IV YEAR MECHANICAL ENGINERING EVEN SEMESTER

IE 6605
PRODUCTION PLANNING AND CONTROL

UNIT - 1
INTRODUCTION

Objectives and benefits of planning and control-Functions of production control-Types of production job- batch
and continuous-Product development and design-Marketing aspect - Functional aspects- Operational aspect-
Durability and dependability aspect aesthetic aspect. Profit consideration- Standardization, Simplification &
specialization- Break even analysis-Economics of a new design.

PARTA
1. Define method study. (April 2015, 2008)
Or
Define method study and state the three different levels in method study. (June 2009)
2. What is break-even point and mention its significance. (June 2014)
Or
What is meant by break-even analysis? (May 2008, May 2011, May 2015)
3. Write the objectives of planning and control? (April 2011)
Or
List the objectives of planning and control? (April 2015)
Or
State any two objectives of production planning and control. (May 2009)
4. List the various function of production planning and control. (June 2012)
Or
List the key function of the production scheduling and control. (Dec 2009)

List the functions of production control. (Dec 2014)

5. Mention any two tools used in time study. (April 2015)
Or
State any four basic methods in time study (May 2009)
6. Define continuous production. (May 2008)
7. What is production planning? (Dec 2009)
8. What is mean by standardization? (Dec 2009)
9. Distinguish between simplification and standardization. (Dec 2008)
Or
Specify the role of simplification and standardization in production planning and control.
(June 2009)
10. Define standardization and list any 1 merit. (June 2012)
11. What is meant by specialization? (June 2012)
12. State the principle initial date required for process planning. (June 2009)
13. What are the benefits of production planning and control? (Dec 2008)
14. Name the three major steps of production. (May 2010)
15. Distinguish between durability and dependability. (May 2010)
16. What are the phases of PPC.
17. Differentiate between routing and scheduling.
18. Differentiate between dispatching and expediting.
19. What do you mean by batch production.
20. What are the 3S’s with respect to product development techniques?

PART B
1. Discuss the 10 functions of production planning cycle (May 2008)

DEPARTMENT OF MECHANICAL ENGINEERING

 IV YEAR MECHANICAL ENGINERING EVEN SEMESTER
(Or)

Give detailed account of the various functions of production planning and control (May 2010)

(Or)

Discuss in detail about the various functions of production and planning control (May 2016)

(Or)

Briefly explain the three major types of production systems and outline the variations in terms of
production planning and control for these three production system. (Dec 2008)

(Or)

Describe the functions of production control (May 2015)

(Or)

Explain production control in detail. (May 2016)

(Or)

Discuss benefits of PPC (Dec 2014)

2. Briefly explain the types of production and List the factors affecting the design of a product

(April 2011) 

(Or)

Write about the Economics of new designs of a product (April 2011)

(Or)

Give a detailed account of the various factors considering while designing a product (Dec
2008) Explain the economics of new design
(May 2015)
(Or)

Discuss the various aspects of product development and design (May

2015)

(Or)

Explain the different aspects of product development and design (Dec 2014)

(Or)

What are the key aspects of marketing for product development and design? Briefly explain

(May 2016)

(Or)

Why it is necessary to analyze the product and explain the various analysis that are carried out

(May 2014)

DEPARTMENT OF MECHANICAL ENGINEERING

 IV YEAR MECHANICAL ENGINERING EVEN SEMESTER
Explain different types of production system. Differentiate between them (Dec 2009)

(Or)

How will you record the process during production? (April 2011)

(Or)

What do you mean by continuous production? Describe various forms of continuous production system
(May 2012)

(Or)

What is production system? Describe the various constituents of production system (May 2012)

(Or)

Explain the characteristics features of (i) batch production and (ii) mass production system (May 2014)
(Or)

Distinguish between batch production and continuous production (Dec 2014)

3. A manufacturer sells an item for rupees 13 for unit. He incurs a fixed cost of rupees 60,000 and a
variable cost of Rs 8 unit. Find the break even production quantity and also the number of units to be
produced to get a profit of Rs 12,000. (Dec 2014)

4. Write detailed notes on (i) standardization (ii) simplification (iii) specialization (May 2008)

(Or)

