(SEM V) THEORY EXAMINATION 2021-22 INDUSTRIAL ENGINEERING

INDUSTRIAL ENGINEERING (KME-503)

B.Tech (Sem V) – Exam Notes & Solved Guide

SECTION A – Short Answer Type (2 Marks Each)

a. Productivity
Productivity is the ratio of output to input. It measures how efficiently resources like men, machines, and materials are used to produce goods or services.

b. Group Technology
Group technology is a manufacturing philosophy where similar parts are grouped into families and produced using similar processes to improve efficiency.

c. Forecasting
Forecasting is the process of predicting future demand based on past data and trends to support planning and decision-making.

d. Scheduling
Scheduling is the process of deciding when and where activities will be performed so that resources are utilized effectively.

e. Cost Curves
Fixed cost remains constant, variable cost changes with output, and total cost is the sum of fixed and variable costs.

f. Safety Stock
Safety stock is extra inventory kept to protect against uncertainty in demand or supply delays.

g. Objectives of Standardization
Standardization aims to reduce variety, improve quality, lower cost, and simplify production and inventory control.

h. Ergonomics
Ergonomics is the study of designing work systems that fit human capabilities to improve comfort, safety, and productivity.

i. Limitations of Graphical Method in LPP
It is limited to only two decision variables and becomes impractical for complex problems.

j. Unbounded and No-Solution Cases in LPP
An unbounded solution occurs when the objective function increases indefinitely. No solution exists when constraints do not overlap.

SECTION B – Descriptive Answers (Attempt Any Three)

a. Process Layout vs Product Layout

A process layout arranges machines by function and is suitable for low-volume, high-variety production. It offers flexibility but involves higher material handling cost.
A product layout arranges machines according to product flow. It is suitable for mass production, provides high efficiency, but lacks flexibility.

b. Material Requirements Planning (MRP) & JIT

MRP is a systematic approach for calculating material requirements based on master production schedule, bill of materials, and inventory records.
Just-In-Time (JIT) focuses on producing only what is needed, when it is needed, minimizing inventory and waste.

c. Break-Even Analysis, ABC & VED

The break-even point is where total cost equals total revenue.
ABC analysis classifies inventory based on value (A: high value, C: low value).
VED analysis classifies items as Vital, Essential, or Desirable based on criticality.

d. Method Study & Principles of Motion Economy

Method study analyzes work methods to improve efficiency.
Principles of motion economy focus on reducing unnecessary movements, proper workplace layout, and balanced use of both hands.

e. LPP by Simplex Method

Given objective and constraints, slack variables are introduced, simplex tables are formed, and iterations are carried out until optimal solution is reached.

SECTION C – Long Answer / Numerical Type

3(a). Exponential Smoothing Forecasting

Formula:
Fₜ₊₁ = αDₜ + (1−α)Fₜ
Using α = 0.1 and given data, forecasts are calculated step-by-step from January to June.
Lower α gives smoother forecasts.

PERT vs CPM
PERT is probabilistic and used when activity times are uncertain.
CPM is deterministic and focuses on cost-time optimization.

3(b). Network Analysis (CPM)

Based on activity precedence and durations (as given on page 2 of the paper), the network diagram is drawn.
Forward and backward pass gives earliest and latest times.
The path with zero float is the critical path, and total project duration is obtained.

4(a). Assembly Line Balancing

Using given task times and precedence, stations are formed based on cycle time = 1 minute.
Line efficiency, balance delay, and smoothness index are calculated using standard formulas.

4(b). Production System

A production system converts inputs into finished goods.
It is classified into continuous and intermittent systems.
An intermittent system produces goods in batches and offers flexibility.

5(a). Product Life Cycle & Concurrent Engineering

Product life cycle includes introduction, growth, maturity, and decline stages.
Concurrent engineering involves parallel development of product design and manufacturing to reduce time and cost.

5(b). Value Engineering

Value engineering aims to improve product value by reducing cost without affecting function.
Steps include information phase, function analysis, creative phase, evaluation, and implementation.

6(a). Queueing Theory (Machine Breakdown Problem)

Breakdowns follow Poisson process.
Repairman service time determines waiting cost and repair cost.
By comparing total expected cost for repairmen X and Y over 8 hours, the better option is selected.

6(b). EOQ with Price Breaks

Total cost is calculated for each price range using EOQ formula.
The lot size with minimum total cost is chosen as the optimal order size.

7(a). LPP for Profit Maximization

Decision variables represent number of products A and B.
Constraints are formed using machine time availability.
Graphical method gives feasible region and optimal profit point.

7(b). Transportation Problem (VAM)

Vogel’s Approximation Method is used to find an initial feasible solution by calculating penalties and allocating minimum costs.