Birla Institute of Technology & Science, Pilani

Work-Integrated Learning Programmes Division

First Semester 2020-2021

Comprehensive Examination
(EC-3 Regular)

Course No. : MBA ZG537

Course Title : LEAN MANUFACTURING
Nature of Exam : Open Book
Weightage : 40% No. of Pages =
Duration : 2 Hours No. of Questions =
Date of Exam : Saturday, 28/11/2020 (AN)
Note:
1. Please follow all the Instructions to Candidates given on the cover page of the answer book.
2. All parts of a question should be answered consecutively. Each answer should start from a fresh page.
3. Assumptions made if any, should be stated clearly at the beginning of your answer.

Q.1. What type of lean practice is helpful to reduce inventory within the organization? Explain with
example [5]

Q.2. What are the factors considered while establishing production cell in the organization? How do
you establish the production cell in lean manufacturing? Explain [6]

Q.3. Calculate the OEE of the production machine with the following data. [6]

S Planned Shutdown Hours or Gross Time 24 Hours (or

N Count Minutes)
o
1 No production, Breaks, Shift 2.66 Hours Meeting and Shift Change
change
2 Planned Maintenance 2.00 Hours Monthly Plant Maintenance
3 Waiting for Operator 1.66 Hours
4 Failure or breakdowns 1.33 Hours Mechanical drive coupling
5 Minor Stops 10 events Jams!
6 Reduced Speed 100 Units Design rate: 12.5 Units/hour
produced Vs.
167 Units
planned
production
7 Yield/ Transition 5 count Startup and adjustment related
8 Defects, rework 1 count
9 Scrap product/output 2 count Waste, non-salvageable
10 Material Flow: output (Kanban 0 Output not needed, no room
full) in queue
11 Start up and Adjustment 1 Hour 1st shift on Monday
12 Tooling and Part Change 0.83 Hour Screw station bits
13 Material flow : Input ( No 0 Waiting for raw materials
Material)
14 Setup and changeover 1.16 Hours 2 size changes

Q.4. “TPM is one of the critical elements in TQM or Lean Manufacturing”? Comment with
example [4]
MBA ZG537 (EC-3 Regular) First Semester 2020-2021 Page 2

Q.5. Why do Indian manufacturing Industries prefer to use TQM Instead of Lean Manufacturing?
Explain. [4]

Q.6. What type of tool or technique you are suggesting to choose appropriate materials, methods
and machines to take decision on enhance existing production cell? Why do you prefer that
tool or technique? Explain [5]

Q.7. Does your organization follow cost reduction or waste elimination? How successful has it
been? How successful is your organization in cost reduction? What do you think are the main
reasons for it? Who is normally involved in activities related to waste elimination in your
organization? [5]

Q.8. Do you see both leaders and managers in your organization? What do you see as the
distinguishing traits? Do leaders in your organization work to develop the people? [5]

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