TEST ID: 408

ACE
Engineering Academy
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Branch: Mechanical Engineering
ESE-Offline Test Series– 2015 (Conventional- 8) Solutions

01(a). CONTROL CHARTS

Control charts are the plots used to monitor
Sol:
output or inputs of a process, which produces
(i) Process control:
a product or service for meeting the
When we consider products or services,
customer’s requirements. When we use
certain amount of variations are commonly
control charts to monitor the processes, it is
present in the quality characteristics which
called as statistical process control (SPC).
customer wants. These variations are due to
two reasons:
Classification of control charts
(i) Chance variations.
(ii) Variations due to assignable causes. Control charts
Chance variations occur in random manner
and there is very little that we can do about
them to control. These are natural to the
Control charts Control charts
process. It is due to aggregation of many For variables For Attributes
relatively small factors present in small
degree. Few example of chance variations are:
quality of raw materials, performance of
operator, minor changes in weather conditions X R or S P nP C U
like temperature, etc. These variations are Chart Chart Chart Chart Chart Chart Chart
essentially uncontrollable, inherent, random,
A control chart tells us whether or not a
chance-governed and commonly present. If
process is in statistical control, or whether or
the process shows only such variations, it is
not more than common cause of variation are
said to be in-control (i.e., statistically
present in the process. It informs us to
controlled).
determine and eliminate any special causes of
A different type of variations are due to some
variation present. The chart characteristics of
assignable cause. These variations are not
a process operating with only common causes
random and are relatively larger. It is
of variation are:
generally caused by only one factor and
1. All points fall within the control limits.
occasionally by a few factors. Some examples
2. An approximately equal number of points
are : Poor quality raw material from a new
on either side of the central line.
supplier, poor surface finish due to wornout
3. There is no specific pattern apparent.
tool, variation in the length of work-piece due
4. Most points are near the centre (the
to poor setting of machine, etc. These
middle third region) although a few (about
variations are sporadic, uncontrollable,
one-third) approach the control lines.
assignable and specific. Once, these variations
are present, process is called out-of-control.
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 :2:
The chart not satisfying the above
characteristic is pinpointing the presence of
special causes of variation, which needs
investigation and, if required, elimination of
such causes. We can therefore define certain
action rules applicable to all control charts in
general; these rules determine the
circumstances when action should be taken.
An action does not mean an action for
elimination (of the special cause); it means an
action for investigation for the cause. For
example, a point falls below the lower control
limit of an attribute chart for defects or of a
range chart for variable (if such a limit exists
that is positive), should prompt an
investigation of the circumstances for such a
situation, so that it can be repeated again in
the future.
Some of the basic action rules are given
below :
Rule 1: Action should be taken when at least
one of the plotted points lies outside the (3)
control limits. If the motive for the special
cause is understood and permanently taken
care of, the out of control reading can be
removed and the new control limits are
calculated. If the reason is not found, then it
must be accepted that the sample value is part
of the system which generated the limits.
Rule 2: (rule of seven). This calls for action if
there are seven consecutive points, either all
on one side of the mean, or all increasing , or
all decreasing. Since the probability of any of
these alternatives occurring by chance is very
small, a special cause in need of investigation
might be present.
Rule 3: Action should be taken when non-
random patterns are clearly shown in the
chart. A cyclic pattern might indicate that the
material from a specific supplier, or the
circumstances of a specific time period, might
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regularly have an undesired (or beneficial)
effect.
Rule 4: (Middle third rule). Action should be
taken when the number of plotted points in
the middle third of the total range between the
control lines is much less than two-thirds of
the total number of points. Care should be
taken when applying this rule in situations
when the distribution of the readings is
skewed, as in the range chart.
(ii) Theory of runs says that a decision is taken
only after the starting of process and see how
the process runs in the specified period. The
decision is not taken before starting the
process. This is done with the help of run
charts.
A run chart, also known as a run- sequence
plot is a graph that displays observed data in a
time sequence. Often, the data displayed
represent some aspect of the output or
performance of a manufacturing or other
business process.
Run sequence plots are an easy way to
graphically summarize a univariate data set. A
common assumption of univariate data sets in
that they behave like:
 Random drawings;
 From a fixed distribution;
 With a common location; and
 With a common scale.
With run sequence plots, shifts in location and
scale are typically quite evident. Also, outliers
can easily be detected.
Examples could include measurements of the
fill level of bottles filled at a bottling plant or
the water temperature of a dishwashing
machine each time it is run. Time is generally
represented on the horizontal (X) axis and the
property under observation on the vertical(Y)
axis. Often, some measure of central tendency
 :3:
(mean or median) of the data is indicated by a
horizontal reference line.
Run charts are analyzed to find anomalies in
data that suggest shifts in a process over time
or special factors that may be influencing the
variability of a process. Typical factors
considered include unusually long “runs” of
data points above or below the average line,
the total number of such runs in the data set,
and unusually long series of consecutive
increases or decreases.
Run charts are similar in some regards to the
control charts used in statistical process
control, but do not show the control limits of
the process. They are therefore simpler to
produce, but do not allow for the full range of
analytic techniques supported by control
charts.
Run Chart
100
90
80
70
60
percentage
50
40
30
20
10
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Date
(iii) A philosophy of manufacturing based on
planned elimination of all waste and
continuous improvement of productivity. It
encompasses the successful execution of all
manufacturing activities required to produce
a final product, from engineering to delivery
and including all stages of conversion from
raw material onward. The primary elements
of zero inventories (synonym for JIT) are to
have only the required inventory when
needed; to improve equality to zero defects;
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CONV – 8 Solutions
to reduce lead times by reducing setup
times, queue lengths, and lot sizes; to
incrementally revise the operations
themselves; and to accomplish these things
at minimum cost. In the broad sense it
applies to all forms of manufacturing job
shop and process as well as repetitive.
The objective of JIT system is to encourage
workforce to participate in the programmes
relevant for work improvement; profits
increase through cost reduction, inventory
reductions and quality improvements. Thus,
waste should be eliminated. This
philosophy is based upon two criteria:
(i) Just-in-Time (JIT) refers to production and
supply of required number of parts when
needed. So, it is referred to as JIT
production system. If work-in-process
inventories including parts and products are
expected to decrease (even to zero), this
system is called stockless (zero-inventory)
production system.
(ii) Another criterion is Jidoka (self-actuation),
i.e., when unusual event happens in a
production line, the worker incharge stops
the line and calls for help in removing the
cause of trouble.
KANBAN AND PULL SYSTEM
Kanban means card in Japanese language. In JIT,
Kanban cards are used to move material through
the production. Two common types of Kanban
cards are
(a) Withdrawal Kanban, and
(b) Production Kanban
The withdrawal Kanban is used to release
material from previous output area or vendor. The
production-Kanban works as instruction to start
production from a previous work centre. Thus,
material is pulled from a previous unit of material
processing or material supplier.

