22657

22223
3 Hours / 70 Marks Seat No

Instructions – (1) All Questions are Compulsory.

(2) Answer each next main Question on a new page.
(3) Illustrate your answers with neat sketches wherever necessary.
(4) Figures to the right indicate full marks.
(5) Mobile Phone, Pager and any other Electronic Communication devices

are not permissible in Examination Hall.

1. Attempt any FIVE of the following. 10

1) State the need of inspection.

To ensure that part, material or a component confirms to the established standard

• To meet the interchangeability of manufacture
• To maintain the customer relation by ensuring that no faulty product reaches the
customer
• Provide the means of finding out shortcomings in manufacture
• It also helps to co-ordinate the functions of quality control, production, purchasing
and other departments of the organization
• To take decision on the defective parts i.e. the possibility of making some of these
parts acceptable after minor repairs

2) State different SQC tools. (Any two)

Xbar chart
R chart
C – chart
P – chart
N – chart
NP – chart
4) State any two symbols use in process chart.

5) Find mean and median for the following data 32-11, 32-12, 32-13, 32-14, 32-15.

2) Draw the symbol of following therbling

6) State the important functions of Process Engineering
process engineering plays a vital role in designing, optimizing, and managing industrial
processes to enhance efficiency, quality, and safety. Key functions include analyzing and
improving existing processes, developing new techniques, modifying designs, and
coordinating process improvement projects. They also focus on ensuring smooth
production flow, reducing defects, and implementing best practices.

7) Draw a scatter diagram showing negative corerelation between two variables.

SCATTER DIAGRAM
• To identify the correlations that might exist between a quality characteristic and a factor that might
be driving it.
• A scatter diagram shows the correlation between two variables in a process. These variables could be
a Critical To Quality CTQ characteristic.

8) With the help of a block diagram show the basic structure of cause and effect
diagram.
 9) List out the various factors affecting quality of product.
Internal Factors:
Materials:
Manufacturing Processes:
Management and Leadership:
Workforce:
Machines and Technology:
Cost and Price:
Design and Development:
Continuous Improvement:
External Factors:
Market Conditions:
Regulatory and Compliance Requirements:
Global Supply Chain:
Technological Advancements:
Economic Conditions:

11) Define method study. State it's objectives.

Definition :-Method study is the technique of systematic recording and critical examination of
existing and proposed ways of doing work and developing an easier and economical method
13) Enlist various QC tools.
1. Histogram.
2. Check Sheet.
3. Pareto Diagram.
4. Brainstorming.
5. Cause & Effect Diagram (ishikawa/fishbone diagram)
6. Control Charts.
7. Scatter Diagram

2. Attempt any THREE of the following. 12

1) Explain the concept of line balancing.

Line balancing means the balancing the (assembly/production) line. 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). 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. It
shows that the line is unbalanced. One way to partially balance the line is to have three
machines of type A, 2 of type B, with every machined of type C. Another approach to
balance the line will be to give some other task to machines B and C so that they do not
remain idle. The main objective of line balancing will be distributing task evenly over the
work stations so that idle time of men and machines is minimized
 Objectives of Line Balancing (four objectives for 2marks)
1. To equalize the workload among the workers:
Workload should be distributed equally at each stage of assembly line with respect to
overall assembly time.
2. To identify the bottleneck operation:
Identify the bottleneck operation and improve the stage by doing some modifications or
corrections.
3. To establish the speed of production line:
To divide the work properly with respect to worker’s movements. Sometime, combine the
operations for improvement the speed of production line.
4. To determine the number of workstations:
Industrial Engineer should do the time study of each stage and as per sequence of
assembly determine the number of workstations for completing all assembly operations.
5. To determine the percentage workload of each operator:
Workload at each stage should be distributed equally in terms of percentage too.
6. To assist in plant layout:
Line balancing can be done in such a way that it should utilize the minimum space in a
factory. Therefore, space saving can be possible

2) Compare acceptance sampling with 100% inspection. (Four points)

3) Enlist objectives of method study.