Discuss about standardization simplification and specialization (April 2011)

(Or)

Explain standardization and simplification along with their advantages and disadvantages if any

(May 2010)

5. Discuss in detail:(i) break even analysis (ii)Samuel eilon Model (Dec 2009)

(Or)

Explain the principle and purpose of break even analysis (May 2010)

(Or)

Draw and explain break even analysis. (May 2016)

DEPARTMENT OF MECHANICAL ENGINEERING

 IV YEAR MECHANICAL ENGINERING EVEN SEMESTER
UNIT - 2
WORK STUDY

Method study, basic procedure-Selection-Recording of process - Critical analysis, Development -

Implementation - Micro motion and memo motion study – work measurement - Techniques of work
measurement - Time study - Production study - Work sampling - Synthesis from standard data - Predetermined
motion time standards.

PARTA

1. Define time study. (Dec 2009)

2. List the various allowances considered during the time study. (May 2010)
3. List the steps involved in time study. (June 2014)
4. Define method study. (May 2010, Dec 2014)
5. Define Motion Study. (Dec 2014)
6. Distinguish work study and method study. (April 2011)
Or
Distinguish between method study and time study. (June 2012)
7. What is work measurement? (May 2008)
8. Name all the techniques used for work measurement. (Dec 2008)
9. Mention any four objectives of work study. (June 2012)
10. What is predetermined standard study? (May 2011)
11. What is the main concept of predetermined motion time system (PMTS)? (May 2012)
12. Distinguish between micro motion and macro motion study. (Dec 2009)
13. Mention the important consideration that would be used paid attention to select a process for method
study. (Dec 2008)
14. What are therbligs? Give any two therbligs which symbols. (June 2014)
15. Distinguish between operation and inspection.
16. What SIMO chart?
17. Differentiate between cycle graph and chrono cycle graph.
18. Distinguish between cumulative timing and feedback timing.
19. What is meant by work sampling?
20. What is performance rating?

PART B

1. Explain the various steps for Time study (May 2008)

Or
Explain briefly the following techniques of work measurement.

(i) Time study

(ii) Production study

(iii) Work sampling. (May 2016)

2. Explain the different charts and diagrams which are used in method study (May 2012)

Or
Briefly explain the different tools and techniques used in the recording face of method study

(Dec 2008)

Or
Explain the man type flow process chart with an example. (May 2016)

DEPARTMENT OF MECHANICAL ENGINEERING

 IV YEAR MECHANICAL ENGINERING EVEN SEMESTER
Or
State and explain in brief the steps involved in conducting the method study procedures (Dec 2009)

Or
Discuss two times each of the charts and diagrams used in the recording phase of the method study
(May 2010)

Or
Describe the basic procedure of method study (May 2015)

Or
Explain the method of study procedure (Dec 2014)

Or
Explain the different charts and diagrams which are used in method study. (May 2016)

3. Explain the steps involved in work study (May 2014)

Or
Briefly discuss the step in work sampling study (May 2014)

Or
What is production study? explain (May 2015)

4. Describe predetermined motion time standard (May 2008)

Or
Explain micro motion and memo motion study (May 2008) (April 2011)

Or
Write short notes on the following (i) micro motion study (ii) memo motion study (May 2016)

Or
Discuss the principles of motion economy applied to

(i) use of human body

(ii) Arrangement of workplace

(iii) Design of tools and equipments. (May 2012)

5. Explain in detail about the techniques of work measurement and give an example (April 2011)

Or
Discuss the advantages and disadvantages of work sampling (May 2008)

Or
Write short notes on (i) Work sampling (ii)Synthetic data(iii) PMTS (Dec 2009)

Or
Explain the procedural steps involved in the work sampling study and illustrate how work sampling is
used for the computation of standard time for an operation which involves both manual and missing
elements (Dec 2008)

Or
Briefly explain (i) performance rating (ii) work sampling (iii) standard data and (iv) PMTS (May
2010)

Or
Describe the Different techniques of work measurement (Dec 2014)

DEPARTMENT OF MECHANICAL ENGINEERING

 IV YEAR MECHANICAL ENGINERING EVEN SEMESTER
6. An industry manufacturing only one item which it sells for Rs 13 per unit has a fixed cost equal to Rs
60,000 and variable cost Rs 8 per unit calculate

(i) Number of units to be produced at break-even

(ii) to obtain a profit Rs 13,000 how much units to be produced.