The process of Kanban system follows these steps
Step 1: The withdrawal Kanban reaches the
output area of previous stage. The worker brings
the Kanban to the store location of the previous
level.
Step 2: There could be a situation when enough
material is available. After comparing and
matching the part required on the production
Kanban with the withdrawn Kanban, the worker
removes the production-Kanban from the
container and places the withdrawal Kanban. The
removed production-Kanban is placed on the
production Kanban post.
Step 3: The production at the previous work-
centre starts when the post for production-Kanban
contains specified number of production-Kanban.
Objective Ideas
JIT
Waste
Automation
Eliminator
Trouble Free
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Step 4: The material at the previous work-centre,
which has just been tagged with withdrawal
Kanban, is transported to the next work-centre. It
is placed in this work-centre till the required
production starts here. In case of material
requisitioned from vendors, the work-centre
releases withdrawal Kanban at the time when
material is just needed from vendors.
Step 5: Once the material reaches at a work-
centre, the worker checks the withdrawal Kanban,
removes it and places it in the withdrawal-
Kanban-post. The material, however, is used for
production or shipment.
Technique
Pull system with Kanbans
Single minute exchange of die (SMED)
Level (smoothing) production (Fixed steady rate of production)
Cellular (flow) manufacturing
Standard operations
Multi-process (skill) handling
Multi-functional workers
Industrial engineering (IE)
Jidoka (automation)
Visual control
A cooperative spirit
Continuous improvement
Total productive maintenance (TPM)
Problem solving
Puka Yoka sustems
Reliable vendors
Quality inspection
Small lot sizes
Total quality control (TQC)
Quick low cost set-ups
 :5: CONV – 8 Solutions

