(SEM V) THEORY EXAMINATION 2022-23 INDUSTRIAL ENGINEERING

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.

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:

(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=QD​Co​+2Q​Ch​

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∗=Ch​2DCo​​​

Hence,

EOQ=2DCoCh\boxed{EOQ = \sqrt{\frac{2DC_o}{C_h}}}EOQ=Ch​2DCo​​​​

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.