CONFIDENTIAL

UNIVERSITI TUN HUSSEIN ONN MALAYSIA

FINAL EXAMINATION
SEMESTER II
SESSION 2013/2014
COURSE NAME

INDUSTRIAL ENGINEERING

COURSE CODE

BDA 4012/BDA40102

PROGRAMME

3 BDD

EXAMINATION DATE

JUNE 2014

DURATION

2 HOURS

INSTRUCTION

SECTION A: PLEASE ANSWER ALL

QUESTIONS IN THIS SECTION.
SECTION B: PLEASE ANSWER
THREE (3) QUESTIONS FROM FOUR (4)
QUESTIONS PROVIDED IN THIS
SECTION.

THIS PAPER CONSISTS OF NINE (9) PAGES

CONFIDENTIAL

BDA4012/BDA40102

SECTION A
Please answer all questions in this section.
Q1.

(a)

Industrial Engineering is a discipline built upon a collection of methodological

tools brought together to effect an integrated or "total" approach to
problemsolving in engineering and management, with productivity
improvement as its
overall objective. Explain the different between Industrial
Engineer with
engineers from other disciplines.
(4 marks)
(b)

Explain the job scope of the Industrial Engineer in manufacturing and service
industry.
(4 marks)

(c)

According to the International Ergonomics Association (IEA) defines ergonomics

or human factors as the scientific discipline concerned with the understanding of
interactions among humans and other elements of a system, and the profession
that applies theory, principles, data and methods to design in order to optimize
human well-being and overall system performance. Discuss FIVE (5) benefits of
ergonomics in the workstation/workplace.
(5 marks)

(d)

Many industries have successfully implemented ergonomic solutions in their

facilities as a way to address their workers Musculoskeletal Disorder (MSD)

injury risks. To reduce the chance of injury, work tasks should be designed
to
limit exposure to ergonomic risk factors. Engineering Controls are the
most
preferred method for controlling ergonomic risk factors because they
are
more permanent and effective. Using appropriate sketches, construct the
concepts of engineering control for preventing and controlling ergonomic risk
factors for workstation i - vi (Figure Q1 (d)).
(12 marks)

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Ergonomics Issues
Example:- Prolonged standing at
work

Solutions

- When standing for long periods of

time, rest one foot on a sturdy object
above floor height and switch legs
periodically.
Ergonomics Issues
(i) Over reaching the wrists
(ii) Over reaching the elbows

(iii) Over reaching the hands

(iv) Back bending while work

(v) Overhead work

(vi) Wrist bending while using a tool

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Figure Q1(d): Ergonomics Issues at Industrial Workstations

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SECTION B
Please answer THREE (3) questions from four (4) questions provided in this section.
Q2

(a)

Explain 5 (FIVE) factors that influence identification of facilities location.

(5 marks)

(b)

Klinik Pergigian 1M is considering new location for dental services. The

historical data of dental activities are summarized in Table 1.

Population Area
Pura Kencana
Bandar U
Taman Manis
Kampung Baru
Sri Gading
Ayer Hitam
(i)

Table 1: Medical activity information

Coordinate X
Coordinate Y
Frequency of Dental Service
(KM)
(KM)
(per month)
7
3
15
1
1
20
4
2
20
6
3
10
7
2
15
14
4
15
Suggest an optimal location based on the Minisum technique.
(14 marks)

(ii)

The estimated cost per distance-activity is RM0.50. Based on an optimal

location selected, estimate the Minisum cost.
(6 marks)

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Q3

(a)

Using appropriate diagrams, explain TWO (2) differences between Product

Layout and Process Layout.
(5 marks)

(b)

Super Assembly SB produces a new assembly model in flow line to meet

customer demand 14,400 units per week. The assembly line is running 40 hours
per week. Details assembly data are summarized in Table 2.
Table 2: Assembly line information.

Task
A
B
C
D
E
F
G
H
I
J
K
L
(i).

Performance Time
(second)
5
3
4
3
6
5
2
6
1
4
4
7

Immediate
Predecessors
None
A
B
A
D
C, E
F
G
F
F
J
H, I, K

Draw a precedence diagram of this assembly operation.

