Production Management

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M Production Management - 1
Select The Blank

Question The ________ breakdowns usually cost more, partly due to damage don
adjustment components and partly due to emergency actions.
Correct Answer Unexpected
Multiple Choice Multiple Answer

Question Which of the following schedules are recommended to prepare and follo
part of preventive maintenance system?
Correct Answer Preventive inspection schedule , Cleaning and upkeep schedule , Lubric
schedule
Multiple Choice Single Answer

Question One of the characterstic of layout is about the flow of material / personne
good layout the flow should be
Correct Answer Unidirectional

Question Which kind of natural delays and interruptions are considered during est
of activity time?
Correct Answer Shop efficiency , Breakdowns , Absenteeism

Question Which of the following aspects are essential to ensure quality of purchas
items?
Correct Answer Defining right quality for the job , Vendor performance evaluation , Makin
that suppliers understand the requirements
True/False
Question An activity should represent an operation or set of operations which can
performed using a particular kind of equipment or a special skill.
Correct Answer TRUE

Question Which characteristics are verified in cent percent sampling?
Correct Answer All important characteristics

Question Which of the following symbols are used in flow process chart but not us
operation process chart?
Correct Answer Storage , Delay , Transport
Select The Blank

Question OC curve of ideal sampling plan suggests that all lots less than 3% defec
have the probability of acceptance of ________.
Correct Answer One

Question Where the ignorance towards the degradation of machine leads to?
Correct Answer Eventual breakdown

Question Which are three different bases to establish an activity time?
Correct Answer Past experience , Judgement , Historical data

Question What are the uses of failure statistics analysis?
Correct Answer To forecast the defect , To identify causes of major repetative failures , To
quantify the frequency of preventive inspection
Select The Blank

Question One detachable ticket is prepared for each ________.
Correct Answer Operation

Question What do you mean by the study of repetitive short cycle operations whic
involve quick hand / feet motions?
Correct Answer Micromotion study
Select The Blank

Question The ________ is necessary when the job requires detailed of one or mo
the job characteristics with the help of special equipment which is not av
at the producing company.
Correct Answer Inspection order
Select The Blank

Question The ________ is the maintenance work initiated on a result of knowledg
condition of an item from routine or continuous checking.
Correct Answer Condition monitoring
True/False
Question In case of backward pass computation, the latest event time of the end e
equals to the earliest event time minus duration of that activity.
Correct Answer FALSE

Question What do you mean by a single event which represents the joint completi
more than one activities?
Correct Answer Merge event
Select The Blank

Question The ________ is the watch dog which ensures that every element of pro
and activities which could affect the quality of end product are regulated
extent desirable.
Correct Answer Quality control

Question Which of the following is a cause of plant breakdown?
Correct Answer Overloading of machines

Question Who prepares the daily production report?
Correct Answer Shop Supervisor

Question Why graphical method of recording is preferred over the descriptive meth
during method study?
Correct Answer It segregates effective part form ineffective parts , It reduces effort involv
writing , Critical examinations easier and more effective
Select The Blank

Question Capacity decisions have a direct influence on performance of production
in respect of ________
Correct Answer Delivery performance
Select The Blank

Question An Ideal OC curve is ________ shaped curve that accpets all the lots wi
quality equal to or better than AQL .
Correct Answer Rectangular
True/False
Question With a general OC curve, probability of acceptance of lots of good qualit
never unity.
Correct Answer TRUE
Match The Following

Question Correct Answer
Crash cost of an activity Cc
Normal time of an activity Tn
Crash time of activity Tc
Normal cost of an activity Cn

Question What do you understand by identification of defects in materials, compon
machining processes or men to fix responsibility of defectives, thereby
preventing or minimising occurance of defectives?
Correct Answer Preventive function

Question Which of the following situations demand the technical consideration wh
selecting a job for method study?
Correct Answer Jobs having inconsistent quality , Operations inviting frequent requests f
supervisors for relaxation in allowed time because of variations in materi
tool performance , Jobs in which too many man-hours are spend in chec
and rechecking work

Question What is the nature of the sampling plan for critical defects?
Correct Answer Tight
True/False
Question The steeper the OC curve, the better is the discrimination between good
bad lots.
Correct Answer TRUE
True/False
Question Systematic maintenance system can completely eliminate the wear and
machines.
Match The Following

Scheduling of interrelated activities of small projects Critical Path Analysis
with consideration of uncertainty of duration of
activities.
Two machines & processing time depends on Johnson's Two Machine Algorithm
sequence of job loading
Sufficient orders and resonable choice of machines Index Method
Time relationship between when a product is required Critical Ratio Scheduling

and when it can be made available
True/False
Question Operation Process Chart provides information on time and distances
True/False
Question The event numbers as far as possible reflect the logical relationships of t
activities.
Correct Answer TRUE
Select The Blank

Question The ________ is a set of tools and techniques by which products are ma
comply with the specifications at minimum cost to the firm.
Correct Answer Quality control system
Select The Blank

Question Production control work is ________ in case of floor inspection as comp
with the centralised inspection.
Correct Answer easier

Question What is the relation between duration of an activity and length of an arro
Correct Answer No relation
True/False
Question Process Sheets for parts in batch production are not maintained as stand
process sheet
True/False
Question Three time estimates are transformed into expected time before using it
network.
Correct Answer TRUE
Select The Blank

Question The ________ are the definitions of the measurable as well as nonmeas
characteristics of the product.
Correct Answer Specifications

Question Which of the following situations demand that the human consideration s
be given preference over other considerations?
Correct Answer Inconsistent earnings where the earnings are tied to output , Poor morale
evidenced by petty or trivial complaints , Repeated cases of accidents an
health hazards

Question Which of the following are examples of specifications?
Correct Answer Commercial standards , Assembly and testing instructions , Bill of materi

Question What does the additional cost incurred to reduce the duration of an activ
one unit of time represent?
Correct Answer Activity cost slope

Question Document raised by Sales department for goods manufactured to stock
called
Correct Answer Shipment order

Question How many of the following are types of specification?
Correct Answer Material specifications , Dimensional specifications , Performance specif

Question Which of the following are activities of corrective maintenance?
Correct Answer Modifications and improvements , Overhauling , Emergency repairs
True/False
Question Scrap allowance is added to net requirement of material while ordering f
material
Correct Answer TRUE
Production Management - 2
True/False
Question A properly designed sampling plan can control sampling errors and comp
eliminate them.

Question Which of the following cases indicated that the operation has occurred?
Correct Answer Movement of components to assembly section , Raw material movemen
worker's trip to grinder to sharpen the tools

Question Which manufacturing method is ideal for the use of air gauges as inspec
device?
Correct Answer Mass

Question Out of two basic criteria for the selection of a manufacturing method, one
must be able to meet the specifications of final product and the other is,
be
Correct Answer Cost effective method


Question Any premise in which persons are employed for purpose of making any
product/s is called
Correct Answer Factory
True/False
Question Cent percent inspection does not mean inspection of component for 100
quality characteristics.
Correct Answer TRUE
Select The Blank
Question An Ideal OC curve is ________ shaped curve that accpets all the lots wi
quality equal to or better than AQL .
Select The Blank

Question The ________ breakdowns usually cost more, partly due to damage don

Question How to reveal the capability of the sampling plan to discriminate between
lots and bad lots?
Correct Answer Operating characteristics curve ( OC )

Question Which of the following may be the objectives of project crashing?
Correct Answer To achieve uniformity in requirement of resources , To complete the proje
the least possible time , To reduce project cost below it's normal cost
Match The Following

Forcasting requirement for indirect material Past consumption analysis technique
Inventory control by classification ABC Analysis

Structure of the product BOM
Material Planning for dependent demand MRP
Match The Following

First off inspection First piece produced after tool change
Critical operation inspection After whose no rework is possible
Patrolling inspection Inspection at the place of actual production
Key operation inspection Costlier operation
Select The Blank

Question The ________ is the maximum percentage defective that for the purpose
sampling inspection can be considered satisfactory as a process averag
Correct Answer Acceptable quality level
Question Which are the different methods of recording actual progress of work?
Correct Answer Display boards , Progress cards , Network updating

Question Provision of drainage facilities is important for the following type of indus
Correct Answer Chemical Process
True/False
Question Under MRP system for common items order for procurement is placed b
requirement for each product
True/False
Question Originating process of raw material influence Process Planning
Correct Answer TRUE
True/False
Question Lubrication survey should never be done for a new machine.

Question Which are the subtasks of the maintenance phase of the method study?
Correct Answer Monitoring and control , Performance appraisal , Audit on savings

Question What do you understand by the metallergical aspects of product which fo
the vital part of engineering function?
Correct Answer Material specifications

Question Document raised by Sales department for goods manufactured to stock
called
Correct Answer Shipment order

Question Who is responsible for return of surplus material?
Correct Answer Dispatcher
Select The Blank
Question Production control work is ________ in case of floor inspection as comp

Question The ratio of output to input of a production system is commonly known a
Correct Answer Productivity

Question Which of the following information is available in summary of part in a ch
during methods study?
Correct Answer Frequency of each symbol , Total time for each symbol , Total distance tr
by the object

Question Which of the following are examples of consumption of physical effort du
recording for method study?
Correct Answer Bending , Positioning , Unloading

Question Which of the following causes can be responsible for derailing the produ
schedule in a factory?
Correct Answer Errors in drawings , Delay in receipt of material from vendor , Excessive
absenteeism

Question Which is the ideal place to write a description of an activity in a network?
Correct Answer Above the arrow

Question Which of the following cases indicates change in physical characteristic?
Correct Answer Turning , Grinding , Drilling
True/False
Question Objective of Work Study is to improve Productivity
Correct Answer TRUE

Question Which are the major types of defects?
Correct Answer Minor , Major , Critical
Select The Blank

Question A ________ is another form of subcontracting.
Correct Answer Hiring capacity
Select The Blank

Question The ________ is the maintenance work initiated on a result of knowledg
Select The Blank

Question An ________ history card is the record of all repairs, replacements and
engineering changes carried out in the equipment during it's period of se
Correct Answer Equipment history card

Question What do you understand by the measurement of work to establish allowe
for a job for the defined method?
Correct Answer Work measurement

Question Which kind of relationship exists between those activities which can be c
out simultaneously and both activities require definite time to finish?
Correct Answer Concurrent activities

Question Which of the following products should be produced by using mass prod
Correct Answer Refrigerator , Tyre for automobile , Television Set
Select The Blank

Question A ________helps to avoid crowding of jobs at a particular machine by ch
route of some of the jobs or by diverting work to other machine.
Correct Answer Control board
Select The Blank

Question A good maintenance system is not a luxary but a ________.
Correct Answer Necessity
Select The Blank
Question Production Planning is a centralised activity which includes functions suc
________
Correct Answer Scheduling

Question The process of changing inputs into outputs thereby adding some value
can be defined as
True/False
Question The problems concerning movements can be better visualized by drawin
diagram, either, flow diagram or string diagram.
Correct Answer TRUE

Correct Answer Material specifications , Dimensional specifications , Performance specif
True/False
Question As a general rule, the number of tail event of an activity is more than tha
head event.

Question Which of the following concepts must be understood for the achievemen
quality?
Correct Answer Quality of conformance , Purpose of product , Quality of design

Question Which of the following factors affect the quality control function?
Correct Answer Quality of workmanship , Production aids , Manufacturing facilities
Production Management - 3

Question Which portion of the perforated route sheet should be signed by the ope
supervisor?
Correct Answer Lower portion
Select The Blank
Question Work study is also called ________ study
Correct Answer Time and Motion

Question Which are the factors on which the structure of the transportation cost
depends?
Correct Answer Average distance of shipment , Characteristics of the commodity , Mediu
shipment

Question What do you understand by the difference between the specification limi
which manufacturing process is expected to produce?
Correct Answer Design tolerance
True/False
Question Quality can not be inspected into a product, it must be manufactured into
the supplier.
Correct Answer TRUE

Question A good plant layout helps in
Correct Answer Reducing handling costs
True/False
Question Floor inspection delays the identification of faults which can not be rectifi
immediately before large lots are spoiled.
Select The Blank

Question Goods after final inspection should accompany ________to enable dispa
department to identify and draw correct reference.
Correct Answer Forwarding note
True/False
Question In case of two handed process chart, inspection symbol is used when ch
touch or feel is involved.
Correct Answer TRUE
Question Which of the following are characteristics of an operating characteristics
Correct Answer Producer risk , Consumer Risk , Acceptable Quality Level

Question Technique of Value Engineering can be effectively employed in design of
product to
Correct Answer To meet the intended function at lowest cost

Question Technique which can help an organization to reduce inventory is called
Correct Answer MRP
True/False
Question Since value of c can never be negativee, hence" if LCLp works out to be
negative, it is taken as zero."
Correct Answer TRUE

Question Which of the following schedules are recommended to prepare and follo
Correct Answer Preventive inspection schedule , Cleaning and upkeep schedule , Lubric
schedule

Question What do you mean by the study of repetitive short cycle operations whic
involve quick hand / feet motions?
Correct Answer Micromotion study
True/False
Question A sampling plan which perfectly discriminates will have vertical OC curve
Correct Answer TRUE

Question Which of the following are examples of gross materials?
Correct Answer Timber , Iron ore , Sugar cane
True/False
Question The time chart, if necessary, may be modified considering the limitations
resource.
Correct Answer TRUE

Question Why graphical method of recording is preferred over the descriptive meth
Correct Answer It segregates effective part form ineffective parts , It reduces effort involv
writing , Critical examinations easier and more effective
Select The Blank

Question The ________ is the probability that a good lot will be rejected by the sa
plan.
Correct Answer Producer's risk
True/False
Question Systematic maintenance system can completely eliminate the wear and
machines.

Question What are the benefits of inspection and quality control?
Correct Answer Adequate maintenance of quality , Ensures parts are within specified lim
accuracy , Gives economy in production through reduction of defective w
Select The Blank

Question The ________ advocates maintenance procedures whereby the conditio
plant is constantly watched through systematic inspection to unearth unh
conditions and preventive
Correct Answer Preventive Maintenance
Select The Blank

Question Capacity decisions have a direct influence on performance of production

Question Inadequate production capacity ultimately leads to
Correct Answer Poor Customer Service
Match The Following

Template Two dimensional cutouts
REL chart Degree of closeness
Flow diagram Tracing movements
Travel chart Distance and frequency of movements
Select The Blank

Select The Blank

Question The ________ is the probability that a bad lot will be accepted by the sam
plan.
Correct Answer Consumer's risk

Question Which document is used for returning the surplus material?
Correct Answer Stores Return Note
Select The Blank

Question The ________ is specified to indicate the maximum permissible variabili
dimensions product or parts.
Correct Answer Tolerance

Question How should a dummy activity be represented in a network?
Correct Answer By dotted line

Question When should operator or supervisor is supposed to sign the perforated r
sheet?
Correct Answer After completion of operation

Question Which of the following observations are expected from the preventive
maintenance person?
Correct Answer Wrong allignments , Overheating defects , Excessive play

Question Which of the following symbols are used in flow process chart but not us
operation process chart?
Correct Answer Storage , Delay , Transport
Question Route Sheet generally contains following information
Correct Answer Material Specification , Sequence of operation , Skill of Labour
True/False
Question In case of forward pass computation, the earliest event time of a plain ev
equals the earliest event time of the preceding event plus duration of act
emanating from the preceding event.
Correct Answer TRUE

Question In case of Batch Production which kind of labour is expected?
Correct Answer Skilled in one specific Manufacturing Process

Question Following are some of the factors considered for evaluation of alternative
layouts
Correct Answer Flow of Material , Equipment utilization , Ease of supervision

Question Which of the following situations demand that the human consideration s
evidenced by petty or trivial complaints , Repeated cases of accidents an
health hazards

Question Material Planning is an integral part of
Correct Answer Production Planning
Match The Following

Toung Sweet
Eye Crack
Nose Burnout
Ear Impact

Question What is the meaning of surplus material in context with stores issue orde
Correct Answer Materials issued are not fully consumed
Question Which are the subfactors of community facilities or social infrastructure?
Correct Answer Accomodation , Educational , Entertainment
Select The Blank

Question The ________ pertain to the climatic conditions which the component , p
or material should withstand.
Correct Answer Environmental specifications

Question Which is the alternative way of indicating the load other than numerical w
case of Gantt chart ?
Correct Answer Graphical approach
True/False
Question Shop order is one of the subsidiary order
Correct Answer TRUE
Select The Blank

Question The easiest way to bring the delayed job within the promised delivery tim
using extra shift or weekly holiday is ________.
Correct Answer Overtime working
LIST OF ATTEMPTED QUESTIONS AND ANSWERS

Your Answer Cracks , Burrs , Texture

Question Which of the following is the criteria for the percentage
defectives in the zone of the indecision?
Correct Answer Lots having the percentage defective more than AQL but less
than LPTD
Your Answer Lots having the percentage defective more than AQL but less
than LPTD

Question In mass/batch production organizations where goods are
produced for stocking, Work Order is raised on the basis of
Correct Answer Sales Programme
Your Answer Sales Order
Match The Following

Question Correct Answer Your Answer
Fixed Position Layout Project Layout Functional Layout
Product Layout Line Layout Project Layout
Process Layout Functional Layout job layout
Combined Layout Mixed Layout Mixed Layout

Question What do you understand by the measurement of work to
establish allowed time for a job for the defined method?
Your Answer Work measurement
Select The Blank

Question In case of an OC curve, the risk of rejecting a good quality lot
may vary between ________.
Correct Answer 0.01 to 10%
Your Answer 0.01 to 10%
True/False
Correct Answer True
Your Answer False

