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PRODUCTION MANAGEMENT UNIT-I PART-A 1. Classify the manufacturing systems? 2. What are the factors affecting forecasting? 3. List out the quantitative forecasting techniques? 4. Define forecasting? 5. What are the three factors in selection of a forecasting technique? 6. What is meant by regression? 7. Define the term production management? 8. What is forecasting accuracy? Mention the types of errors. 9. What is qualitative forecasting technique? 10. What are the types of demand pattern? PART-B 1. The sales particulars of a company for 13 years of operation are furnished below. Year 1 2 11 6 3 11 9 4 12 7 5 14 6 6 14 5 7 15 3 8 15 8 9 16 0 10 16 5 11 17 7 12 19 0 13 205

Lumber sales 96

a) Fit a simple regression for the above details. b) Forecast the sales for the 14th year of operation. 2. 3. 4. 5. 6. Discuss the classifications of forecasting techniques with suitable comments. Discuss all the types of manufacturing systems with its characteristics and examples. List and explain the types of forecast in decision making? What is linear regression and explain with a suitable graph and examples. Describe elaborately the simple moving average method with suitable examples.

UNIT-II PART-A 1. What do you mean by Aggregate planning? 2. What is the aim of linear decision rule? 3. List out the computer softwares used in transportation model? 4. Name the various methods used to solve the aggregate planning problems. 5. What are the inputs required for linear decision rules? 6. List out the various pure strategies? 7. What is mixed strategies in Aggregate planning? 8. Name the different capacities which are generally used to manufacture a product.

9. Mention few assumptions while using linear programming model. 10. What is goal programming? PART-B 1. 2. 3. 4. 5. 6. Describe the procedure steps to find optimum solution of given transportation model. Discuss the significance of aggregate planning strategies? Explain the various methods at the basic feasible solution for transportation model? Explain the concepts of linear decision rules and its applications. Briefly explain the various aggregate planning methods with suitable examples? Alpha associates produce mini-computers that have a seasonal demand pattern. The available capacities during regular time & over time, as well as other cost data are as follows. Available production capacity Demand forecast 1 700 2 1000 3 2000 4 1200

Period Regular time Over time Subcontract Period 1 2 3 4 900 1000 1100 700 350 350 350 350 600 600 600 600 Unit of demand

Available initial inventory =200 units, Over time cost/unit = Rs. 150/-, Desired final inventory =150 units, Subcontracting= Rs 175/-, Regular time cost/unit = Rs.125/Inventory cost/unit/period = Rs.25/Formulate this problem as a transportation model to determine optimum production levels & means of production for the next four quarter periods. Also solve the model. UNIT-III PART-A 1. What is inventory control? 2. What is meant by lead time? 3. What are the various inventory management techniques? 4. What are the various models of inventory? 5. What is inventory holding cost? 6. Briefly explain the inventory model with price breaks. 7. What is meant by quantity discount? 8. What are the costs associated with inventory? 9. Define the term Inventory turnover? 10. What is economic order quantity? PART-B

1. Describe any two Inventory control techniques. 2. A pesticide company has a demand for 5, 00,000 containers. Each empty container cost is Rs. 1.50. Empty containers are supplied by the subcontractor. The ROL system of stock replishment is followed. Ordering cost is Rs.20.00 per order and Inventory carrying cost is Rs. 20% of cost per container. The demand is constant through out the year. The lead time is 32 days. Determine i) Economic order quantity ii) Lead time consumption iii) Reorder level iv) Average Inventory 3. The demand for an item in a company is 20000 units/ year and the company can produce 2500 units per month. The cost of one set up is Rs. 600 and holding cost of one unit per month is Rs.0.20 paise. Determine a) Optimum manufacturing quantity, b) The maximum Inventory, c) The time between orders, d) The number of orders per year, d) The optimum annual cost if the cost of the item per unit is Rs. 2.50. Assume no shortages. 4. The annual demand of a product is 40,000 units. The average time is 4 weeks. The standard deviation of demand during the average lead time is 70 units per week. The cost of ordering is Rs. 350 per order. The cost of purchase of the product per unit is Rs.8. The cost of carrying per unit per year is 12% of purchase price. The maximum delay in lead time is 12 days and the probability of this delay is 0.20. Assume a service level of 0.90. a) If Q system is followed, find the reorder level. b) If P system is followed, find the maximum Inventory level. 5. Azad toolings has a requirement for 2, 00,000 metal bushings per annum. The company orders the metal bushings in lots of 45,000 units from a supplier. The ordering cost is Rs. 50 and the carrying charges are expressed as 25% of the unit cost. The bush cost is Rs. 20 each. The company wants to know what percentage of their order quantity differs from economic order quantity and how the cost varies for the two. Find the optimal order quantity 6. The annual demand for an automobile component is 2400 units. The carrying cost is Rs.0.40/units/year. The ordering cost is Rs.20/-order and the shortage cost is Rs 10/unit/year. Find the optimal values of the following: a) Economic order quantity (EOQ), b) Maximum inventory, c) Maximum shortage quantity, d) Cycle time, e) Inventory period (t1), f) Shortage period (t2) UNIT-IV PART-A 1. Define MRP? 2. Define the term JIT? 3. What are the inputs to MRP? 4. What are the benefits of JIT? 5. List out the objectives of MRP? 6. Define the term dependent demand? 7. How MRP differs from Inventory control system? 8. What are the basic elements of JIT? 9. What is Kanban card? 10. Define Supply chain management.