Part Number _____ Preceding

process Part Number______
Part Name_______ Part Name ________ Process
Stock loacation at which to store:
Box Box Issue Container Capacity
Capacity type No. Subsequent
process (b) Production Kanban

(a) Withdrawal kanban

01(b).  2
d  31.66
4
Sol: Pinitial = 3kN d = 6.34mm
P = 10 kN  Nearest standard specification M8 is
Factor of safety, f .s = 2 chosen.
Syt = 400 N/mm2
Kc = 2 Kb 01(c).
Step 1:permissible tensile stress Sol:
S (i) The different forces acting during welding are
(t)per = yt (a) Gravity force
fs
(b) Surface tension
400
=  200 N / mm 2 (c) Eletromagnetic pinch force
2 (a) Gravity force : Gravity force helps the
Resultant load on bolt molten metal droplet to detach from tip of
Kc = 2Kb the electrode and attach to workpiece. But
 Kb  in case of overhead welding this is
P  P 
 Kb  Kc 
reversed.
(b) Surface tension : Surface tension force
 K  act in any welding position and it always
 10  10 3   b 
 3K b  an attaching force.
P = 3333.33 N (c) Electromagnetic pinch force : When
Resultant load R = Pi + p current flows in the same direction an
= 3000+3333.33 attractive force will develop and this force
= 6333.33 N is proportional to the square of current.
Size of bolt: (ii) Short circuit transfer :
R In short circuit transfer where there is a
(t)per =
A periodic contact between electrode and
R 6333.33 molten pool result in arc getting
A= =
 t per 200 extinguished. The current flow increases
which results in transfer of molten metal
A = 31.66mm2 from the electrode to weld pool.
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 :6:
Globular Transfer : When the settings of
current are higher the molten droplet size
increases and get detached by gravity and
molten metal will be filled drop by drop.
Spray transfer : When the current density
is raised higher the droplet increases
proportionally and significant amount of
electromagnetic forces starts acting and
droplets are pinched off resulting in spray
transfer.
01(d).
Sol: When many number of machines are
connected to the host computer having bulk
memory using telecommunication lines or
LAN so that a person sitting front of the
computer can able control all the machines is
called DNC. The DNC with flexible and
random movement of the material is called
FMS. For obtaining flexible and random
movement of the material, an automated
guided vehicle will be used in the DNC. The
FMS is used for batch production
applications, i.e. for medium volume of
production with medium variety of
components.
Dividing the components manufactured in
the industry into a few number of groups or
part families based certain similarity is
called group technology. The similarities
used may be manufacturing, design, size,
shape, material, cost etc. the machines
required for manufacture of each group of
components separately in different shop
floors is called group technology layout. If
FMS is implemented in each and every shop
floor independently is called FMC or
cellular manufacturing.
With this when a component enters into a
shop floor, it will come out as finished goods
only so that no transportation is required
from one to another shop floor. The FMC is
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manly used for manufacture of group of
components having similarities.
01(e).
Sol: Drive unit is the device used for converting
electrical energy pulses into mechanical
energy which is required for movement of
the axis of a machine tool. Hence for
converting electrical to mechanical energy
the device used is the electrical motor. Out
of the motors available at the time of
development the stepper motor is the most
suitable and preferable motor as drive unit in
the NC machine.
The stepper motor will take the input
information in the form of electrical energy
pulses and converting into mechanical
energy in the form of revolutions, but either
by changing the no.of pulses of electrical
energy input or by the changing rate of
pulses of electrical energy input, the speed
of the motor can be changed.
For Example :
If the specification of motor is
200 pulses = 1 revolution of motor
= 1 revolution of lead screw
= 1 pitch of liner distance
travelled by axis = 5mm
1 pulse = 5/200 = 0.025mm = I BLU
(basic length unit) or also taken as positional
accuracy of machine tool.
02(a).
Sol: Monte Carlo is the code name given by Von
Neuman and Shulam to the technique of
solving problems which are quite expansive
for mathematical development and
experimental solutions and to difficult for
analytical treatment
 Define problem
 Construct appropriate model
 Define starting condition for simulation
 :7: CONV – 8 Solutions