Your Answer Poor Machine Utilization

Question Which of the following schedules are recommended to prepare
and follow as a part of preventive maintenance system?
Correct Answer Preventive inspection schedule , Cleaning and upkeep schedule
, Lubrication schedule
Your Answer Preventive inspection schedule , Cleaning and upkeep schedule
, Lubrication schedule

Question What is the reason of fluctuations, if the control chart evaluates
that the process is in a state of statistical control?
Correct Answer Random variability
Your Answer Random variability
True/False
Question Even in a small set up wherein maintenance of a machine is
looked after by a mechanic cum worker, he should report directly
to the person responsible for the manufacturing operations.
Correct Answer True
Your Answer True

Question What do you mean by the chart on which the major activities and
entry points of materials are recorded to have graphic view of
operations and inspections involved in the process?
Correct Answer Operation process chart
Your Answer Operation process chart

Question Plant Layout decisions are considered to be
Correct Answer Strategic
Your Answer Strategic

Question What are the uses of the instruction manual provided by the
manufacturer of a machine?
Correct Answer It gives instructions regarding installation and operation of the
equipment , It contains note on common troubles with causes
and remedies for troubleshooting , It enlists points, frequency
and type of lubrication
Correct Answer False
Your Answer True
Select The Blank

Question The ________ must ensure that the product satisfy the
functional requirements of it's usage.
Correct Answer Quality of design
Your Answer Quality of design

Question Which of the following are examples of pure materials?
Correct Answer Bakeries , Ice factories , Woolen
Your Answer Bakeries , Ice factories , Woolen
Select The Blank

Question The ________ are the definitions of the measurable as well as
nonmeasurable characteristics of the product.
Your Answer Specifications

Question Site factors for plant location include
Correct Answer Suitability of land
Your Answer Suitability of land
Select The Blank

Question The ________ is the probability that a good lot will be rejected
by the sampling plan.
Your Answer Producer's risk

Question Which of the following defects can be observed during
preventive inspection by using human senses?
Correct Answer Deviation from normal sound , Excessive Vibration , Leakage of
a gas
Your Answer Deviation from normal sound , Excessive Vibration , Leakage of
a gas
Select The Blank

Question The ________ includes preventive maintenance activities whose
ASSIGNMENT
Q.1) What is “Operations Management”? What are the objectives of Operations

Management? Enlist key elements of Operations Management.
Answer.1)
An operation may be defined “as the process of changing inputs into outputs thereby
adding value to some entity”.Right quality, right quantity, right time and right price are
the four basic requirements of the customers and as such they determine the extent of
customer satisfaction. And if these can be provided at a minimum cost, then the value of
goods produced or services rendered increases. Thus the objectives of production
management are “to produce goods and services of the right quality, in the right
quantities, according to the time schedule and a minimum cost”.
Objectives of production management may be amplified as under:
• Producing the right kind of goods and services that satisfy customers’ needs
(effectiveness objective).
• Maximizing output of goods and services with minimum resource inputs (efficiency
objective).
• Ensuring that goods and services produced conform to pre-set quality specifications
(quality objective).
• Minimizing throughput-time- the time that elapses in the conversion process- by reducing
delays, waiting time and idle time (lead time objective).
• Maximizing utilization of manpower, machines, etc. (Capacity utilization objective).
• Minimizing cost of producing goods or rendering a service (Cost objective).
Key elements of Operations Management
1. Product selection and design
The right kind of products and good designs of the products are crucial for the success of an
organizing. A wrong selection of the product and/or poor design of the products can render the
company’s operation ineffective and non-competitive. Products/services, therefore, must be
chosen after detailed evaluation of the product/services alternatives in conformity with the
organization’s objectives. Techniques like value engineering may be employed in creating
alternate designs, which are free from unnecessary features and meet the intended functions at the
lowest cost.
2. Process selection and planning

Selection of the optimal “conversion system” is as important as choice of products/services and
their design. Process selection decisions include decisions concerning choice of technology,
Equipment, machines, material handling systems, mechanization and automation. Process
planning involves detailing of processes if resource conversion required and their sequence.
3 Facilities (Plant) location
Plant location decisions are strategic decisions and once plant is set up at a location, it is
comparatively immobile and can be shifted later only at a considerable cost and interruption of
production. Although problem of location choice does not fall within preview the production
function and it occurs infrequently, yet it is of crucial importance because of its major effect on
the performance of every department including production. Therefore, it is important to choose
the right location, which will minimize total “delivered customer” cost (Production and
distribution cost). Locational decisions involve evaluation of locational alternatives against
multiplicity of relevant factors considering their relative importance to the organization and
selecting those, which are operationally advantageous to the organization.
4. Facilities (Plant) layout and materials handling
Plant layout is concerned with relative location of one department (Work centre) with another in
order to facilitate material flow and processing of a product in the most efficient manner through
the shortest possible time. A good layout reduces material handling cost, eliminates delays and
congestion, improves co-ordination, provide good housekeeping etc. while a poor layout results
in congestion, waste, frustration, inefficiency and loss of profit.
5. Capacity Planning
Capacity planning concerns determination and acquisition of productive resource to ensure that
their availability matches the demand. Capacity decisions have a direct
Influence on performance of production system in respect of both resource productivity and
customer service (i.e. delivery performance). Excess capacity results in low resource productivity
while inadequate capacity leads to poor customer service. Capacity planning decisions can be
short-term decisions. Long-term capacity planning decisions concern expansion/contraction of
major facilities required in the conversion process, economics of multiple shift operation,
development of vendors for major components etc. Short term capacity planning decisions concern
issues like overtime working, sub-contracting, shift adjustments etc. Break even analysis is a
valuable tool for capacity planning.
6. Production Planning and Control (PPC)
Production planning is the system for specifying the production procedure to obtain the desired
output in a given time at optimum cost in conformance with specified standard of quality, and
control is essential to ensure that manufacturing takes place in the manner stated in the plan.
7. Inventory control
Inventory control deals with determination of optimal inventory levels of raw materials,
components, parts, tools; finished goods, spares and supplies to ensure their availability with
minimum capital lock up. Material requirement planning (MRP) and just-in-Time (JIT) are the
latest techniques that can help the firm to reduce inventory.
8. Quality assurance and control
Quality is an important aspect of production system and it must ensure that services and products
produced by the company conform to the declared quality standards at the minimum cost A total
quality assurance system includes such aspects as setting standards of quality, inspection of
purchased and sub-contracted parts, control of quality during manufacture and inspection of
finished product including performance testing etc.
9. Work study and job design
Work-study, also called time and motion study, is concerned with improvement of productivity in
the existing jobs and the maximization of productivity in the design of new jobs. Two principal
component of work-study are:
(i) Method study

(ii) Work measurement
Method study has been defined (BS 3138) as the systematic recording and critical examination
of the existing and proposed ways of doing work, as a means of developing and applying easier
and more effective methods and reducing costs. Method study when applied to production
methods yields one or more of the following benefits:
• Improved work environment

• Improved facility layout
• Better utilization of facilities
• Greater safety
• Lesser materials handling
• Smooth production flow
• Lower work-in-process
• Higher earnings for the workmen
10. Maintenance and replacement
Maintenance and replacement involve selection of optimal maintenance Preventive and/or

breakdown) policy to ensure higher equipment availability at minimum maintenance and repair
cost. Preventive maintenance, which includes preventive inspection, planned lubrication,
periodic cleaning and upkeep, planned replacement of parts, condition monitoring of the
equipment and machines, etc. is most appropriate for critical machines.
11. Cost reduction and cost control
Effective production management must ensure minimum cost of production and in this context
cost reduction and cost control acquires significant importance. There are large number of tools
and techniques available that can help to make a heavy dent on the production cost.
Q.2) What is batch Production? What are its key characteristics? Compare these
characteristics with those of project production.
Answer.2)
Batch production is characterized by the manufacture of a limited number of a product

(but many such quantities of different products) produced at periodic intervals and stocked in
warehouses as finished goods (or finished parts) awaiting sales (or withdrawal for assembly).
Typical examples of batch production are: process industries such as pharmaceuticals, paints,
chemicals; medium and heavy engineering industry engaged in the manufacture of electric
motors, switch gears, heavy motor vehicles, internal combustion engines; manufacture of ready
made garments; manufacture of assembly shops such as machine tools; sub contractors which
take on machining of batches of components to the drawings of a large manufacture etc.
Characteristics of batch production
(a) Short runs:

Short production runs and frequent changes of set also characterize batch
production up. The equipment and the assembly set up is used for a limited
number of parts or assemblies and is then changed to make a different product. The
production is generally made to stock.
(b) Skilled labour in specific trades:

The labour force is expected to posses skill in one specific manufacturing
process, Turning, milling, drilling, welding, grinding, hobbing, fitting etc.
The operator may perform simpler machine set-ups but the separate machine tool setter
performs those involving complex operations.
(c) Supervision to possess knowledge of a specific process

The supervision has considerable knowledge of a specific process. Supervisor in
the grinding section for example, may not expert in turning and drilling work but s
expected to possess a find of knowledge of different types of grinding operations.
Similarly a supervisor in the gear shop is expected to have sound knowledge in working
of different types of gear cutting machines.
(d) Limited span of control:

The amount of supervision required in batch production is lower than that of
jobbing production. The ration of direct workmen to supervisors is more or less a
function of batch size. The smaller the batches, the lower are the ratio of direct workers
to supervisors, and vice versa. This is because smaller lots require each supervisor to
spend a great deal of his time in allocating new work, giving instructions, follow up on
the shop floor for proper movement of materials from and to the machines, identifying
delays and interruptions, and arranging, in consultation with planning, work load in his
section to keep his men busy.
(e) General purpose machines and process type of layout

Plant and equipment is procured and arranged to obtain maximum flexibility.
General purpose machines and handling equipment capable of performing variety of operations
with minimum set –up times are installed in lieu of variety of products. The machines are
arranged to give process layout-layout by function. Similar machines capable of doing similar
types of operations are grouped together and kept at one place. Presses for example, are put
together and kept at one place milling machines are placed together at another place, drilling
machines are kept at the third place, gear cutting machines are located at the fourth place and so
on. Each Group of machines is usually designated as a work centre or a section or a shop.
(f) Manual materials handling:

Materials handling in batch production as compared to jobbing production are
small. Individual components and parts are placed in trolleys and trays and are
transported as unit loads. Materials handling may be mechanized by deploying power
driven trucks.
(g) Manufacturing cycle time affected due to queues:

The manufacture cycle time is comparatively smaller than jobbing production but
is much more than mass and flow production. The batches of work tend to queue up at
different machines due to differing cycles times, batch sizes and sequence of operations.
(h) Large work-in-progress:

Work in progress is comparatively large due to varying work content of different
components, imbalance in manufacturing times, formation of queues between the
machines.
(i) Flexibility of production schedules:

Disruptions due to machine breakdown or absenteeism do not seriously affect
production as job can be shifted to another machine or another operator from another
machine can be shifted.
(j) Need to have production planning and control:

Functions of production planning and control in a batch production unit are more
complex than those in jobbing production or mass and flow production:
• Materials control and tools control functions are important. Some kind of replenishment
system needs to be used to ensure routine replenishment
• Detailed operational layout and route sheets are prepared for each part of the product.
• Loading and scheduling needs to be more detailed and more sophisticated since every
machine requires to be individually scheduled.
• Progressing function is very important to collect information on progress of work. A

separate progress card needs to be maintained to record progress of each component.
• Expediting is generally necessary since quite often jobs, due to imbalances in work
content, tend to lag behind
Q.3) (a) Why are locational decisions important? What factors should be taken into
account while deciding location of a unit to manufacture washing machines?
Answer.3a)
Locational decisions generally arise when:
• A new manufacturing (or servicing) unit is to be set up.

• Existing plant operations are difficult to expand due to poor selection of site earlier.
• The growth of the business makes it advisable to establish additional facilities in new
territories.
• There is emergence of new social (chronic labour problems) political (political instability
or economic conditions that suggest a change in the location of the existing plant.
• The product development has over weighted the advantages of the existing plant.
• The changes in the industrial Policy of the Government, favoring decentralizing and
dispersal of industries to achieve overall development of the country, do not permit
expansion of the existing plant
FACTORS GOVERNING PLANT LOCATION
Plant location studies are conducted in three phases:
(i) General territory selection

(ii) Community selection, and
(iii) Site selection
1. Proximity to market:
Every company is in business to market and it can survive only if their product reaches the
consumers on time and at the competitive price. The ratio of selling costs to sales generally
increases with distance. Therefore, in the choice of location o the plant, the factor of “proximity
to the market” is given the highest priority. Locating a plant nearer to the market is preferred if:
• The product is fragile.

• The product is susceptible to spoilage.
• The promptness of service is required.
• The product is relatively inexpensive and transportation costs add significantly to the
cost.
Bread, soap factories, etc. require the market to be nearby. If factory cannot be started in
Bombay, it may be started in Thane, Kalyan or Poona. If the product is exported, location near
ports is desirable. This is particularly important for producers who sell bulky commodities,
which incur high transportation costs
Nearness to market not only lowers transportation costs but also gives many other benefits
namely:
• A good many administrative problems, which cause perpetual headaches and add to costs,
are avoided.
• Liaison with dealers or whole sellers can be maintained economically and easily
• Other costs such as commission to middlemen, which at times run as high as 20 to 50
percent can be reduced significantly.
• Customer’s accounts do not remain outstanding for settlement. This recovery is easy and
less time saving which itself reduces selling costs.
2. Proximity to source of raw materials:
Since raw materials usually constitute 50 to 60 percent of the total product cost, it is important
that the firm gets its requirements of raw materials at the right time and at the reasonable price for
which the plant must be located in the neighborhood of some source which can meet the raw
materials requirement of the unit “Proximity to supply of raw materials” factor assumes still
greater importance if raw materials are of perishable nature or if they are expensive to transport,
or if their weight is substantially reduced by processing.
Proximity to sources of raw materials is equally important for small units. This is because
usually small units are not considered important customers. They get least priority and in the
event of scarcity are the one to be struck off first from the list. The availability of materials to
small units to a large extent thus depends on their follow up and personal visits to the supplier’s
plant which is possible only if the buyer’s plant is close by.
3. Infrastructural facilities:
Infrastructural facilities consider availability of utilities like power water, disposal of waste etc.
These form the life-blood of many types of industries without which there facilities may come to
a stand still. Underestimating the need of any one of the utilities can be extremely costly and
inconvenient.
Certain industries, for example, aluminium, steel, etc are power intensive and must be located
close to the sites of power generation failing which the shortage of, or increase in cost of
generating power may spell problems for their survival.
Similarly, chemical process industries like paper and pulp, cement, steel, sugar laundries, metal
plating, food preparation etc. requires perennial source of water. Mineral content of water may
also be an important factor. Treatment of water is an expense to be considered while comparing
economics of different locations.
Drainage facilities are important for process industries otherwise disposal of process waster can
create lot of difficulties.
4. Transport facilities:
Transportation cost to the value added is a key determinant of the plant location. The structure of
the transportation cost depends on (i) Characteristics of the commodity (ii) average distance of
shipment (iii) medium of shipment: rail, road, and air sea.
The need for transport arises because raw materials and fuel are to be moved to factory site and
finished goods are to be transported from factory to markets. Other things being equal since
transport cost has a major effect on product cost, the regions well served by transport facilities are
most suitable for industrial locations.
5. Labour and wages:
Plant location should be such that required labour is easily available in the neighbourhood.
Importing labour from outside is usually costly and it causes lot of administrative problems.
Availability of required labour locally is better since problem of arranging accommodation and
other related problems do not arise. Since normally workers with specific skills are required,
some sort of training facility should also be available in the neighborhood. Skilled employees are
easily available if ITI’s, or Engineering colleges are there in the neighbourhood.
6. Legislation and taxation:
The policies of the state Government and Local Bodies relating to issue of licenses, building
codes, labour laws, etc. are the factors in selecting/rejecting a particular community/site.
In order to disperse industries and ensure balanced economic growth, both Central and State
government offer a package of incentives for setting up industries in particular locations.
Exemption from excise duty, sales tax and octroi, soft loans from financial institutions, subsidy in
electricity charges, etc. are some of the incentives offered.
Since taxes and duties levied by the State Government and Local bodies substantially influence
product cost, the incidence of such taxes/levies must be taken into account while selecting a
community/site.
7. Climatic conditions:
Climatic factors may not have a major influence these days because of modern air conditioning
facilities available today. However, it may be important factor for certain industries like textile
mills, which require high humidity.
8. Industrial and labour attitudes:
Community attitudes towards supporting hostile trade union activities are an important factor.
Locating facilities in a certain region/community may not be desirable as frequent labour
problems and interruptions are harmful to the plant in the long run. Political situation in the state
and attitude of the government towards labour activities also influences selection of the site for
the plant.
9. Safety requirement:
Safety factor may be important for certain industries such as:

