About this previous year paper
SECTION A – Short Answer Type Questions (2 Marks each)
(a) What is Productivity?
Productivity is defined as the ratio of output to input in a production process. It measures the efficiency with which resources (labor, materials, capital, energy, etc.) are utilized to produce goods or services.
Productivity=OutputInput\text{Productivity} = \frac{\text{Output}}{\text{Input}}Productivity=InputOutput
Types of Productivity:
Labor Productivity – Output per labor hour.
Machine Productivity – Output per machine hour.
Total Factor Productivity – Overall efficiency considering all inputs.
Importance:
Indicates organizational efficiency.
Helps in cost control and competitive advantage.
Guides management in performance evaluation and improvement.
(b) Differentiate Between Method Study and Work Measurement.
| Basis | Method Study | Work Measurement |
|---|---|---|
| Objective | To find the best way of performing a task | To determine the time required for performing the task |
| Focus | Process improvement | Time standardization |
| Tools Used | Flow process chart, motion study | Stopwatch, time study sheet |
| Outcome | Simplifies work and reduces fatigue | Provides standard time for scheduling and costing |
Conclusion:
Both are integral to work study, aiming to increase productivity and efficiency in industrial operations.
SECTION B – Long Answer Type Questions (10 Marks each)
(a) What is Material Requirements Planning (MRP)? Describe Its Structure and JIT System.
Material Requirements Planning (MRP):
MRP is a computer-based inventory and production planning system that ensures materials and components are available for production at the right time and quantity.
Objectives:
Ensure materials are available for production and delivery.
Maintain minimum inventory levels.
Schedule manufacturing activities efficiently.
Structure of MRP:
Master Production Schedule (MPS): Defines when and how much finished product is needed.
Bill of Materials (BOM): Lists components required for each product.
Inventory Records: Tracks availability of raw materials and components.
MRP Processing: Calculates net requirements and generates planned order releases.
Just-In-Time (JIT) Manufacturing:
A lean production approach that eliminates waste by producing only what is needed, when it is needed, and in the quantity needed.
Difference Between MRP and JIT:
| Aspect | MRP | JIT |
|---|---|---|
| Approach | Push system | Pull system |
| Basis | Forecast demand | Actual customer demand |
| Objective | Inventory control | Waste elimination |
(b) Derive the Formula for Economic Order Quantity (EOQ).
EOQ Definition:
It is the optimum order quantity that minimizes total inventory costs — i.e., the sum of ordering and holding costs.
Let:
DDD = Annual demand (units)
CoC_oCo = Ordering cost per order (Rs.)
ChC_hCh = Holding cost per unit per year (Rs.)
Total Cost (TC):
TC=DQCo+Q2ChTC = \frac{D}{Q}C_o + \frac{Q}{2}C_hTC=QDCo+2QCh
To minimize TC, differentiate w.r.t QQQ:
d(TC)dQ=−DCoQ2+Ch2=0\frac{d(TC)}{dQ} = -\frac{DC_o}{Q^2} + \frac{C_h}{2} = 0dQd(TC)=−Q2DCo+2Ch=0
Solving for QQQ:
Q∗=2DCoChQ^* = \sqrt{\frac{2DC_o}{C_h}}Q∗=Ch2DCo
Hence,
EOQ=2DCoCh\boxed{EOQ = \sqrt{\frac{2DC_o}{C_h}}}EOQ=Ch2DCo
Significance:
EOQ balances the trade-off between ordering and holding costs, ensuring minimum total inventory cost and efficient stock management.
SECTION C – Very Long Answer Type Questions (10 Marks each)
(a) Explain Flexible Manufacturing System (FMS) and Its Types of Flexibilities.
Definition:
A Flexible Manufacturing System (FMS) is an integrated system of computer-controlled machines, material-handling systems, and robots capable of producing a variety of products with minimal human intervention.
Main Components:
Workstations: CNC machines or robots performing operations.
Material Handling System: Conveyors, AGVs (Automated Guided Vehicles).
Computer Control System: Centralized controller for scheduling and monitoring.
Human Interface: Operators, maintenance, and supervision.
Types of Flexibility:
Machine Flexibility: Capability to perform different operations.
Routing Flexibility: Ability to follow alternative paths for material flow.
Volume Flexibility: Ability to adjust production rate.
Product Flexibility: Capability to handle new product designs.
Expansion Flexibility: Ease of adding new machines or modules.
Advantages:
Increased productivity and quality.
Reduced lead time and inventory.
Adaptability to market changes.
(b) Explain the Concept of Value Engineering and Steps Involved in Value Analysis.
Definition:
Value Engineering (VE) is a systematic and creative approach aimed at improving product value by reducing cost without compromising quality or performance.
Formula:
Value=Function or PerformanceCost\text{Value} = \frac{\text{Function or Performance}}{\text{Cost}}Value=CostFunction or Performance
Steps Involved in Value Analysis:
Information Phase: Collect data about product, function, and cost.
Functional Analysis: Identify and classify functions as basic or secondary.
Creative Phase: Brainstorm ideas to improve function or reduce cost.
Evaluation Phase: Evaluate alternative ideas based on feasibility and economy.
Development Phase: Select the best alternative and develop design.
Implementation Phase: Apply changes and monitor improvements.
Uses:
Reduces unnecessary cost.
Improves product efficiency and performance.
Encourages innovation and teamwork.
Example:
Replacing a metal part with a polymer component having equal strength but lower cost.