 Specify number of simulations Time to assemble one unit

line  100
 Use the above results to experiment with cycle time  no. of work stations
model 234
 Evaluate results of simulation  100  86.67%
90  3
 Formulate proposal
Balance delay = 100 - line
Process is done by usage of Random
= 100 – 86.67 = 13.33 %
numbers to identify various states
Idle time = (90 – 80) + (90 – 79) + (90 – 75)
representation.
= 10 + 11 + 15 = 36 seconds
02(b).
Maximum work allotment to a work station
Sol: Number of microwave ovens = 40 = 80 seconds
Time available = 3600 seconds Hence, every 80 seconds one unit can come
3600 out of the line.
Cycle time  = 90 seconds
40
Time to assemble one unit = 234 seconds 02(c).
Number of work stations
Time to assemble one untit Sol: FMS with automated retrieval of raw

cycle time material, automated storage of finished
234 goods and automated inspection system is
 ~ 3 called CAM. For automated retrieval and
90 storage AS/RS will used and for automated
inspection co-ordinate measuring machine
Work station II (CMM) will be used. CMM is the
25
C automated inspection device used for
Work station I
inspecting more than one dimension
20 55 40 40 simultaneously.
A B D 14 H The inputs required for CAM are
G  2-D production drawings
5
E
 Bill of materials ( BOM)
 Raw materials.
35 Work station III
F The process steps are
 Generation of part program
 Retrieving the raw materials from
stores
Work Elements Time Processing of raw materials
stations  Inspection using CMM
I A, B, E 20 + 55 + 5 = 80  Decision making
II C, D, G 25 + 40 + 14 = 79
III F, H 35 + 40 = 75 The outputs from the CAM are
 Acceptable components

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 :8: ESE Offline Test

03(a).
Sol:
(i) Steps in Time Study (Stop Watch Method)
The general step are :

1. Select  Select work for work measurement.

2. Record  Obtain and record all relevant information about job, operator and the
surrounding conditions.
 Record complete work description.
3. Divide  Breakdown operation into elements.
4. Examine  Examine the detail breakdown.
 Ensure the most effective method and motions being used.
 Determine sample size.
5. Measure  Use time measuring device like stop-watch to measure and record the time
taken by the operator in performing the elements of the job.
6. Observe  Assess the effective speed of working of the operator as compared to standard
rate in the perception of observer.
7. Compile  Compile the basic cycle-time for operation or work cycle.
8. Determine  Determine the standard time by adding relaxation and personal allowances in
base time.
9. Define  Define the total procedure of performing an activity along with time standards

(ii) Average observed Time :  RRA 

2  21  1 25  1 30  1 33 ST  NT1  
  100 
2 111  31.21  0.1  34.32 min
42  25  30  33 130
 
5 5 03(b).
= 26 minutes
Sol: Value means different things to different
Engineer I : people. The designer relates value with
AOT  R 26 100 reliability, purchaser with price paid for
NT    26 min
SR 1000 item, production person equates the value
 RRA  with what is costs to manufacture and sales
ST  NT1   = 26 (1+ 0.1) = 28.6 min person with customer is willing to pay.
 100 
The value is of four types:
Engineer II : 1. Cost Value: It is the sum of all costs
AOT  R 26 120 incurred in manufacturing the product. The
NT    31.2 min
SR 100 cost value is the sum of raw material cost,
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 :9: CONV – 8 Solutions