- Nuclear power plants
- Explosive factories
Location of such industries close to border areas is undesirable.
10. Community facilities (or social infrastructure):
Community facilities imply accommodation, educational, entertainment and transport facilities.
Accommodation is needed unless the employees are local residents. Accommodation should be
easily available, comparatively cheap and near some public transport stop.
The locational area should be fully developed, be accessible by road and should have a
convenient and efficient public transport system operating between the area and the township to
enable employees, officials, customers and suppliers to make easy trips for their work
11. Community attitudes:
Community attitudes towards work (i.e. whether the people in the location are hard working or
otherwise) as well as their attitudes towards the incoming entrepreneurs (helpful and cooperative
or otherwise) can make or mar an industry. Locational decisions, therefore, must take such
factors also into account particularly while setting up labour intensive units.
12. Supporting industries and services:
Locational factors should also include proximity of services needed by the firm. A firm desirous
of getting some or all parts made from outside or some of the operations done from outside must
see that such sub-contractors are located in the neighbourhood. Getting a job done from units
located at far off places will mean not only additional transportation cost but also time consuming
and costly. Also if units are too far off, the control on quality of work done by them cannot be
exercised.
13. Suitability of the land:
Site selection should also take into account topography and soil structure of the land. The soil
structure must be capable of bearing loads of foundations. Though modern building techniques
can overcome the limitations of the soil, but if considerable improvement is required then
selection of a low cost and may ultimately turn out to be expensive.
14. Availability and cost of the land:
Site size (Plot size) must be large enough to accommodate the present production facilities,
parking and access facilities but also leave sufficient room for future expansion. As a general
rule, a site five times the actual plant size is considered minimum for all these things including
future expansion.
ECONOMY SURVEY OF THE SITE SELECTION:
An ideal location is one where the cost of obtaining materials and processing them into finished
product plus the cost of distributing the finished product to customers is minimum.
One of the most commonly used approaches consists of following steps:
Step 1: Prepare a list of all relevant factors.
Step 2: Estimate expenses on materials, transport, wages, power etc for each location on
each of the above factors.
Step 3: Collect data on intangible factors like community facilities, community attitudes etc.
Step 4: Analyse the tangible data for each location and calculate rate of return on
investment.
Step 5: Select provisionally a locational based on financial data.
Step 6: Compare the intangible data for the different locations and select the optimal
location considering intangible data.
Q.3) (b) What are objectives of a good layout? Discuss any six principles of a good layout?
Answer.3)(b)
OBJECTIVE OF A GOOD PLANT LAYOUT
Only through an efficient layout, the organization can attain the following objectives:
(i) Economy in handling of materials, work-in-process and finished goods.
(ii) Minimization of product delays.
(iii) Lesser work-in-progress and minimum manufacturing cycle time.
(iv) Efficient utilization of available space.
(v) Easy supervision and better production control.
(vi) Greater flexibility for changes in product design and for future expansion.
(vii) Better working conditions by eliminating causes of excessive noise, objectionable odor
smoke etc.
PRINCIPLES OF A GOOD LAYOUT
(i) Overall integration of factors:

A good layout is one that integrates men, materials, machines and supporting
activities and others in a way that the best compromise is obtained
No layout can satisfy each and every principle of a good layout. Some criterion may
conflict with some other criterion and as a result no layout can be ideal it has to
integrate all factors into the best possible compromise.
(ii) Minimum movement:

A good layout is one that permits the minimum movement between the
operations.
The plant and machinery in case of product layout and departments in case of
process layout should be arranged as per sequence of operations of most of the
products.
 Since straight line is the shortest distance between any two points, men
and materials as far as possible should be made to move along the
straight path
A door may be made in a wall or a hole may be drilled in a ceiling if that eliminates or
reduces material handling in place of stairs or a distant door.
(iii) Uni-direction flow:
A good layout is one that makes the materials move only in the forward direction,
towards stage of completion, with any backtracking.
 Since straight line is the shortest distance between any two, points,
materials as far as possible should be made to move on the principle of
straight line flow. And when straight line flow is not possible, other
flows like U-shaped flow, circular flow or zig zag flow may be adopted,
but the layout may ensure that materials move in the forward direction
(Fig 4.1)
 To ensure forward flow, equipment if necessary may be duplicated.
(iv) Effective use of available space:

A good layout is one that makes effective use of available space both
horizontal and vertical
• Backtracking and duplicated movements consume more time, involve un-necessary

materials handling, add to cost and lead to inefficiency.
• Raw materials, work-in-progress and finished goods should be piled vertically one above
another rather than being strewn on the floor.
• Pallets or equivalents should be made use of to pile up several layers one above another
• Area below the work tables or in the cupboards built into the wall are welcome since they
reduce requirement of space
(v) Maximum visibility:

A good layout is one that makes men, machines and materials ready observable at all
times.
• All departments should be smoothly integrated, convenient to service and easy to

supervise
• Every piece of positioning or screening or partitioning should be scrutinized and

carefully planned.
• Special cupboards, enclosures, offices, partitions etc. should be avoided except when
their utility is established beyond doubt.
(vi) Maximum accessibility:

A good layout is one that makes all servicing and maintenance point readily
accessible.
• Machines should be kept sufficiently apart and with reasonable clearance from
The wall so that lubrication, adjustment and replacement of belts, removal of parts at the
time of repairs etc can be done conveniently by the maintenance staff.
Area in front of electrical panels and fire extinguishers should be kept free from
obstructions.
Q.4) How does production planning differ from production control? What are the key
functions of production planning and control?
Answer.4)
Production planning versus production control.
Planning (Planning the work) Control (Working the Plan)

Planning involves collection and maintenance Control involves dissemination of data
of data regarding time standards, materials and preparation of reports regarding output,
their specifications, machines and their machine and labour efficiency, percent
quantities, tools and their process capabilities, defectives etc.
drawings and operational layouts etc.
Planning is seeing that requirements tool,

machines, men, instructions, authorization and
the like-will be available at the right time and Control is seeing the requirements are actually
in the right quantities and are of proper quality. made available at the right place and in the
right quantities.
Planning involves preparations of load charts
and fitting various work orders into
uncommitted time available on the company’s
facilities (men or machines). Control involves actual seeing that the jobs are
started and completed as per schedule prepared
Planning involves preparation of all necessary by the scheduling cell of the PPC.
forms and paper work.
Control involves actual issue of forms and
Planning involves designing suitable feed back paper work.
as to what may happen.
Control involves keeping track of what is
happening and collecting information as to
Planning involves forwarding thinking what has happened.
regarding the remedial action to be taken if the
job falls behind schedule. Control involves suggesting remedial action
when the job is falling behind schedule.
Planning therefore is a centralized
Activity (in the office) and includes such Control is thus a diffused activity (in the shops)
functions as materials control, tools control, and includes functions such as dispatching,
process planning and scheduling. progressing and expediting.
FUNCTIONS OF PRODUCTION PLANNING AND CONTROL:
Production planning and control is normally assigned two sets of functions:

(I)Regular functions and
(ii) Optional functions.
(i) Regular functions are those, which are generally assigned to PPC in most of the
organizations through the importance of the function, may vary from industry to
industry.
(ii) Optional functions are those, which may be assigned to PPC depending upon policy
of the management of the firm.
Common (or Regular Functions) Optional Functions
Order Preparation includes activities like Cost Estimation concerns preparations of

making of work orders, converting work orders Preproduction cost estimates to be used by
to shop orders, preparing auxiliary orders and sales department for quotation purposes
releasing such orders to those concerned to (Alternatively this may be assigned to Costing
authorize their activities Department Or Industrial Engineering
Department)
Materials control concerns preparations of Work measurement concern fixation of time to

materials estimates, indenting non-stock be allowed to a qualified workman to carry out
materials, ascertaining availability of materials a specific task, under specified conditions and
purchased to stock, continual follow-up with at the defined level of performance. Work
purchase and stores for timely receipt of measurement employs scientific, well-known
materials, and advising stores to allocate techniques like time study, work sampling
required quantities or available materials standard data, production study, analytical
(alternatively on their receipt) against specific estimating etc. (Alternatively, work
shop orders. measurement function may be assigned to
Industrial Engineering department.
Sub-Contract concerns offloading of certain
Process planning or Routing concerns fixation work on outside vendors for economic reasons
of method of manufacture: operations and their or to augment the existing manufacturing
sequence, machine tool for each operation, jigs facilities (Sub-contract work alternatively) be
and fixtures, measuring instruments and gauges handled by Materials/purchase Department)
etc. to enable shops to produce goods of the
right quality at the lowest cost.
Capacity planning concerns estimation of
Tools control concerns preparations of requirements of men and machines as the basis
estimates of cutting tools (Standards as week of decision making to meet the firm’s increased
As non-standards tools), gauges and measuring volume of business (Some companies prefer to
instruments, jigs and fixtures etc indenting non- assign this function to Engineering department.
stick tooling: follow up with tool room for
timely manufacture of jigs and fixtures;
periodical replenishment of worn-out-non-
consumable tooling (e.g. work arbors, collets,
copying masters, Allen keys, spanners, etc.
Scheduling concerns preparation of machine Demand forecasting concerns making

loads, fixation of calendar dates of various projection of company’s product market.
operations to be performed on a job, Though, long term forecasts are given by Sales
coordination with sales to confirm delivery Department but short term forecasts required
dates of new items and periodical preparation for materials planning, machine loading, sub
of dispatch schedules of regular items. contracting etc may be prepared by PPC
department
Dispatching concerns preparation and

distribution of shop orders and manufacturing
instructions to the concerned department as
their authority to perform the work according
to the predetermined schedule.
Progressing concerns collection of data from

manufacturing shops, recording of progress of
work, and comparing progress against the plan.
Expediting concerns intensive progress chasing

to identify delays and interruptions which may
hold up production, devising cures from time to
time to keep rate of production in line with the
schedule, communicating possible failure in
delivery commitments to Sales Department.
Q.12 (a) What is critical path? What does it signify? How is it identified?
Answer.2)(a)
Critical path analysis, an important aid to planning, scheduling and coordinating the
activities if large scale projects. Is a synthesis of two independent techniques: Programme
Evaluation and Review Technique (PERT) and Critical Path Method (CPM).
Though the two techniques were developed independently, they are only superficially different.
The two method have many features in common and are now combined into a technique called
Critical Path Analysis (CPA) or Network Analysis.
There are three basic different between a PERT network and CPM network:
• PERT is event oriented while CPM is activity oriented (i.e. PERT prepares network from
events while CPM builds if from activities)
• PERT provides for an allowance for uncertainty while CPM does not (i.e. PERT makes
three time estimates for each activity while CPM makes one time estimate)
• Activity time in CPM technique are related to costs while it is not so in PERT since it is
event oriented
Significance of critical path
Critical path analysis offers several advantages. It
(i) Forces through pre-planning. Each and every activity compromising the project is
identified and recorded. Nothing is left to memory or chance which prevents crises
in scheduling
(ii) Increases coordination of tasks as technological relationship between the activities
suggests which activities can run simultaneously and which should succeed others.
(iii) Helps computations of different project duration’s for different level of resources and
thereby select a plan that minimizes total project cost.
(iv) Indicates optimal start and finish times of each activity of the project.
(v) Defines areas of responsibility of different departmental heads for timely execution
of the project.
(vi) Facilitates progress reporting and limits unnecessary discussion at the progress
meetings.
(vii) Identifies troubles spot often in advance and apply remedial measures.
(viii) Enables the plan to be revised in accordance with changes/changing circumstances.
(ix) Helps to exercise “control by exception” and prevents cost overruns.
A Project comprises a series of activities and the identification of the individual activities requires
knowledge and experience of the men responsible for the planning of the project. Even the
preliminaries-mere listing of the activities-make the operating personnel:
• Think of details about the project well in advance.

• Observe critically the way in which the various activities interact or compete for scarce
resources
• Improve upon the original plans even before network is formally drawn and analyzed.
A project, therefore, must be torn into a set of identifiable activities. There are no set rules but
general guidelines are as under:
• An activity should represent the smallest unit of the operation or set of operations over
which management desires control.
• An activity should represent an operation or set of operations, which can be performed

using a particular kind of equipment or a special skill. For example in
construction project, plumbing is considered as one activity while wiring can be
considered as another activity since the first activity requires plumbers and the second
activity needs electricians.
Q.12) (b)
Activity Optimistic Most Likely Pessimistic

1-2 02 03 10
1-3 02 04 06
1-4 02 06 10
2-5 01 01 01
3-5 04 05 12
4-5 02 03 04
4-6 02 05 08
5-6 03 05 13
Answer:
(a) Expected time of an activity can be obtained from the three time estimates using the formula:
te = a + 4m +b
6
where a = Optimistic time

m = most likely time
b = pessimistic time
For activity (1-2)
a = 2
m = 3
b = 10
te = 2 + 4 x 3 + 10
6
te = 24 = 4
6
Expected times of all activities of the network, calculated on above lines, are tabulated below.
Activity Three time estimates Expected time

1-2 02-03-10 4
1-3 02-04-06 4
1-4 02-06-10 6
2-5 01-01-01 1
3-5 04-05-12 6
4-5 02-03-04 3
4-6 02-05-08 5
5-6 03-05-13 6
4 5 6
6 3
6
3
4 6
1 4 2 1 5
Critical path is 1-3,3-5,5-6 and the duration for the project is 16 weeks (4+6+6)
Variance is
Vi = (b –a) X (b – a)
6 6
V1-3 = 4
9
V3-5 = 16
9
V5-6 = 25
9
V = V1-3 + V3-5 + V5-6
V = 5
Standard deviation Z = T - Tcp

σ
= 19 -16
√5
= 3
2.236
= 1.34
The approximate probability value when Z = 1.34 is 0.9099
∴The probability of completion of critical path by the schedule time of 19 weeks = 91%
Q.5) What is preventive maintenance? Why it is better than Breakdown Maintenance?
What are the key activities of Preventive Maintenance?
Answer.5)
Preventive maintenance anticipates failures and adopts necessary actions to check

failures before they occur. It includes activities like inspection, lubrication cleaning and unkeeps,
minor adjustments and replacements found necessary at the time of inspection etc. Preventive
maintenance can be either: running maintenance or “shut down maintenance”. Running
maintenance includes maintenance activities (e.g. minor adjustments In machines revealed
through inspections, lubrication, cleaning and unkeep etc.) Which are carried out when the
machine is still running. Shutdown maintenance includes preventive maintenance activities such
as minor component replacement whose needs are identified through inspections, which require
stoppage of Machines. Preventive inspection is one of the key activities of preventive
maintenance which is usually performed by making use of human senses – watch) eye),
listen (ear), Touch (hand, leg, body) smell (nose) and taste (tongue) – but the trend is Changing
towards use of condition monitoring instruments. Such maintenance. Practice is known as
predictive maintenance or condition based maintenance.
Q.10) (a) What are X-R Charts? How are they made and used in controlling a process?
Answer.10)
X-R chart is a pair of chart consisting of a average (called X chart) and a range
Chart (called R chart) placed one below another on a piece of graph paper. The X chart is used to
control the mean value of the characteristic an R-chart is used to restrict the range of variations in
the values. X-R charts are drawn when the characteristics are measurable. Each chart consists of
three values: a central line, upper control limit and lower control limit. The central line represents
the arithmetic average of the sample means which equals the mean of the population, u. The
upper and lower control limits are located at three standard deviation on either side of the central
line.
Samples of fixed size are drawn at regular intervals and measurements are taken. The
samples wise values of the mean and range are plotted in their respective X and R charts.
The spread of sample points in the charts is studied to decide the remedial action (if any) to be
taken. The X chart analyses whether or not the mean of the quality Characteristics is within
control while R-chart analyses whether or not the variability is within control.
STEPS TO PREPARE X-R CHART
A pre-requisite to the preparation of the chart is the decision on the following aspects:
• Quality Characteristics refer to the property of the product, which is to be assessed. The
quality characteristics must be capable of being measured. In case of more than quality
characteristics, separate chart is made for each quality characteristic.
• Sample size refers to number of pieces comprising each sample. Sample size is an
important decision. It is a common practice to use sample of n = 4 or 5 to have low
appraisal cost. Large samples such as n = 15 or 20 are used if the process standard
deviation is large.
• Sample Population refers to the number of samples to be collected to construct a control
chart. The number of samples must be sufficient. Usually, 20 samples each of size 4 or 5
are enough to have good estimates of the process average (X) and dispersion (R).
• Time Interval measures the time gap between consecutive samples. Time interval, as a
genera rule, should be proportional to the average frequency of out-of-control conditions.
It is a fairly complex decision since a number of factors such as cost economy,
susceptibility of the process to disturbances; convenience of the inspector etc. requires to
be considered.
The making of X-R Charts involves the following Steps:
Step 1: Collect Data
(a) Collect sufficient samples spread over a reasonable period. Each sample must be
of equal size.
(b) Measure each component comprising the sample for the given quality
characteristic
(c) Record individual measurements on a work data sheet.
Step 2: Calculate mean (X) and Range (R) of each sample

A The mean which is written as X (X bar) is average of each sample and is
Obtained by totaling the individual measurements of the units comprising the
sample and dividing the total by the sample size (number of units in each sample)
B The range, which is written as R, is obtained as the difference between the
highest and the lowest measurement of a sample.
C The values of X and R are recorded sample wise either on the extreme right of
the individual measurements on the data sheet or in a separate table.
Step 3: Calculate grand Average (X) and mean Range (R)
A The grand average, which is written as, X (X double bar) is the average of the
sample averages and is obtained by dividing the total of the averages of all the
samples by the total number of samples.
B The mean range, which is written as, R (R bar) is the average of the ranges and is
obtained by dividing the total of the ranges of the samples by the total number of
samples.
Step 4: Set up Control chart for the average
A Set up a control chart with the central line drawn at X (X double bar), upper
control limit located X + A2R (R bar) and the lower control limit set up at X-A 2R.
B Plot the averages to see whether the process was under control when samples
were drawn.
C If all points fall within the control limits, the process is said to be under control
D If process is not under control (indicated by some points falling outside the
control limits), eliminate points outside the control limits and compute new trial
control limits for the remaining points.
E Repeat step 4 (d) until all points fall within the control limits
F Control limits in a particular situation should be revised from time to time as
additional data is accumulated.
Step 5: Calculate control limits of the range chart
A The control chart for range chart is set up with central line as R, upper control
limit (UCLR) located at D4R above the central line and lower control limit
(LCL) at D3R below the central line
B Plot the value of the range of each sample.
C If all points fall within the control limits no modification is necessary unless it is
desired to reduce the process dispersion
D if range chart exhibits lack of control indicated by some points falling outside the
control limits, eliminate those points out of control and compute new trial control
limits
E Repeat step 5 (d) until all points fall within the control limits.
F Control limits in a practical situation should be revised time to time as
additional data is accumulated.
Step 6: Use control chart
A Collect samples of fixed size at specified intervals of time.

