DEPARTMENTOF MECHANICALENGINEERING

QUESTION BANK

VIIISEMESTER –IE6605PRODUCTIONPLANNING ANDCONTROL

QUESTION BANK
UNIT I INTRODUCTION
Objectives and benefits of planning and control-Functions of production control -Types of production – job, batch
and continuous - Product development and design - Marketing aspect - Functional aspects - Operational aspect
-Durability and dependability aspect aesthetic aspect. Profit consideration- Standardization, Simplification &
specialization- Break even analysis-Economics of a new design.

PART-A

1. Define production planning and control.

2. List various functions of PPC.

3. What is production system?

4. List the objectives of PPC.

5. What are the phases of production planning and control?

6. List the types of production system.

7. What are the objectives of product analysis?

8. List the various factors that influence the product design.

9. What is meant by standardization?

10. State the aims and advantages of standardization.

11. Define batch Production.

12. Define job Production.

13. What is meant by simplification?

14. List out the managerial uses of break even analysis.

15. What do you understand by break even analysis?

16. Write the significance of BEP.

17. What is Break Even Point?

18. List out the assumptions in Break even analysis.

19. How the plant layouts are related to type of production

20. Differentiate between product design and product development.

PART-B

1. i) What do you understand by production planning and objective of production planning? (E)

ii) Formulate the levels of production planning and Factors determining production planning.
2. i) What do you understand by production control and objective of production control?
(E)

ii) Formulate the scope of production control and Factors determining production control.

3. i) Compare the Relationship between production planning and production control with neat block diagrams (M)

ii) Explain the function of production planning and control with help of neat sketch.

4. Explain the phases of production planning and control. (M)

5. List out the function of Production planning and control. (E)

6. i) List out the limitation of break even analysis. (M)

ii)Enumerates the margin of safety and angle of incidence.

7. Tabulate the Comparison between types of Production. (E)

8. i) Explain the functional and operational aspects of product design. (E)

ii) Explain the durability, dependability and aesthetic aspects of product design.

9. i) Enumerates job shop and batch production systems. (E)

ii) Enumerates mass and continuous production systems.

10. Annual fixed costs at a small textile shop are Rs.50000 and variable costs are estimated at 50% of the Rs.40/unit
selling price. (a) Find the BEP. (b) What profit (or loss) would result from a volume of 3250 units?
(T)

11. i) Explain the product design and product development. (M)

ii) Explain the marketing aspects of product design.

12. The fixed costs for the year2000-01 are Rs.600000 variable cost per unit is Rs.40. Each unit sells at Rs.160
determine (i) breakeven point in terms of physical units and in terms of rupees (ii) if a sales volume of 5500
units has been expected, then what will the profit earned (iii) if a profit target of Rs.120000 has been budgeted
compute the number of units to be sold. (iv) If the company sells 6500 units , calculate the margin of safety and
profit. (T)

PART -C

13. Madison industries has the following data on costs at two volumes of production for a product that sell for Rs.50
(a) construct a two volume, break even chart. (b) Compute the variable cost, the contribution and the BEP (c)
using the contribution from (b), estimated the profit at a volume of 8000 units. (T)

Labour Material Overhead Other FC Total

6000 unit Rs. 60000 Rs.36000 Rs.54000 Rs.80000 Rs. 230000

10000 unit Rs.100000 Rs.60000 Rs.60000 Rs.80000 Rs. 300000

14. The annual fixed costs of a product are known to be Rs.3lacs and the annual net profit Rs.60000 the average
monthly sale being 1000 units a new design is contemplated involving the expenditure for preparation
amounting to Rs.120000 to be returned in two years .it is expected that with new production methods the P/V
ratio may be increased by 5 percent what should the annual sales figure for the new design be (i) so that the
same net profit will be realized (ii) so that in addition to this profit a yield of 10 percent on the capital invested
will be obtained. (T)
 UNIT II / WORKSTUDY
Method study, basic procedure-Selection-Recording of process - Critical analysis, Development
- Implementation - Micro motion and memo motion study – work measurement - Techniques of work
measurement - Time study - Production study - Work sampling - Synthesis from standard data -
Predetermined motion time standards.

