SULIT

SULIT


UNIVERSITI TEKNIKAL MALAYSIA MELAKA
UJIAN PERTENGAHAN SEMESTER I
MI D TERM TEST SEMESTER I
SESI 2013 /2014
SESSION 2013/2014

FAKULTI KEJURUTERAAN PEMBUATAN

KOD MATAPELAJARAN : BMFG 3113
SUBJ ECT CODE

MATAPELAJARAN : PENGENALAN KEPADA SISTEM PEMBUATAN
SUBJ ECT I NTRODUCTI ON TO MANUFACTURI NG SYSTEMS

PENYELARAS : DR ZUHRIAH EBRAHIM
COORDI NATOR

KURSUS : BTMI dan BTMM
COURSE

MASA : 2 JAM
TI ME 2 HOURS


TARIKH : 5 NOVEMBER 2013
DATE

TEMPAT : BK8 dan BK9, FPTT
VENUE

________________________________________________________________________________________
ARAHAN KEPADA CALON
I NSTRUCTI ON TO CANDI DATES

1. Kertas soalan ini mengandungi SEPULUH (10) soalan.
This question paper consists of TEN (5) questions.
2. Jawab SEMUA soalan.
Answer ALL questions.
3. Setiap soalan hendaklah dijawab pada ruang yang disediakan.
Use given space for every question answered.

KERTAS SOALAN INI TERDIRI DARIPADA (13) MUKA SURAT SAHAJA
(TERMASUK MUKA SURAT HADAPAN)
THI S QUESTI ON PAPER CONTAI NS OF (13) PAGES I NCLUSI VE OF FRONT PAGE

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(BMFG 3113) SULIT
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Answer ALL questions.
Chapter 1: Essential of Manufacturing

Q1 Differentiate between Production, Manufacturing, and Manufacturing Systems.
(10 marks)

PRODUCTION
The transformation of raw materials into products by a series of energy
applications, each of which effects well defined changes in physical or
chemical characteristics of the materials
[3 marks]


MANUFACTURING

[3 marks]


MANUFACTURING SYSTEMS
An integrated combination of processes, machine systems, people,
organizational structures, information flows, control systems and computers
whose purpose is to achieve economic product manufacture and
internationally competitive performance.
[4 marks]




(BMFG 3113) SULIT
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Q2 (a) Describe the principle of manufacturing using a diagram.
(5 marks)

[ 2 marks]
Material flow 1 mark
Information flow 1 mark
Cost flow 1 marks


(b) Explain briefly three categories of production quantity. Give one example for each
category.
(5 marks)
Three categories:
i. Low production (1 to 100 units per year), example: Aeroplane, ship.
ii. Medium production (100 to 10,000 units per year), example: Washing
machine, limited edition products.
iii. High production (more than 10,000 units per year) , example: Coca-cola,
mobile phone.



(BMFG 3113) SULIT
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Q3 (a) Compare between Cellular Manufacturing and Job Production in terms of material
flow.
(5 marks)
CELLULAR MANUFACTURING


JOB PRODUCTION


(BMFG 3113) SULIT
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(b) Describe TWO techniques used for Productive Operation.
(5 marks)
1- Optimum Routing ---[1 mark]
An operation route with least time (or cost).
an optimum routing problem has a finite number of combinations.
thus, the solution can be always obtained by calculating the total
production times (or costs) of all possible routes by trial and error.
[1.5 marks]

2- Line Balancing ---[1 mark]
aims at optimum decision making in regard to:
3- c
ycle time
2- number of work station or production stages
3- grouping of work elements in a same workstation such that their
precedence order is assured.
[1.5 mark]


Chapter 2: Process Systems for Manufacturing

Q4 Explain briefly three methods that can be used to reduce the transportation time and cost
in material flow.
(10 marks)
1- Reduce transfer distance.---[1 mark]
optimal plant layout
single stage of conversion activities
multiple functional machine tools
[2 mark]

(BMFG 3113) SULIT
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2- Decrease the number of transfer activities. ---[1 mark]
handling materials/parts/components as a group with standard shape,
volume, weight, etc.
using unit-load method
[3 marks]
3- Determine the optimal transfer route & speed ---[1 mark]
constructing a straight continuous route with minimal crossings.
zero/minimum WIP
[2 marks]


Q5 (a) Given product in Figure 1, build the Bill of Materials for the product.
(6 marks)


Figure 1








(BMFG 3113) SULIT
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[6 marks for the components with quantity]


(b) Find the optimal number of workstations for assembling a product with an assembly
sequence and operation times shown in Figure 2. The cycle time is given as 8minutes.
(Circle the workstations determined).
(4 marks)


Optimum no. of workstation = 4 ---[1 mark]
[1.5 mark for each circle]
(2) (1) (1) (1) (2)
(2)
(2)
(BMFG 3113) SULIT
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OR


Optimum no. of workstation = 4 ---[1 mark]
[1 mark for each circle]
OR


Optimum no. of workstation = 4 ---[1 mark]
[1 mark for each circle]


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Q6 Explain the difference between process type layout and group technology cell
layout. Include sketches of both layouts.
(10 marks)



Group tech layout
(BMFG 3113) SULIT
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Q7 Propose a group technology layout based on the production information shown
in Table 1.
(10 marks)
Table 1
Machine
Job
M1 M2 M3 M4 M5
J1 P1 P3 P2
J2 P1 P2
J3 P2 P1
J4 P1 P2
J5 P1
M Machine
J Job
P Process


Machine
Job
M1 M2 M3 M4 M5
J1 P1 P3 P2
J3 P2 P1
J4 P1 P2
J2 P1 P2
J5 P1

Machine
Job
M1 M4 M3 M2 M5
J1 P1 P2 P3
J3 P1 P2
J4 P1 P2
J2 P1 P2
J5 P1








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Q8 Explain five (5) strategies that can be used to address fluctuation in demand.
( 10 marks)

Capacity Options Demand Options
1. Use inventories to absorb changes
in demand
2. Accommodate changes by varying
workforce size
3. Use part-timers, overtime, or idle
time to absorb changes
4. Use subcontractors and maintain a
stable workforce
5. Change prices or other factors to
influence demand
6. Influencing demand
7. Back ordering during high-
demand periods
8. Counter seasonal product and
service mixing

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Q9 Define and differentiate MRP and ERP.
(10 marks)


Q10 Explain the differences between process strategy options ( Make to order, Assemble
to order, and Stock to forecast) for Master Production Schedule (MPS) activity.
Name an example of product that is suitable for each strategy.
(10 marks)

(BMFG 3113) SULIT
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***END OF TEST QUESTIONS***