B Measure each unit of the sample for the quality characteristics, calculate mean
and the range of each sample.
C Plot the values of X and R of each sample in their respective charts

D Study the trend of the points to interpret and suggest remedial action
Q10 (b) ABC company produces a solvent, which must contain 3 percent of alcohol. It tries
to maintain the actual percentage at 3 + 0.3 percent. It tests hourly in samples of five. The
following table shows the results of last five samples. Set up a control chart for mean and
examine whether the process is under control.
A) Solution:
(i) Collect data
(ii) Calculate mean (X bar) and range(R bar)
Sample No. Arithmetic Mean (X bar) Range(R)
1 2.92 0.3
2 2.98 0.1
3 3.06 0.1
4 3 0
5 3 0.2
(iii) Calculate grand average and the mean range
X(X bar) = 2.92 + 2.98 + 3.06 + 3 + 3

5
= 2.992
R = 0.3 + 0.1 + 0.1 + 0 + 0.2

5
= 0.14
(iv) Set Up control chart for the average
Central Line = CLx = X(X bar) = 2.992
Upper Control Limit = UCLx = X (X bar) + A2.R(R bar)
= 2.992 + 0.5768 x 0.14
= 3.476
Lower Control Limit = UCLx = X (X bar) - A2.R(R bar)
= 2.992 - 0.5768 x 0.14
= 2.507
(v) Set up a range chart
Central line CLR = R(R bar) = 0.14
Lower control limit = LCLR = D3.R (R bar)
= 0 x 0.14
= 0
Lower control limit = UCLR = D4.R (R bar)
= 2.114 x 0.14
= 0.29596
Q.6) What is method study? Describe the procedural steps to develop easier and effective
methods.
Answer.6)
Method study is the systematic recording and critical examination of existing and
proposed ways of doing work, as a means of developing and applying easier and more effective
methods and reducing costs.
Method study is an organized approach and its investigation rests on the following six basic steps
outlined in the block diagram
• Select the work to be analyzed.
• Record all facts relating to the existing method.
• Examine the recorded facts critically but impartially.
• Develop the most economical method commensurate with plant Requirements
• Install the new method as standard practice.
• Maintain the new method.
Selection of the job
Selections of the jobs to be studied for methods improvement by the method study
practioner is a managerial responsibility and it (selection) may be based on economic
technical or human consideration. Economic consideration justifies selection based on
the economic worth (i.e. money saving potential) of the job.
Technical consideration identifies jobs, which require studies to overcome manufacturing
difficulties (excessive rejection, relaxation in prefixed performance standards, inability if
the shops to stick to specified machining parameters such as speeds, feeds, depth of cut
etc., inconsistent quality etc.) Human consideration in job selection is usually given
weightage while introducing method study practices for the first time.
Recording of facts
Systematic recording is the most crucial step in method improvement. Since recording
by long hand (or by descriptive method) has its limitations, it is not recommended for use
in method study. Instead, five symbols and eight charting conventions are used to record
facts relating to the job under study. Five typical symbols are O, ||, , D and V and eight
charting conventions concern composition of the chart, reject, rework, repletion, change
of state, introducing of new material, combined events and numbering of events. The
document on which details of the process are recorded by the above referred symbols and
conventions is called chart. There are four basic types of chart: (i) operation process
chart (ii) Flow process chart (iii) multiple activity charts and (iv) two handed process
chart.
Besides charts, two types of diagrams-flow diagram and string diagram are drawn when
recording details of an existing layout. Travel chart is another typical chart, which is
used to record frequency of movements (weight x distance) between work
centres/departments.
Repetitive short cycle operation which involves quick hand/feel motions (i.e. microscopic
motions) may be studied with micro motion study. Glibreth, founder father of micro
motion study, also developed photographic techniques called cyclograph and
chronocylegraph to record path of the motions of the members of the body.
Critical examination
Critical examination aims to analyze the facts critically and thereby give rise to
alternatives, which form the basis of selection and development of easier, and effective
methods.
Critical examination is conducted through a systematic and methodical questioning

process. Each activity recorded on the chart, whether it relates to processing or
inspection, or material handling, or to any other aspect, is picked up one at a time and is
examined minutely. The questioning process is considered under five major heads,
namely the purpose, the place, the sequence, the person and the means. These five
aspects in critical examination are referred to as five governing considerations.
Development and selection:
Development and selection stage concerns short listing of ideas generated at the critical
examination stage, testing each short listed idea for its technical and economic feasibility,
and making selection among the alternatives wherever choice exists. To develop ideas
and to ascertain their technical and economical feasibility, the method study practioner
needs to solicit the cooperation of personnel from different departments of the company.
Various techniques available for the development and selection purpose are: cost benefit
analysis, break even analysis, investment analysis and critical path analysis.
Installation
‘Installation’ (or implementation) of the proposed method involves preparation of project

report on recommendations making oral presentation to the top management, securing
approval of the decision maker, assisting line management during implementation,
arranging training of workmen, and getting jobs (operations) retime after implementation,
arranging training of workmen, and getting jobs (operations) retimed after
implementation.
Maintenance
“ Maintenance” phase is the follow up phase after implementation, which serves as a

monitoring and control mechanism. It helps to ensure that the revised methods are set
into concrete and workmen do not revert back to old methods. It also provides an
opportunity to the practitioner to assess the effectiveness of the approach followed by
him and makes changes in the methodology (if required).
Q.9) (a) What desirable conditions need to be present to be present to guarantee success of
an incentive scheme?
Answer.9)
A good wage incentive plan should have the following characteristics.
• Administrative simplicity:
The incentive system should be simple and must be easily understood by the workers and
their representatives. An incentives scheme, which can be understood, only by engineers and
mathematicians or a scheme which involves the use of complex formulate or references and
cross-references is sure to fail. The incentive scheme should be such that workmen can
calculate their own earnings easily and quickly.
• Minimum clerical work:

The system should fit into existing system of production and cost control. It should not
involve any significant addition to the clerical work.
• Maximum coverage:
The system should cover as many workmen as possible. A scheme if applied to a few
workmen creates a demoralizing effect on the morale of those not covered by the scheme.
• Direct
Incentive payments should increase at least in direct proportion to the increase in output by
the operator. There are two reasons:
Firstly because it is more difficult to producer extra units and secondly because saving in the
overheads are far greater at higher levels of production.
• Period of Payment
The period of payment should be as short as possible
• Adequate guaranteed minimum hourly rate

The scheme must ensure adequate guaranteed minimum hourly rate to all incentive workers
regardless of their output. Such an hourly guaranteed rate is normally referred to as the
guaranteed base rate.
The guaranteed base rate must be realistic and should be at least equal to the hourly rate
payable to a non-incentive worker doing similar job in the industry. Incentive earnings of the
workers should never be regarded as a substitute for poor wages.
• Accurate and yet attainable performance standards

Performance standards should be set through systematic work measurement studies. The
experts to that there is no dispute or malpractice and yet the standards are attainable so that a
worker working at normal pace can attain them should base the standards of measurement on
the assessment.
Further the incentive plan should be such that it provides an opportunity to all average
workers to earn reasonable earnings.
• Consistency of the standards

Standards once fixed should not be changed unless there is a permanent change in methods,
or change in equipment, or change in material and plan should provide for the provisions to
modify the performance standards.
• Inbuilt check on process rejections

A good incentive scheme should exercise a check on the operator against achieving higher
bonus by poor workmanship. Payment should be made only for pieces declared acceptable
by the inspection department and a workman constantly producing substandard pieces should
be liable for disciplinary action.
• Payment of partially completed jobs

The problem of payment for the incomplete work arises only in case of long cycle jobs.
Situations do arise when the jobs are of very long cycle duration and cannot be finished
within the bonus period. Similarly, a semi-finished job may require to be handed over by one
operator to another at the end of shift, or prior to having a holiday. The scheme should
clearly spell out as how assessment of work done by the workmen on the same job will be
carried out and how disputes arising out of such assessment would be resolved.
• Payment of Idle Time

Adequate safeguards must be provided to compensate the operator for the time lost due to
reasons beyond his control. A good incentive scheme should ensure that an operator does not
suffer financial loss for reasons attributable to the managerial weakness, e.g.: lack of material
due to bad buying, breakdowns of the machines due to poor maintenance practices, non-
availability of work etc. Thus an operator rendered idle because of factors attributable to the
management should be given a lieu bonus.
• Safeguards
The scheme should be fair not only to the employees but also to the employer. Safeguarding
clauses as under should be incorporated to protect.
a. Management’s right to change a standard when there are changes in methods. Materials
and machines
b. Management’s right to withdraw or discontinue temporarily a scheme during bad period.
c. Management’s right to initiate disciplinary action against operators who continually
produce sub-standard articles.
d. Management’s right to initiate disciplinary action against employees who, time and again,
do not achieve minimum standard of production even in the presence of fair and accurate
standards.
e. Management’s right to initiate disciplinary action against employees who, time and again
are found using speeds and feeds higher than those recommended in the process sheet (or
operational layouts)
• Maximum ceiling on the earnings

The system should have built-in-control against higher earnings beyond a certain limit.
Firstly, the system should discourage workers to work beyond a certain limit otherwise too
attractive an incentive scheme may induce the worker to work more and more and thereby
adversely affect his health. Secondly, the system should ensure that in case of loose standards
the company does not lose financially.
• Consistency of Plan
The plan should be consistent over a period of time. Frequent changes in the plan make it’s
functioning difficult. Faith in plan is lost if there are frequent revisions.
• Acceptance of Labour Body

The scheme should finally have acceptance of the labour body. The body of workers’
representatives to prevent any misunderstanding and ill-feeling later on must accept the basic
incentive plan and its provisions.
• Continuous Use
The scheme should be in continuous use. The temporary use of the scheme in good times and
its discontinuation in bad times makes it’s functioning difficult.
• Define End Results

The plan must result in reduction in per unit labor cost.
Q 13)
Answer 13)
i) Average Cycle time = 0.22 + 0.24 + 0.28 + 0.26 + 0.25

5
= 0.25
Normal Time = Observed time x Rating

100
= 0.25 x 80
100
= 0.2
Similarly, average cycle time and normal time for all the elements are calculated and
tabulated as below
Element Avg. cycle time Rating Normal time

A 0.25 80 0.2
B 0.15 100 0.15
C 0.35 120 0.42
D 0.102 90 0.0918
E 0.12 100 0.12
Total Normal time = 0.2 + 0.15 + 0.42 + 0.0918 + 0.12
Total Normal time = 0.9818
ii) Relaxation Allowance = 15 x 0.9818

100
= 0.1473
Contingency Allowance = 5 x 0.9818

100
∴Standard time = 0.0491
Normal time + Relaxation Allowance + Contingency Allowance

= 0.9818 + 0.1473 + 0.0491
∴Standard time = 1.1782

Your Answer Condition monitoring
Select The Blank

Your Answer Operation

Question Which of the following is the most popular technique for Project
Production?
Correct Answer PERT & CPM
Your Answer PERT & CPM
Select The Blank

Your Answer Necessity

Question The process of changing inputs into outputs thereby adding
some value to entity can be defined as
True/False
Question An activity should represent an operation or set of operations
which can be performed using a particular kind of equipment or a
special skill.
Correct Answer True
Your Answer False

Question Which of the following are types of sampling plan?
Correct Answer Single sampling plan , Double sampling plan , Multiple sampling
plan
Your Answer Single sampling plan , Double sampling plan , Multiple sampling
plan
True/False
LIST OF ATTEMPTED QUESTIONS
AND ANSWERS
which is not available at the
producing company.
Your Answer Job card

Question Which of the following are the
basic requirements of quality
standard?
Correct Answer Deifinite , Undesrstandable ,
Economically viable
Your Answer Deifinite , Undesrstandable ,
Economically viable
True/False
Question In case of forward pass
computation, the earliest event
time of the first event is zero.
Correct Answer True
Your Answer True

Question Which kind of possible defectives
can be reduced due to first off
inspection?
Correct Answer Due to mistakes in reading blue
prints , Due to errors in tooling ,
Due to wrong machine set up
Your Answer Due to mistakes in reading blue
prints , Due to errors in tooling ,
Due to wrong machine set up ,
Due to purposely done mistakes
by unsatisfied worker
True/False
Question A sampling plan which perfectly
discriminates will have vertical OC
curve.
Correct Answer True
Your Answer True

Question Which of the following is a part of
preparing manufacturing order set
as a primary function of
dispatching?
Correct Answer Operational layouts , Move orders
, Pre-filled stores issue orders
produce defectives.
Your Answer False
True/False
Question A sampling plan which perfectly discriminates will have vertical OC curve.
Correct Answer True
Your Answer True

Question The process of changing inputs into outputs thereby adding some value to
entity can be defined as
Your Answer Manufacturing

Question Which are the different methods to record details of the existing method
Correct Answer Charts , Diagrams , Templates or models
Your Answer Control plans , Charts , Templates or models
Select The Blank

Question The ________ breakdowns usually cost more, partly due to damage done to
the adjustment components and partly due to emergency actions.
Your Answer Unexpected

Question Gross requirement of products is determined on the basis of
Correct Answer Both forecast and pending orders
Your Answer Past sales
Select The Blank

Question The ________ is the probability that a bad lot will be accepted by the
sampling plan.
Your Answer Acceptable quality level
Select The Blank

Question The easiest way to bring the delayed job within the promised delivery time by
Correct Answer Delay , Operation , Inspection
Your Answer Operation , Inspection , Production
True/False
Question In case of centralised inspection, inspection rooms generally
become bottleneck and cause delay in taking action regarding
rejection or rework.
Correct Answer True
Your Answer True
Select The Blank

Question The ________ advocates maintenance procedures whereby the
condition of the plant is constantly watched through systematic
inspection to unearth unhealthy conditions and preventive
Your Answer Preventive Maintenance
True/False
Question The problems of congestion, bottlenecks and backtracking can
not be visualized by using templates and models.
Your Answer False

Question Which varaible is taken along the abscissa or X axis?
Correct Answer Time
Your Answer Quality
True/False
Question Delay in completion of projects result in unwelcome additions to
the fixed manufacturing expenses.
Correct Answer True
Your Answer True
Select The Blank

Question The term ________ emplies the foregone profit due to inability of
company to produce.
Correct Answer Opportunity cost
Your Answer Idle wages


Question MRP is based on the concept of inventory demand which is of following type
Correct Answer Dependent and independent
Your Answer Dependent and independent

Question Main objective of a good plant layout is
Correct Answer Reduce material handling cost
Your Answer Reduce material handling cost
True/False
Question As a general rule, the number of tail event of an activity is more than that of it's
head event.
Your Answer False
Select The Blank

Question The ________ is the probability that a good lot will be rejected by the sampling
plan.

Question Which of the following are important considerations concerning activity times?
Correct Answer Activity time should be obtained from the person responsible for the
completion of an activity , Activity time must be independent of any influence which the
preceding or succeeding activity may have on it. , Activity time may assume that just the normal
quantity of resources required to carry out the activity are available.
Your Answer Activity time should be obtained from the person responsible for the completion
of an activity , Activity time must be independent of any influence which the preceding or
succeeding activity may have on it. , Activity time may assume that just the normal quantity of
resources required to carry out the activity are available.
Select The Blank

Question The ________ pertain to the climatic conditions which the component , product
Your Answer Environmental specifications

Question Following are some of the factors considered for evaluation of alternative layouts
Your Answer Flow of Material , Ease of supervision , Delivery performance

Question Which of the following are assignable cause?
Correct Answer Large varaitions in hardness of material , Tool wear , Errors in setting
Your Answer Large varaitions in hardness of material , Tool wear , Errors in setting
True/False
Question All activities must not be tied up into the network
Your Answer False
Select The Blank

Question In case of an OC curve, the risk of rejecting a good quality lot may vary between
________.
True/False
Question In case of X bar, if the process is not under control indicated by some points
falling outside the control limits, such points outside the control limits are eliminated and new
trial control limits for the remaining points are computed.
Correct Answer True
Your Answer True

Question What is the base for considering activity time as single time estimate or three
time estimate?
Correct Answer Level of uncertainty
Your Answer Availability of labour
Select The Blank

Question The ________ is the maximum percentage defective that for the purpose of
sampling inspection can be considered satisfactory as a process average.

