Q 1.

Attempt any FIVE of the following: (5x2=10)

A) rocedure of method study –
1. Select the work to be analyzed.
2. Record all facts relating to the existing method.
3. Examine the recorded facts critically but impartially.
4. Develop the most economical method commensurate with plant requirements
5. Install the new method as standard practice.

B) Objectives of quality control (any four) –

1. Improved Income
2. Cost Reduction
3. Interchangeability
4. Customer’s Satisfaction
5. Optimum Quality
6. Integration of Quality Effects
7. Quality Mindness.
C) Six sigma with an example –
Six-sigma is defined as ‘a disciplined and systematic data drive approach for eliminating Defects in any
process of manufacturing company or service industry’.

For example: When number of observations are plotted in the form of frequency polygon For any
variable characteristic, such as, diameter of shafts produced, then frequency Polygon shows a smooth
curve obtained by joining various points (observations) on the Graph (Normal distribution curve).
D) Consideration in Display Design –
Following consideration should be taken in the design of display
1. Environmental Conditions. 2. Worker’s Capacity. 3. Safety. 4. Nature of work
6. Biological factors

E) Supply chain management –

Supply chain management is the handling of the entire production flow of a good or service
To maximize quality, delivery, customer experience and profitability.
OR
Supply chain management (SCM) is the optimization of a product’s creation and flow from
Raw material sourcing to production, logistics and delivery to the final customer.
f) Variable and attribute measurement –
Variable measurement- ‘When measurements are carried out to find quality characteristic
Of a component, the quality is said to be expressed by ‘variables’. For example length of
Bar in mm.
Attribute measurement- ‘When a record shows only the numbers of work pieces/items or
Products conforming and non-conforming to any specified requirement, it is said to be
Attribute’. For example, GO and NO GO gauge.
g) Applications of P chart and C Chart-
Applications of P Chart-
(a) To find out average proportion of defective articles submitted for inspection, over a
Period of time.
(b) In a sampling inspection of large lots.
(c) To bring attention to management, any changes in average quality level.
(d) To identify and correct the causes of bad quality.
(e) Provides useful record of quality history management.
Applications of C Chart-
(a) Number of surface defects in an aircraft wing.
(b) Number of defects such as blowholes, cracks in a casting.
(C) Number of imperfections observed in a cloth of unit area.
(d) Number of surface defects in galvanized sheet.
(E Number of small holes in glass bottles.
 Q.2. Attempt any THREE of the following: (3x4=12)
a. Multiple activity chart with an example-
It is a chart where activities of more than subject (worker or equipment) are recorded on a
Common time scale to show their inter-relationship. Multiple activity chart is made to
• Study idle time of the man and machines.
• Determine number of machines handled by one operator
• Determine number of operators required in teamwork to perform the given job.
A Multiple activity chart consists of a series of bars (columns) placed against a common Time
scale. Each subject is allocated one bar and the activities related to the subjects are Represented
in this bar. The columns are placed against a common time scale which starts at Zero and ends
at cycle time of the job. The task to be recorded is broken into smaller Elements and time for
each element is measured with the help of a stop watch. The Activities are then recorded in the
chart in their respective columns. Multiple activity chart is extremely useful in organizing teams
of operatives on mass Production work. This is also used in maintenance. It is used to determine
the number of Machines which is operator can handle. It is useful in:
• Reducing idle time of machines and operators.
• Combine or eliminate some of the operations.
 It helps to explore ways to increase utilization of men and machines.
Example
b. Criteria’s for selecting a manufacturing process-
1. Quantity of the product .( 2) Cost for tooling, manufacturing machines and equipment (3) Time
required for processing (4)Level of skilled labor required (5) Process supervision (6) Energy consumption
(7) Availability of material and cost of material (8) Capabilities required to processes material
(9). Product dimensions and size (10). Surface finish required (11). Design tolerances (12)Waste
produced by the process (13) Maintenance costs (14). Other costs.

C. Anthropometric data for designing an adult male as an operator to control a machine

Anthropometric data be applied for in the following steps :

1. Identify the important dimensions which come in contact with machine.

2. Identify the user population using the machine.
3. Determine the principles to use. ( Either Extreme, average, adjustable)
4. Select the percentile range to accommodate. (5% or 95%)
5. Find relevant body dimensions from Anthropometric table.
6. Make modifications if required
7. Test critical dimensions with a mock-up, user testing, or a virtual model.