(iii) The profit is 25000 units produced and sold (May 2012)

UNIT - 3
PRODUCT PLANNING AND PROCESS PLANNING

Product planning-Extending the original product information-Value analysis-Problems in lack of product

planning-Process planning and routing-Pre requisite information needed for process planning- Steps in process
planning-Quantity determination in batch production-Machine capacity, balancing- Analysis of process
capabilities in a multi product system.

PARTA
1. What is value analysis? (Dec 2009, May 2015)
Or
State the aims of value analysis. (May2012)
Or
Define the term value analysis (June 2012)
2. Mention the different types between value engineering and value analysis. (June 2014)
3. Define product planning (May 2015)
4. List the advantages of process planning. (May 2010)
5. What is the problem of machine balancing? (June 2012)
Or
What is meant by machine balancing? (Dec 2009)
Or
6. What is machine capacity? (Dec 2014)
Or
7. Analyze the machine capacity and balancing. (May 2011)
8. Mention any two methods used to evaluate the functional worth of the component.
(June 2009)
9. Write difference between routing and planning. (May 2011)
10. Mention the factors affecting the routing procedure. (May 2010)
11. Enumerate the problems that will result due to lack of production planning. (Dec 2008)
12. Distinguish between production planning and production control. (May 2010)
13. State pre request information needed for process planning. (Dec 2014)
14. Mention at-least six uses of value analysis.
15. What are the factors affecting process planning?
16. What is the purpose of machine loading chart?
17. What are the criteria for the selection of batch sizes?
18. List the various information required for process planning.
19. List the factors affecting the selection of batch size.
20. Name the general approaches to process planning.

PART B
1. Discuss in detail phases of applying value analysis (May 2008)

Or

DEPARTMENT OF MECHANICAL ENGINEERING

 IV YEAR MECHANICAL ENGINERING EVEN SEMESTER
Discuss value analysis and Value Engineering (Dec 2014)

Or
With an example, explain the value engineering procedure. (May 2012)

Or
Explain briefly the steps in value analysis  (May 2014)

2. Explain the steps involved in (i) production planning (ii) process planning (May 2008)

Or
Briefly explain about the approaches to process planning. (May 2016)

Or
Summarize the pre-requisite information needed for process planning with the steps involved in
process planning
(Dec 2008)

Or
Explain the importance of process planning with reference to production control. Discuss the activity
involved in process planning (Dec 2009)

Or
Enumerate the prerequisite information needed for process planning (May 2010)

Or
Discuss in detail the various steps in process planning. (May 2012)

Or
Define process planning. Discuss in detail steps of the same (May 2015)

Or
Explain the steps involved in the standard procedure for process planning. Also explain various type of
process planning methods (May 2010)

3. What are the types of charts used for product planning and explain anyone up in detail? (April 2011)

Or
Explain the various problems faced in production planning (April 2011)

Or
Describe problems of lack of product planning (Dec 2014)

Or
Describe the problem due to lack of product planning. (May 2015)

4. Write short notes on (i) quantity determination in batch production (ii) Analysis of process capability in
a multi product system. (Dec 2008)

Or
Explain how production quantity in batch production is determined (Dec 2014)

Or
Write detailed notes on analysis of process captive capacities in a multi product system. (Dec 2009)

Or
Explain the procedure for capacity planning for single multistage system. (May 2010)

Or

DEPARTMENT OF MECHANICAL ENGINEERING

 IV YEAR MECHANICAL ENGINERING EVEN SEMESTER
How will you analyze the process capability in a multi product system. (May 2010)

Or
Explain how process capability are analyzed in a multi product system. (May 2015)

Or
Explain analysis of process capability in a multi product system. (Dec 2014)

5. A Gear manufacturer has gear shaper and Gear hobbers. The gear can be processed on gear shaper as
well as gear hobber. The following information is given. Which of the two machines will you choose to
do the job in if the order quantity is (i) 1000 numbers and order is unlikely to repeat , and (ii) 1000
numbers and the Order is likely to repeat for 3 years 