Question What do you mean by lowest possible direct cost required to complete an activity
within it's normal time?
Correct Answer Normal cost
Your Answer Normal cost
Select The Blank
Select The Blank

Question A ________helps to avoid crowding of jobs at a particular machine by change of
Your Answer Move order
Select The Blank

Question The ________ is the watch dog which ensures that every element of production
and activities which could affect the quality of end product are regulated to the extent desirable.
Your Answer Quality control

Question Any premise in which persons are employed for purpose of making any product/s
is called
Your Answer Factory
Match The Following

Emerson Efficiency Plan Wage Payment Wage Payment
Craft Facilities Planning Facilities Planning
Work Sampling Machine utilization Machine utilization
Gantt Chart Production Scheduling Production Scheduling
Select The Blank

Your Answer Hiring capacity

Question In an organization there may not be a formal PPC department if
Correct Answer Work is highly repetitive in nature , Planning activities are performed by
the line staff , Number of workmen is not very large
Your Answer Work is highly repetitive in nature , Planning activities are performed by the line
staff , Number of workmen is not very large

Question Which of the following cases can be treated as delay during recording of method
study?
Correct Answer Operators awaiting instructions from supervisor , Worker waiting for his
turn at tools stores , Jobs awaiting at the machines for their turn
Your Answer Operators awaiting instructions from supervisor , Worker waiting for his turn at
tools stores , Jobs awaiting at the machines for their turn
True/False
Question Inspection order is must even for simple jobs which can be inspected by shop
inspector with the tooling available on shop.
Your Answer False

Question Order preparation process for products manufatured to order requires following
documents
Correct Answer Sales Order , Work order , Shop order
Your Answer Sales Order , Work order , Purchase order

Question Technique of Value Engineering can be effectively employed in design of a
product to
Your Answer Reduce lead time
True/False
Question Cent percent inspection is often more practical and economical than sampling
inspection.
Your Answer False

Question Scale model used for layout analysis have following advantages
Correct Answer Nontechnical person finds it easy to comprehend , Ovehead facilities can
be shown , Models can be shifted easily
Your Answer Nontechnical person finds it easy to comprehend , Ovehead facilities can be
shown , Models can be shifted easily

Question Which of the following technique is event oriented ?
Correct Answer Project Evaluation & Review Technique
Your Answer Project Evaluation & Review Technique

Question What is the meaning of " Product features" according to J.M.Juran?
Match The Following

Crash cost of an activityCc Cc
Normal time of an activity Tn Tn
Crash time of activity Tc Tc
Normal cost of an activity Cn Cn

Question What are uses of diagrams in method study?
Correct Answer Study different plant layouts and select the most optimum one , Study the
extent of traffic over the different routes of the plant , Identify the extent of backtracking, cross
traffic and obstacles encountered during the movement of material.
Your Answer Study different plant layouts and select the most optimum one , Study the extent
of traffic over the different routes of the plant , Identify the extent of backtracking, cross traffic
and obstacles encountered during the movement of material.
True/False
Question A load chart specifies the work to be carried out by each person of company
during shift hours.
Your Answer True

Question Route Sheet generally contains following information
Correct Answer Material Specification , Sequence of operation , Skill of Labour
Your Answer Material Specification , Sequence of operation , Skill of Labour
True/False
Question Cellular layout is based on the concept of Group Technology
Correct Answer True
Your Answer True
Correct Answer Time
Your Answer Standard deviation

Question Which are the advantages of suburban location?
Correct Answer Avaialability of adequate land at lower cost , Both skilled and unskilled
labour can be available , Plant expansion is easier due to less or no restriction for building and
construction
Your Answer Avaialability of adequate land at lower cost , Both skilled and unskilled labour
can be available , Plant expansion is easier due to less or no restriction for building and
construction
Select The Blank

Question The ________ is the maintenance work initiated on a result of knowledge of the

Question Expediting function is concerned with following activities
Correct Answer Progress chasing to identify delays which may hold up production ,
Communicating possible delays in delivery date commitment to sales department , Devising cures
to keep rate of production in line with schedule
Your Answer Recording progress of work , Progress chasing to identify delays which may hold
up production , Communicating possible delays in delivery date commitment to sales department
Select The Blank

Question Production control work is ________ in case of floor inspection as compared
Your Answer time consuming
Select The Blank

Your Answer Overtime working
True/False
Question In case of forward pass computation, the earliest event time of the first event is
zero.
Correct Answer True
Your Answer True

Question What is represented by an arrow in a network?
Correct Answer Activity
Your Answer Activity
True/False
Question As a general rule, a site five times the actual plant size is considered minimum
for parking, access facilities and future expansion.
Correct Answer True
Your Answer True
True/False
Question Independent float either affects the float of preceding activities or that of
succeeding activities.
Your Answer False

Question The document raised by PPC which authorises different functions to take action
as per instruction is called
Correct Answer Work Order
Your Answer Work Order

Question A good layout makes effective use of space. Utilization of space for a department
like Stores can be measured by
Correct Answer Proportion of Cubic volume space utilized
Your Answer Ratio of area utilised to area available

Question The process of changing inputs into outputs thereby adding some value to entity
can be defined as
True/False
Question Floor inspection delays the identification of faults which can not be rectified
Your Answer False

Question Management often fails to realize the importance of efficient layout due to
following reason
Correct Answer losses resulting from poor layout are not directly shown in the financial
statements
Your Answer losses resulting from poor layout are not directly shown in the financial
statements
Select The Blank

Question The ________ is the defect level for which lots are regarded as bad lots.
Correct Answer Lot Tolerance Percentage Defective
Your Answer Lot Tolerance Percentage Defective

Question Which method of critical path determination begins with the end event and
moves backward to the start event of the project network?
Correct Answer Backward pass computation
Your Answer Backward pass computation
True/False
Question Complexity and difficulty of Planning is influenced by types of layout
Correct Answer True
Your Answer False
True/False
Question For p-chart, p bar is the ratio of total number of units inspected to the total
number of units defectives.
Your Answer True


Question MRP utilises the following information
Correct Answer Master production schedule , Product structure , Lead time for
procurement/manufacturing
Your Answer Master production schedule , Lead time for procurement/manufacturing , list of
machines
Your Answer Above the arrow
Select The Blank

Question The ________ breakdowns usually cost more, partly due to damage done to the

is called
Your Answer Factory
True/False
Question Systematic maintenance system can completely eliminate the wear and tear of
machines.
Your Answer True

Question Which of the following are types of non-destructive testing?
Correct Answer Visual Testing , Eddy current , Magnetic flow detectors
Your Answer Visual Testing , Eddy current , Magnetic flow detectors
Select The Blank

Your Answer Time and Motion

Question Providing flexibility in plant layout means
Correct Answer Layout can be changed without much cost if required
Your Answer Layout can be changed without much cost if required

Question Which of the following aspects are essential to ensure quality of purchased
items?
Correct Answer Defining right quality for the job , Vendor performance evaluation ,
Making sure that suppliers understand the requirements
Your Answer Defining right quality for the job , Vendor performance evaluation , Making sure

Question Which of the following are scheduling techniques?
Correct Answer Critical Path Analysis , Index Method , Johnson's two machine algorithm
Your Answer Critical Path Analysis , Index Method , Johnson's two machine algorithm
Select The Blank

Question The ________ advocates maintenance procedures whereby the condition of the
plant is constantly watched through systematic inspection to unearth unhealthy conditions and
preventive
True/False
Question A network should be progression of activities always moving forward.
Correct Answer True
Your Answer True

Select The Blank

Question The ________ is necessary when the job requires detailed of one or more of the
job characteristics with the help of special equipment which is not available at the producing
company.
Your Answer Inspection order

Question Order preparation process for products manufatured to order requires following
documents
Correct Answer Sales Order , Work order , Shop order
Your Answer Sales Order , Work order , Shop order

Question What do you understand by the selection of the job for the method study on the
basis of money saving potential of the job?
Correct Answer Economic consideration
Your Answer Economic consideration
Select The Blank

Question Production Planning is a centralised activity which includes functions such as
________
Your Answer Scheduling

Question Scale model used for layout analysis have following advantages
Correct Answer Nontechnical person finds it easy to comprehend , Ovehead facilities can
be shown , Models can be shifted easily
Your Answer Nontechnical person finds it easy to comprehend , Ovehead facilities can be
shown , Models can be shifted easily

Question Which is the ideal place to inspect jigs and fixtures in a mass manufacturing unit?
Correct Answer Separate inspection room
Your Answer Separate inspection room

Question How to reveal the capability of the sampling plan to discriminate between good
lots and bad lots?
Your Answer Operating characteristics curve ( OC )
True/False
Question It would not affect the project completion time if non-critical activities take little
loner time than planned.
Correct Answer True
Your Answer True
Select The Blank

Question The ________ includes preventive maintenance activities whose needs are
identified through inspection which requires stoppage of machines.
Correct Answer Shutdown Maintenance
Your Answer Shutdown Maintenance
Match The Following

Forcasting requirement for indirect material Past consumption analysis technique Past
consumption analysis technique
Inventory control by classification ABC Analysis ABC Analysis
Structure of the product BOM BOM
Material Planning for dependent demand MRP MRP
True/False
Question The dispatching function is of very importance in flow and mass production
units.
Your Answer True

Question Which features should be covered by the specifications of materials while
defining the qualitative requirement?
Correct Answer Material composition , Dimensions , Any heat treatment if required
Your Answer Material composition , Dimensions , Cost of material
Select The Blank

Select The Blank


Question Which of the following is the most popular technique for Project Production?
Select The Blank


can be defined as
True/False
Question An activity should represent an operation or set of operations which can be
performed using a particular kind of equipment or a special skill.
Correct Answer True
Your Answer False

Question Which of the following are types of sampling plan?
Correct Answer Single sampling plan , Double sampling plan , Multiple sampling plan
Your Answer Single sampling plan , Double sampling plan , Multiple sampling plan
True/False
Question In case of forward pass computation, the earliest event time of a plain event
equals the earliest event time of the preceding event plus duration of activity emanating from the
preceding event.
Correct Answer True
Your Answer False

Question Which of the following are ideal situations for the preventive inspection?
Correct Answer Weekly off and holidays , Non-production hours , Stand-up equipment
Your Answer Weekly off and holidays , Non-production hours , Stand-up equipment

Question What do you mean by the chart on which the major activities and entry points of
materials are recorded to have graphic view of operations and inspections involved in the
process?
Your Answer Flow Process chart
Match The Following

Fixation of inventory level Reorder level Reorder level
Symptom of ill planned purchasing Over ordering Over ordering
Factor influencing material planning Lead time Lead time
Net requirement of material under MRP Stock on hand Stock on hand

Question Taxes / duties levied is one of the important determinant for location decision as
taxes/duties substantially influence
Correct Answer Product cost
Your Answer Product cost

Question Which kind of gauge consists of electrical contacts operating a series of colloured
signal lamps which indicate whether the dimension is correct, oversize or undersize?
Correct Answer Multiple gauging
Your Answer Multiple gauging

Question Which of the following are minimum requirement for a good quality of design?
Correct Answer Resonable cost , Resonable procurement time , Resonable manufacturing
time
Your Answer Resonable cost , Resonable procurement time , Resonable manufacturing time
Select The Blank

Question OC curve of ideal sampling plan suggests that all lots less than 3% defectives
Correct Answer One
Your Answer One
Select The Blank

Your Answer Open purchase order
True/False
Question An ideal OC curve is never possible only with cent percent inspection.
Your Answer True
Match The Following

Table lubrication Weekly Six monthly
Draining and refilling of oil reserviors of plunger pump Yearly Yearly
Parts lubricated with oil nipple Daily Weekly

Tools and slideways two to three times a day Daily
True/False
Question The operator should not stop production if first piece is not approved by the
inspector.
Your Answer False

Question Which of the following causes can be responsible for derailing the production
absenteeism
Your Answer Errors in drawings , Delay in receipt of material from vendor , Excessive
absenteeism
True/False
Question For p-chart, the central line of fraction defectives is determined by average
percentage defectives.
Correct Answer True
Your Answer True

Your Answer Recording progress of work , Communicating possible delays in delivery date
commitment to sales department , Devising cures to keep rate of production in line with schedule

Question When should operator or supervisor is supposed to sign the perforated route
sheet?
Your Answer After completion of operation
Select The Blank

company.
Question What are the benefits of reconditioning?
Correct Answer Eliminates problems and frequent breakdowns , Increases life of an
equipment , It helps to plan requirement of replacement spares
Your Answer Eliminates problems and frequent breakdowns , Increases life of an equipment ,
It helps to plan requirement of replacement spares

Question Which of the following processes or activities are denoted by using symbols
while recording in method study?
Correct Answer Transport , Delay , Storage
Your Answer Transport , Rejection , Storage

Question Which is the zone beyond LTPD in case of Oc curve of a general plan?
Correct Answer Zone of rejection
Your Answer Zone of rejection
True/False
Question A properly designed sampling plan can control sampling errors and completely
eliminate them.
Your Answer True
Select The Blank

Select The Blank

True/False
Question Grouping of machines gives a lot of flexibility in loading and scheduling
Correct Answer True
Your Answer True
True/False
Question A lot declared rejected in sampling inspection should not be inspected 100% in
any case.
Your Answer False

Question Which of the following are the basic requirements of quality standard?
Correct Answer Deifinite , Undesrstandable , Economically viable
Your Answer Absolute uniformity , Undesrstandable , Economically viable
True/False
Question The plotting of activities - critical, non-critical and dummy activities- is strictly
according to their precedence relationship.
Correct Answer True
Your Answer True

Your Answer Modifications and improvements , Overhauling , Lubrication as per schedule

Question Following is not a function of PPC
Correct Answer Product Planning
Your Answer Order Processing

Question Which of the following three methods used to select the qualified supplier?
Correct Answer By vendor plant surveys , By reputation , By experience
Your Answer By vendor plant surveys , By the perofrmance of first lot , By experience
Select The Blank

Match The Following

Pessimistic timeb p
Expected time Te Te
Optimistic time a o
Most likely time m m

Your Answer Display boards , Job cards , Progress cards

Question One of the characterstic of layout is about the flow of material / personnel. In a
Your Answer Unidirectional

Question What is indicated by the hugging points lying close to mean of the process in X
bar-R- control chart?
Correct Answer Biases in measurements , Recording done without actual measurements ,
Improper selection of samples
Your Answer Biases in measurements , Recording done without actual measurements ,

Question Operation Layout generally contains following information
Correct Answer Part Sketch , Standard Time , Jigs and fixtures
Your Answer Sequence of operations , Standard Time , Jigs and fixtures

Question What do you mean by the graphical representation of the project which is
composed as series of connected arrows and circles to describe the interrelationship of the
activities involved?
Correct Answer Network
Your Answer Flow chart

Question Where does the SPC exercises the control to prevent the occurances of
defectives?
Correct Answer On manufacturing process
Your Answer On manufacturing process

Question Which photographic technique is used to record path of motions of the members
of the body during method study?
Correct Answer Cyclograph
Your Answer Pictograph
Select The Blank

Question An Ideal OC curve is ________ shaped curve that accpets all the lots with quality
equal to or better than AQL .
Your Answer Bell
True/False
Question In Gantt Chart, the horizontal lines devide vertical lines into sections which
represents either operations or work centres.
Correct Answer True
Your Answer True
Select The Blank

Question Goods after final inspection should accompany ________to enable dispatch
Your Answer Forwarding note
Select The Blank

Question Capacity decisions have a direct influence on performance of production system
Your Answer Quality
True/False
Question Floor inspection promotes tendency of machines to drift out of limits and
produce defectives.
Your Answer False
True/False
Correct Answer True
Your Answer True

can be defined as

Question Which are the different methods to record details of the existing method during
method study?
Select The Blank


Select The Blank

Question The ________ is the probability that a bad lot will be accepted by the sampling
plan.
Select The Blank



within it's crashed time?
Correct Answer Crash cost
Your Answer Total cost
Question What do you understand by the extent the products manufactured conforms to the
laid down design?
Correct Answer Quality of conformance

Question Which kind of possible defectives can be reduced due to first off inspection?
Correct Answer Due to mistakes in reading blue prints , Due to errors in tooling , Due to
wrong machine set up
Your Answer Due to mistakes in reading blue prints , Due to errors in tooling , Due to wrong
machine set up
Select The Blank

Your Answer Open purchase order
True/False
Question An ideal OC curve is never possible only with cent percent inspection.
Your Answer True
Match The Following

Table lubrication Weekly Six monthly
Draining and refilling of oil reserviors of plunger pump Yearly Yearly
Parts lubricated with oil nipple Daily Weekly
Tools and slideways two to three times a day Daily
True/False
Question The operator should not stop production if first piece is not approved by the
inspector.
Your Answer False

absenteeism
absenteeism
True/False
Question For p-chart, the central line of fraction defectives is determined by average
percentage defectives.
Correct Answer True
Your Answer True

Your Answer Recording progress of work , Communicating possible delays in delivery date
commitment to sales department , Devising cures to keep rate of production in line with schedule

sheet?
Select The Blank

company.