PART-B 1. Discuss the silent characteristics of JIT? 2. Describe the important elements of a JIT manufacturing system. 3. Describe the major tools and techniques of JIT manufacturing system. 4. Explain the working principle of Kanban system. 5. Discuss in detail the strategies of supply chain management? 6. Compute the EOQ for the following data and mention the MRP calculations. The initial on hand quantity = 30 units.The average demand per week (D) = 20.83 units per week. The average of 12 weeks projected requirements = 21 units per week (approx) Carrying cost per unit per week (Cc) = Rs.2.50, Setup cost per setup (Co) = Rs.2.50.

UNIT-V PART-A 1. Define Scheduling? 2. Classify the scheduling strategies? 3. Write down the priority sequencing rules? 4. What are the inputs to scheduling? 5. Mention the principles of scheduling? 6. What is backward scheduling? 7. What is Index method of Assignment problem? 8. What is critical ratio scheduling? 9. What is Gantt chart? 10. What is expediting? PART-B 1. The owner of a small machine shop has 4 machinists available to assign jobs for the day. Five jobs are offered with expected profit for each machinist on each job as follows. A 1 2 3 4 68 71 87 48 B 78 84 92 64 C 50 61 111 87 D 101 73 71 77 E 82 59 81 80

Find the assignment of machinists to jobs that will result in a maximum profit. Which job should be declined? 2. Write down the procedure steps of hugarian method for solving assignment problem. 3. Find the sequence that minimises the total time in hours, required to complete the following tasks. Each job in processed in the order ACB. 1 M/C A M/C B M/C C 12 7 3 2 6 8 4 3 5 9 1 4 11 4 5 5 5 7 2 6 7 8 3 7 6 3 4

4. Use graphical method to minimise the time required to process the following jobs on five machines in the sequence given. Also calculate the total elapsed time to complete both the jobs. Sequence Time (hrs) Sequence Time (hrs) A 7 B 9 B 6 C 7 C 5 A 7 D 11 D 6 E 5 E 11


5. A company wished to assign 4 salesmen to 4 districts. The volume of sales matrix is given below make the optimal assignment which results in maximum volume of sales. Salesman A 1 2 3 4 250 350 500 400 B 300 400 375 350 C 420 200 400 420 D 400 250 350 300

6. Jobs each of which must be processed on the machines M1, M2 . M6. The processing times

in hrs are given. i) Find the optimal sequence ii) Minimum total elapsed time. iii) Idle time associated with machines. Jobs A M1 18 M2 8 M3 7 M4 2 M5 10 M6 25


17 11 20

6 5 4

9 8 3

6 5 4

8 7 8

19 15 12

PRIST UNIVERSITY Puducherry campus

Unit 1 PART - A 1. 2. 3. 4. 5. 6. 7. 8. 9. Define the term quality control and explain its objectives What are the benefits of statistical quality control Differentiate between inspection and quality control. What are the applications of quality control? What are the categories of quality cost? What are the objectives of quality control? What is meant by accuracy? What are The Dimension Of Quality for a service Industry? What are the dimension of quality for a Manufacturing seetor


1. Explain the various steps in quality control programme (16) 2. Explain the term quality of performance and state the factors which control them.(16) 3. a) Define the term quality control and explain its advantage over inspection techniques.(8) b) i) What is the difference between accuracy and precision (4) ii) What is the application of quality cost? (4) 4. Discuss briefly about the Customers Perception on Quality. (16) 5. Explain the elements of quality cost (16) Unit II PART- A 1. What are the difference between P chart & R chart? 2. State the objective of chart and R chart 3. What is the objective of the control chart? 4. What is meant by process capability? 5. What are the types of control charts?

