ONLINE FINAL EXAM

SEMESTER I, SESSION 2021/2022

COURSE CODE : SEMM/SKMM/SKMP3813

COURSE NAME : INDUSTRIAL ENGINEERING

SKMM/SKMB/SKMP/SKMV/SEMM/
PROGRAMME : SEMP/SEMB/SEMV/SEMMH/SEMPH

QUESTION NO. : QUESTION 1/4

DURATION : 45 MINUTES

DATE : 19/02/2022

PART : 1 (10:00 AM – 11:50 AM)

INSTRUCTIONS TO CANDIDATES:

1. This paper consists of two questions.

2. It is divided into two parts.
a. Part 1 – Questions 1 & 2 (10:00 AM to 11:50 AM)
b. Part 2 – Questions 3 & 4 (02:00 PM to 03:50 PM)
3. Each question will be answered one at a time.
4. 45 MINUTES is allocated for Question 1.
5. Each question is protected by a password and it is published at a
specified time.
6. A buffering time of 10 MINUTES is given for answer script
submission.
7. Only HAND WRITTEN ANSWER SCRIPT is acceptable.
8. Write your FULL NAME on each page of your answer script.

WARNING!

Students caught copying/cheating during the examination

are liable for disciplinary actions and the school may recommend
the students to be expelled from the University.
 -2-
SEMM/SKMM/SKMP 3813

QUESTION 1 (20 MARKS)

1.1 Company OneA Sdn. Bhd. manufactures plastic table. The quality department conducted
inspection of defects on each table surface. A total of 15 tables were collected and
inspected. Types of defects discovered during inspection were flow lines, sink marks,
vacuum voids, surface delamination and short shots. The defects found on each table
surface are summarized in Table 1.1.

Table 1.1: Count of defects per each table surface

Subgroup Count of defects
1 8
2 4
3 10
4 2
5 8
6 2
7 10
8 12
9 6
10 0
11 18
12 10
13 0
14 4
15 14

a) Determine the appropriate type of control chart for the above quality inspection.
Then, establish the control limits for the suggested control chart. Assume that the
process includes 99.73% of the associated random variation.
Note: All answers need to be calculated up to two (2) decimal points.
(3 marks)

b) Based on the answer to Question 1.1(a), plot the control chart, comments on the
plots and suggest any action to be taken.
(4 marks)
 -3-
SEMM/SKMM/SKMP 3813

1.2 The customer of product AR has given a specification for its diameter 205 ± 0.5cm. The
standard deviation () of the current process is 0.08cm. The process is known to operate
at a mean (µ) diameter of 205.3cm. Determine Cp and Cpk of the process and interpret the
Cpk result with help of sketches.
(3 marks)

1.3 A product ZZ is made up of three (3) components Y1, five (5) subassemblies B and two
(2) subassemblies C. B is assembled from three (3) subassemblies D and four (4)
components E. Each D is assembled from two (2) components P8 and four (4)
components F. Each C is made up of two (2) components G and three (3) components R.
Table 1.2 shows lead time and on-hand inventory for product ZZ, subassemblies and
components.
Table 1.2: Lead time and on-hand inventory data
Lead Time On-hand inventory
Item
(week) (unit)
ZZ 1 0
Y1 3 118
P8 2 0
R 2 0
B 2 545
C 1 178
D 1 500
E 2 0
F 2 0
G 3 235

a) Construct a time phased product structure for product ZZ to fulfil the demand in
week 13.
(3 marks)
b) Gross requirements for product ZZ in week 13, 11 and 10 are 132, 200 and 250,
respectively. Develop a net material requirement plan for B, G and P8 using the
table provided in Attachment I (Please print OR copy this table and attach together
with your answer script). Ordering of materials/parts is based on lot-for-lot policy.
(7 marks)
 -4-
SEMM/SKMM/SKMP 3813

VERSI BAHASA MELAYU

SOALAN 1 (20 MARKAH)

1.1 Syarikat OneA Sdn. Bhd. merupakan pengeluar meja plastik. Jabatan kualiti
melaksanakan pemeriksaan kecacatan ke atas setiap permukaan meja. Sebanyak 15 meja
telah diambil dan diperiksa. Jenis-jenis kecacatan yang telah dijumpai semasa
pemeriksaan ialah flow lines, sink marks, vacuum voids, surface delamination dan short
shots. Kecacatan yang ditemui bagi setiap permukaan meja telah diringkaskan dalam
Jadual 1.1.