Correct Answer Eliminates problems and frequent breakdowns , Increases life of an
equipment , It helps to plan requirement of replacement spares
Your Answer Eliminates problems and frequent breakdowns , Increases life of an equipment ,
It helps to plan requirement of replacement spares

Question Which of the following processes or activities are denoted by using symbols
while recording in method study?
Correct Answer Transport , Delay , Storage
Your Answer Transport , Rejection , Storage

True/False
Question A properly designed sampling plan can control sampling errors and completely
eliminate them.
Your Answer True
Select The Blank

Select The Blank

True/False
Question Grouping of machines gives a lot of flexibility in loading and scheduling
Correct Answer True
Your Answer True
True/False
any case.
Your Answer False

True/False
Question The plotting of activities - critical, non-critical and dummy activities- is strictly
according to their precedence relationship.
Correct Answer True
Your Answer True

Your Answer Modifications and improvements , Overhauling , Lubrication as per schedule

Question Following is not a function of PPC
Correct Answer Product Planning
Your Answer Order Processing

Question Which of the following three methods used to select the qualified supplier?
Correct Answer By vendor plant surveys , By reputation , By experience
Your Answer By vendor plant surveys , By the perofrmance of first lot , By experience
Select The Blank

Match The Following

Pessimistic timeb p
Expected time Te Te
Optimistic time a o
Most likely time m m



Your Answer Biases in measurements , Recording done without actual measurements ,

Your Answer Sequence of operations , Standard Time , Jigs and fixtures

Question What do you mean by the graphical representation of the project which is
composed as series of connected arrows and circles to describe the interrelationship of the
activities involved?
Correct Answer Network
Your Answer Flow chart

Question Where does the SPC exercises the control to prevent the occurances of
defectives?
Correct Answer On manufacturing process
Your Answer On manufacturing process

Question Which photographic technique is used to record path of motions of the members
of the body during method study?
Correct Answer Cyclograph
Your Answer Pictograph
Select The Blank

Your Answer Bell
True/False
Question In Gantt Chart, the horizontal lines devide vertical lines into sections which
represents either operations or work centres.
Correct Answer True
Your Answer True
Select The Blank

Select The Blank

Your Answer Quality
True/False
Question Floor inspection promotes tendency of machines to drift out of limits and
produce defectives.
Your Answer False
True/False
Correct Answer True
Your Answer True

can be defined as

Question Which are the different methods to record details of the existing method during
method study?
Select The Blank


Select The Blank

plan.
Select The Blank




laid down design?

machine set up

Question One of the sophisticated operations research techniques used in material planning
is
Correct Answer Dynamic programming
Your Answer Dynamic programming
True/False
Question Job life is one of the factors that influence Process Planning
Correct Answer True
Your Answer True

Question Following are some of the Principles of Management advocated by F W Taylor
Correct Answer Selection of best worker for each particular task , Division of work
between worker and management , Training and development of the workmen
Your Answer Selection of best worker for each particular task , Division of work between
worker and management , Training and development of the workmen

Question Product layout is employed for manufacturing following products
Correct Answer refrigirators
Your Answer ships
Select The Blank

Your Answer Job

Question Which of the following situations demand the technical consideration while
Correct Answer Jobs having inconsistent quality , Operations inviting frequent requests
from supervisors for relaxation in allowed time because of variations in materials and tool
performance , Jobs in which too many man-hours are spend in checking and rechecking work
Your Answer Jobs having inconsistent quality , Operations inviting frequent requests from
supervisors for relaxation in allowed time because of variations in materials and tool performance
, Jobs in which too many man-hours are spend in checking and rechecking work
True/False
Question Quality control determines what, when, and how much to inspect while
inspection actually conducts examination of goods.
Correct Answer True
Your Answer True
Select The Blank

Select The Blank

Question The term ________ emplies the foregone profit due to inability of company to
produce.
Your Answer Opportunity cost
True/False
Question All activities must not be tied up into the network
Your Answer False
True/False
Question F W Taylor devised a system for classifying motions into basic divisions called
Therbligs
Your Answer True

Question Which of the following may be the objectives of project crashing?
Correct Answer To achieve uniformity in requirement of resources , To complete the
project in the least possible time , To reduce project cost below it's normal cost
Your Answer To complete the project in the least possible time , To achieve uniformity in
requirement of resources , To improve the labour efficiency

Your Answer Recording done without actual measurements , Improper selection of samples

Question Following is one of the techniques used for Material Planning for high value
material
Correct Answer MRP
Your Answer MRP
Select The Blank

plan.

True/False
Question The event numbers as far as possible reflect the logical relationships of the
activities.
Correct Answer True
Your Answer False

Question Material Requirement Planning is very useful in following situations
Correct Answer Long Lead time for procurement , Several levels of assemblies in product
, Long manufacturing cycle
Your Answer Long Lead time for procurement , Several levels of assemblies in product , Long
manufacturing cycle
True/False
Question Cent percent inspection is often more practical and economical than sampling
inspection.
Your Answer False
Select The Blank

Question The ________ must ensure that the product satisfy the functional requirements of
it's usage.
Your Answer Quality of conformance
True/False
Question Both, preventive and breakdown maintenance work must be assigned to the same
team.
Your Answer False
Question Following is one of the tasks of Production Control
Correct Answer Actual issue of forms and documents
Your Answer Actual issue of forms and documents

Question Process Engineer does not get sufficient time for designing tooling for most
economic production run when
Correct Answer Delivery time is less
Your Answer Delivery time is less

Question Components of Production Management include
Correct Answer Capacity Planning , Job Design , Production Planning
Your Answer Capacity Planning , Production Planning , Manpower Planning

Question Which of the following products should be produced by using mass production?
Your Answer Refrigerator , Tyre for automobile , Television Set

can be defined as
Select The Blank


Question What is the specific name for the Gantt chart when it shows at a glance the
scheduling of various operations involved in a job?
Correct Answer Job Schedule
Your Answer Load Chart
Select The Blank

Question A set of activities to keep an equipment in the specified condition is called as
________.
Correct Answer Maintenance
Your Answer Maintenance

Your Answer Crash cost

Question Which of the following factors decide the choice between the cent percent and
sampling inspection?
Correct Answer Nature of inspection , Natural tolerance versus design tolerance ,
Vendor's quality rating
Your Answer Nature of inspection , Natural tolerance versus design tolerance , Vendor's quality
rating
Select The Blank


Question Which of the following are examples of attributes?
Correct Answer Cracks , Burrs , Texture
Your Answer Cracks , Burrs , Texture

Question Which of the following is the criteria for the percentage defectives in the zone of
the indecision?
Correct Answer Lots having the percentage defective more than AQL but less than LPTD
Your Answer Lots having the percentage defective more than AQL but less than LPTD

Question In mass/batch production organizations where goods are produced for stocking,
Work Order is raised on the basis of
Your Answer Sales Order
Match The Following

Fixed Position Layout Project Layout Functional Layout

Product Layout Line Layout Project Layout
Process Layout Functional Layout job layout

Question What do you understand by the measurement of work to establish allowed time
for a job for the defined method?
Your Answer Work measurement
Select The Blank

________.
True/False
Correct Answer True
Your Answer False

Question Which are the distinct functions of scientific quality control?
Correct Answer Acceptance function , Preventive function , Assurance function
Your Answer Acceptance function , Feedback function , Preventive function
Match The Following

Interruption for machine utilisation Preventive maintenance Preventive maintenance
Input for scheduling Overlapping of operations Strings
Technique of scheduling Critical Path Analysis Critical Path Analysis
Scheduling Device Strings Blackboard
Select The Blank

Your Answer Rectangular
True/False
Question Breakdown of machines, absenteeism of worker does not dislocate the
manufacturing activity in process layout
Correct Answer True
Your Answer True
True/False
Question Since value of c can never be negativee, hence" if LCLp works out to be
negative, it is taken as zero."
Correct Answer True
Your Answer True

Your Answer Worker
True/False
units.
Your Answer True

Question Which are major benefits of identifying the critical path?
Correct Answer It helps to identify the set of activities and events which are critical and
as such must be carefully controlled and monitored , It identifies activities to be given preference
in allocation of resources. , It helps to exercise "control by exception".
Your Answer It helps to identify the set of activities and events which are critical and as such
must be carefully controlled and monitored , It helps to exercise "control by exception".

items?
Your Answer Defining right quality for the job , Vendor performance evaluation , Making sure
Select The Blank
True/False
Question After goods have been manufactured, route sheets and operation layouts should
not be collected back.
Your Answer False
True/False
Question In case of centralised inspection, inspection rooms generally become bottleneck
and cause delay in taking action regarding rejection or rework.
Correct Answer True
Your Answer True

Question MRP is based on the concept of inventory demand which is of following type
Correct Answer Dependent and independent
Your Answer Dependent and independent

is called
Your Answer Factory

Question Components of Production Management include
Correct Answer Capacity Planning , Job Design , Production Planning
Your Answer Capacity Planning , Job Design , Production Planning

Question Which of the following is the criteria for the percentage defectives in the zone of
the indecision?
Correct Answer Lots having the percentage defective more than AQL but less than LPTD
Your Answer Lots having the percentage defective more than AQL but less than LPTD

Question Which of the following are examples of addition during recording for method
study?
Correct Answer Brazing , Welding , Riveting
Your Answer Brazing , Welding , Riveting
Select The Blank

Select The Blank

Your Answer Rectangular

absenteeism
absenteeism

Question Which of the following situations demand the economic consideration while
Correct Answer Unorderly movement of men and materials , Excessive process
defectives , Too many suggestions received for improvement from a department or section
Your Answer Unorderly movement of men and materials , Excessive process defectives ,
Inconsistent quality
True/False
Question During set up of X bar-R control chart, control limts should be practically revised
from time to time as additional data is accumulated.
Correct Answer True
Your Answer False

Match The Following

Toung Sweet Sweet
Eye Crack Crack
Nose Burnout Burnout
Ear Impact Roughness
Select The Blank

True/False
Question Floor inspection delays the identification of faults which can not be rectified
Your Answer False
True/False
Question Cent percent inspection is required on WIP prior to the key, critical or costly
operation.
Correct Answer True
Your Answer True

Question The document which incorporates details of process planning for a job is called
Correct Answer Route Sheet
Your Answer Route Sheet
True/False
Question Repetitive movements between work stations which are difficult to be traced on
string diagrams can be conveniently shown on flow diagrams.
Your Answer True


product to
Your Answer To meet the intended function at lowest cost

Question What can be the worst effect due to excessive vibration?
Correct Answer Breakdown
Your Answer Breakdown

Question What is the relation between duration of an activity and length of an arrow?
Your Answer No relation

Your Answer Tight
Select The Blank



Question Which of the following techniques is used by industrial engineering department
to obtain the utilisation index?
Correct Answer Work Sampling Studies
Your Answer Break Even Analysis

Question Which of the following factors play important role while selecting or rejecting a
particular site from legislation and taxation point of view?
Correct Answer Labour laws , Building codes , Policies regarding issue of licences
Your Answer Labour laws , Building codes , Policies regarding issue of licences

Question Which of the following cases can be referred as operation in method study
recording?
Correct Answer Change in physical characteristic , Consumption of physical effort ,
Change in chemical characteristic
Your Answer Change in physical characteristic , Consumption of physical effort , Movement of
material
True/False
Question An activity can share the same tail event and same head event with any other
activity.
Your Answer True
Select The Blank

it's usage.

Your Answer Bakeries , Ice factories , Woolen
Select The Blank

Question The ________ are the definitions of the measurable as well as nonmeasurable
Your Answer Specifications

Question Site factors for plant location include
Correct Answer Suitability of land
Your Answer Suitability of land
Select The Blank

plan.

Question Which of the following defects can be observed during preventive inspection by
using human senses?
Correct Answer Deviation from normal sound , Excessive Vibration , Leakage of a gas
Your Answer Deviation from normal sound , Excessive Vibration , Leakage of a gas
Select The Blank

Your Answer Working Maintenance
True/False
Question Independent float either affects the float of preceding activities or that of
succeeding activities.
Your Answer False

Question Lack of material planning results in the following
Correct Answer Over ordering , under ordering , stockouts
Your Answer Over ordering , under ordering , stockouts
True/False
Question F W Taylor devised a system for classifying motions into basic divisions called
Therbligs
Your Answer False
Select The Blank

Match The Following

Factor Analysis Method to evaluate layouts Technique for evolving and analysis of layouts
Minimization of production delays Objective of good layout Objective of good

layout
Maximum visibility Principles of good layout Principles of good layout
Scale model Layout analysis Method to evaluate layouts

Question Following is one of the techniques used for Material Planning for high value
material
Correct Answer MRP
Your Answer MRP

Question What do you understand by totality of features and characteristics of a product or
service that bears on it's ability to satisfy the customer?
Correct Answer Quality
Your Answer Quality
Select The Blank

Your Answer Worker
True/False
Question Cent percent inspection is required on WIP prior to the key, critical or costly
operation.
Correct Answer True
Your Answer True

items?
Your Answer Vendor performance evaluation , Making sure that suppliers understand the
requirements , Defining right quality for the job

is called
Your Answer Factory
Question Which of the following technique is event oriented ?
Correct Answer Project Evaluation & Review Technique
Your Answer Project Evaluation & Review Technique
Select The Blank


Question Which of the following concepts must be understood for the achievement of
quality?
Your Answer Quality of conformance , Quality of design

Question Following are some of the factors considered for evaluation of alternative layouts
Your Answer Flow of Material , Equipment utilization , Ease of supervision
Match The Following

Toung Sweet Sweet
Eye Crack Crack
Nose Burnout Burnout
Ear Impact Impact

Question Which are the subtasks of the maintenance phase of the method study?
Correct Answer Monitoring and control , Performance appraisal , Audit on savings
Your Answer Monitoring and control , Performance appraisal , Audit on savings

Question Which of the following are characteristics of an operating characteristics curve?
Correct Answer Producer risk , Consumer Risk , Acceptable Quality Level
Your Answer Producer risk , Consumer Risk , Acceptable Quality Level
Select The Blank

Your Answer Partial

Question Why stores issue order should not be issued as soon as it is prepared?
Correct Answer Material may or may not be available at the time of preparation
Your Answer Inventory investment will increase

Your Answer Tight
Select The Blank

________.

Question Plant layout facilitates processing of products in most effective manner through
the following
Correct Answer Shortest possible distance , Shortest processing time , Minimum
movement
Your Answer Shortest possible distance , Shortest processing time , Minimum movement
True/False
Question After goods have been manufactured, route sheets and operation layouts should
not be collected back.
Your Answer False

Question Process planning is the process of
Correct Answer establishing shortest and most economic path of production
Your Answer establishing shortest and most economic path of production

can be defined as
Select The Blank

Question The ________ is specified to indicate the maximum permissible variability in the
dimensions product or parts.
Your Answer Tolerance
Select The Blank

Select The Blank

True/False
Question A load chart specifies the work to be carried out by each person of company
during shift hours.
Your Answer True
Select The Blank

True/False
Question Under MRP system for common items order for procurement is placed based on
requirement for each product
Your Answer True

laid down design?
Select The Blank

company.

Your Answer Deifinite , Undesrstandable , Economically viable
True/False
zero.
Correct Answer True
Your Answer True

machine set up , Due to purposely done mistakes by unsatisfied worker
True/False
Correct Answer True
Your Answer True

Question Which of the following is a part of preparing manufacturing order set as a
primary function of dispatching?
Correct Answer Operational layouts , Move orders , Pre-filled stores issue orders
Your Answer Operational layouts , Rejection reports , Move orders , Pre-filled stores issue
orders
Select The Blank

engineering changes carried out in the equipment during it's period of service.
Your Answer Equipment history card
True/False
Question Specifications is the basic tool of inspection.
Correct Answer True
Your Answer True
Match The Following

Forcasting requirement for indirect material Past consumption analysis technique

Economic order quantity
Inventory control by classification ABC Analysis ABC Analysis
Structure of the product BOM BOM
Material Planning for dependent demand MRP MRP

Question The document raised by PPC which authorises different functions to take action
as per instruction is called
Correct Answer Work Order
Your Answer Job Instructions

Your Answer Shop Supervisor
True/False
any case.
Your Answer True

Question How is the probability of acceptance in case of Acceptable Quality Level
(AQL )?
Correct Answer Very high
Your Answer Average

Your Answer Display boards , Progress cards , Network updating
True/False
units.
Your Answer True
True/False
Question Proper care and storage is not an essential part of a well planned lubrication
system.
Your Answer False
Select The Blank


Select The Blank

Question Production Planning is a centralised activity which includes functions such as
________

Question Which rule is used for numbering of events?
Correct Answer Fulkerson's Rule
Your Answer Fulkerson's Rule
Select The Blank

Select The Blank

engineering changes carried out in the equipment during it's period of service.
Your Answer Equipment warranty card

Your Answer Sequence of operations , Part Sketch , Standard Time

Question How to reveal the capability of the sampling plan to discriminate between good
lots and bad lots?
Your Answer Operating characteristics curve ( OC )
True/False
Question Shape od an OC curve is a function of sample size and the acceptance number.
Correct Answer True
Your Answer True


Question Which of the following cases indicated that the operation has occurred?
Correct Answer Movement of components to assembly section , Raw material movement
, A worker's trip to grinder to sharpen the tools
Your Answer Movement of components to assembly section , Raw material movement , A
worker's trip to grinder to sharpen the tools

Question Process type layout is suitable when
Correct Answer there is wide variation in processing time of operations
Your Answer there is wide variation in processing time of operations
True/False
Question In case of backward pass computation, the latest event time of the burst event
equals the smallest of the difference between the latest event time of the head event less duration
of the activity converging on the head event.
Correct Answer True
Your Answer True
Select The Blank

Question The ________ are the definitions of the measurable as well as nonmeasurable
Your Answer Drawings
Select The Blank

it's usage.
Select The Blank

Your Answer Collaboration

Question Which of the following concepts must be understood for the achievement of
quality?
Your Answer Quality of conformance , Quality of design

Question Which of the following are major inputs to scheduling?
Correct Answer Overlapping of operations , Effective Capacity per work centre ,
Performance standards
Your Answer Effective Capacity per work centre , Performance standards
Select The Blank
________.