PART A

1. What is method study?

2. List the objectives of Motion study.

3. What is Motion study?

4. Explain the various techniques of method study

5. Explain predetermined motion time studies?

6. Distinguish Motion and Memo motion studies.

7. State about critical analysis.

8. State about some recording techniques.

9. What is Therbligs?

10. Name the few charts used in motion studies.

11. What is meant by Ergonomics?

12. How idle time affect productivity?

13. How rest pauses improves productivity?

14. State about Pre determined Time studies (PDTS).

15. Distinguish Motion studies and predetermined motion studies (PDMS).

16. State how Ergonomics affects the productivity.

17. State about Work measurements.

18. Infer about work sampling.

19. Explain about Time study.

20. Why some allowances have to be added in normal time?

PART-B

1. Explain in details about Method study. (E)

2. Explain about Motion Studies in details. (E)

3. Describe about Therbligs in details. (M)

4. Illustrate the various charts used in motion studies. (M)

 5. Elucidate the critical analysis in method study. (M)

6. Discuss various recording techniques used in method study. (M)

7. Discuss in detail about micro motion and Memo motion studies. (M)

8. Estate about Work Measurements in detail. (M)

9. Describe in details about production study. (T)

10. Elucidate about Time study. (M)

11. Explain in details about Pre determined time and motion studies. (M)

12. Write in details about synthesis from standard data. (M)

PART C

1. Enumerate in detail about the importance Ergonomics with a simple case study. (T)

2. Illustrate the contribution of work study in improving productivity. (T)

UNIT III PRODUCT PLANNING AND PROCESS PLANNING

Product planning-Extending the original product information-Value analysis-Problems in lack

of product planning-Process planning and routing-Pre requisite information needed for process
planning- Steps in process planning-Quantity determination in batch production-Machine capacity,
balancing- Analysis of process capabilities in a multi product system.

PART-A

1. What is product planning?

2. What is the purpose of feasibility study in relation to product planning?

3. List the activities of advanced product planning.

4. List the information that can be obtained from the system operation concept.

5. How can you increase the value of a product?

6. What is value analysis?

7. Differentiate primary and secondary functions with respect to value analysis.

8. Mention at least six uses of value analysis.

9. When do you apply value analysis?

10. What is meant by process planning?

11. Differentiate between process planning and product planning.

12. Draw a simple stock control model with and without buffer stock.

13. List the factors affecting the selection of batch size.

14. What are the criteria for the selection of batch size?

15. List the information that can be obtained from the system maintenance concept.

16. What are the information required for machine loading?

17. What is meant by machine balancing?

18. What is the purpose of machine loading chart?

19. If the cycle time of the product is 3min. determine the machine output per hour.

20. Distinguish between value analysis and value engineering.

PART-B:

1. (i) What is meant by product planning? Explain in details the various steps involved in the product planning
process? (E)

(ii) ) Explain the various phases of value engineering?

2. Explain how the stock control of batch production is performed: (E)

(i) without a buffer stock and (ii) with a buffer stock.

3. (i) What do you mean by minimum-cost batch size? Also derive an expression for it. (M)

(ii) What is meant by machine loading? Also enumerate the various methods to the cycle time to a minimum.

4. Explain the importance of process planning with reference to production control. Discuss the activities involved
in process planning. (M)

5. What do you mean by machine balancing? Also explain the effect of balancing on number of machines required
with an illustration. (M)

6. Write detailed notes on analysis of process capacities in a Multi product system. (T)

7. Summarize the pre-requisite information needed for process planning with the steps involved in process
planning. (M)

8. Write short notes on: (M)

(i) Quantity determination in batch production. (ii) Analysis of process capability in a multi-product system

9. Explain the procedure for capacity planning for single/multi stage system. (E)

10. Explain the steps involved in the standard procedure for process planning. Also explain various types of process
planning method. (T)

11. (i) Discuss value analysis and value engineering. (T)

(ii)Explain how production quantity in batch production is determined.

12. (i) Describe problems of lack of product planning. (M)

(ii)Explain briefly the steps in value analysis.

13. (T)
 PART –C

1. (i) What is value analysis? Describe the basic steps involved in the value analysis. (T)

(ii) Compare and contrast the manual process planning with the CAPP

2. A gear manufacture has gear shaper and gear hobbers. The gear can be processed on gear\shaper as well as
gear hobber. The following information is given. Which of the two machines will you choose to do the job if the
order quantity is (i) 1000 numbers and order is unlikely to repeat, and (ii) 1000 numbers and the order is likely to
repeat for 3 years? (T)

UNIT IV PRODUCTION SCHEDULING

Production Control Systems-Loading and scheduling-Master Scheduling-Scheduling rules-Gantt charts-

Perpetual loading-Basic scheduling problems - Line of balance – Flow production scheduling- Batch
production scheduling-Product sequencing – Production Control systems-Periodic batch control-Material
requirement planning kanban – Dispatching-Progress reporting and expediting- Manufacturing lead time-
Techniques for aligning completion times and due dates.

