : Hlement 120.14, 0.14, 0.15, 0.16, 0.20, 0.14, 0.18, 0.16, 817, 0.13 Blement 2 5 0.05, 6.05, 6.06, 0.06, 0.08, 0.05, 0.09, 0.07, (0.07, 0.09 During dhe time study clement t was sated at 90% and elesnent 2 st 12046 Tout allowance to be given forthe operation i fixed wi 12%. Determine the standart time for the operation, & (a) Inagazes gale plaaming what are the options management has i mexting Fiucuating demands? (2) What are kinds of cost invotved associated with the options? (6) A mini st stouewurals and shoes. plans produces many prodvet groups ike round, e projected aggreyate demand 2 Gat, for al pragducts in standard is showa below Period Expected Peviod Expected demand demand ' 200 9 2 180 6 230 4 220 u 240 4 150 2 210 100 b M40 ; 6 200 ! | 4. 450 5, | 8 300, 16, iagenwat wants to make a choice beiween GH) promeiny st awaiforn site of 200 units per periedt and (b) aay other sultabte ptan. Phe asstinpstions ae ¢ 1, AN shortages ara bck 2. Maximion overtime is 20% of ra | 3. Overtime is preferead to sub contracting |4 6 7, 8 9. si R ular tine production before the perio 1 is 18 Cost oF 5 gular time production = Rs, 20,000/enit Rs, 26,000rait Cost of 6 Post of sub contracting = Rs, 29,000/anits units (9) Cost of set up change (increase or decrease) = Rs, 5,000/anit Inventory carrying cost = Rs, 2,000/miv/period est an alt OVperioa, pate plan and evaluate it with dhe managements plan of producing at an uniform rate of 10i f é i i a = ee ce me \S ABM (2nd Sin.) ~ Production and Operations Management ~ 14 2014 PRODUCTION AND OPERATIONS MANAGE ENT Fourteenth Paper Pull Marks — 80 ‘he figures in the margin indicate full marks Candidates are required to give their answers in their own words as far as practicable Answer amy five questions 1. (@) How many schedule sequences can be created if five jobs are processed through three machines ? 4 {b) Moulded items are produced in two stages. The table given below relates to six jobs to ges Sy atst Se ¢ processed through sta Jobs Jk Ss da sd Ss 4 (Colouring) | * (Moule 86 49 3 a8 8 7 6 10} imminsy ()Obmin the optimal sequence for the joh GH Bstimaie the maint processing, tine for all jobs. 4 Gi) Detenuine job and processing stage idle times. 4 2. (2) What ove the basic considerations for selecting & suitable tocation for an integrated steel plant ? 4 (b) Three altemative facations are being considered for setting ups of a shipyard. The eclevant data relating to the follow multi-criieria are tabled below Transport Hub ELA Availability Index Contains Handling Capacitylyn Akemnate Fixed Working Locations Capitel RxCr) — Capital (Rs.Crlyi.) fadox la 2000 700 10,000 3 3 12 1800 600 16,000 3 2 13 00 wT. 14,000 _ Sere: Preference 3 Weizhtages 9 asetaeeat eee (High Weightage = 5, Medium Weiglttage ~ 2 , Low Weightage = 1 ) Use MCDM snethod to yank the three locations in order of preference 12 [Curn Over2 3. (@) In fine layout, how the backtracking of the work piece is prevented, 4 (b) The various tasks comprising a job is given below immediate ‘Task Time TW predecessors (minutes) a 09 b a 04 € b 06 a ¢ 02 e € 03 f de 04 8 f 0.7 h 8 Ll 46 12 4. Indian Fine blanks company wants to use SPC to monitor the diamete of the blanks, Every 3 sninutes, they took random samples as below from the blanking press production Jine and carefully measured the dimmeter of the blanks. ‘Phe results are zeported in the table below. | 3509 | Ba 553.0, 4 [3 1 330.8 sis Values of 82, D3 and D4 | Samo cae ya Ls (2) What kind of comrol cha diameter of the fine blanks ? ' (b) Determine the three-sigma contro! fimits for this chart 22 (©) Plot the average diameter for each saraple on the appropriate chavt Js the process in-control with respect 10 the average volume? What action should be taken ? m1 (@) What kind of contre! ebart should be used to monitor the spreud or dispersion of values of diameter ? 