Jadual 1.1 (Rujuk Table 1.1)

-----------------------------------Sila rujuk versi Bahasa Inggeris--------------------------------

a) Tentukan jenis carta kawalan bersesuaian bagi pemeriksaan kualiti di atas.

Kemudian kirakan had-had kawalan bagi jenis carta kawalan yang anda cadangkan.
Andaikan bahawa proses merangkumi 99.73% variasi rawak yang berkaitan.
Catatan: Hadkan semua pengiraan kepada dua (2) titik perpuluhan sahaja.
(3 markah)
b) Berdasarkan kepada jawapan bagi soalan 1.1(a), plot carta kawalan di atas dan beri
komen ke atas plot yang anda perolehi serta cadangkan sebarang tindakan yang
perlu diambil.
(4 markah)
1.2 Pelanggan produk AR telah memberikan spesifikasi diameter produk AR iaitu 205 ±
0.5cm. Sisihan piawai () proses sediada adalah 0.08cm. Proses beroperasi pada purata
(µ) diameter 205.3cm. Tentukan nilai Cp dan Cpk bagi proses dan tafsir keputusan Cpk
dengan bantuan lakaran.
(3 markah)

1.3 Produk ZZ di perbuat dari tiga (3) unit komponen Y1, lima (5) unit subpemasangan B
dan dua (2) unit subpemasangan C. B dipasang dari tiga (3) unit subpemasangan D dan
empat (4) unit komponen E. Setiap unit D terhasil dari pemasangan dua (2) unit
komponen P8 dan empat (4) unit komponen F. Setiap C di perbuat dari dua (2) komponen
G dan tiga (3) komponen R. Jadual 1.2 menunjukkan masa mendulu dan inventori di
tangan bagi produk ZZ, subpemasangan dan komponen.

Jadual 1.2 (Rujuk Table 1.2)

-----------------------------------Sila rujuk versi Bahasa Inggeris--------------------------------

a) Bina struktur produk berfasa-masa untuk produk ZZ bagi memenuhi permintaan

pada minggu ke-13.
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SEMM/SKMM/SKMP 3813

