Date & time

Weightage

Component type

BITS -PILANI, DUBAIDUBAIINTERNATIONAL ACADEMIC CITY

DUBAI

ME UC412 -Production Plannina and Controls

Final Comprehensive Examination

26th May 2008, 10.00 to 1.00pm

40%

Closed book

PART -A (10x1 = 10)

1

2

3

4

5

6

7

8

9

10

Differentiate between make to order, made to stock and made to assembly

Consider your college as a production system in which the final product is a graduate. For this system

Define quality from the producer's and customer's perspective.

What is the difference between assignment and transportation models used in aggregate planning?

What are HOC" Curves significance in manufacturing

Define reliability and its significance in the production process.

what is meant by simultaneous engineering

What are the merits and demerits of crashing a project.

What is meant by poke yoke give examples.

Differentiate between correlation and regression techniques used in forecasting.

List the different types of kanban and their significance in production controls

PART -8 (6 x5 = 30)

2

41.b

2

Why companies traditionally use control charts with 3-sigma instead of 2-sigma limits

A company produces three products A, B& C. The following are the resources requirements

The manufacturer has a daily production budget of

Rs.2000and a maximum of 660 hrs of labour. Maximum

daily customer demand is for 200 quantities of A, 300 B's

and 150 C's. the selling price of A is Rs 15, B is 20 and Cis

12. The firm desires to know the optimal product mix that will

maximize the profit. Formulate and solve the linear

programming model using graphical method.

How does the AQL relate the producer's risk (a) and the L TPD relate to the consumer's risk (j3).

Develop a house of quality for a domestic air conditioner. Develop customer requirements related to

easy to use, cost, capabilities and other features as applicable.

2.a.

4

33.a

3

BITS -PILANI, DUBAIDUBAIINTERNA TIONAL ACADEMIC CITY

DUBAI

A company produces Product "A" whose annual demand is 12,400 per year. The transportation and

handling cost are Rs 2600 each time a shipment is ordered by the distribution cerlter. The annual

carrying cost is Rs 3.75 per product.

1. Determine the optimal order quantity and the minimum total annual cost.

2. If company were to relocate its distribution center, it would reduce its transpor1ation and handling

cost to Rs 1900 per order but increase the carrying cost by Rs 4.50 per product. Should the

company relocate based on inventory cost?

What is meant by lean manufacturing? List down the techniques used to bring forth it .3.b

2

4

4.8

4.b

45.8

A service center has six cars to be processed. Processing time ( in days) and due dates information

for each car are given below

Job Processing Time Due Date Sequence the jobs by FCFS,

A 2 3 SPT, SLACK and EDD rules.

B 1 2 Calculate the mean flow time and

C 4 12 mean tardiness of the six jobs

D 3 4 under each sequencing rule.

E 4 8 Which rule will you recommend

F 5 10

2Sob. Write Short notes on

1. Influence of inventory control in SCM

2. Various forecasting models

BITS, Pilani -DubaiDubai International Academic City, UAE

First Semester 2007- 2008MEUC 412 -Production Planning and Control

Test -II

2th November2007

Test -II (Open book)

20%

20

Date

Component

Weight

Maximum marks

1 An assembly line consists of three workstations (WS) with each station's activity time as shown.

Determine

I WS 1 L~ I WS 2L_~ _J WS 3 II 5 minutesr--- -I 3 minutesr I 4 minutes I

1. The maximum output when the system is fully in operational for 8 hours of production time.

2. If the line currently assembles 10 units every hour when fully functional, then the line's balance

delay at this rate of output.8

2 The following table of probabilistic time estimates (in weeks) and activity predecessor~; are provided for a

project. Determine the following: The expected time to complete the project, The variance of the project's

total completion time, The probability that the project could be completed in 34 weeks and The probability

that the project will take longer than 33 weeks to complete.

Activity Time Estimates Activity'(week~) Predecessor

a m

3 The following forecasting information is for a company that uses an adjusted exponential smoothing

model to predict demand for a product it produces.8Adjusted

Period Demand Forecast Trend Forecast

Janua~ 1220 1200 28 604

Februa~ 1245 1208

If the firm uses smoothing constants a = 0.40 and 13 = 0.30, determine the trend factor and the adjusted

forecast for Februa~ .