Objectives of Method Study
1 Improvement of manufacturing processes and procedures.
2. Improvement of working conditions.
3. Improvement of plant layout and work place layout.
4. Reducing the human effort and fatigue.
5. Reducing material handling
6. Improvement of plant and equipment design.
7. Improvement in the utility of material, machines and manpower.
8. Standardization of method.
9. Improvement in safety standard.
4) Draw two handed process chart for replacing refill of a ball point pen with
appropriate process chart symbols.(only condition may change)
7) Calculate standard time for grinding housing on cylindrical grinder
Normal time - 15min
Performance rating factor 125 -
Process allowance 10% of normal time -
Rest and personal allowance 20% of normal time -
Also find observed time for the operator
8) What is the effect of various environment factors such as temperature, noise, light
on the efficiency of operator.
Temperature:
In order to perform task efficiently, the operator should feel neither too hot not nor
cold, but Comfortable.
Optimum air temperature for most of the manufacturing operation ranges in between
18 and 23°C.
When heavy work is to be done, the temperature should be lowered, and when office
work is to be done, it should be little higher.
The effect of heat can be minimized by:
• Isolating heat sources to reduce direct transmission by radiation of heat between
body and the heat source.
• Shielding.
• Installation and provision for adequate local ventilation to get rid of smokes, fumes
etc.
• Permit rest pauses in extreme hot conditions
Noise :
Noise has been defined as 'unwanted sound'.
It creates both, short term and long term effects on human performance.
These effects may be internal and physiological in nature, resulting in the auditory
system being unable to hear the sound, which may be in the form of work related
discussion between two or more than two machine operators or instructions being
given by supervisor or engineer to a group of machine operators.
Noise produces three effects :
(1) Annoyance, (2) Loss of hearing power and (3) Reduced efficiency at work.
• If the noise level is too high, it can be stopped at source by better maintenance of
equipment, plugging ears and providing sound insulating walls.
• Sudden loud sound, which are entirely unexpected, can lead to increase in blood
pressure, Sweating and muscular contraction.

9) Explain man-machine relationship in terms of ergonomics.

Man–machine system is a system in which the functions of a human operator (or a

group of operators) and a machine are integrated. This term can also be used to
emphasize the view of such a system as a single entity that interacts with external
environment.
• It is combination of one or more human beings at
one or more physical components interacting to
bring about some desired output from given inputs.
• It consists of following types Manual system, Mechanical system, Automated system
• All these are related to the nature of man himself, to his abilities and limitations. Today
the industrial working has become very complex because of rapid technological
development and increased demand of product.
• With the result the man has been subjected to heavy stresses (mental and physical)
and as such he either fails to get best output out of himself or suffers operation breakdown.

10) State merits and demerits of acceptance sampling.

Merits of Acceptance Sampling:

(i) The method is applicable in those industries where there is mass production and the industries
follow a set production procedure.
(ii) The method is economical and easy to understand.
(iii) Causes less fatigue boredom.
(iv) Computation work involved is comparatively very small.
(v) The people involved in inspection can be easily imparted training.
(vi) Products of destructive nature during inspection can be easily inspected by sampling.
(vii) Due to quick inspection process, scheduling and delivery times are improved.
Demerits of Acceptance Sampling:
It does not give 100% assurance for the confirmation of specifications so there is always some
likelihood/risk of drawing wrong inference about the quality of the batch/lot.
(ii) Success of the system is dependent on, sampling randomness, quality characteristics to be
tested, batch size and criteria of acceptance of lot.

3. Attempt any THREE of the following. 12

1) Why allowances are considered while calculating standard time?
Standard time = Normal time + Allowances
Allowances are considered while calculating standard time because;
Method study investigation tries to minimize the energy expended by the worker in performing
the operation.
However, the job will still require the expenditure of human effort.
Therefore, a worker is not able to work throughout the day continuously. Therefore he requires
sometime for recovery from fatigue and for relaxation.
He also requires some additional time for his personal needs and other reasons.
This additional time other than basic time is known as allowance.

2) Explain the producer's risk and consumer's risk.