(3 markah)
b) Keperluan kasar bagi produk ZZ pada minggu 13, 11 dan 10 masing-masing ialah
132, 200 dan 250 unit. Sediakan satu rancangan keperluan bahan bersih untuk B,
G dan P8 dengan menggunakan format jadual yang disediakan di Lampiran I (Anda
boleh cetak ATAU salin jadual tersebut dan lampirkan bersama skrip). Pesanan bahan
mentah/komponen berdasarkan kepada polisi lot-for-lot.
(7 markah)

~~~~~~~~~~~~~~~~~~~~End of Question 1~~~~~~~~~~~~~~~~~~~~~

 ONLINE FINAL EXAM
SEMESTER I, SESSION 2021/2022

COURSE CODE : SEMM/SKMM/SKMP3813

COURSE NAME : INDUSTRIAL ENGINEERING

SKMM/SKMB/SKMP/SKMV/SEMM/
PROGRAMME : SEMP/SEMB/SEMV/SEMMH/SEMPH

QUESTION NO. : QUESTION 2/4

DURATION : 45 MINUTES

DATE : 19/02/2022

PART : 1 (10:00 AM – 11:50 AM)

INSTRUCTIONS TO CANDIDATES:

1. This paper consists of two questions.

2. It is divided into two parts.
a. Part 1 – Questions 1 & 2 (10:00 AM to 11:50 AM)
b. Part 2 – Questions 3 & 4 (02:00 PM to 03:50 PM)
3. Each question will be answered one at a time.
4. 45 MINUTES is allocated for Question 2.
5. Each question is protected by a password and it is published at a
specified time.
6. A buffering time of 10 MINUTES is given for answer script
submission.
7. Only HAND WRITTEN ANSWER SCRIPT is acceptable.
8. Write your FULL NAME on each page of your answer script.

WARNING!

Students caught copying/cheating during the examination

are liable for disciplinary actions and the school may recommend
the students to be expelled from the University.
 -2-
SEMM/SKMM/SKMP 3813

QUESTION 2 (20 MARKS)

Asmi Deco Sdn. Bhd. is a well known mobile homes contractor. The company recently has
taken a project of converting old school bus into home. Activity M takes four (4) weeks to
complete during normal time and during crashing period, the company needs to complete
activity M in three (3) weeks, means activity M is allowed to crash maximum one (1) week.
Table 2.1 shows detail activities, time and cost incurred for the project.

Table 2.1: Activities and related information for project

Time (weeks) Cost (RM)
Activity Predecessor(s)
Normal Crash Normal Crash
M - 4 3 2,000 3,000
N M 10 7 1,000 2,000
O M 7 6 1,675 2,675
P O 7 3 1,500 5,650
Q N,O 5 4 1,000 1,350
R P,Q 3 3 1,200 1,200
S R 5 3 1,250 2,300
T S 3 2 900 1,300
U S 4 3 980 2,000
V U 5 4 1,000 2,000

a) Construct a network diagram using AON and estimate the expected completion time for
the above converting old school bus into home project. Determine the total project cost
based on this completion time. Determine also the critical path.
(8 marks)
b) The client for the project requested the company to shorten completion time by two (2)
weeks. Determine which activities should be crashed with minimum additional cost.
Provide the revised project network with numerical proof.
(8 marks)
c) Based on your answer to Question 2(a), there are some issues to accomplish activity R,
hence normal activity R has to be extended by two (2) more weeks. Determine the new
expected completion time and critical path for converting the old school bus into home
project.
(4 marks)
 -3-
SEMM/SKMM/SKMP 3813

VERSI BAHASA MELAYU

SOALAN 2 (20 MARKAH)

Asmi Deco Sdn. Bhd. merupakan kontraktor terkenal rumah mudah alih. Terbaru, pihak
syarikat memperolehi projek menukar bas sekolah lama kepada rumah kediaman. Aktiviti M
mengambil masa siap empat (4) minggu dalam waktu normal dan masa siap ketika crashing
ialah tiga (3) minggu, ini bermakna aktiviti M maksimum dibenarkan untuk crash hanya satu
(1) minggu sahaja. Jadual 2.1 menunjukkan perincian aktiviti-aktiviti, masa dan kos terlibat
bagi projek tersebut.

Jadual 2.1 (Rujuk Table 2.1)

-----------------------------------Sila rujuk versi Bahasa Inggeris--------------------------------

a) Bina gambar rajah rangkaian menggunakan AON dan tentukan jangkaan masa siap untuk
projek menukar bas sekolah lama kepada rumah kediaman. Tentukan jumlah kos projek
berdasarkan kepada jangkaan masa siap ini. Tentukan juga laluan kritikal.
(8 markah)

b) Pelanggan bagi projek ini meminta agar projek disiapkan dua (2) minggu lebih awal dari
jangkaan masa siap. Tentukan aktiviti mana yang harus dipendekkan dengan kos
tambahan minimum. Sediakan rangkaian projek yang telah dikemaskini dengan bukti
pengiraan yang bersesuaian.
(8 markah)

c) Berdasarkan kepada jawapan anda di Soalan 2(a), terdapat berbagai isu/masalah untuk
menyiapkan aktiviti R, justeru aktiviti normal R dilanjutkan/ditambahkan lagi sebanyak
dua (2) minggu. Tentukan masa jangkaan siap baru dan laluan kritikal bagi projek
menukar bas sekolah lama kepada rumah kediaman.
(4 markah)

~~~~~~~~~~~~~~~~End of Question 2~~~~~~~~~~~~~~~~

 ONLINE FINAL EXAM
SEMESTER I, SESSION 2021/2022

COURSE CODE : SEMM/SKMM/SKMP3813

COURSE NAME : INDUSTRIAL ENGINEERING

SKMM/SKMB/SKMP/SKMV/SEMM/
PROGRAMME : SEMP/SEMB/SEMV/SEMMH/SEMPH

QUESTION NO. : QUESTION 3/4

DURATION : 45 MINUTES

DATE : 19/02/2022

PART : 2 (2:00 PM – 3:50 PM)

INSTRUCTIONS TO CANDIDATES:

1. This paper consists of two questions.

2. It is divided into two parts.
a. Part 1 – Questions 1 & 2 (10:00 AM to 11:50 AM)
b. Part 2 – Questions 3 & 4 (02:00 PM to 03:50 PM)
3. Each question will be answered one at a time.
4. 45 MINUTES is allocated for Question 3.
5. Each question is protected by a password and it is published at a
specified time.
6. A buffering time of 10 MINUTES is given for answer script
submission.
7. Only HAND WRITTEN ANSWER SCRIPT is acceptable.
8. Write your FULL NAME on each page of your answer script.