D. Difference between process inspection and final inspection –

Sr. Process Inspection Final Inspection
No.
1) Process inspection for manufacturing refers to Final inspections take place when
inspection at any point along the production production is complete.
cycle.
2) This is done to check the parameters within The overall product is measured against
each section of the process. engineering, customer requirements,
and standards.
3) It is possible to stop the production It not possible to stop the production as
at the moment if rejection is identified. it is the post inspection procedure.
4) Eg. Inspection of raw materials or Wastage is not minimized if rejection
semi-finished products. takes place.
Q.3.Attempt any THREE of the following: ( 3x4=12)
A . Differentiate between flow process chart and travel chart.

Sr. No Flow Process Chart Travel Chart

1) Flow Process Chart is defined as the process Travel Chart is defined as the record of the
chart which sets out the sequence of the amount of travel by the worker or material
flow of a product through the various while going from machine to machine or
departments by recording the event using from one department to another.
the appropriate process chart symbols.
2) Generally flow chart records a Travel chart records complex movements.
simple and main movements.
3 Flow process chart uses symbols for It uses a tabular format for the
representation of movements representation of movements.
4) It is used to identify the flow of man, It is used to identify the frequency of
machine and material movements.
b. Prepare a two handed process chart for a task of cutting glass tubes using appropriate
Process chart symbol.
 C. Explain Heuristic approach of line balancing.
1. Line Balancing means balancing the production or assembly line.
2. Line balancing is the arrangement of the individual processing and assembly tasks at the
Workstation so that the total time required at each workstation is same and the flow of
Production will be smooth.
3. The main objective of line balancing is to distribute task evenly over the workstations so That
idle time of man and machine is minimized..
4. Heuristic method involves two stages for line balancing
i. Drawing the precedence diagram which determines the priority order of
element.
ii. Assignments of elements to the stations.
5. Task can be assigned in two ways:
i. Permutability of task: It means that any number of tasks or steps of the column
can be Combined to make their total time closer to cycle time.
ii. Transferability of task: For making the total time equal to the cycle time tasks
or steps May be shifted laterally.
6. Consider an example: Suppose there are three machines (workstations) A, B and C Which can
process 5, 10 and 15 pieces per unit time respectively and the pieces flow From A to B to C
(precedence constraint).

7. Since A has minimum capacity i.e. of processing only 5 pieces per unit time naturally Work
station (machine) B will remain idle for 50% of its time and machine C for 66.66% Of its
time.
8. It shows that the line is unbalanced
9. Line can be balanced by addition of one or more machine A which has the capacity of 5
Pieces per unit.
D .Explain compatibility in the design of Toggle switch and Push button.
1. Compatibility is central concept in the study of displays and controls and gives Relationship
between signals, control responses and the expectations of the operator.
2. The most common two categories are as follows:
i. Spatial Compatibility: It refers to the physical arrangements of display and control
Components.
ii. Movement Compatibility: It refers to the relationship between the movement of
Control devices and display.
3. Compatibility in the design of toggle switch:
i. Toggle switch should be positioned on machine in such a way that it should be
easily Accessible to operator.
ii. Toggle switch should confirm with the anatomy of the operator’s hand.
iii. Toggle switch should provide desired movement on display when it is operated.
iv. E.g. if toggle switch is positioned upwards, display should indicate either open,
on,Start, increase.
v. Toggle switch should be painted in either red or black colour to grasp the attention
of An operator.
4. Compatibility in the design of Push button
i. Push button should have concave surface, so that the finger force may be
transmitted More effectively.
ii. Push button is used for emergency purpose so it should be positioned on machine
in Such a way that it should be easily accessible to the operator.
iii. Diameter of pushbutton should be able to accommodate the fingertip without
sliding.
iv. Push button should give desired movements on controls of machine when it is
Operated.
v. It should be made of such material which is easily distinguishable and preferably
can
vi. Shine even in the dark so that there should no problem in locating it
 Q.4 Attempt any THREE of the following. (3x4=12)
A project consists of 8 activities. Precedence relation and activity times are given. Draw the
Network and compute the critical path.