(i) α- Risk (Producer’s Risk) :-Sometimes it happens 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. In other words, the
probability of rejecting a lot which has actually been satisfactory by the producer according to
acceptable quality level is known as producer’s risk. Thus, the risk of rejecting a lot of good items
is known as producer’s risk. Producer’s risk is designated as the alpha (α) risk.
(ii) β – Risk (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. In other words, the probability of accepting
a lot which has actually been satisfactory by the consumer according to a predetermined standard
is known as consumer’s risk. Consumer’s risk is designated as the Beta (β) risk.

3) Explain cost of quality.

Cost of quality is a method for calculating the costs that companies incur ensuring that products
meet quality standards, as well as the costs of producing goods that fail to meet quality standards.
Cost of quality includes
Market research cost
Product research and development cost
Design cost
Cost of manufacturing
Cost of inspection
Cost of quality assurance

4) Apply principles of ergonomics for design of lever for hand press machine.

Following ergonomics principle should be considered while designing lever for hand press
Neutral Posture to be maintain while handling machine handle
Reduce Excessive Force
Keep it Easy to Reach
Work in Power or Comfort Zone .The power zone refers to the zone where interacting with objects has
the least amount of effort spent, it is also known as “hand shake zone”.
Reduce Excessive Motion
Reduce Static Load
Minimize Pressure Points
Provide Clearance
Enable Movement and Stretching
Reduce Excessive Vibration

5) Enlist the allowances consider while calculating standard time and explain any one.

Standard time = Normal time + Allowances

Allowances are considered while calculating standard time because;
Method study investigation tries to minimize the energy expended by the worker in performing the
operation.
However, the job will still require the expenditure of human effort.
Therefore, a worker is not able to work throughout the day continuously. Therefore he requires
sometime for recovery from fatigue and for relaxation.
He also requires some additional time for his personal needs and other reasons.
This additional time other than basic time is known as allowance

6) Draw OC curve and explain the producer's risk and consumer's risk.

(i) α- Risk (Producer’s Risk) :-Sometimes it happens 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. In other words, the
probability of rejecting a lot which has actually been satisfactory by the producer according to
acceptable quality level is known as producer’s risk. Thus, the risk of rejecting a lot of good items
is known as producer’s risk. Producer’s risk is designated as the alpha (α) risk .
(ii) β – Risk (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. In other words, the probability of accepting a lot which
has actually been satisfactory by the consumer according to a predetermined standard is known as
consumer’s risk. Consumer’s risk is designated as the Beta (β) risk.
(iii) AOQ (Average Outgoing Quality): AQL is acceptable, Quality level, it indicates maximum
number of defectives that consumer accepts. Probability of acceptance for AQL is higher as
shown in Fig
(iv) LTPD : LTPD (Lot Tolerance Percent Defective) is also called as Rejectable Quality Level
(RQL), which is, defectives which customer finds definitely unacceptable. The probability for
LTPD is lower
7) Differentiate inspection and quality control. (Four points)

8) A spindle is processed on three machines A, B and C which can process 5, 10 and 15

spindles per hour respectively and spindles flows from A to B to C. Suggest suitable
dedicated production line to produce at least 100 spindles per 8-hour shift. (same as
Line balancing) Calculate the project duration.
10) Tabulate various times and mark EST and LFT on the arrow diagram.
11) Draw a two handed process chart to assemble a nut and bolt.
 12) Classify the man-machine systems.
1. Based on Level of Automation:
 Manual Systems:
These rely primarily on human input and control, with the machine acting as a tool or
support. Examples include a worker using a hand saw or a driver manually operating a car.
 Semi-Automatic Systems:
These involve a combination of human and machine control. Humans make decisions and give
commands, while machines execute those commands. An example is a machine that requires
human intervention to start or change its operating mode.
 Automatic Systems:
These systems operate with minimal or no human intervention. Machines sense, process
information, make decisions, and take action autonomously. An example is an automatic
telephone exchange.
2. Based on Control Method:
 Open-Loop Systems:
These systems are initiated by a human and require no further control. Once started, the action
proceeds without feedback or adjustment. Examples include firing a bullet from a gun or
priming a pump.
 Closed-Loop Systems:
These systems use feedback to maintain a desired outcome. Humans set goals, and the system
adjusts its actions based on feedback to achieve those goals. An example is a thermostat that
regulates temperature.
3. Based on Human-Machine Interaction:
 Simple:
In these systems, the human interacts with the machine using basic tools or controls.
 Complex:
These systems involve more advanced interfaces, displays, and control methods.
 Open-loop/Closed-loop:
This classification highlights the type of control used in the system, whether it's a one-time
action or a continuous process with feedback.