PART A

1. List the key functions of the production scheduling and control.

2. List any six priority rules used for job sequencing.

3. Show the various recording methods for progressing purpose.

4. Name the various MRP output reports.

5. Recall the functions of expediting.

6. Show the various charts that are used in line-of-balance analysis.

7. Illustrate the purpose of operation programme chart.

8. Summarize any six benefits of implementing MRP system.

9. Compare aggregate planning and master scheduling.

10. Interpret the data required for production scheduling.

11. Identify the purpose of (a)workload chart and (b) Scheduling chart

12. Choose the various inputs required for MRP.

13. Select any six benefits of implementing MRP system.

14. Analyze the purpose of the master production schedule.

15. Examine the functions of dispatching.

16. Distinguish Product sequencing and priority sequencing.

17. Compare master Scheduling and EBQ Scheduling.

18. Explain scheduling? What are the objectives of scheduling?

19. Predict the use of Gantt charts and objective charts.

20. Discuss about production planning and production control.
 PART-B

1. Define Gantt charts? Explain their types? How are they constructed? (E)

2. Define priority sequencing? Explain any six priority rules used for job sequencing. (M)

3. A manufacturing facility has five jobs to be scheduled on a machine. Their sequence of arrival, processing
time, and due-date are given in the table below. (T)

Job Processing Time Due Date

(in sequence of arrival) (DayS) (i.e., days from now)

A 7 8
B 4 3
C 5 7
D 2 9
E 6 6

Schedule the jobs using (i)FCFS, (ii)SPT, (iii)DDate ,(iv)LCFS, and (v)STR rules. Also compare the results
(using the performance measures of total completion time, average completion time and average lateness.

4. i) Explain how Johnson's rule can be used for scheduling on three machines. ii) Five jobs are to be processed
on three machines the processing time in hours are given below find optimal sequence of jobs so the total
elapsed time (i.e., total flow time ) is minimized. (T)

Job J1 J2 J3 J4 J5

A 5 7 6 9 5
B 2 1 4 5 3
C 3 7 5 6 7

5. Write short notes on (M)

i) Aggregate run-out method of batch scheduling

ii) Line-of-balance method.

6. Discuss the concept, input characteristics, working, outputs and benefits of MRP? (E)

7. Identify the functions of Dispatching? Explain the various documents raised by the dispatcher. (E)

8. i) Explain progressing and it types? (M)

ii) Write the functions of progressing.

9. Choose five jobs in waiting for setting processed on a machine. Their sequence of arrival, processing time and
due- date are given in the table below. (T)
 Job Processing time Due date
(sequence of Arrival) (days) (days from hence)

A 4 6
B 5 7
C 3 8
D 7 10
E 2 3

Schedule the job using FCFS, SPT, DDate, LCFS, STR and random rules. Compare the result.

10. Examine six jobs that are processed on two machines A and B. The job is processed in sequence so that B
should follow A. Determine the optimal order in which the jobs should be sequenced. Also draw Gantt chart.
(T)

Job 1 2 2 4 5 6
Processing time in M/C A 3 5 4 7 1 3
(hrs)
Processingtimein M/c B 2 6 2 1 4 6
(hrs)

11. Four different jobs are to be done on 4 different machines. The matrix below gives the cost (in rupees) of
producing each job I on each one of the machines j. How should the job be assigned to the machine so that the
total cost is minimum. (T)

jobs Machines
M1 M2 M3 M4
J1 5 7 11 6
J2 8 5 9 6
J3 4 7 10 7
J4 10 4 8 3

PART C

1. i) Explain the procedure for developing master production schedule. (M)

ii) Define perpetual scheduling? Explain the steps in making perpetual schedule.