Activity Immediate Predecessor Activity time( Weeks)

P - 12
Q - 20
R - 28
S P 12
T P,Q 28
U T,S 12
V S 8
W U,V 8
1. Network Diagram

 Path 1 = P-Q-R-S-V-W
= 12+20+28+12+8+8
Path 1 = 88
 Path 2 = P-T-U-W
= 12+28+12+8
Path 2 = 60
 Path 3 = P-Q-T-U-W
= 12+20+28+12+8
Path 3 = 80
 Path 4 = P-Q-R-S-U-W
= 12+20+28+12+12+8
Path 4 = 92
Critical Path is P-Q-R-S-U-W as project duration is 92 Days.
B .Apply ergonomics aspects for designing of Hand Wheel for driving a car.
1. Hand wheel is a device which provides controlling torque via both hands.
2. Hand wheel of car should be positioned in front of driver’s seat so that it can be easily
Accessible .
3. Diameter of hand wheel should be such that driver’s hand can be comfortably
Positioned.
4. Shape of hand wheel which comes in contact with the driver’s hand should confirm
With the anatomy of driver’s hand
5. Surface of the hand wheel should be smooth and shiny and it should not harm driver’s
Hand.

C Apply ergonomics aspects for designing displays.

1. Display are the devices through which user (operator) can receive the
information From the machine.
2. Scale on the display should be divided into suitable linear divisions like 0-10-15
or 0-10-20 and not 0-5-23-33.
3. The size of letter or number on indicator is given as Height of letter or number
>/200.
4. The number of sub divisions between numbered divisions on display should be
Minimum.
5. Vertical figures should be used for stationary dial, while radially oriented figures
for Rotating dials.
6. The pointer on display should have knife edge to avoid parallax error.
7. Numbering should increase in clockwise direction on circular scale, rightward on
Horizontal scale and upward on vertical scale.
D Show the following elements on OC curve and explain it.
Α = 0.10
AQL = 0.01
Β = 0.05
LTPD = 0.25. Values of α and β in diagram are 0.05 and 0.01

1. Α = 0.10
It is Producer’s RiskSometimes it happen that in spite of good quality, the sample
taken may show defective units As such the lot will be rejected. In spite of good
quality the lot is rejected, such a type of risk of Rejection is known as producer’s risk.
Thus, the risk of rejecting a lot of good items is known as Producer’s risk.

2. AQL = 0.01.
3. AQL stands for Acceptable Quality Level
It indicates that maximum number of defectives that customer accepts.
Also, probability of acceptance For AQL is higher.
4. Β = 0.05
It is Consumer’s Risk
Sometimes it may happen that the quality of the lot is not good but the sample results
show Good quality units as such the consumer has to accept a defective lot. Such a risk
is known as Consumer’s risk.
5. LTPD = 0.25
LTPD stands for Lot Tolerance Percent Defective
It indicates unsatisfactory quality level and customer not accepts it due to high number
of Defectives in the lot.
e. The record of number of defectives on daily samples of size 300, for 24 days is given
below. Prepare a control chart for number of defectives (np) and establish revised control
limits (Assume 3 σ Limits)

Day 1 2 3 4 5 6 7 8 9 10 11 12
No.of 10 5 10 12 11 9 22 4 12 24 21 15
defec
t
Day 13 14 15 16 17 18 19 20 21 22 23 24
No.of 8 14 4 10 11 11 26 13 10 9 13 12
defec
t
Answer:-
Lots=N=24. Sample Size=300

Sr.No Lot size (n) No.of defectives

1 300 10
2 300 5
3 300 10
4 300 12
5 300 11
6 300 9
7 300 22
8 300 4
9 300 12
10 300 24
11 300 21
12 300 15
13 300 8
14 300 14
15 300 4
16 300 10
17 300 11
18 300 11
19 300 26
20 300 13
21 300 10
22 300 9
23 300 13
24 300 12
Total 7200 jobs 296 defectives
From the drawn np chart we observed that, there are huge variation in the defects. For
Example point 24 of day 10 & point 26 of day 19 are out of control. It means that dispersion is
More. Therefore it is very essential to maintain centering of the process. It is suggested that
Values of defects should lie in the range of 2.01 to 22.64
Q.5 Attempt any Two of the following.
a. Worker operating on a machine performs the following elements. The description of
Element, their observed time and rating are given. Compute the standard time for the
Component.
Element Description Observed Time Rating Relaxation
allowance
A Position the job 0.23 80% 10%
B Switch on and 0.09 100% 11%
lower drill
C 2.8 90% 12%
D 0.05 80% 10%
E 0.15 110% 11%