4. Attempt any TWO of the following. 12

2) Write advantages of hand wheel used as a control.

Control hand wheels let you make incremental adjustments. The rotation of the
wheel can be fine-tuned, making it ideal for applications requiring accuracy, such as
positioning machinery, adjusting tension, or regulating flow rates
3)Ten castings were inspected in order to locate defects in them.
Castings 1 2 3 4 5 6 7 8 9 10
No. of defects 2 3 2 4 5 4 3 4 0 6

Draw C chart and find control limits.

4) Explain importance of TQM

1. Focus on Customers
2. Continual improvement
3. Employee involvement & empowerment
4. Top management commitment
5. Strategic and Systematic Approach
6. Process centered
7. Fact-based Decision Making
8. Effective Communication.

5) Write any two advantages and limitations of ISO 9000.

Advantages of ISO 9000:-
1. ISO 9000 gives international recognition of ability, credibility and expertise,
thereby increasing the number of customers.
2. ISO 9000 provides a competitive edge in the domestic and global markets.
3. It motivates the employees and develops pride in them for achieving excellence in
quality. It helps to enhance quality image of the company.
4. It provides a climate for consistent improvement in quality.
5. It creates a more effective and efficient operation.
6. It helps to increase the level of customer satisfaction and relation.
7. It reduces audits.
8. It helps in the improvement of the marketing process.
9. Enhance the motivation of employees as well as awareness and morale.
10. It promotes international trade.
11. Helps in increasing the profit
12. It helps in the reduction of wastage and increase productivity.
13. It is a common tool for standardization.
Disadvantages of ISO 9000:-
1. Most of companies have less funding available, therefore companies are finding
Difficulties to adopt ISO system.
2. ISO 9000 registration need heavy document workload.
3. ISO 9000 registration process require long time.
4. Implementation of this system is very demanding of resources.
5. Work culture need to be changed/improved.
6) Differentiate between variable control chart and attribute control chart based on any
four parameters.
7) Describe any two of the following in connecter with a man-machine system
i) Design of visual display ii) Design of Controls iii) Design of workplace
 8) Enlist the benefits of Kaizen.
1. Increased Productivity and Efficiency:
 Kaizen encourages the elimination of waste and streamlining of processes, resulting in increased
efficiency and productivity.
2. Reduced Waste and Improved Resource Management:
 Kaizen focuses on identifying and eliminating waste in all forms, including unnecessary steps,
waiting times, and overproduction.
3. Improved Quality and Customer Satisfaction:
 Kaizen promotes a culture of continuous quality improvement, leading to fewer defects and
higher-quality products or services.
4. Enhanced Employee Morale and Engagement:
 Kaizen empowers employees by involving them in the process of continuous improvement,
fostering a sense of ownership and responsibility.
5. Improved Safety Practices:
 Kaizen encourages the identification and elimination of safety hazards, leading to a safer work
environment.
6. Cost Reduction and Improved Financial Performance:
 By eliminating waste, optimizing processes, and improving quality, Kaizen can lead to significant
cost savings for businesses.
7. Cultivating a Continuous Improvement Culture:
 Kaizen fosters a culture of continuous learning and improvement, where employees are encouraged
to constantly seek ways to improve their work and the processes they use.
9) What is meant by "5S" Explain each "S" in detail.
Explain how 5S principle can be effectively applied to your college library
1. Sort (Seiri): Separate necessary books and get rid of anything that isn’t needed. If
items are needed in another work area, move them to the correct place in library.
2. Straighten (Seiton): Take the remaining books and organize them. Use labeling,
containers, color coding or anything else that makes sense for the items you are
straightening.
3. Shine (Seiso): Clean and inspect the rack area.
4. Standardize (Seiketsu): Create processes and standards for the first three
steps.Keep it simple so it’s easy to sustain. Checklists are helpful.
5. Sustain (Shitsuke): Consistently apply the standards to maintain and improve
operations in library