2.Two jobs J1 and J2 are to be processed on five machines M1,M2,.....,M5. The processing time and Machine
sequences are as follows. Schedule the 2 jobs on 5 machines so that the processing time is optimum.
(T)

Job 1:

MachineSequence M1 M2 M3 M4 M5
Processtime(min) 2 5 6 6 7

Job 2:
 MachineSequence M3 M1 M4 M5 M2
Processtime(min) 5 6 4 3 7

3. i) Explain the procedure by which scheduling 2 jobs in m machines can be done with suitable examples.(T)

ii) Two major parts P1 and P2 for a product require processing through five machine centers. The
technological sequence of these parts on the six machines and the manufacturing times on each machines are
given below.

PartP1 PartP2
Sequence of machines Time(hours) Sequence of machines Time(hours)

A 3
B 4
C 2
D 6
E 2
B 5
C 4
A 3
D 2
E 6

UNIT- V/ INVENTORY CONTROL AND RECENT TRENDS INPPC

Inventory control-Purpose of holding stock-Effect of demand on inventories-Ordering procedures. Two

bin system -Ordering cycle system-Determination of Economic order quantity and economic lot size-
ABC analysis-Recorder procedure-Introduction to computer integrated production planning
systemselements of JUST IN TIME SYSTEMS-Fundamentals of MRP II and ERP.

PART A

1. Define the terms inventory and inventory control.

2. Name the different types of inventories.

3. Mention at least four reason for keeping inventory.

4. Define the following term (a) lead time (b) re-order point.

5. When do you use ABC analysis?

6. List the "seven wastes" that becomes the target of elimination in JIT process.

7. Differentiate between pull systems and push system.

8. Interpret P system and Q system.

9. Compare One bin system in P model with two bin system in Q model.

10. Differentiate between anticipation and fluctuation inventories.

11. Identify any four objectives of inventory control.

12. Choose any six inventory control techniques.

13. Distinguish between MRPII and ERP.

14. Identify any four ERP packages that are widely used in India.

15. Distinguish between Independent and Dependent demand.

16. Examine the cost that are included in procurement cost and Inventory carrying cost.

17. Explain fixed-order quantity model?

18. Recommend the use of kanban in Production control system.

19. Discuss about i)MRPII ii)EOQ

20. Contrast lot size inventories with transportation inventories.

PART B

1. List and explain different types of cost in inventory system. (E)

2. Define EOQ? Derive the expression for EOQ when the demand of the item is uniform, the production rate is
infinite and no stocks-outs are allowed. (M)

3. i) Define Inventory and How inventories can be categorized in different ways. (M)

ii) Show the cost associated with procuring and holding inventories.

4. i) Explain the terms: lead time, Stock out, buffer stock, inventory carrying cost. (T)

ii) Distinguish between in-process inventory, safety stock inventory, and seasonal inventory.

5. The annual demand for an item is 3200 units. The unit cost is Rs.6 and the inventory carrying charges are
estimated as 25%per annum. If the cost of one procurement is Rs150,Determine (T)

i) Economic Order Quantity,

ii) Number of orders per year,

iii) Time between two consecutive orders

iv) Optimalcost.

6. Summarize fixed –period quantity inventory model? Also compare and contrast P-system with Q- system. (E)

7. i) Identify the effect of variation in demand on inventory control with suitable illustration.

ii) Explain selective control of inventory and explain various types. (M)

8. Explain ABC analysis? Explain its significance in the inventory control with suitable example. (E)

9. i) Describe a two card kanban system. (M)

ii) Compare and contrast a pull production system and push production system.

10. i) Discuss the important modules in ERP software. (M)

ii) Explain the methodology adopted in implementing ERP.

11. i) Examine the concept of JIT. How does it help the manufacturing system to improve productivity? (T)
 ii) Discuss the various basic elements of JIT that must be addressed for successful JIT implementation.

12. Perform ABC analysis on the following sample of items in an inventory (T)

Item Annual Price/unit (inRs)

consumption (units)
A 5950 5
B 21250 4
C 1000 8.75
D 2087 5
E 27600 2.50
F 28000 0.50
G 36000 0.25
H 911 4.10
I 300 2.90
J 29450 0.30
K 11500 8.15
L 3934 5

PART C

1. Explain in detail, the fixed –order quantity

inventory model? Also list merit, demerit and
sustainability of this model. [M]

2. Monthly consumption of an item is 500units. The

price per unit is Rs.25. Inventory carrying cost is
16 percent and ordering cost is Rs 50 per order.
Lead time of 1 month stock. For a ROL i.e., Q-
system determine

i) Re- Order Quantity ii) Minimum Level iii) Re-

order level, iv) Maximum level v) Average
inventory (T)