WARNING!

Students caught copying/cheating during the examination

are liable for disciplinary actions and the school may recommend
the students to be expelled from the University.
 -2-
SEMM/SKMM/SKMP 3813

QUESTION 3 (20 MARKS)

3.1 The estimated transaction cashflows of a project is summarized as follows:

Expenditure
i. Initial investment now: RM 100,000
ii. Annual operating expenses: RM 4,000

Income
Annual income of RM 25,000 starting year two (2) until year twelve (12).

The project has a salvage value of RM 10,000. Determine the project equivalent value at
the end of its life. Assume the growth rate is 7.5% per year and the project life is 12
years.
(4 marks)

3.2 Figure 3.1 shows a cash flow diagram for an engineering project. The project has an
initial investment of RM 80,000 and expenditure of RM 15,000 every month for five (5)
years.

A2 = RM?/6 months
0 1 12 18 60 months

A1 = RM 15,000/month

i = 12% per year compounded monthly

RM 80,000

Figure 3.1: Cash flow of an engineering project

You have been asked to determine the minimum income required for every six (6)
months starting from the middle in year two (2) until at the end of year five (5) to cover
all the project costs.
(6 marks)
 -3-
SEMM/SKMM/SKMP 3813

3.3 The management of Mala Sdn. Bhd. in the process of evaluating on 5-Axes CNC
machining center offered by the local suppliers. Quotations were received from various
vendors and finally the technical committee has shortlisted the models to two CNC
Machine makers only as shown in Table 3.1.
Table 3.1: Detailed offers on the 5-Axes CNC machining center

Item Maker X Maker Y

Initial first cost RM 650,000 RM 850,000
RM 1,000 in first
year then increased
linearly by RM 500
Annual operating costs RM 4,000
per year from the
second year
onwards
Market value at end of life RM 10,000 RM 25,000
Useful life, n (year) 5 10

Analyze the above data and decide which CNC machine maker would you recommend
to the management? Use Present Worth method to compare offer from the mixer
makers. Assume that the MARR is 24.5% per year. Show all the calculations.
(10 marks)

VERSI BAHASA MELAYU

SOALAN 3 (20 MARKAH)

3.1 Anggaran transaksi aliran tunai bagi sebuah projek adalah diringkaskan seperti berikut:
Perbelanjaan
i. Pelaburan awal sekarang: RM 100,000
ii. Kos operasi tahunan: RM 4,000

Pendapatan
i. Pendapatan tahunan sebanyak RM 25,000 bermula tahun 2 sehingga tahun 12.

Projek mempunyai nilai salvaj sebanyak RM 10,000. Tentukan nilai setara projek
diakhir hayatnya. Anggapkan bahawa kadar pertumbuhan adalah 7.5% per tahun dan
hayat projek adalah 12 tahun.
(4 markah)
 -4-
SEMM/SKMM/SKMP 3813

3.2 Rajah 3.1 menunjukkan rajah aliran tunai bagi satu projek kejuruteraan. Projek ini
mempunyai pelaburan awal sebanyak RM 80,000 dan perbelanjaan sebanyak RM 15,000
setiap bulan selama 5 tahun.

Rajah 3.1 (Rujuk Figure 3.1)

-----------------------------------Sila rujuk versi Bahasa Inggeris--------------------------------

Anda diminta untuk mengira pendapatan minimum yang diperlukan setiap enam bulan
bermula pertengahan tahun ke 2 sehingga akhir tahun ke 5 untuk menampung kos
keseluruhan projek.
(6 markah)

3.3 Pengurusan syarikat Mala Sdn. Bhd. Sedang dalam proses penilaian ke atas mesin
sepusat CNC 5-paksi yang ditawarkan oleh pembekal tempatan. Sebutharga telah
diterima daripada beberapa pembekal dan akhir sekali jawatankuasa teknikal telah
menyenarai pendek model mesin kepada dua pembuat mesin sahaja seperti yang
ditunjukkan dalam Jadual 3.1.