Gear shaper Gear hobber

Machine time per piece (min) 12 04

Machine cost per hour (Rs) 45 120

Set up time (min) 60 90

Tooling up cost (Rs) 400 2000

(May 2014)

6. Explain various functions of routing. (May 2016)

UNIT - 4
PRODUCTION SCHEDULING

Production Control Systems-Loading and scheduling-Master Scheduling-Scheduling rules-Gantt charts-

Perpetual loading-Basic scheduling problems - Line of balance – Flow production scheduling- Batch production
scheduling-Product sequencing – Production Control systems-Periodic batch control-Material requirement
planning kanban – Dispatching-Progress reporting and expediting- Manufacturing lead time-Techniques for
aligning completion times and due dates.

PARTA
1. What are gantt charts? (May 2015)
Or
Draw the symbols used in process chart for the activities inspection and transport.
(June 2012)
Or
What is Gantt chart and how it is constructed. (June 2014)
2. Distinguish between single machine scheduling & flow shop scheduling. (June 2012)
Or
Compare and contrast flow production and batch production scheduling. (June 2009)
3. List the merits and demerits of batch production. (June 2012)
4. Distinguish scheduling and sequencing. (May 2011)
5. State “Line Balancing”. (May 2011)
Or
State the objectives of line balancing. (Dec 2008, May 2010)
6. With reference to line balancing, define the terms (a) Line efficiency and (b) Balance delay.
(June 2014)
7. What is Master scheduling? (May 2012)
8. Write down the advantages and disadvantages of Master scheduling. (Dec 2008)
9. List the function of expediting. (May 2012)
10. How is quality determined in batch production? (April 2008)
11. What is product sequencing? (Dec 2014)
12. List any five priority sequencing rules. (Dec 2008)

DEPARTMENT OF MECHANICAL ENGINEERING

 IV YEAR MECHANICAL ENGINERING EVEN SEMESTER
13. Write a note on perpetual loading. (Dec 2014)
14. Differentiate between aggregate planning and master scheduling.
15. What is MPS?
16. What are the uses of line of balancing?
17. What is the purpose of operation program chart?
18. What are the functions of dispatching?
19. What are the functions of expediting?
20. What is MRP?

PART B
1. What is perpetual loading ?Describe (May 2015)

2. Discuss periodic batch control. (May 2015)

3. Discuss the information flow for master scheduling (May 2008)

(Or)

How to achieve targets in batch production scheduling? Give an example. (April 2011)

(Or)

Write detailed notes on (i) flow production scheduling (ii) batch production scheduling. (May 2008)

(Or)

Discuss in detail about the various factors that affect scheduling. Explain any one technique used in
loading and scheduling process. (Dec 2008)

(Or)

Write short notes on (i) aggregate run out method of batch scheduling (ii) line of balance method

(Dec 2009)

(Or)

Distinguish between single machine scheduling and flow production scheduling. (May 2012)

(Or)

What are the assumptions in flower shops scheduling. (May 2012)

(Or)

Discuss the scheduling approaches followed in job and floor shops along with their merits and demerits
(May 2010)

(Or)

List and explain the basic forms of schedules. (April 2011)

(Or)

Discuss about the basic scheduling problems in various case study. (April 2011)

(Or)

Briefly discuss different Measure of Performances in single machine scheduling with independent jobs.
(May 2012)

DEPARTMENT OF MECHANICAL ENGINEERING

 IV YEAR MECHANICAL ENGINERING EVEN SEMESTER
(Or)

Discuss the following

(i) Flow production scheduling

(ii) Periodic batch control

(iii) Kanban (Dec 2014)

(Or)

Explain shop floor scheduling in detail. (May 2016)

(Or)

Briefly explain follow up process. (May 2016)

4. Discuss about machine capacity and balance balancing with case study. (April 2011)

(Or)

Explain various methods of line balancing. (May 2016)

5. With an example explain gantt chart. (May 2008)

(Or)

What are the gantt charts? Explain their types. How are they constructed? (Dec 2009)

(Or)

What are gantt charts? Explain their types? How are they constructed? (May 2016)

(Or)