4 A restaurant currently uses 62,500 boxes of napkins each year at a constant daily rate. The cost to order

napkins is $200.00 per order and the annual carrying cost for one box of napkirls is $1.00. If the

restaurant orders the optimal (EOQ) number of boxes each time, determine the followi!ng: The number of

orders placed during the year, The time between orders, The total annual inventory and ordering cost for

BITS, Pilani -DubaiDubai International Academic City, UAE

First Semester 2007- 2008MEUC 412 -Production Planning and Control

napkins and The average inventory for napkins

5 The following set of jobs must be processed serially through a two-step system. If Johnson's Rule is used

to sequence the jobs then the order in which the jobs would be performed would be

Then the make span time (in hours) for all jobs. Using Gantt Chart display the schedule of the activities.

Process

1

Process

2

I

Job~.c

h;-I

E

12

8

7

9

11

6

1410

5 8

8

8

BITS -Pilani, DubaiDubai International Academic City

Dubai

MEUC 412 -Production Planning and ControlsTest-1

Evaluation componentDate & time

Weight ageComponent type

Test-116th March 2008 -Scheduled test hour25%Closed book

1

2.

A farmer has to decide whether to plant corn or soybeans. The probabilities that the next harvest prices of these 4

commodities will go up, stay the same or go down are 0.25, 0.25 and 0.50 respectively. If the prices go up, the

corn crop will price a sum of Rs 30,000 & the soy will price a sum of Rs.10000. If the prices remain

unchanged, it is a break even. But if the prices go down the corn and soybeans will sustain losses Rs. 35,000

and Rs 5000, respectively.

a. Represent the problem as a decision tree

b. Which crop should the farmer grow

National outdoor school (NOS) is preparing for a summer campsite to train individuals in wilderness survival. 4

NOS estimates that attendance can fall into one of four categories: 200, 250, 300 and 3513 persons. The cost of

the campsite will be the smallest when the size meets the demand exactly. Deviations above or below the ideal

demand levels incur additional costs resulting from building surplus (unused) capacity, Dr losing income

opportunities when the demand is not met. Let A1 to A4 be the camp sizes of the campsites (200, 250,300 and

350) and S1 to S4 the level of attendance; the table below summarizes the cost matrix for the situation. Analysis

the problem for all four criteria and suggest

3.

4.3

5

\3

'\4

Discuss in brief what you understana oy acceptance sampling

The meat is stored in a container at 40°F. The manager has decided to construct a chart to monitor the

temperature inside the container. 20 samples were taken in day to construct the chart. The following are the

temperatures sample observations. Perform a pattern test to analyses for non randomness in the system.

I sample remperature

1--3i3-41.9

36.2

~-~~41.0

38.1

39.1

44.8

44.8

41.9

34.3

45.7

33.3

37.2

33.3

39.1

41.0I~I

41.9

41.0

43.8

43.8

39.1

42.9

45,7

I..-1---

BITS -Pilani, DubaiDubai International Academic City

Dubai41.0

45.7

44.8

38.1

44.8

44.8

40.0

34.3

45.7

36.2

39.

41.9

33.3

35.3

44.8

43.8

33.3

33.3

32.4

43.8

33.3

33.3

42.9

38.1

41.9

45.7

37.1

45.7

33.3

32.4

42.9

40.0

42.9

45.7

41.0

34.3

38.1

44.8

41.0

43.8

45.7

39.1

36.2

44.8

36.2

39.1

36.2

43.8

43.8

35.3

45.7

35.3

33.3

40.0

42.9

43.8

41.9

45.9

42.3

39.1

34.3

43.8

33.3

34.3

39.1

35.3

41.9

41.9

32.4

38.1

35.30

40.0

44.4

32.4

34.4

7

10.

13.

15.

.

~".

5.

6.

7.

3

3

3

What are the roles of TQM & QC in quality management?

Draw a fish bone diagram to identify the problems timely delivery of pizza by the delivery boy

Explain how the house of quality matrix helps in product development with an example.

~