Jadual 3.1 (Rujuk Table 3.1)

-----------------------------------Sila rujuk versi Bahasa Inggeris--------------------------------

Analisa data di atas dan buat keputusan pembuat mesin CNC manakah yang anda akan
cadangkan kepada pihak pengurusan? Gunakan kaedah Present Worth untuk
membanding tawaran dari pembuat mesin. Anggapkan bahawa MARR adalah 24.5% per
tahun. Tunjukkan semua jalan penyelesaian.
(10 markah)

~~~~~~~~~~~~~~~~~End of Question 3~~~~~~~~~~~~~~~~~~~

 ONLINE FINAL EXAM
SEMESTER I, SESSION 2021/2022

COURSE CODE : SEMM/SKMM/SKMP3813

COURSE NAME : INDUSTRIAL ENGINEERING

SKMM/SKMB/SKMP/SKMV/SEMM/
PROGRAMME : SEMP/SEMB/SEMV/SEMMH/SEMPH

QUESTION NO. : QUESTION 4/4

DURATION : 45 MINUTES

DATE : 19/02/2022

PART : 2 (2:00 PM – 3:50 PM)

INSTRUCTIONS TO CANDIDATES:

1. This paper consists of two questions.

2. It is divided into two parts.
a. Part 1 – Questions 1 & 2 (10:00 AM to 11:50 AM)
b. Part 2 – Questions 3 & 4 (02:00 PM to 03:50 PM)
3. Each question will be answered one at a time.
4. 45 MINUTES is allocated for Question 4.
5. Each question is protected by a password and it is published at a
specified time.
6. A buffering time of 10 MINUTES is given for answer script
submission.
7. Only HAND WRITTEN ANSWER SCRIPT is acceptable.
8. Write your FULL NAME on each page of your answer script.

WARNING!

Students caught copying/cheating during the examination

are liable for disciplinary actions and the school may recommend
the students to be expelled from the University.
 -2-
SEMM/SKMM/SKMP 3813

QUESTION 4 (20 MARKS)

4.1 Table 4.1 summarizes the input and output records for a product in year 2020 and 2021
produced in a manufacturing company. The company operates 20 days a month and 8
hours per day.

Table 4.1: Input and output records of a product in 2020 and 2021
Item 2020 2021
Finished good
Quantity (unit) 20,000 30,000
Price (RM/unit) 100 120
Work-in-progress (% completed) 25 30
Quantity (unit) 4,000 5,000
Labour
No of workers 5 7
Average salary (RM/hour) 10 12
Material
Raw material (kg) 40,000 35,000
Price (RM/kg) 5.5 6
Capital
Cash (RM) 300,000 100,000
Deflator 1 1.1
Other expenses
Gas, electricity and water (RM) 20,000 25,000
Deflator 1 1.05

a) Compare the performance of the company in year 2020 and 2021. Which year is
more productive?
(6 marks)

b) Assume that the company targets to increase total productivity by 10% in year 2022
with 15% more output than 2021. Other inputs are the same as in 2021 except the
no of labours. Determine how many labours are required in 2022?
(4 marks)
 -3-
SEMM/SKMM/SKMP 3813

4.2 Installing a complete set of new sporty exhaust system on a passenger car at the Man-
PeleSETE Exhaust Centre Sdn. Bhd. involves five (5) work elements. All elements are
performed manually except element 3 is carried out using an automatic Metal Inert Gas
(MIG) welding machine. Table 4.2 shows the timing of a male worker performing these
tasks using a snap-back stopwatch.
Table 4.2: Time study data for installing one set of new exhaust system

Observation cycle (min)

Job element
1 2 3 4
1. Inspect & remove old exhaust system 10 12 11 11
2. Select correct exhaust components 6.5 7.5 6 8
3. MIG welds new exhaust system 5 5 5 5
4. Install & inspect installation works 9 20* 11 10
5. Complete paper works 2.5 3 3.5 3
*Air nut driver jammed

The company operates 20 days a month 8 hours per day. The overall rating for the manual
tasks is 90%. The management and workers union agreed to give specific allowances for