6. What are the uses of

, R, and charts? 7. Differentiate between a defects and defectives 8. What is meant by sample and sampling? 9. Differentiate between attribute and variable. 10. List the measure of process capability 11. What are the measures of dispersion?

PART- B 1. a) Enumerate the differences between variable charts & attribute chart (8) b) i)Explain the benefits of statistical tolerance (4) ii) What are the purposes of process capability analysis? (4)
2. Certain charts for

and sigma are maintained on the resistance in ohms of a certain rheostat

coil based on a subgroup size of five. After 30 subgroups, , = 2419.5 and = 107.6 a) Determine the centre line and 3- sigma control limits for and chart. b) Estimate the value of assuming that the process is operating in statistical control. c) Assuming that the distributing generation by the process is approximately normal, what proportion of the rheostat coils meet specifications of 85 10 ohms? (16) 3. Control chart for and R are maintained on certain dimensions of a manufactured part, and R are computed for each = 412.83 and

measured in mm. The subgroup size is 4. The values of subgroup. After 20 subgroups limits for the

R = 3.39. Calculate the values of 3 sigma

and R chart and estimate the value of

on the assumption that the process is in statistical control. (16)

4. A Sub-group of 5 items each are taken from a manufacturing process at a regular interval. a certain quality characteristics is measured and and R value computed. After 25 subgroups it is found that =357.50 and R-8.80. if the specification limits are 14.40 0.40 and if the process is in statistical control, what conclusions can you draw about the ability of the process to produce items within specifications? Unit III PART-A 1. 2. 3. 4. 5. 6. What are the merits and demerits of acceptance sampling? State the advantage and limitations of acceptance sampling over 100% inspection. What is the difference between single sampling plan and double sampling plan. Draw a neat sketch of an OC curve showing it difference zone. What is quality assurance? Discuss the scope of inspection

7. What is AQL? 8. What is AOQL? 9. What is LTPD? 10. What is an OC curve? 11. What is producers risk? 12. What is consumers risk?

PART B 1. Discuss the following acceptance sampling plans with flow chart 1. Single sampling plan 2. Double sampling plan 3. Sequential sampling plan 2. Explain the types of inspection in ABC.(16) (5) (5) (6)

3. Explain the types of sampling plan which are in practice in industry with respective Acceptance criteria (16). 4. Explain the characteristics of OC curve (16) 5. (a) Explain AOQL with diagram and differentiate AQL and AOQL. (b) Explain the concept of consumers risk and producers risk. 6. In a double sampling plan N-5000, N1-100, C1 0, N2 100, C2-1. d) Use Poissons table to compute the probability of acceptance of a 1% defective lot. e) Assume that a lot reject by this sampling plan will be 100% inspection. What will be the AOQ if the submitted product is 1% Defective? Considering both the inspection of rejection lots, what will be the average number of articles inspected per lot if the submitted product is 1% defective? Unit- IV PART- A 1. Define Inherent availability 2. Define Active availability 3. Define Operational availability 4. What is the Difference between product quality & process quality? 5. Define reliability 6. What the importance of reliability 7. What are the basic elements of reliability? 8. State and explain the factors to be considered in designing for reliability. 9. What is meant by reliability engineering? 10. What is the objective of reliability engineering? 11. What is MTBF? 12. What is MTTR?

13. Define failure rate.

PART- B 1. 2. 3. 4. Explain the important aspects of the Reliability Engineering (16) Explain the network modeling of series and parallel configuration system(16) Explain the MTBF and Product Reliability (16) (a) Explain the three types of reliability tests for testing life (b) Distinguish between reliability and Quality control.

5. (a) The resistance tolerance of a 100 ohm resistor, as purchased, is 100% This type of resistor may drift up 15% in resistance value after 2 years of operation. What are the worst case considerations for the application of this resistor? (b) Ten transformers were tested for 500 hours each within prescribed operating conditions, and one transformer failed exactly at the end of the 500 hours exposure. What is the failure rate for this types of transformer? 6. (a) Discuss in detail the bathtub curve for the life history of products. (b) Explain (i) The accelerated life testing (ii) Environmental stress Screening (ESS) (iii) Accelerated life Testing

UNIT V PART -A 1. An electronic system has a MTBF of 1000 hours and a MTTR of 40 hours. Determine its availability. 2. What are shape parameters? State its effect on the failure rate 3. Three lamps are connected in parallel to produce light in a hall. The reliabilities are 0.92, 0.95 and 0.96. Find the reliability of the total lamp system. If the systems are connected in series, determine the reliability of the system. 4. What is meant by product development? 5. What is meant by optimization in reliability engineering? 6. What is meant by pareto analysis?