labour cost, tooling cost and other overhead overall cost without sacrificing quality and
costs to produce the product. reliability.
2. Exchange Value: It is the measure of all Value analysis is applied to the existing
the properties, and features of the product product with a view of improving its value
which make the product possible of trading while the value engineering is applied to the
(exchanging) with other products. product at the design stage and thus ensures
3. Use Value: It is the value of the product prevention rather than elimination. The value
which constitutes the amount of its cost analysis is an analysis after the fact and it is a
included to make the product work. remedial procedure
4. Esteem Value: It is the amount of cost
included into the product to enhance its 04(a).
customer appeal (desire to own).e.g., for a
motorcar bumper, its use value is very less Sol :
than its esteem value. (i) The required to lower the load
d
Value of a product varies according to the TR=F  m tan(  )
place and consideration. A balance between 2
use the esteem value is to be obtained. Where, dm – mean diameter
 - Helix angle of screw,  - friction angle
The term value analysis is used by a product
to obtain the relationship between ‘Utility’ Coefficient of friction   0.2
and ‘Cost’ while consumer uses it to find the tan   
relationship between ‘Utility’ and ‘Price’. As   tan 1 
a formula, the term value can be expressed as
follows: Friction angle,   11.3090
Worth 
Value  Helix angle, tan  
Cost d m
( Use  Esteem) for the Pr oducer   2P = 2  20 = 40

Cost Mean diameter, dm = d – 0.5P
Worth = 80  0.5  20 = 70 mm
Value 
Pr ice 40
( Use  Esteem) for the Consumer tan  
   70
Pr ice
  10.3080
The worth of an item depends upon two
factors, i.e., the performance desired from the dm
item, and second specific feature of TL= F  tan(  )
2
appearance which desired by the consumer
30  103  70  103
and for the consumer is ready to pay. =  tan(11.309  10.308)
2
Value analysis is an organized creative = 18.32 N.m
approach to ensure that essential functions of
a product or service are provided at minimum Collar Torque

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 D  D1  Velocity at 1, V1 = 2gh1
TC = F 0 
 4  = 2  981  10
 160  90  3 V1 = 140.07cm/s
= 0.2  30  10 3     10
 4  
m 12
Volume flow rate, Q  =
TC = 375 N.m  7900
-3 3
Q = 1.51810 m /s
Total Torque to lower the load Q = 1518.98 cm3/s
T = TL + TC
= 18.32 + 375 = 393.32 N.m Q = A1V1
1518.98 = A1140.07
(ii) Torque required to raise the load  A1 = 10.844 cm2
d  2
TR = F  m tan(  ) d1  10.844
2 4
30  1000  70  10 3 d1 = 3.715cm
 tan(11.309  10.308) A1
2  1.8708
= 416.08 N.m A2
A1
Collar friction remain same A2 
T = TR + TC 1.8708
= 416.08 + 393.32 = 809.404 N.m A2 = 5.795 cm2
 2
tan  d 2  5.796
Overall efficiency   4
tan(  )  d2 = 2.71 cm
tan(10.308)
=
tan(11.309  10.308)
= 45.98 % 05(a).
Sol: Caulking is an operation in which outer
04(b). bevelled edges of the plates is hammered
Sol: In order to avoid aspiration effect and driven in by a caulking tool, which is in
A1 h2 the form of blunt edged chisel.
  The riveted joint must be air tight joint in
A2 h1
applications such as boilers and other pressure
A1 and A2 are cross sectional areas at point vessel.
1 and 2  The outer edges of the plates used in boilers
h2 = 25 + 10 are bevelled so that this bevelled edges are
h2 = 35 cm caulked. The blows of caulking tool closes the
h1 = 10 cm surface asperities and cracks on the contacting
A1 35 surfaces between two plates and also between

A2 10 the rivet and the plates, resulting in leak proof
joint.
A1
 1.8708
A2
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 : 11 : CONV – 8 Solutions

