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Anna University – Regulation 2013

IE6605 - Production Planning and Control

16Mark Questions

PART-B
Unit I
INTRODUCTION

1. Discuss the various aspects of Product Design and Development in detail.

(April/May 2016)

2. A manufacturer sells an item for Rs.13 per unit. He incurs a fixed cost of
Rs.60,000 and 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. (April/May 2016)

3. What are the assumptions made in break-even analysis? An example of a

analysis company reveals the following information. Determine break even
sales volume. The profit at the budgeted sales volume. The profit if the actual
sales drop by 10%. The profit if the actual sales increase by 5% for budgeted
sales. (April/May 2016)

Cost Element Variable Fixed cost

cost

Direct material 32.8 -

Direct labour 28.4 -

Factory overheads 12.6 1,89,900

Distribution overheads 4.1 58,400

General administration overheads 1.1 66,700

Budgeted sales 18,50,000

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4. Discuss the functions of production planning and control: (April / May 2015)

5. Write a note on Economics of new design. (April/ May 2015)

6. Explain the objectives and benefits of planning and control (Nov/Dec 2014)

7. Describe Standardization.

8. Write a note on Simplification.

9. Briefly discuss about Specialization.

10. Explain the characteristics features of (i) Batch Production and (ii) Mass
Production (iii) Continuous Production (April/May 2014)

11. Why it is necessary to analyze the product. Explain the various analysis that are
carried out? (April/May 2014)

UNIT II

WORK STUDY

1. The elemental times for 4 cycles of an operation using a stop watch are
presented below: Calculate the standard time for the operation if Elements 2
and 4 are machine elements (ii) For other elements, the operator is rated at
110% (iii) Total allowances are 15% of the normal time (April/May 2016)

Elements Cycle time in minutes

1 1.5 1.5 1.3 1.4

2 2.6 2.7 2.4 2.6

3 3.3 3.2 3.4 3.4

4 1.2 1.2 1.1 1.2

5 0.51 0.51 0.52 0.49

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2. A work sampling study was concluded to establish the standard time for an
operation. The observation of the study conducted are given below: (April/May
2016)

(1) Total number of observations : 160

(2) Manual (hand controlled) work : 14

(3) Machine controlled work : 106

(4) Machine idle time : 40

(5) Average performance rating : 80%

(6) Number of parts produced : 36

(7) Allowance for personal needs and fatigue : 10%

(8) Study conducted needs : 3 days

(9) Available working hours/day : 8 hrs

3. How the standard time for a simple manual job is made up? Explain the various
allowances used to build the standard time. (April/May 2016)

4. Explain in detail about Effective “Therblings” with suitable examples.

5. Explain the steps involved in work study.

6. Briefly discuss the steps in work sampling study.

7. Write a note about Work measurement techniques.

8. Describe about Micro motion and Memo motion study.

9. Describe about Method study and its procedure in detail.

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UNIT III

PRODUCT PLANNING AND PROCESS PLANNING

1. Define value analysis and present a FAST Diagram for a PEN. (April/May
2016)

2. Define process planning and explain the various factors considered for
selecting a process and equipment. (April/May 2016)

3. Explain how process capabilities are analyzed in a multi product system.

(April/May 2015)

4. Describe the problems due to the lack of Product Planning. (April/May

2015)

5. What are the Steps in process planning? Explain in detail (April/May 2015)

6. Discuss about Product planning. (April/May 2015)

7. 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 if the
order quantity if (i) 1000 numbers and order is unlikely to repeat (ii) 1000
numbers and the order is likely to repeat for 3 years? (April/May 2014)

Gear Shaper Gear

Hobber

Machine time per 12 4

piece (min)

Machine cost per 45 120

hour (Rs.)

Set up time (min) 60 90

Tooling up cost (Rs.) 400 2000

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8. What is Machine capacity, balancing? (Nov/Dec 2014)

9. Describe in detail about Quantity determination in batch production

problems (Nov/Dec 2014)

10. Write a note on Prerequisite information for process planning (Nov/Dec

2014)

UNIT – IV

PRODUCTION SCHEDULING

1. What is preventive maintenance.(April/May 2016)

2. A small scale unit manufactures a product and it is expected to apply with week
1, 120 in week 4, 120 in week 6, 100 in week 8. Each product is made of 2
housings, a shaft assembly and one wheel. For these components order
quantities, lead times and inventories on hand at the beginning of period as
given below. Apart from the above requirement, another 180 shaft assembly is
required for another customer 600 units of housing are already scheduled to be
received as beginning of week 2. Complete the material requirement plan for
housing shaft and wheel. Show that quantities of order must be released and
when they must be released in order to satisfy the MPS. (April/May 2016)

Part Order Lead Inventory on

quantity time head

Housings 600 2 weeks 200

Shaft
400 3 weeks 440
assembly

Wheel 800 1 week 100

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3. Explain Batch production scheduling in detail.

4. Explain Scheduling techniques in detail.

5. Explain Sequencing rules in detail.

6. 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 tasks 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 (iv)
What is the efficiency of your line balance?

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

Precedence
- - - a b c d e f g h,i j
tasks

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

7. Briefly explain the various techniques used for loading and scheduling
(April/May 2015)

8. Explain different techniques employed for aligning completion times and due
dates (April/ May 2015)

9. Explain the following (i) GANTT Chart construction (ii) MRP (Nov/Dec 2014)

10. Explain the Period Batch Control, Flow Production Scheduling (April/May
2015)

11. Sequence the following jobs to minimize the processing times on the two
machines. Also compute the idle times of the machines. (April/May 2015)
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Job 1 2 3 4 5 6

Machine 1 5 9 4 7 8 6

Machine 2 7 4 8 3 9 5

UNIT – V

INVENTORY CONTROL AND RECENT TRENDS IN PPC

1. Alpha industry estimates that it will sell 12,000 units of its products for the
forthcoming year. The ordering cost is Rs. 100 per order and the carrying
cost per unit per year is 20 percent of the purchase price per unit. The
purchase price per unit is Rs. 50. Find (i) Economic order quantity (EOQ)
(ii) No. of orders per year (iii) Time between successive orders. ( April/May
2016)

2. Describe the elements of JIT System? (April/May 2016)

3. A manufacturer has to supply his customers 3600 units of his product per
year. Shortages are not permitted. Inventory carrying cost amounts Rs.1.2
per unit per annum. The set up cost per run is Rs.80. Find (i) Economic
order quantity (ii) Optimum number of orders per annum (iii) Average
annual inventory cost (iv) Optimum period of supply per optimum order.
(April/May 2014)

4. Explain briefly the procedure for ABC analysis and list its merits and
demerits.

5. Write a note on ERP: ( April/May 2015)

6. What are the Effects of demand on inventories? (April/May 2015)

7. Explain the Ordering procedure in detail.

8. Perform ABC analysis on the items given below and classify them based on
ABC analysis. (Nov/Dec 2014)
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Item 101 102 103 104 105 106 017 108 109 110

Annual
Consumpti 200 100 2,000 400 6,000 1,200 120 2,000 1,000 80
on (Units)

Unit Cost
40 360 0.20 20 0.04 0.8 100 0.70 1 400
(Rs.)

9. Following components are required for repairing oil engines. Classify the
same by ABC analysis (April/May 2016)

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

Unit
100 200 50 300 500 3000 1000 7000 5000 60
Cost(Rs)

Annual
Consumption 100 300 700 400 1000 30 100 500 105 1000
(units)

10. Discuss in detail about MRP-II. (April/May 2016)