Ros Ne 13ME64 (To be filled by the candidate) (2013 Batch Onwards) COIMBATORE INSTITUTE OF TECHNOLOGY (Government Aided Autonomous Institution) COIMBATORE 641 014 B.E. DEGREE EXAMINATIONS, APRIL 2017 (Sixth Semester) MECHANICAL ENGINEERING BRANCH 43ME64 PRODUCTION PLANNING AND CONTROL (Common to PT BE Mechanical VI Sem.) Time : 3 Hours Max: 75 marks INSTRUCTIONS Answer all questions in Part A and as per choice in Part B. Part A and Part B questions should be answered separately in the same answer sheet. 3. Question No.11 is compulsory. Ro PART-A (10X 2 = 20) 1 Define modular design concept and list the features of it. Why do forecasting methods need to be monitored or controlled? Extended Play Stereo, Inc., sells 750 super power amplifiers per year and expects sales to continue at that rate. The holding cost is 22 percent of the unit cost per year, and the amplifiers cost Rs. 180 each. The cost to process a purchase order is Rs.18. () Whatis the E0Q? (i) How much will the company spend each year to order and hold super power amplifier? : ‘Why is trial and error method of aggregate planning widely used? State two general differences between independent and dependent demand. State the significance of Bill of material in production drawing. Draw product structure tree of a product of your own choice. 1s capacity requirements planning important? Justify your answer. een one List down the methods for performing lot sizing. 10. Awork center has the following open orders and planned orders for the period i. Calculate the total standard time required on this work center in the period i from the following information. ‘Order quantity ‘Setup time Run time(hrs/piece) Released Orders Part A 150 7 05 Part B 200 15 06 Planned Orders Pant 300 35 04 PartD ‘400 4 0.15 Contd..."1. 12, 13. 14. 15. a) by a) b) b) a) b) PART-B (6x11 = 55) Describe the major modules of Master Production Schedule (MPS) and the relationships among MPS, MRP, and CRP. m ‘What is the objective of Johnson's rule? Under what conditions it would be used? 4) ‘A production scheduler must determine the sequence in which to process four (6) customer orders. Each of the orders must go. through two principal operations: insertion and soldering, The scheduler has developed these production time estimates for the four orders: ‘Customer Order ‘Component Flow Soldering Number Insertion(hours) (hours) A 69 5.9 B 7.3 64 C 57 49, D 2.6 3.6 Ifthe operations need not change over to new jobs at the same time: (3) Use Johnson's rule to set the sequence of producing the orders in the two operations. (i) How many hours will be required to produce all the orders through both the operations? (OR) Explain what is meant by a material with dependent demand. Give an example and explain why its demand is independent. @® The Call-Us Plumbing supply company stocks thousands of plumbing items sold to regional plumbers, contractors, and retailers. ‘The firm's general manager, wonders how much money could be saved annually if EOQ were used instead of the firm's present rules of thumb. He instructs an inventory analyst, to conduct an analysis of ‘one material only (Material #3925, a brass valve) to see if significant savings might result from using the EOQ. Inventory analyst develops the following estimates from accounting information: Demand = 10,000 per year, quantity of material ordered at ‘each order point = 400 valves per order (present order quantity), carrying cost = Rs.0.40 per valve per year, and S = Rs.5.50 per order. om Describe the process of CRP with a neat sketch. : © Explain the relationship between material requirements planning and scheduling decisions, From where in the MRP system does the information for making shop-floor scheduling decisions come? © (OR) Explain the mathematical programming models for aggregate planning. ®) ‘Why is aggregate planning in produce-to-order firms difficult? What can operations managers do to overcome these difficulties? Explain how aggregate planning differs between produce-to-stock and produce-to-order firms. ® Contd.16. 17. 18. b) a) » a) b) 13ME64 Name and describe three qualitative forecasting methods used in business today. ‘Which qualitative forecasting methods would be appropriate for new products? Describe how forecasting is integral to business planning. © Explain how the moving averages method is different from the weighted moving averages method. Does AP = 3 or AP = § have the higher impulse response? Explain. ©) (OR) Define LDR and explain the costs involved in planning production and employment. (4) ‘An organization with a stable work force uses inventory, overtime, and subcontracting to meet demand requirements. No shortages are permitted, and demand must be satisfied through in-house production or subcontracting. The following data are available for the upcoming periods: Period Expected Regular ‘Overtime ‘Subcontract demand(units) | capacity (units) | capacity (units) | capacity (units) 41 1000. 600. 180 200 2 500, 500) 150) 200 3 700 600 180. 200, 4 ‘800 (650 200 200 5 ‘900 ‘600 180 200 6 [200 ‘600 180, 200 Total ‘4800 3550 1070 4200. ‘The beginning inventory at the start of period 1 is 200 units and the desired ending inventory for period 6 is 100 units. The relevant cost data are as follows: Regular cost /unit Rs.100 ‘Overtime cost! unit : Rs.125 ‘Subcontract cost/ unit Rs. 130 Inventory holding cost / period Rs. 2/ unit Determine the production plan that will satisfy demand at minimum cost. ” Define CRAFT and list down its features. What are the major disadvantages of using CRAFT? (4) Given the following initial layout, flow matrix, and cost matrix. Use CRAFT pair-wise ‘exchange technique to find the final CRAFT layout. @ 6 4 A TB] 7 ¢ [Tp] 7 Initial Layout Department [4 [2 [3 [4 1 12/3 2 3 214 3 112 2 4 213 [0 Flow Matrix (OR) Contd...49. a) _llustrate the types of manufacturing scheduling with an example each. ® b) The following table shows or Monday. The jobs have different operations they must times are in days. Jobs are listed in order of arrival. ders to be processed at a machine shop as of 8 a.m. go through. Processing Job Processing time | Due date(days) | Remaining number (days) of operations A 8 20 2 B 10 18 4 Cc 5. 25. 5 D 1 7 3 E 3 35. 4 () Determine the processing sequence at the first work center using each of the following rules: a) FCFS b) S/C (i) Compute the effectiveness of each sequence using each of the measures: (1) average completion time (2) average job lateness (3) average ‘fumber of jobs at the work centers. @