1 (e) Determine the three-sigma contro! timits for this chart 22 (D) Plot the diameter range for each sample on the appropriate chart. 's the peocess in-control with respect to the diameter mange ? What action should be taken ? 23 5. @) Why demands of components, assemblies and sub assemblies in a MRP situation are called lumpy demand ? Explain by giving examples, 2 () Explain the terms manufacturing lead time and purchase lead time, 2 (©) What are the inpuis and ontpnts of a typical MRP system ? 212 (d) ‘The lead time to procure paracetamol from a supplier is 4 weeks AC present 54 kgs of the drug is available with us, There is also a scheduled receipt of 45 kgs of it in 4 weeks. ‘The production vequirement of the diug over the next nine months are as below or Lo HEE feat tate fo) Tf we use aan order quantity of 45 kgs, when shall we release the orders for paracetamol ? 8 6. (a) Distinguish between CNC , DNC and PLC. (b) What is a 3D printer ? Why it is called Additive Manufacturing ? (c) What are the 6 pillars of World Class Manufactuning ? 3 (@) Jo & Flexible Mamnfacturing System, what exactly is meant by flexabitity ? 5 or (@) A company manufactures 10,000 cricket balls in a shift. ‘The defects in the balis mansfaeiured can be a misprint of the logo, improper polish, wht and separated seatn thread, Al the end of a shift, it was under oF overwei found that 10 balls we poor polish and 10 balls did not have proper logo printed on the balls. What is the sigma limit of the process ? The following valves are given 7 underfoverweight, 3 balls had bad seams, F batl had DPMO — Sigma 691,500 4 3,08,500 2 66,8003 6200 4 34 6 (b) What is the finicamental difference between the TQM approach and the six sigma approach ? Explain giving examples, 4 (©) Write true or false 165 () DPMO means defects per million occurrences, cls can occur even with a mean shift (i) Six sigma quality lev equal to 1.5 times the standard deviation. Gil) Half the tolerance is equal to the distance from the target 10 the upper specification limit. [Turn Over}\b 4 Gy) A change in the quality levet from 3 to 4 sigma represents a § fold improvement (¥) Six sigma represents a quality level of 3.4 defects per thousand opportunities. 7. A manufacturer sells special purpose cutting tools to workshops . The annual demand is approximately 2400 tools . The company pays Rs. 2800 for each tool and estimates that the annual holding cost is 30 percent of its value. ft costs approximately Rs, 200 to place an order (managerial and clerical costs). The company currently orders 200 tools per month. (a) Determine the economic order quantity (20Q), (2) How many orders will be placed per year using, the BOQ? (©) Determine the osdesing, holding, and total costs for the EOQ. (@) Wa discount of 11% is offizred by the supplies , for exer quantity of 500 and more , will you take the discount ? (e) What is selective inventory contro} ? (1) Brietly deseribe Features of VED analysis and SN analysis, or (@) What is Aggregate Phuming 2 What ate the different costs involved in aggregate planning, ? How are fluctuation demands accommodated in this planning, process ? yar (®) The following data rel es to assembly of a processing system Aciivity Duration (Wks) Interdepencial A 5 B 8 A c 7 A D 9 A BE 6 B F 5 c G 10 D HW 1 BG I 8 B (i) Draw the activitystime schedule for the above processing job. (i) Find the project duration time i weeks. Gi) (project schedule is given 40 weeks and rebate allowed Rs. 15,000/wk saving, and project cost estimated Rs, 80,000 ; Indirect Cost estima Rs, 4,000Avk ; ‘Tender Price = Rs, 3,25,000, what will be the estimated profit. If (Gili) redixce floor space and © 2 Ga) lower production cost. 2d 2. (@) In job-shop scheduling, wha is the difference between taniness ‘and lateness? 