7. Define Redundancy 8. What are the Objective Redundancy Selection Criteria? 9. What are the procedures in product developments?

PART-B 1. a) i) What is reliability? Explain in detail the different techniques employed in improving the reliability. (10) (ii) Explain briefly the product life cycle (6) 2. Explain the procedures in product development. 3. Write short notes on the following 1. MTTR (4) 2. MTBF (4) 3. Marginal test (4) 4. Availability and reliability (4) 4. Describe fault tree analysis with a suitable example.(16) 5. Explain the importance of reliability (16) 6. Explain the Pareto analysis with an example. Give the merits of demerits 7. Explain the various stages of failure Mode Effect Analysis.

PRIST UNIVERSITY M.TECH MANUFACTURING TECHNOLOGY TOTAL QUALITY MANAGEMENT QUESTION BANK UNIT I Part A 1. 2. 3. 4. 5. Define TQM. Mention any four concepts of TQM. What are the quality functions? Define the concepts of quality cycle. What are the dimensions of quality?

6. What are the benefits of TQM?

Part B 1. Explain in detail the history of quality control. 2. (i) Explain the quality policy. (ii) Explain the leadership concepts. 3. List the 14 principles of Deming's philosophy and explain it. 4. (i) Explain the economics of quality. (ii) Explain the decision making. (iii) Explain the customer satisfaction. 5. Explain the TQM leaders role in detail. 6. (i) Explain on PDSA Cycle. (ii) Explain on Juran's ten steps to quality improvement.

UNIT II Part A 1. What are the seven tools of management? 2. 3. 4. 5. 6. Define process capability index. Define Process capability. What is the Main objective of control chart? Define control chart. Define quality policy statement.

Part B 1. Explain seven tools of management in detail. 2. The following are the X and R values of 4 subgroups of readings:
X = 10.2, 12.1, 10.8, and 10.9; R = 1.1, 1.3, 0.9, and 0.8.

The specification limits for the components are 10.7 0.2.


Establish the control limits for X and R charts.

(ii) Find the process capability. (iii) Will the product able to meet its specification? 3. Ten samples of equal size are taken to prepare a p- chart. The total number of parts in these 10 samples was 1200, and the total number of defects counted was 155. Determine the centre, UCL and LCL for the p- chart. 5. Explain the process of engineering techniques for implementing the quality plan in detail.
4. Write down the construction procedure for X and R charts in detail.

6. An np chart is to be established on a painting process that is in statistical control. If 35 pieces are to be inspected every 4 hours, and the fraction non conforming is 0.06, determine the central line and control limits.

UNIT III Part A 7. Define OC curve. 8. Give the application of work sampling. 1 What is acceptance sampling? 2 What is average outgoing quality limit? 1. What is producers risk? 2. What is the basis for sampling inspection? Part B 1. Describe the procedure for conducting work sampling in an organization. Also mention the advantages and disadvantages of this technique. 2. Define operating characteristic of curves and explain its significance. 3. Define inspection. Analyse the essential elements of an inspection plan 4. Explain the characteristics of acceptance sampling. 5. Write short notes: (i) Random numbers (ii) Sampling plan (iii) Sampling risk

(iv) Advantages and disadvantages of sampling inspection. 6. Describe the procedure for sampling inspection. UNIT IV Part A 1 2 What are the objectives of JIT? Define FTA.

3 4 5 6

Define QFD. Define Kaizen. Mention the objectives of quality team. What are the methods followed for capturing customer requirements?

Part B 1. Explain Quality function deployment with suitable application. 2. Explain Taguchi methods in quality engineering. 3. Explain 5s principles in detail. 4. Explain FMEA documentation in detail. 5. Explain JIT techniques in detail. 6. Explain the relevance of TQM in the context of human resource development.

UNIT V Part A 1. Define ISO 9001:2000 standard. 2. Mention the objectives of audit. 3. Define documentation. 4. Define internal audit. 5. Define ISO. 6. Draw the documentation pyramid. Part B 1. Explain: (i) ISO 9001 requirements (ii) Quality management system. 2. Explain documentation in detail. 3. Explain the benefits of ISO registration in detail. 4. (i) What are the elements of ISO 9001:2000 quality system? (ii) Explain ISO 14000 with an industrial application. 5. Explain the steps followed to get ISO 2000 certification for an educational institute. 6. Explain the steps followed to implement a quality management system.