(6 marks)

(ii).

Determine the cycle time.

(4 marks)

(iii).

Based on grouping tasks into minimum numbers of workstations, determine the line efficiency,
and balance delay.
(10 marks)

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Q4

(a)

Explain what is Just-In-Time (JIT) and what does it do in achieving continuous

improvement.
(5 marks)

(b)

The MH Sausage Sdn. Bhd. can produce hot dogs at a rate of 5000 per day.
Company supplies hot dogs to local restaurants at a steady rate of 250 per day.
The cost to prepare the equipment for producing hot dogs is RM66. Annual
holding costs are 45 cents per hot dog. The factory operates 300 days a year.
Determine;
i.) The optimal run size
ii.) The number of runs per year
iii) The maximum inventory level
(8 marks)

(c)

The product structure tree as shown in figure Q4(c) indicates the components
needed to assemble one unit of product T. Develop the material requirements for
ordered part C and part B that will be needed to complete 120 units of T by the
start of week 5. Lead times for items are one week for level 0 items, one week for
level 1 items, and two weeks for level 2 items. There is a scheduled receipt of 60
units of A at the end of week 1, 100 units of B at week 2 and 100 units of C at the
start of week 1. Lot-for lot ordering is used for all parts except part B using lot
size rules (Lot size = 100).
(12 marks)
Level

0
1

A (3)
C(2)

B (2)
D

E(4)

Figure Q4(c): Product structure tree for item T

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Q5

(a)

Business Excellence Model (BEM) can be considered as a Total Quality

Management Model and one example of Industrial Systems Model. Currently,
BEMs are used in at least 83 countries as a key mechanism to help organisations
to improve. Explain TWO (2) benefits of using BEM.
(4 marks)

(b)

Suggest two situations in which the following basic Quality Control tools suitable
to be used:
(i)
(ii)
(iii)

Ishikawa Diagram
Control chart
Pareto Diagram
(6 marks)

(c)

Table 3 shows the average and range in kilograms for products being
manufactured in Company A. The subgroup size is 4.
(i)

Determine upper and lower control limits for X chart and R chart. Use
the information in Table 4 to compute the control chart limits.
(13 marks)

(ii)

Is the process in control? Briefly explain your answer.

(2 marks)

Table 3: The average and range in kilograms for products being manufactured in
Company A
Subgrou
p
Number
1
2
3
4
5
6
7
8
9
10
11
12
13

476
466
484
466
470
494
486
496
488
482
498
464
484

32
24
42
26
24
24
28
23
24
26
25
24
24

Subgrou
p
Number
14
15
16
17
18
19
20
21
22
23
24
25

482
500
496
478
484
500
476
485
490
464
469
474

22
23
23
25
24
23
25
29
25
22
27
22

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Table 4: Factors for calculating X and R control charts

Size of
sample (n)
2
3
4
5
6
7
8
9
10

Factor for UCL and

LCL for X -charts
(A2)
1.880
1.023
0.729
0.577
0.483
0.419
0.373
0.337
0.308

Factor for LCL for Rcharts (D3)

Factor for UCL for Rcharts (D4)

0
0
0
0
0
0.076
0.136
0.184
0.223

3.267
2.575
2.282
2.115
2.004
1.924
1.864
1.816
1.777

END OF QUESTIONS

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Appendix I
FINAL EXAMINATION
SEMESTER / SESSION : SEMESTER II /2013/2014
PROGRAM : 3BDD
COURSE : INDUSTRIAL ENGINEERING
COURSE CODE: BDA4012/BDA40102

StdTime

TotalNorma lTime
1 Allowance NormalTime Average cycle Time Rating EQU
ATIONS
n

f x, y wi x ai y bi
i 1

TC VC FCQ

CL x x A 2 R
Average completion time = sum of total flow time / Number of jobs
Utilization = Total jobs processing time / sum of total flow time
Average number of jobs in the system = Sum of flow time/ Total processing time

UCL D
R

LCL

D3 R

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Standard Time, ST
Total observatio n time
1

Productive % Rating
Total output
1 allowance

n xy x y
n x x
2

b=

y b x

a=