Question Which of the following activities can become a part of a preventive maintenance
system?
Correct Answer Condition monitoring , Planned Lubrication , Preventive inspection
Your Answer Condition monitoring , Planned Lubrication , Preventive inspection
True/False
Question Delay in completion of projects result in unwelcome additions to the fixed
manufacturing expenses.
Correct Answer True
Your Answer False
True/False
Your Answer True

can be defined as

Question Which of the following defects can be observed during preventive inspection by
using human senses?
Correct Answer Deviation from normal sound , Excessive Vibration , Leakage of a gas
Your Answer Deviation from normal sound , Excessive Vibration , Leakage of a gas
Match The Following

When to inspectStages of inspection Stages of inspection
What to inspect Specification Stages of inspection
How to inspect Inspection devices Specification

How much to inspect Sampling or cent percent inspection Inspection devices

Question How does the control chart of statistical quality control helps the operating
personnel?
Correct Answer Identify the presence of an assignable cause before it develops
Your Answer Identify the presence of an assignable cause before it develops
Match The Following

Fixed Position Layout Project Layout Project Layout
Product Layout Line Layout Line Layout
Process Layout Functional Layout Functional Layout

Your Answer Minor , Major , Critical

Question Which of the following factors related to the labour and wages are considered
while deciding the plant location?
Correct Answer Prevailing wage pattern , Productivity of labour , Industrial relations
Your Answer Prevailing wage pattern , Productivity of labour

Your Answer Low Productivity
Select The Blank

Your Answer Material composition , Dimensions , Cost of material

Question Which of the following method can be adopted to overcome the problem of
rushing up a job for it's timely completion?
Correct Answer Use of optimum speeds and feeds , Subcontracting , Job splitting
Your Answer Use of optimum speeds and feeds , Use alternative materials , Job splitting
True/False
Question Kanban system is essentially a computer based system for production scheduling
and control
Your Answer False
True/False
Question The event numbers as far as possible reflect the logical relationships of the
activities.
Correct Answer True
Your Answer True
Select The Blank

plan.


is called
Your Answer Factory
Select The Blank


Correct Answer Material specifications , Dimensional specifications , Performance
specifications
Your Answer Material specifications , Dimensional specifications , Performance specifications
True/False
Question In case of control chart, large smaples such as n=15 or 20 are used if the process
standard deviation is small.
Your Answer False
True/False
Question The control chart for number of defectives is more convenient to make than
control chart for fraction defectives sincethe fugure of number of defectives units can be directly
taken from the inspection report.
Correct Answer True
Your Answer True
True/False
Question In case of X bar-R charts,it is ensured that the assignable causes are detected
before the tolerances are violated, upper and lower statistical limits are worked out and inserted
into a chart.
Correct Answer True
Your Answer True
Select The Blank


Question Which phase of method study is concerned with analyzing the facts critically,
generating alternatives which form the basis for selection and development of improved
methods?
Correct Answer Critical examination
Your Answer Critical examination

Question What is the relation between duration of an activity and length of an arrow?
Your Answer Directly proportional

Your Answer All important characteristics

Question How to calculate float?
Correct Answer Parallel critical path time minus Non-critical path time
Your Answer Parallel critical path time plus Non-critical path time
Select The Blank


Question What is the meaning of surplus material in context with stores issue order?
Your Answer Materials issued are not fully consumed

product to
2nd Attempt

Question What is the cause of inherent variation or internal variation?
Correct Answer Cumulative effect of number of chance causes
Your Answer Worker's efficiency


Your Answer Zone of acceptance

Question Which of the following cases indicates change in physical characteristic?
Correct Answer Turning , Grinding , Drilling
Your Answer Chemical reaction , Grinding , Drilling
True/False
Question Originating process of raw material influence Process Planning
Correct Answer True
Your Answer True
Select The Blank

________.
True/False
Question Skill of labour force in a product type layout is usually higher than in the process
type of layout
Your Answer False
True/False
Question Planned lubrication is said to be the nervous system of the equipment.
Correct Answer True
Your Answer True

Question Which of the following can be termed as operation while recording for method
study?
Correct Answer Information received , Addition or subtraction , Information given
Your Answer Information received , Addition or subtraction , Information given
Select The Blank

plan.
Your Answer Consumer's risk

Question Which of the following products should be produced by using mass production?
Your Answer Refrigerator , Tyre for automobile , Television Set

Question Which industry out of the following industries require maximum consideration
for safety factor while selecting plant location?
Correct Answer Nuclear power plant
Your Answer Nuclear power plant

Correct Answer Large varaitions in hardness of material , Tool wear , Errors in setting
Your Answer Large varaitions in hardness of material , Tool wear , Errors in setting
Select The Blank

Question The ________ is a set of tools and techniques by which products are made to
comply with the specifications at minimum cost to the firm.
Correct Answer Quality control system
Your Answer Quality control system
True/False
Question Operation process charts though indicates the sequence of events but do not show
movements.
Correct Answer True
Your Answer False
True/False
Question Maintenance function must be decentralised apart from a size of a manufacturing
organisation for it's better functioning.
Your Answer False
Match The Following

What to inspect Specification Specification

How to inspect Inspection devices Inspection devices
How much to inspect Sampling or cent percent inspection Sampling or cent percent
inspection
True/False
Question Dust gets mixed with lubricants, forms an abrasive substance and causes pre-
mature failure of machinery.
Correct Answer True
Your Answer True

is called
Your Answer Factory

Question Which kind of labour force is required in case of Jobbing Production?
Correct Answer Highly Skilled
Your Answer Contract Labour only
Select The Blank



can be defined as

absenteeism
absenteeism
Select The Blank


Correct Answer Critical , Minor , Major
Your Answer Minor , Major , Critical
Select The Blank

Question A ________helps to avoid crowding of jobs at a particular machine by change of
Your Answer Control board

Question Process planning is the process of
Correct Answer establishing shortest and most economic path of production
Your Answer Planning of business processes
Select The Blank



Your Answer Overloading of machines
Question Which is the ideal place to inspect jigs and fixtures in a mass manufacturing unit?
Correct Answer Separate inspection room
Your Answer Separate inspection room

Question Who is responsible for return of surplus material?
Correct Answer Dispatcher
Your Answer Supervisor
Select The Blank

its usage.

Question Which are reason due to which the progress of work is rarely in line with its
plan?
Correct Answer Absenteeism , Machine breakdowns , Substandard performance against
prefixed production standards
Your Answer Absenteeism , Change in operation sequence , Machine breakdowns
True/False
Question While numbering as per Fulkerson's rule, arrows emerging from the initial event
are deleted so as to create one or more initial events.
Correct Answer True
Your Answer True

Question What are the uses of the instruction manual provided by the manufacturer of a
machine?
Correct Answer It gives instructions regarding installation and operation of the equipment
, It contains note on common troubles with causes and remedies for troubleshooting , It enlists
points, frequency and type of lubrication
Your Answer It gives instructions regarding installation and operation of the equipment , It
contains note on common troubles with causes and remedies for troubleshooting , It enlists
True/False
Question Any proposed change must not be intimated to workers in advance.
Your Answer True
True/False
Question Process Planning is concerned with decisions regarding requirement of machines
and manpower for meeting customer demand
Your Answer False
Select The Blank


Your Answer Defect in materials , Recording done without actual measurements , Improper
selection of samples

Question How industry has responded to the fact of existence of inherant variability of the
manufacturing process?
Correct Answer Inclusion of certain tolerance on the basic dimensions in the drawing
Your Answer Inclusion of certain tolerance on the basic dimensions in the drawing

Question The document which incorporates details of process planning for a job is called
True/False
Question The control chart for number of defectives is more convenient to make than
control chart for fraction defectives sincethe fugure of number of defectives units can be directly
taken from the inspection report.
Correct Answer True
Your Answer True
Select The Blank

produce.
Your Answer Opportunity cost
Match The Following
Select The Blank

________.
Also check these
1. Shop interdepartmental transport 1. Tool order
2. Issue of tools for production 2. Stores return note
3. Return of surplus material 3. Move order
4. Release of manufacturing orders 4. Job card
5. Inspection report
6. Rejection note
1. Craft
1. Charting technique
2. Work Sampling
2. Sampling Inspection
3. Gantt Chart
3. Machine utilization
4. Emerson Efficiency Plan

4. Wage Payment
5. Facilities Planning
6. Production Scheduling
1. Proximity to market
1. Productivity of labour
2. Industrial and labour attitude

2. Fragile product
3. Legislation and taxation

3. Safety factor
4. Community Facilities
4. Transport facility
5. Licenses
6. Educational facility
1. Minimization of production delays

1. Objective of good layout
2. Maximum visibility
2. Principles of good layout
3. Scale model
3. Method to evaluate layouts
4. Factor Analysis
4. Modelling approach to layouts
5. Technique for evolving and analysis of layouts
6. Layout analysis
1. Symptom of ill planned purchasing

1. Single source of supply
2. Factor influencing material planning

2. Over ordering
3. Net requirement of material under MRP

3. Price of material
4. Fixation of inventory level

4. Stock on hand
5. Lead time
6. Reorder level
1. Interruption for machine utilisation

1. Overlapping of operations
2. Input for scheduling

2. JIT
3. Technique of scheduling
3. Blackboard
4. Scheduling Device
4. Strings
5. Preventive maintenance
6. Critical Path Analysis
1. Control board
1. Work order of item currently being worked on the machine
2. Top compartment of control board

2. Pictorial view of machine loading activity
3. Middle compartment of control board

3. Work order which requires maximum lead time to complete
4. Bottom compartment of control board

4. Bunch of work orders which can be processed on other machines
5. Bunch of work orders arranged in a sequence in which they are to be

processed.
6. Work order of item to be processed next on the machine
1. Critical operation inspection

1. First piece produced after tool change
2. Patrolling inspection
2. Inspection done remotely
3. Key operation inspection

3. After whose no rework is possible
4. First off inspection

4. Inspection at the place of actual production
5. Costlier operation
6. Last operation
1. High production volume low variety

1. Group layout
2. Low production volume high variety

2. Process Layout
3. Grouping into families of similar product
3. Cellular Layout
4. unit production of very large product

4. Product Layout
5. Space layout
6. Fixed Position Layout
1. Consumption of effort
1. Giving directions or instructions
2. Information given
2. Chemical reaction
3. Subtraction
3. Welding
4. Change in chemical characteristic

4. Removal of worn-out part from a machine
5. Press shop operation
6. Posting a ledger
Cellular layout is based on the concept of Group Technology ……… True/False
What is the reason of fluctuations, if the control chart evaluates that the process is not in a state of
statistical control?
Planned variability, Nonassingnable variability, Assignable variability
Random variability
A good layout results in
Lower costs, High employee motivation , Better forecasts Better production planning
Multiple Answers
Which of the following method can be used to record the facts during the method study?
Micro motion study Photograph Cyclograph Cyclograph
Which of the following situations demand that the human consideration should be given
preference over other considerations?
Inconsistent earnings where the earnings are tied to output
Poor morale evidenced by petty or trivial complaints
Repeated cases of accidents and health hazards
Major contributors in the development of Control Charts, Sampling plan are

F H Dodge
H G Roming
Walter Schewhart
L H C Tippet
The document raised by PPC which authorises different functions to take action as per instruction
is called
Work Order
Work Instructions
Production Order
Job Orientation
True/False
Question It pays in the long run to inform the customer regarding expected delays in the
deliveries.
Correct Answer True
Your Answer True

Question Fixed position layout is adopted when
Correct Answer product is very heavy involving assembly of large number of parts
Your Answer product is very heavy involving assembly of large number of parts
Select The Blank


Correct Answer Avaialability of adequate land at lower cost , Both skilled and unskilled
labour can be available , Plant expansion is easier due to less or no restriction for building and
construction
Your Answer Avaialability of adequate land at lower cost , Both skilled and unskilled labour
can be available , Plant expansion is easier due to less or no restriction for building and
construction
Select The Blank

Your Answer Worker
Select The Blank


Question Following are some of the factors which influence process planning
Correct Answer Order Quantity , Process capability of machine , Delivery Dates
Your Answer Order Quantity , Delivery Dates , Plant layout
True/False
Question Availability of training schools, colleges and management institutes reduces the
company's internal training needs.
Correct Answer True
Your Answer False

Your Answer Bakeries , Ice factories , Lime stone
Match The Following

Craft Facilities Planning Production Scheduling
Work Sampling Machine utilization Sampling Inspection
Gantt Chart Production Scheduling Charting technique
Match The Following

Fixation of inventory level Reorder level Stock on hand
Net requirement of material under MRP Stock on hand Price of material

Question Which of the following are steps to identify the critical path in a small network?
Correct Answer Compare the durations of all paths to identify the longest path. , Sum up
the durations of activities along each path. , Enumerate all paths in the network and list down
activities on each path.
Your Answer Compare the durations of all paths to identify the longest path. , Sum up the
durations of activities along each path. , Enumerate all paths in the network and list down
activities on each path.
Select The Blank

________.
True/False
Question Tool breakage has got nearly zero chances in case of eventual breakdown.
Your Answer False

Question Which are the three types of float?
Correct Answer Total float , Independent float , Free float
Your Answer Total float , Dependent float , Free float

Correct Answer Overlapping of operations , Effective Capacity per work centre ,
Your Answer Effective Capacity per work centre , Ratio of skilled to unskilled labour ,

is called
Your Answer Factory
Select The Blank

Select The Blank

Your Answer Overhauling
Select The Blank

Question OC curve of ideal sampling plan suggests that all lots less than 3% defectives
Correct Answer One
Your Answer One

Question How to calculate activity cost slope?
Correct Answer Activity cost slope = ( Crash cost - Normal cost ) / ( Normal time - Crash
time )
Your Answer Activity cost slope = ( Normal cost - Crash cost ) / ( Normal time - Crash time )

Correct Answer Resonable cost , Resonable procurement time , Resonable manufacturing
time
True/False
Question In case of control chart, large smaples such as n=15 or 20 are used if the process
standard deviation is small.
Your Answer True
Select The Blank

Question Production control work is ________ in case of floor inspection as compared
Your Answer labourious

Question Production Planning includes
Correct Answer Predetermination of manufacturing requirements
Your Answer Predetermination of manufacturing requirements

Question How does the control chart of statistical quality control helps the operating
personnel?
Your Answer Reduces chances of rejections

Your Answer Reduced salvage value of machine

Question What do you understand by the metallergical aspects of product which forms the
vital part of engineering function?
Your Answer Performance specifications


Question Which of the following possibilities can be explored by using flow process chart?
Correct Answer Eliminating the operations or combining the operations with another ,
Reducing the distance traveled by the workmen or materials , Avoiding the waiting time and
thereby reduce production losses
Your Answer Reducing the distance traveled by the workmen or materials , Reducing
rejections drastically , Avoiding the waiting time and thereby reduce production losses

Your Answer Process Planning
True/False
Question Dust gets mixed with lubricants, forms an abrasive substance and causes pre-
mature failure of machinery.
Correct Answer True
Your Answer True

Question Which of the following activities are used while recording for method study?
True/False
Question In case of centralised inspection, inspection rooms generally become bottleneck
and cause delay in taking action regarding rejection or rework.
Correct Answer True
Your Answer True
Select The Blank

Question The ________ advocates maintenance procedures whereby the condition of the
plant is constantly watched through systematic inspection to unearth unhealthy conditions and
preventive
True/False
Question The problems of congestion, bottlenecks and backtracking can not be visualized
by using templates and models.
Your Answer False

Correct Answer Time
Your Answer Quality
True/False
Question Delay in completion of projects result in unwelcome additions to the fixed
manufacturing expenses.
Correct Answer True
Your Answer True
Select The Blank

produce.

Question Taxes / duties levied is one of the important determinant for location decision as
taxes/duties substantially influence
Your Answer Order procurement

Correct Answer To forecast the defect , To identify causes of major repetative failures ,
To quantify the frequency of preventive inspection
Your Answer To forecast the defect , To identify causes of major repetative failures , To
quantify the frequency of preventive inspection
True/False
Correct Answer True
Your Answer True

Select The Blank

plan.
True/False
Question The component produced on completely automatic machines may be subjected to
sampling inspection while parts produced on semi-automatic and completely manual operated
machines require cent percent inspection.
Correct Answer True
Your Answer False


Question Which of the following factors play important role while selecting or rejecting a
particular site from legislation and taxation point of view?
Your Answer Labour laws , Policies regarding issue of licences , Productivity of labour

True/False
Question Site selection should also take into account topography and soil structure of the
land.
Correct Answer True
Your Answer True

Question Which manufacturing method is ideal for the use of air gauges as inspection
device?
Correct Answer Mass
Your Answer Batch
True/False
Question Kanban system is essentially a computer based system for production scheduling
and control
Your Answer False

Question Which are three different bases to establish an activity time?
Correct Answer Past experience , Judgement , Historical data
Your Answer Past experience , Judgement , Historical data
True/False
Your Answer False

Question Which of the following policies is advisable in case of low product variety and
large volumes?
Correct Answer Low Skilled Labour & Special Purpose Machines
Your Answer Semiskilled Labour & General Purpose Machines
Select The Blank

Your Answer Delivery performance
True/False
Question In case of X bar, if the process is not under control indicated by some points
falling outside the control limits, such points outside the control limits are eliminated and new
trial control limits for the remaining points are computed.
Correct Answer True
Your Answer True
Select The Blank

Select The Blank

company.
Match The Following

Crash cost of an activityCc Cc
Normal time of an activity Tn Cn
Crash time of activity Tc Tc
Normal cost of an activity Cn Tn
True/False
Question Lubrication survey should never be done for a new machine.
Your Answer False

Your Answer Reducing handling costs

Question Out of two basic criteria for the selection of a manufacturing method, one is, it
must be able to meet the specifications of final product and the other is, it must be
Correct Answer Cost effective method
Your Answer Cost effective method

Question Which of the following is a part of preparing manufacturing order set as a
primary function of dispatching?
Correct Answer Operational layouts , Move orders , Pre-filled stores issue orders
Your Answer Operational layouts , Move orders , Pre-filled stores issue orders
Select The Blank


Your Answer Minor , Critical , General

Question Which kind of labour force is required in case of Jobbing Production?
Correct Answer Highly Skilled
Your Answer Highly Skilled

Question Which are the sources of information to update the progress card daily?
Correct Answer Detachable ticket , Daily production report , Job Card
Your Answer Detachable ticket , Daily production report , Job Card
True/False
zero.
Correct Answer True
Your Answer True