WELDING TECHNOLOGY UNIT-I PART-A 1) What is meant by HAZ in a welded metal? 2) Which is depends upon temperature distribution in welding? 3) Write the formula for heat flow equation for one dimension and three dimensional? 4) What is the TTT diagram? 5) What is the CCT diagram? 6) What is the different between TTT & CCT diagram? 7) Mention the various zone of a weldment? 8) What are the different microstructure found in a weld mental and HAZ of the welds? 9) What are the different micro structural phases encounted in fusion welding of steel? 10) Write short notes about (i) Bainite (ii) Martensite PART-B 1. What is mean by TTT diagram and explain it? 2. What is mean by CCT diagram and explain it? 3. Drive equation for temp distribution in a semi-infinite plate. 4. What are the various zone of weldment and explain it? 5. Write in Detail about general theory of Solidification of metals and alloys. 6. Explain the microstructure products in weldments. UNIT-II PART-A 1) Which welding method is suitable to weld HSLA Steels? 2) How can classify the carbon steel? 3) How are stainless steel classify? 4) Write any two problems faced in welding martensitic stainless steels? 5) Which welding method is suitable for ferritic stainless steel? What will be the quality of welding? 6) What is Schaeffer diagram? What is the use of Schaeffer? 7) By which way carbide precipitation can be avoid in stainless steel welds? 8) What is the application of Q& T steels? 9) Where Cr Mo steels are used and why? 10) Define weldability?

PART-B 1. Explain about the weldability of carbon steel. 2. a) Explain about the weldability of HSLA steel. b) Explain about the weldability of Quenched and Tempered steel. 3. What are the problems encountered with welding of Cr-Mo steels and what are the remedial actions? 4. a) Explain about the weldability of Ferrite Stainless steel. b) Explain about the weldability of Martensitic steel. 5. Explain the problems encountered with welding of austenitic stainless steels and what are the remedial actions? 6. Write the significance of Schaffler diagram and Delong diagrams. UNIT-III PART-A 1) How is aluminum alloys classified? 2) What are the problems encounted in welding of aluminum and what will be the effect? 3) Which welding process is used for Aluminum alloys? 4) What is weld Backing? 5) List out the problems faced in welding Non Ferrous metal? 6) What are the welding methods suggested to weld titanium alloy? 7) What is the use of Titanium alloy? 8) What are the physical properties of titanium alloys? 9) What are the problems associated with welding of titanium? 10) What are the steps involved in arc welding of titanium and its alloy? PART-B 1. Explain in detail about the welding procedure adopted for welding of aluminum and its alloy. 2. Explain in detail about GTAW of aluminum and its alloy. 3. What are the problems involved in welding of aluminum? Explain the precautions that should be taken to avoid the problems. 4. Explain the Characteristics and classification of titanium and its alloy. 5. Explain in detail about the welding procedure adopted for welding of titanium and its alloy in Arc welding process. 6. What are the various problem encountered in titanium and its alloy. UNIT-IV PART-A 1) Mention the different type of weld defects? 2) Mention any two general sources of weld defects in convention arc welding processes. 3) What is crack? 4) Mention different types of cracks? 5) What are the remedies suggested to avoid lamellar tearing? 6) What are the important factors contribute to reheat cracking? 7) Define Residual stress? 8) What are the possibilities to reduce welding residual stresses? 9) What are the various methods to control residual stress? 10) What is vibratory stress relief? PART-B 1. Explain the following kinds of cracks i) Longitudinal Crack; ii) Transverse Cracks 2. Write short notes on:

i) Chevron crack; ii) Lamellar crack 3. Explain the following kinds of cracks i) Reheat Cracks; ii) Stress Corrosion Cracks. 4. Explain the principle and operation of X-ray diffraction method of residual stress measurement. 5. Explain about the vibratory stress relief method of controlling residual stress. 6. Explain the theory for controlling of distortions in weldments.

UNIT-V PART-A 1. Define weldability? 2. Define metallurgical compatability. 3. Mention the various hot cracks weldability test. 4. Mention the various cold cracks weldability test. 5. Define Creep rupture. 6. Define Galvanic Corrosion. 7. What are the assessments of weldabilty? 8. Mention any four service weldability tests? 9. What is the purpose of preheating steel before welding? 10. What is meant by weld decay in stainless steel? PART-B 1. Write short notes on: i) Murex test; ii) Varestraint test. 2. Explain in detail about any two types of hot crack weldability test. 3. Explain the following cold crack weldability test with neat sketch i) Tekken test; ii) Lehigh restraint test 4. List out the various Service weldability tests. Explain in detail about any two of them. 5. Explain briefly about the following service weldability test. i) Impact test; ii) Hardness test; iii) Corrosion test; iv) Creep test. 6. Explain briefly about creep rupture test?