Eleme Observ Rati Relaxati

Basic time Allowance Standard
nt ed ng on Observed time=Normal
Time allowanTime×Rating time+Allowance
ce 100
A 0.25 80% 10%=0.25X80/100=0. 0.2X10/100=0.02 0.2+0.02=0.22
2
B 100 11% =0.09X100/100= 0.09X11/100=0.00 0.09+0.0099=0.0
0.09 % 0.09 99 999
C 2.8 12% =2.8X90/100=2.5 2.52X12/100=0.30 2.52+0.03024=2.
90% 2 24 8224
D 0.05 10% =0.05X80/100=0. 0.04X10/100=0.00 0.04+0.004=0.04
80% 04 4 4
E 0.15 11% =0.15X110/100= 0.165X11/100=0.0 0.165+0.01815=
110 0.165 1815 0.181
%
Standard Time 3.36
b. Draw and explain histogram, scatter diagram and Pareto chart with suitable examples.

 Histogram: The most commonly used graph for showing frequency distributions, or How
often each different value in a set of data occurs.

• Pareto chart :
- The pareto chart is one of the too in 7 basic tools of quality management
- Pareto chart is a chart that contains bar and line graph which is also known as
pareto Diagram or paraeto analysis.
- Bar graph shows number of defects in decending order and line graph shows
Cumulative persentage of defects.
The purpose of pareto giagram is to highlight the higest occurring type of defects.

• Scatter diagram: Graphs pairs of numerical data, one variable on each axis, to look for
a Relationship.
 • It is a tool to get relationships between two variables. This is a graph where one
Variable is plotted on the x-axis whereas the other is plotted on y-axis. It can be cause
And effect relation also you put on the respective axis.
C The following tensile strength readings were taken from a line processing a heap of steel
After heat treatment :

Date 1 2 3 4 5 6 7 8 9
Reading 95.5 93.0 96.5 87.5 90.5 96.0 100.0 98.0 97.0
Date 10 11 12 13 14 15 16 17 18
Reading 96.0 93.5 98.0 90.0 94.0 89.5 96.5 92.0 98.5
Date 19 20 21 22 23
Reading 96.5 92.0 97.0 97.0 91.0
Construct a two days moving average and range chart for the data. Analysis the results.

Date Reading 2 days 2 days 2 days Combination

moving moving moving for X R
total average range conventional
control chart
1 95.5
2 93.0 188.5 94.25 2.5
3 96.5 189.5 94.75 3.5 A 94.5 6.25
4 87.5 184 92 9 B 3.37 6.25
5 90.5 178 89 3 C 90.5 6.0
6 96.0 186.5 93.25 5.5 A
7 100 196 98 4 B
8 98.0 198 99 2 C
9 97.0 195 97.5 1 A
10 96.0 193 96.5 1 B
11 93.5 189.5 94.75 2.5 C
12 98.0 191.5 95.75 4.5 A
13 90.0 188 94 8 B
14 94.0 184 92 4 C
15 89.0 183.5 91.75 4.5 A
16 96.5 186 93 7 B
17 92.0 188.5 94.25 4.5 C
18 98.5 190.5 95.25 6.5 A
19 96.5 195 97.5 2 B
20 92.0 188.5 94.25 4.5 C
21 97.0 189 94.5 5 A
22 99.5 196.5 98.25 2.5 B
23 91.0 190.5 95.25 8.5 C
EX=2084.75. ER=95.5
For Combination A
X̅= 94.5. R̅= 6.25 n= 3 , A2 = 1.03. D3= 0 D4 = 2.28
Control limits for X chart
UCL = X̅+ A2 R̅
= 94.5 + 1.03 X 6.25
= 100.93
LCL = X̅- A2 R̅
= 94.5 – 1.03 X 6.25
=88.06
Control limits for R chart
UCL = D4 X R̅ = 2.28 X 6.25
= 14.25
LCL = D3 X R̅ = 0 X 6.25
=0