Described Gantt charts. what are the uses? (Dec 2014)

6. Briefly explain the different documents raised by dispatching department (Dec 2008)

(Or)

Explain ordering procedure. (Dec 2014)

(Or)

Explain the common methods adopted in industries for progress reporting. (Dec 2008)

(Or)

Briefly explain the various techniques adopted for aligning completion time and due dates. (May 2010)

(Or)

Explain techniques of online aligning completion time and due dates. (Dec 2014)

(Or)

Explain any one of the techniques for aligning comfort completion time and due dates. (May 2015)

7. What are the common causes of delay? how can they be avoided ?explain. (May 2010)

DEPARTMENT OF MECHANICAL ENGINEERING

 IV YEAR MECHANICAL ENGINERING EVEN SEMESTER
8. An assembly line is to be designed to operate 7.5 hours per day and supply a steady demand of 300
units per day. The following table shows the task and their performance times.(i) Draw the precedence
diagram (ii) What is the cycle time? (iii) Assign tasks to work stations stating your logical
rules and (iv) What is the efficiency of your Line balance?

Task a b c d e f g h i j k l

Preceeding - - - a b c d e f g h,i J,k

tasks

Performance 70 40 45 10 30 20 60 50 15 25 20 25
time (sec)

(May 2014)

(Or)

There are seven jobs which are to be processed first on machine I and then on machine II , process time in
Hours is given below. Find the optimal sequence and total elapsed time

Task a b c d e f g

Machine I 6 24 30 12 20 22 18

Machine II 16 20 20 13 24 2 6

(May 2014)

(Or)

Sequence the following jobs to minimize the processing times on the two machines. Also compute the idle time
of the Machines

Job 1 2 3 4 5 6

Machine 1 5 9 4 7 8 6

Machine 2 7 4 8 3 9 5

(May 2015)

UNIT - 5
INVENTORY CONTROL AND RECENT TRENDS IN PPC

Inventory control-Purpose of holding stock-Effect of demand on inventories-Ordering procedures. Two bin

system -Ordering cycle system-Determination of Economic order quantity and economic lot size- ABC analysis-
Recorder procedure-Introduction to computer integrated production planning systemselements of JUST IN
TIME SYSTEMS-Fundamentals of MRP II and ERP.

PARTA

DEPARTMENT OF MECHANICAL ENGINEERING

 IV YEAR MECHANICAL ENGINERING EVEN SEMESTER
1. Write the uses of two bin system. (April 2008)
Or
List the advantage of two bin system (April 2015)
Or
Brief about two bin-system. (Dec 2014)
2. What id MRP? List the various inputs required for it. (Dec2009)
Or
What are the basic inputs for MRP? (June 2009)
3. Define just in time. (Dec 2009)
Or
List the key elements of just in time. (May 2009)
Mention basic elements of JIT manufacturing. (June 2014)
Or
What are the goals of JIT? (June 2012)
Or
What are the basic principles of JIT? (May 2010)
4. Mention at least four reasons for keeping an inventory. (Dec 2009)
Or
List the various cost components involved in inventory decisions. (June 2009)
List the different types of inventories a manufacturing organization keeps. (June 2014)
Or
How can you classify the inventor based on material flow? (June 2012)
5. What is MRP II? (May 2015)
6. Expand “ERP”? (April 2011, Dec 214)
Or
What is ERP? (May 2012)
7. What is ABC analysis? (May 2008)
Or
Give the importance of ABC analysis. (May 2011)
8. How do you represent mathematically the manufacturing lead time?  (June 2009)
Or
What is manufacturing Lead time? (April 2008)
9. Distinguish between P and Q system of inventory. (June 2012)
10. Compare excess stock and stock out situations. (Dec 2008)
11. Spell out the basic assumptions involved in determination of EOQ using formula developed by Harris. 
(Dec 2008)
12. Why are inventories maintained? (May 2010)
13. Differentiate between anticipation and fluctuation inventories.
14. What is procurement cost?
15. Differentiate between independent and dependent demand.
16. Define the term buffer stock and reorder quantity.
17. What do you mean by fixed order quantity model?
18. List out any six selective inventory control techniques.
19. What do you mean by Kanban production control system?
20. Differentiate between pull and push system.