5. Attempt any TWO of the following. 12

1) Explain following ⅰ) Six sigma ii) POKA-YOKE

ⅰ) Six sigma
 Focus on the customer: Six Sigma prioritizes meeting customer needs and
expectations.
  Data-driven decision-making: Decisions are based on data analysis rather than
guesswork.
 Process improvement: Six Sigma focuses on streamlining and optimizing business
processes.
 Variation reduction: The goal is to minimize variation in processes to reduce defects
and errors.
 Defect reduction: Six Sigma aims to achieve near-zero defects in products and
services.
 Continuous improvement: Six Sigma promotes a culture of continuous learning and
improvement.

ii) POKA-YOKE
Key Principles:
 Preventing Errors:
Poka-yoke focuses on designing systems where mistakes are impossible or highly
unlikely. This can be achieved through physical constraints, automated checks, or visual
cues.
 Early Error Detection:
When errors do occur, poka-yoke aims to make them immediately obvious, allowing for
quick correction before they cause significant problems.
 Corrective Action:
Poka-yoke can also include mechanisms that help operators correct errors easily and
quickly.

2) 10 samples of size 5 have been collected with following observations

Sr.No 1 2 3 4 5 6 7 8 9 10
X 7.0 7.5 8.0 10.0 9.5 11.0 9.5 4.0 3.5 4.0
R 2 3 2 2 3 4 3 2 3 2
Given A2 = 0.58, D3 = 0, D4 = 2 .11 and d2 = 2.32. Find control limits for overline X and R
chart and calculate standard derivation and process capability.

3) Explain critical path method with suitable example and write its applications.
The Critical Path Method (CPM) is a project management technique used to schedule
and manage complex projects by identifying the longest sequence of tasks, known as the
critical path, that directly impacts project completion time. By focusing on these critical
tasks, project managers can optimize resource allocation, mitigate risks, and ensure
timely project delivery.

Example:
Imagine a software project with several tasks:
 Task A: Design the user interface (3 days)
 Task B: Develop the backend logic (5 days)
 Task C: Write unit tests for Task A (2 days)
 Task D: Write unit tests for Task B (3 days)
Task E: Integrate all components (4 days)
Critical Path:
Task A → Task B → Task E:
This path takes a total of 12 days (3 + 5 + 4) and is the longest path through the
project. Any delay in these tasks will directly impact the overall project completion time.
Task A → Task C → Task E:
This path takes 9 days (3 + 2 + 4) and has slack time, meaning it can be delayed without
affecting the final project date.
Applications of CPM:
Construction:
CPM is widely used in construction projects to manage complex schedules, resource
allocation, and prevent delays,
Software Development:
CPM helps project managers identify critical coding, testing, and integration tasks to
ensure timely software releases.
Manufacturing:
CPM can optimize production schedules, manage dependencies between different
manufacturing processes, and improve overall efficiency.
Project Management:
In general, CPM is a valuable tool for planning, scheduling, and controlling the execution
of complex projects across various industries,

4) In a manufacturing process, the numbers of defective found in the inspection of 10 lots of

defectives found in the inspection of 10 lots 400 items are given below.
.

5) In a project, there are 6 events. Their precedence relationships A / R are , A angle C A

angle D B angle F. B angle G C angle E E angle F D angle E D angle F The activity
between different events consume time as mentioned in table below. Identify the critical
path. (Ref. Fig. No. 1)

6) Outline an appropriate process chart for the activity "Replacement of Punctured Tyre".
7) Explain the types of displays and draw sketch of any two.