2 (8) What ithe numberof possible sequences in ease Fa job shop with 5 jobs and 2 meehines ? 2 (©) nani problem there are 6 jobs with processing tines 4,8 5, 9,2 and 6 units respectively. Due dates ave 10,8, 12,15, 9 and 20 units respectively Find the optimum sequence so as to minis the mean flow time: ‘ (@ Find out Mean Flow time, Average Inventory, Mean Tandiness and ‘Mean Eas at 3. Flex and Co, purcises pope ells in bulk with an annaal demand of £6500 units. costs the company Rs 75 to place an der. If stated thatthe Fnventry erring cost 8 25% por ust per year. (a) What should be the optimal order quantity, given the folowing 2 rice break ? (6) A company follows 4 perce roview system in which the average annual demand = 20,000 nis, Unit price = Re 10, Ordering cost » Rs 100, Inventory carrying cost rate = 279%, “vg, lea time ® weeks. nd, out the review period.4. A Prodetion manager is eoscenved about the diameter ofthe outer race of @ bearing manufactured in the factory. He never wanted the Aimeter to be more than 160 em and less tha 137 em, He decided to doa study othe samples for 10 days and collected three bearings and measured ths diameter. Following is the samples and the reaings Sample no Readings 1 150 160158, 60159155 Iss 150 150, Aso 15058 10135 150 159160145 150150150. 13155. 160 6060. 160 150160 165 TE 03267 1.880 3) 0 257s 107 4 0 22079 1046 Rel Tne Capac» 200 nitsperigd “Max Overtine = 20% of Keeler Vme Capcity etn feb Subcontract ‘Assiumied Initial Inventory 0 inal Ril ine Pro, Capiy~ 180 ‘Maximum regular prod /month = 19 units Makin vetine prod not Govt el pris = 30 Cont of OT prd= Re 5h Inver crying month Vit Cox of sconating pra Rs ht Opening inventory = 10 its I Cost of p= 200i change per o:easion 4 units 6 (@) What are the compsnenis of « Time-Seres Forecasting Medal usa (0) The folowing abe elses to monthly demand fr a Fert ae over 10mm psi Month (2015) Demand (Te) Feb 2 lan 30 Mar 48 April May June daly Aue Spek "0 S060 70 55. gs? 4 the month wise demand forthe eonesponding denned for Re. cate year was Month 2014) Demand (Te) fan 40 Feb 30 Mar oo April May 450 Fstimate the de-sensonaised Des Revised Forecasts for 2015 for the product, June July Aug so 6. is, ck et (©) What are Tracking Signals? Mention two such signal 2 nerd 5. Formulate the most economic monthly prod sont prod onthe bss of loving forcast of geet en Ie =| oat Ae 2 a mt Further informatie ; VAM haps tekiogeod ; 1. (@) Wo ae te fats i te 0 eons fr hvaion sfetscony? ° (Wa re the ls apical fr singe end lean iis? Sets to adelante asa oe. and 1 (oectesne bet part oat fra ity. bel bua Ssh on muse dion varies ia ‘conseratons and corresponding preference weightage Factors applied : Highest = 3, Moderate» 2, Bie= (Wei 7 ep4 J Working Exot Ga capital: SAREE Porental sp Location Cost Capitalve SN indes POR! Suppo | tis cca MHMALIMES “nies “TE u ao ito 1 3 2 > BP 2 2 be 3S 3 2 Weighages eer eeneaa vce appropriate wultiplicaive criteria model nd behiy (preference ranking forthe locations (€) tw the case ofa tied ranking how would you resolve (He or A camer manures ended aber ms wes RP availability is some {Wsproduction materials planaing, On addiive’s availability To counter swkien spurts in is requirements, a safely stock of Sui Ye recommend. The able below provides al vequisite information on Haas, intuit During which woeks should the reeigts be planned? When shold slaced ? What would be the on han stock a! week 8 ? IFordering cost Pater, holling cost is Rs. 6 / unit / eck. What is the total cost aa