PART B
1. Discuss the different costs associated with inventory. (May 2008)

Or
Explain about the various costs associated with the inventory control. Give appropriate examples for
each cost element. (May 2010)

Or
Discuss in detail about the P and Q systems of inventory replace replenishment along with their merits
and demerits. (Dec 2008)

DEPARTMENT OF MECHANICAL ENGINEERING

 IV YEAR MECHANICAL ENGINERING EVEN SEMESTER
Or
What is the inventory system? Explain about ordering procedure and ordering cyclic system (April 11)

Discuss the effect of demands on inventories. (May 2015)

2. Discuss in details (i) JIT (ii) ERP  (May 2008)

Or

Discuss any two elements of JIT System. (Dec 2014)

Or
Define ERP. Explain its main functions and methodology adopted in implementing ERP.
(Dec 2009)
Or

How the ERP and MRP II play an important role in production planning and control? (April 2011)

Or

Describe the elements of Just in time systems. (May 2015)

Or
What is ERP briefly explain (May 2015)

3. Derive an expression for EOQ with uniform demand rate without shortages. (May 2008)

Or
Derive the economic ordering quantity (EOQ) formula for purchase model with shortages(May 2012)

Or
Derive the formula for determining the economic order quantity. State its assumptions, advantages and
disadvantages. (May 2010)

Or
The annual demand for an automobile component is 36,000 units. The carrying cost is Rs 0.5/
unit/year , the ordering cost is 25 per order and shortage cost in Rs 15/ unit/year. Find the EOQ.

(May 2012)

Or
A manufacturer has to supply is customer 3600 unit office product Priya shortages are not permitted
inventory carrying cost amount rupees 12 per unit per annum the setup cost per 1 rupees 80 optimal
number of order per annum economic order quantity average annual inventory cost optimal period of
supply for optimum order. ( May 2014)

4. Explain with the block diagram the basic elements of manufacturing system.  (Dec 2008)

Or
Write detailed note on computer integrated production planning and control. (Dec 2009)

Or
Write short notes on (i) a b c analysis (ii) computer integrated production planning system (iii)
manufacturing resource planning (iv) enterprise resource planning.  (May 2010)

Or
Explain about computer integrated production planning systems. (April 2011)

DEPARTMENT OF MECHANICAL ENGINEERING

 IV YEAR MECHANICAL ENGINERING EVEN SEMESTER
Or
Explain the two aspects of computer integrated manufacturing such organizational part and operational
Park. (May 2012)

Or
Write detailed notes on Computer integrated production planning and control. (May 2016)

5. Explain briefly the procedure for ABC analysis unlisted merits and demerits.  (May 2014)

Or
Determine the optimal order quantity of an inventory item with the following data: annual demand
2800 units, unit cost = Rs 5 , ordering cost = Rs 36 / order carrying cost 20 % of unit cost

Order Quantity < 500 500 < Q < 1250 >1250

Discount % on unit cost Nil 4% 8%

(Dec 2014)

6. Perform ABC analysis on the items given below and classify them based on of ABC analysis 

Item 101 102 103 104 105 106 107 108 109 110

Annual
consumption 200 100 2000 400 6000 1200 120 2000 1000 80
in units

Unit cost in
40 360 0.20 20 0.04 0.8 100 0.70 1 400
Rs.

(Dec 2014)

Or
Following components required for repairing Oil Engines. Classify the same by ABC analysis  

Component
C01 C02 C03 C04 C05 C06 C07 C08 C09 C10
code

Unit cost in
100 200 50 300 500 3000 1000 7000 5000 60
Rs.

Annual
consumption 100 300 700 400 1000 30 200 500 105 1000
in units

(May 2015)

7. Explain ABC analysis in detail. (May 2016)

Or
What do you mean by ABC analysis? Explain briefly. (May 2016)

8. Distinguish between MRP I and MRP II.  (May 2012)

Or
Explain concept MRP-II in detail. (May 2016)

DEPARTMENT OF MECHANICAL ENGINEERING

IV YEAR MECHANICAL ENGINERING EVEN SEMESTER

DEPARTMENT OF MECHANICAL ENGINEERING