 Great care must be exercised to prevent injury Tearing resistance of the plate.
to the plate otherwise caulking will result in Ft  p  d t t  p  20  10  80
opening of joint instead of closing it.  p  20  800 N …. (i)
 Caulking cannot be applied to plates with less
than 6mm thickness. Shearing resistance of the rivet,

Fs  n  1.75   20 2  60 = 32986.7 N ...(ii)
Fullering is similar to caulking process except for 4
the shape of the tool. Equating the relations (i) and (ii)
 The width of the fullering tool is equal to the (p  20)  800 = 32986.7
thickness of the plate being hammered.  p = 61.23, say 62 mm
 The blows of the fullering tool resulting
simultaneous pressure on the entire edge of Thickness of the cover plates
the plate. For double strap butt joint, the thickness of
each cover plate (strap) is given by.
Caulking tool t1 = 0.75t = 0.75 10 = 7.5 mm

Efficiency of the joint

Tearing resistance of the plate
Ft = (p d) t 1 = (62 20)  10 80
fullering tool = 33600 N
70-75o
Crushing resistance of the rivet,
Fc = nd t c = 1 20  10 120 = 24000 N
Shearing resistance of the rivet,
d 2
Fs = n  1.75  
05(b). 4

Sol: Given, t = 10mm; t = 80MPa;  1  1.75   20 2  60 = 32986.7 N
4
c= 120MPa;  = 60MPa. Strength of the unriveted plate (per pitch
Diameter of the rivet: length)
Diameter of the rivet, F = pt t = 62  10  80 = 49600N
d = 6 t ,  6 10  19mm Efficiency of the joint,
The nearest standard size recommended, least of Ft , Fc ,andFs
d = 20mm =
F
24000
Pitch of the rivets :   0.484  48.4%
As the joint is a single riveted, double strap 49600
joint; there is one rivet per pitch length, i.e.,
n = 1 and it is under double shear.
05(c).
The pitch of the rivets may be obtained by
equating the tearing resistance of the plate to Sol: Thermit welding is the joining process in
the shearing resistance of the rivet. which the heat required for melting and
joining of components is obtained due to
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exothermic chemical reaction. When the
initiation of igniting powder is given by
using match box, the heat generated due to
the burning of igniting powder and it is used
for initiating the chemical reaction taking
place in the thermit mixture so that the heat
generated due to the exothermic chemical
reaction of thermit mixture is used for
melting and joining of plates called as
thermit welding. The chemical reaction in
thermit welding is
8Al + 3Fe3O4  9Fe + 4Al2O3 + Heat
broken motor casings, connecting rods,
especially in the welding of pipes.
05(d).
Sol: Gray cast iron expands because graphite
has a relatively high specific volume and
when it precipitates as graphite flakes
during solidification it cause a net
expansion of the metal
05(e).

Fe3O4 + Al is called thermit mixture and due Sol:

to exothermic chemical reaction, three  The function of chills is to increase the rate of
products are produced, they are iron ( used as solidification in critical regions.
filler material ) , aluminum oxide (as slag)  Internal chills are usually made of same
and heat for melting. material as the casting and are left in the
casting
Thermit mixture (8Al + 3Fe3O4) – can be  External chills may be made of the same
ignited only at about 1200C but special material (or) may be iron, copper or graphite.
igniting powders are used to initiate the  Internal chills are mostly avoided in foundries
reaction at much lower temps Barium because there may be problems involved in
Peroxide (Ba2O2) or Ba2O2 + Al or powdered proper fusion of internal chills with the
Manganese are used as special igniting casting.
powders. A thin layer of this igniting powder
is sprinkled on the top of the Thermit mixture.
A red hot metal rod is brought in contact with
thin layer of igniting powder, thereby
initiating the reaction shown above which
releases tremendous amount of heat
producing a temp of about 3000C which will
change the iron into liquid state.
The thermo chemical reaction based on the
ignition of Thermit mixture is
Metal oxide + Al (powder)Al2 O3 + metal +
heat
Thermit welding is basically developed for
joining of railway tack rails in the remote
areas like hill areas and forest areas. Also
thermit welding is used for repair of heavy
parts such as tracks, spokes of driving wheels,

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