Question Which are the distinct functions of scientific quality control?
Correct Answer Acceptance function , Preventive function , Assurance function
Your Answer Acceptance function , Preventive function , Assurance function

Question Which of the following are examples of specifications?
Correct Answer Commercial standards , Assembly and testing instructions , Bill of
material
Your Answer Production schedule , Commercial standards , Bill of material

Question Technique which can help an organization to reduce inventory is called
Correct Answer MRP
Your Answer MRP

Question In case of Batch Production which kind of labour is expected?
Correct Answer Skilled in one specific Manufacturing Process
Your Answer Semiskilled

Question Major contributors in the development of Control Charts, Sampling plan are
Correct Answer F H Dodge , H G Roming , Walter Schewhart
Your Answer F H Dodge , H G Roming , Walter Schewhart

Your Answer Event
True/False
Question Feasibility of time schedule requires that an activity be scheduled before any of
it's predecessors are scheduled.
Your Answer True

Question Which method of critical path determination begins with the end event and
moves backward to the start event of the project network?
Correct Answer Backward pass computation
Your Answer Backward pass computation
True/False
Question Operation process charts though indicates the sequence of events but do not show
movements.
Correct Answer True
Your Answer True

Question Which kind of relationship exists between those activities which can be carried
out simultaneously and both activities require definite time to finish?
Correct Answer Concurrent activities
Your Answer Concurrent activities
True/False
Question One major difference between CPM and PERT is the former's adaptability for the
projects where high degree of uncertainty prevails and activity times during performance are
expected to vary considerably for certain activities.
Your Answer False

Question Following are some of the Principles of Management advocated by F W Taylor
Correct Answer Selection of best worker for each particular task , Division of work
between worker and management , Training and development of the workmen
Your Answer Selection of best worker for each particular task , Division of work between
worker and management , Training and development of the workmen

Your Answer Poor Machine Utilization

Question Which of the following schedules are recommended to prepare and follow as a
Correct Answer Preventive inspection schedule , Cleaning and upkeep schedule ,
Lubrication schedule
Your Answer Preventive inspection schedule , Cleaning and upkeep schedule , Lubrication
schedule

Question What is the reason of fluctuations, if the control chart evaluates that the process
is in a state of statistical control?
Correct Answer Random variability
Your Answer Random variability
True/False
Question Even in a small set up wherein maintenance of a machine is looked after by a
mechanic cum worker, he should report directly to the person responsible for the manufacturing
operations.
Correct Answer True
Your Answer True

Question What do you mean by the chart on which the major activities and entry points of
materials are recorded to have graphic view of operations and inspections involved in the
process?
Your Answer Operation process chart

Question Plant Layout decisions are considered to be
Correct Answer Strategic
Your Answer Strategic

Question What are the uses of the instruction manual provided by the manufacturer of a
machine?
Correct Answer It gives instructions regarding installation and operation of the equipment
, It contains note on common troubles with causes and remedies for troubleshooting , It enlists
Your Answer It gives instructions regarding installation and operation of the equipment , It
contains note on common troubles with causes and remedies for troubleshooting , It enlists

sheet?

Question Which of the following situations demand that the human consideration should
evidenced by petty or trivial complaints , Repeated cases of accidents and health hazards
Your Answer Excessive rejections , Poor morale evidenced by petty or trivial complaints ,
Repeated cases of accidents and health hazards
True/False
Question A network can have more than one starting event but completion event must be
only one.
Your Answer True

Your Answer Above the arrow
Your Answer Material composition , Dimensions , Any heat treatment if required
Match The Following

What to inspect Specification Specification
How to inspect Inspection devices Inspection devices
How much to inspect Sampling or cent percent inspection Sampling or cent percent
inspection

Question How the concept of float is helpful to planners?
Correct Answer To decide priorities in allocation of resources , To minimize the
requirement of resources , To prevent peaks and valleys in requirement of resources
Your Answer To decide priorities in allocation of resources , To minimize the requirement of
resources , To prevent peaks and valleys in requirement of resources
True/False
Question It pays in the long run to inform the customer regarding expected delays in the deliveries.
Correct Answer True
Your Answer True

Question Fixed position layout is adopted when
Correct Answer product is very heavy involving assembly of large number of parts
Your Answer product is very heavy involving assembly of large number of parts
Select The Blank


Correct Answer Avaialability of adequate land at lower cost , Both skilled and unskilled labour can be
available , Plant expansion is easier due to less or no restriction for building and construction
Your Answer Avaialability of adequate land at lower cost , Both skilled and unskilled labour can be
available , Plant expansion is easier due to less or no restriction for building and construction
Select The Blank

Your Answer Worker
Select The Blank


Question Following are some of the factors which influence process planning
Correct Answer Order Quantity , Process capability of machine , Delivery Dates
Your Answer Order Quantity , Delivery Dates , Plant layout
True/False
Question Availability of training schools, colleges and management institutes reduces the company's
internal training needs.
Correct Answer True
Your Answer False

Your Answer Bakeries , Ice factories , Lime stone
Match The Following

Craft Facilities Planning Production Scheduling
Work Sampling Machine utilization Sampling Inspection
Gantt Chart Production Scheduling Charting technique
Match The Following

Fixation of inventory level Reorder level Stock on hand
Net requirement of material under MRP Stock on hand Price of material

Question Which of the following are steps to identify the critical path in a small network?
Correct Answer Compare the durations of all paths to identify the longest path. , Sum up the durations
of activities along each path. , Enumerate all paths in the network and list down activities on each path.
Your Answer Compare the durations of all paths to identify the longest path. , Sum up the durations
of activities along each path. , Enumerate all paths in the network and list down activities on each path.
Select The Blank

Question In case of an OC curve, the risk of rejecting a good quality lot may vary between ________.
True/False
Question Tool breakage has got nearly zero chances in case of eventual breakdown.
Your Answer False

Question Which are the three types of float?
Correct Answer Total float , Independent float , Free float
Your Answer Total float , Dependent float , Free float

Correct Answer Overlapping of operations , Effective Capacity per work centre , Performance
standards
Your Answer Effective Capacity per work centre , Ratio of skilled to unskilled labour , Performance
standards

Question Any premise in which persons are employed for purpose of making any product/s is called
Your Answer Factory
Select The Blank

Question The ________ is the maximum percentage defective that for the purpose of sampling
inspection can be considered satisfactory as a process average.
Select The Blank

Question The ________ is the maintenance work initiated on a result of knowledge of the condition of
an item from routine or continuous checking.
Your Answer Overhauling
Select The Blank

Question OC curve of ideal sampling plan suggests that all lots less than 3% defectives have the
probability of acceptance of ________.
Correct Answer One
Your Answer One

Question How to calculate activity cost slope?
Correct Answer Activity cost slope = ( Crash cost - Normal cost ) / ( Normal time - Crash time )
Your Answer Activity cost slope = ( Normal cost - Crash cost ) / ( Normal time - Crash time )

Correct Answer Resonable cost , Resonable procurement time , Resonable manufacturing time
True/False
Question In case of control chart, large smaples such as n=15 or 20 are used if the process standard
deviation is small.
Your Answer True
Select The Blank

Question Production control work is ________ in case of floor inspection as compared with the
centralised inspection.
Your Answer labourious

Question Production Planning includes
Correct Answer Predetermination of manufacturing requirements
Your Answer Predetermination of manufacturing requirements

Question How does the control chart of statistical quality control helps the operating personnel?
Your Answer Reduces chances of rejections

Your Answer Reduced salvage value of machine

Question What do you understand by the metallergical aspects of product which forms the vital part of
engineering function?
Your Answer Performance specifications


Question Which of the following possibilities can be explored by using flow process chart?
Correct Answer Eliminating the operations or combining the operations with another , Reducing the
distance traveled by the workmen or materials , Avoiding the waiting time and thereby reduce production
losses
Your Answer Reducing the distance traveled by the workmen or materials , Reducing rejections
drastically , Avoiding the waiting time and thereby reduce production losses

Your Answer Process Planning
True/False
Question Dust gets mixed with lubricants, forms an abrasive substance and causes pre-mature failure
of machinery.
Correct Answer True
Your Answer True

Question Which of the following activities are used while recording for method study?
True/False
Question In case of centralised inspection, inspection rooms generally become bottleneck and cause
delay in taking action regarding rejection or rework.
Correct Answer True
Your Answer True
Select The Blank

Question The ________ advocates maintenance procedures whereby the condition of the plant is
constantly watched through systematic inspection to unearth unhealthy conditions and preventive
True/False
Question The problems of congestion, bottlenecks and backtracking can not be visualized by using
templates and models.
Your Answer False

Correct Answer Time
Your Answer Quality
True/False
Question Delay in completion of projects result in unwelcome additions to the fixed manufacturing
expenses.
Correct Answer True
Your Answer True
Select The Blank

Question The term ________ emplies the foregone profit due to inability of company to produce.

Question Taxes / duties levied is one of the important determinant for location decision as taxes/duties
substantially influence
Your Answer Order procurement

Correct Answer To forecast the defect , To identify causes of major repetative failures , To quantify
the frequency of preventive inspection
Your Answer To forecast the defect , To identify causes of major repetative failures , To quantify
the frequency of preventive inspection
True/False
Correct Answer True
Your Answer True
Select The Blank

Question The ________ is the probability that a good lot will be rejected by the sampling plan.
True/False
Question The component produced on completely automatic machines may be subjected to sampling
inspection while parts produced on semi-automatic and completely manual operated machines require cent
percent inspection.
Correct Answer True
Your Answer False

Correct Answer Work is highly repetitive in nature , Planning activities are performed by the line staff
, Number of workmen is not very large
Your Answer Work is highly repetitive in nature , Planning activities are performed by the line staff
, Number of workmen is not very large

Question Which of the following factors play important role while selecting or rejecting a particular
site from legislation and taxation point of view?
Your Answer Labour laws , Policies regarding issue of licences , Productivity of labour

Question Where does the central line is located in case of p-chart?
Correct Answer at p bar
Your Answer at p bar

Question The product layout has following disadvantage
Correct Answer Layout is not flexible
Your Answer Layout is not flexible
Your Answer Production
Select The Blank

Question Production Planning is a centralised activity which
includes functions such as ________
Select The Blank

Question OC curve of ideal sampling plan suggests that all lots
less than 3% defectives have the probability of acceptance of ________.
Correct Answer One
Your Answer One

Question The document which incorporates details of process
planning for a job is called

Question Which of the following are types of non-destructive
testing?
Correct Answer Visual Testing , Eddy current , Magnetic flow
detectors
Your Answer Visual Testing , Eddy current , Magnetic flow detectors

Question What do you understand by the difference between the
specification limits within which manufacturing process is expected to
produce?
Correct Answer Design tolerance
Your Answer Design tolerance

Question Technique of Value Engineering can be effectively employed
in design of a product to
True/False
Question Inspection Order can be a verbal order
Correct Answer True
Your Answer False

Question The ratio of output to input of a production system is
commonly known as
Correct Answer Productivity
Your Answer Productivity
True/False
Question The plotting of activities - critical, non-critical and
dummy activities- is strictly according to their precedence
relationship.
Correct Answer True
Your Answer False
Select The Blank


Your Answer Reducing handling costs
Match The Following

Select The Blank

Question A set of activities to keep an equipment in the specified
condition is called as ________.
Question How to claculate the producer risk in the OC Curve?
Correct Answer Probability that a good lot will be rejected by the
sampling
Your Answer Probability that a good lot will be rejected by the
sampling

Question How non-critical activities are shown in the time chart
during project scheduling?
Correct Answer Thin lines
Your Answer Thin lines

Question Any premise in which persons are employed for purpose of
making any product/s is called
Your Answer Factory
True/False
Question Fixed cost is lower in case of continuous production than
intermittent production.
Your Answer False

Your Answer Low Productivity
True/False
Question Floor inspection promotes tendency of machines to drift
out of limits and produce defectives.
Your Answer False
Select The Blank

Question Capacity decisions have a direct influence on performance
of production system in respect of ________
Your Answer Delivery performance

Question Technique which can help an organization to reduce
inventory is called
Correct Answer MRP
Your Answer MRP
Select The Blank

Question The ________ is the watch dog which ensures that every
element of production and activities which could affect the quality of
end
product are regulated to the extent desirable.
Match The Following

Temperature of motor Body Body
Exhaust gas Smell Smell
Air leakage Listen Listen
Corrosion Watch Watch

Question Which characteristics are verified in cent percent
sampling?
Your Answer All important characteristics

Question What are the benefits of inspection and quality control?
Correct Answer Gives economy in production through reduction of
defective work , Adequate maintenance of quality , Ensures parts are
within specified limits of accuracy
Your Answer Adequate maintenance of quality , Ensures parts are
within specified limits of accuracy , Gives economy in production
through
reduction of defective work

Question In mass/batch production organizations where goods are
produced for stocking, Work Order is raised on the basis of
Your Answer Sales Programme
True/False
Question While making X bar-R-chart, values of X bar and R are
recoded samplewise either on the extreme right of the individual
measurements on the data sheet or in a separate sheet.
Correct Answer True
Your Answer False

Question What is the meaning of surplus material in context with
stores issue order?
Your Answer Materials issued are not fully consumed
True/False
Question Cent percent inspection is often more practical and
economical than sampling inspection.
Your Answer False

Correct Answer Eliminates problems and frequent breakdowns ,
Increases life of an equipment , It helps to plan requirement of
replacement
spares
Your Answer Eliminates problems and frequent breakdowns , Increases
life of an equipment , It helps to plan requirement of replacement
spares
Select The Blank

True/False
Question In case of X bar, if the process is not under control
indicated by some points falling outside the control limits, such
points
outside the control limits are eliminated and new trial control limits
for the remaining points are computed.
Correct Answer True
Your Answer False
Select The Blank

Question The easiest way to bring the delayed job within the
promised delivery time by using extra shift or weekly holiday is
________.
True/False
Question A sampling plan which perfectly discriminates will have
vertical OC curve.
Correct Answer True
Your Answer True

Question Which of the following is the most popular technique for
Project Production?

Question Which of the following are the most suitable cases where
we can use CPA as effective technique of scheduling?
Correct Answer Overhauling of a CNC machine , Purchase and
installation of a newly imported special purpose machine , Design,
production
and testing of prototype of a fighter aircraft.
Your Answer Overhauling of a CNC machine , Purchase and
installation of a newly imported special purpose machine , Design,
production and
testing of prototype of a fighter aircraft.
True/False
Question Sample sizes for the construction of p-chart are typicaly
larger that for Xbar-R-charts.
Correct Answer True
Your Answer True
Select The Blank

Question The ________ advocates maintenance procedures whereby the
condition of the plant is constantly watched through systematic
inspection to unearth unhealthy conditions and preventive
True/False
Question It would not affect the project completion time if
non-critical activities take little loner time than planned.
Correct Answer True
Your Answer True

Question Which of the following are the basic requirements of
quality standard?
Your Answer Deifinite , Undesrstandable , Economically viable

Question What is the location of lower control limit in the X bar-R
control chart?
Correct Answer 3 standard deviations below central line
Your Answer 3 standard deviations below central line

Question Which of the following is not the characteristic of
Project Production?
Correct Answer Continuous flow of material , Highly mechanised
material handling , Virtually zero manufacturing cycle time
Your Answer Continuous flow of material , Highly mechanised
material handling , Virtually zero manufacturing cycle time

Question Which of the following may be the objectives of project
crashing?
Correct Answer To complete the project in the least possible time ,
To reduce project cost below it's normal cost , To achieve uniformity
in requirement of resources
Your Answer To complete the project in the least possible time , To
reduce project cost below it's normal cost , To achieve uniformity in
requirement of resources

Question What is the basic philosophy of statistical process
control?
Correct Answer Prevention is better than cure
Your Answer Prevention is better than cure
Your Answer To decide priorities in allocation of resources , To minimize the


Question Which kind of defect can be called as minor defect?
Correct Answer Which does not reduce the usability of the product for its
intended use
Your Answer Which does not reduce the usability of the product for its
intended use
Select The Blank

Question The ________ is specified to indicate the maximum permissible
variability in the dimensions product or parts.
Your Answer Tolerance
True/False
Question Sampling inspection is best suited when cost of inspection is
much higher than the loss arising from the acceptance of a
defective part.
Correct Answer True
Your Answer False

Question Which element of a network represents a task which has got a
definite beginning and definite end?

Question Following are the commonly used factors considered for
evaluation of layout in factor analysis method
Correct Answer Flow of material , Equipment utilization , Working condition
Your Answer Flow of material , Equipment utilization , Working condition
Select The Blank

transportation and communication facilities

Question Which utilities are considered as infrastructural requirements?
Correct Answer Disposal of waste , Power , Water
Your Answer Power , Labour , Water

Question What do you understand by the timeframe for the maintenance
needs of the equipment?
Correct Answer Maintenance inspection schedule
Your Answer Maintenance inspection schedule

Correct Answer Large varaitions in hardness of material , Tool wear , Errors in

setting
Your Answer Large varaitions in hardness of material , Tool wear , Errors in
setting

Question Which of the following policies is advisable in case of low
product variety and large volumes?
Correct Answer Low Skilled Labour & Special Purpose Machines
Your Answer Low Skilled Labour & Special Purpose Machines

Question Which phase of method study is concerned with analyzing the
facts critically, generating alternatives which form the basis for
selection and development of improved methods?
Correct Answer Critical examination
Your Answer Critical examination
Select The Blank

Your Answer Collaboration
Select The Blank

Question The ________ must ensure that the product satisfy the
functional requirements of it's usage.

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Inventory control by classification ABC Analysis

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