Displays are devices which the man can receive the information from the machine
A good display device is one which allows proper combination of speed, accuracy and sensitivity of
display
Following are the types of display
1. Visual display
a. Qualitative display
. Quantitative display

8) Explain the concept of supply chain management and state it's functions.

Supply chain management (SCM) refers to the management of operations that are involved in the
procurement of raw materials, their transformation into finished goods, and their distribution to the
end consumer.
The five functions of supply chain management include the following:
1. Purchasing
In the manufacturing process, raw materials are required to produce goods and products. It is
important that these materials are procured and delivered on time so that production can begin. For
this to occur, coordination with suppliers and delivery companies will be required to avoid any
potential delays.
2. Operations
Demand planning and forecasting are usually required before materials can be procured, as the
demand market will dictate how many units to be produced and how much material is required for
production.
3. Logistics
Logistics is the part of supply chain management that coordinates all aspects of planning, purchasing,
production, warehousing, and transportation so that the products will reach the end-consumer without
any hindrances
4. Resource Management
Production consumes raw materials, technology, time, and labor. Resource management ensures that
the right resources are allocated to the right activities in an optimized manner..
5. Information Workflow
Information sharing and distribution is what keeps all of the other functions of supply chain
management on track. If the information workflow and communication are poor, it could break apart
the entire chain.
6. Attempt any THREE of the following. 12

1) Explain any six objectives of line balancing

Objectives of Line Balancing
1. To equalize the workload among the workers: Workload should be distributed equally at
each stage of assembly line with respect to overall assembly time.
2. To identify the bottleneck operation: Identify the bottleneck operation and improve the
stage by doing some modifications or corrections.
3. To establish the speed of production line: To divide the work properly with respect to
worker’s movements. Sometime, combine the operations for improvement the speed of
production line.
4. To determine the number of workstations: Industrial Engineer should do the time study
of each stage and as per sequence of assembly determine the number of workstations for
completing all assembly operations.
5. To determine the percentage workload of each operator: Workload at each stage should
be distributed equally in terms of percentage too.
6. To assist in plant layout: Line balancing can be done in such a way that it should utilize
the minimum space in a factory. Therefore, space saving can be possible.

2) Number of defects found in an inspection of 10 assemblies are 2, 3, 2, 5, 2, 3, 5, 3, 0, 1

respectively. Draw C Chart and conclude.
3) Two machines producing components are checked up for the statistical stability. Draw
the 'P' chart for both machines and comment upon the process. Sample size for both
machines are 200.
Machine A

Sample No 1 2 3 4 5 6 7 8 9 10
Defectives 25 28 30 30 20 29 31 26 31 27
Machine B

Sample No 1 2 3 4 5 6 7 8 9 10
Defectives 11 08 22 15 12 27 10 15 10 02
4) Draw an outline process chart for change of SIM card of your Mobile
5.Define quality circle. State the objectives of quality circle.

A Quality Circle is volunteer group composed of members who meet to talk about
workplace and service improvements and make presentations to their management with
their ideas."
OR
Quality circle is problem solving technique which assumes that suggestion for quality
improvement should come from those who have the greatest knowledge about the job.
Objectives of Quality Circle
▪ To contribute towards the improvement and development of the organization or a
department.
▪ To overcome the barriers that may exist within the prevailing organizational structure
so as to foster an open exchange of ideas.
▪ To develop a positive attitude and feel a sense of involvement in the decision making
processes of the services offered.
▪ To respect humanity and to build a happy work place worthwhile to work.
▪ To display human capabilities totally and in a long run to draw out the infinite
possibilities ▪ To improve the quality of products and services.
▪ To improve competence, which is one of the goals of all organizations
▪ To reduce cost and redundant efforts in the long run.
▪ With improved efficiency, the lead time on convene of information and its
subassemblies is reduced, resulting in an improvement in meeting customers due
dates

6.A particular activity on shop floor consists of three elements. Calculate the standard time for
each activity. Total allowances are given as percentage of normal.
7.Following are the inspection results of a castings for a shift. Draw appropriate
control chart and write your conclusion
Given data: A2 =0:58, d3 = 0, d4 = 2.11