these installation tasks as follows: personal, fatigue, medium awkward bending
position, well below bad lighting and tedious task.

a) Determine the total allowances eligible for this exhaust installation work.
Appendix II provides additional information on the recommended allowances
scheme according to the nature of tasks.
(2 marks)

b) Analyse the above time study data and determine the standard time for installing
one complete set of exhaust system on a passenger car? Round up your answer to
the nearest integer value.
(5 marks)

c) After aggressive marketing in the SURIA radio, the company expects to get a
confirm order for 650 cars next month. Currently, the company only has two (2)
mechanics to do the installation works. Can these two workers complete all the
installation works by the end of next month using normal working hours? If cannot
meet, how much overtime should be planned for each worker per day to fulfil the
above demand?
(3 marks)
 -4-
SEMM/SKMM/SKMP 3813

VERSI BAHASA MELAYU

SOALAN 4 (20 MARKAH)

4.1 Jadual 4.1 menunjukkan rekod masukan dan keluaran bagi satu produk pada tahun 2020
dan 2021 yang dihasilkan di sebuah syarikat.

Jadual 4.1 (Rujuk Table 4.1)

-----------------------------------Sila rujuk versi bahasa inggeris--------------------------------

a) Bandingkan prestasi syarikat dalam tahun 2020 dan 2021. Tahun manakah lebih
produktif?
(6 markah)

b) Anggapkan bahawa syarikat mensasarkan untuk meningkatkan produktiviti

sebanyak 10% pada tahun 2022 dengan peningkatan 15% keluaran berbanding
tahun 2021. Lain-lain masukan adalah sama seperti 2021 kecuali bilangan pekerja.
Kirakan berapa ramai pekerja diperlukan pada 2022?
(4 markah)

4.2 Memasang satu set sistem ekzos mewah yang baru ke atas kereta penumpang di syarikat
Man-PeleSETE Exhaust Centre Sdn. Bhd. melibatkan lima (5) elemen kerja. Kesemua
elemen dibuat secara insani kecuali elemen 3 yang dikendalikan oleh sebuah mesin
automatik kimpalan Gas Lengai Logam (MIG). Jadual 4.2 menunjukkan masa seorang
pekerja lelaki melakukan kerja-kerja pemasangan ini dengan menggunakan jam randik
jenis snap-back.
Jadual 4.2 (Rujuk Table 4.2)
-----------------------------------Sila rujuk versi bahasa inggeris--------------------------------

Syarikat beroperasi 20 hari sebulan 8 jam sehari. Kadaran keseluruhan untuk kerja-kerja
insani adalah 90%. Pihak pengurusan dan kesatuan pekerja bersetuju untuk memberikan
elaun khas bagi kerja-kerja pemasangan ini seperti berikut: peribadi, keletihan,
kedudukan membongkok ganjil sederhana, pencahayaan buruk di bawah paras
baik dan tugas rumit.

a) Kira jumlah elaun yang layak bagi kerja pemasangan ekzos ini. Lampiran II
menyediakan maklumat tambahan mengenai skim elaun yang disyorkan untuk
pelbagai jenis tugas.
(2 markah)

b) Analisis data kajian masa di atas dan kira masa piawai bagi memasang satu set
lengkap sistem ekzos kereta penumpang. Bundarkan jawapan anda kepada nilai
integer yang terdekat.
 -5-
SEMM/SKMM/SKMP 3813

(5 markah)

c) Setelah melakukan pemasaran bertubi-tubi di radio SURIA, pihak syarikat

menjangkakan pesanan pasti sebanyak 650 kereta pada bulan hadapan. Buat masa
ini, syarikat hanya mempunyai dua (2) orang mekanik sahaja untuk menjalankan
kerja pemasangan. Bolehkah dua orang pekerja ini menyiapkan kesemua kerja
pemasangan pada akhir bulan depan dalam tempoh bekerja biasa? Jika tidak boleh
tercapai, berapa banyak kerja lebih masa yang perlu dirancang bagi setiap pekerja
per hari untuk memenuhi permintaan di atas?
(3 markah)

~~~~~~~~~~~~~~~~~~~End of Question 4~~~~~~~~~~~~~~~~~~~~~~~