Sahil Purohit 160450119007

ASSIGNMENT- 1
1. What is production? Explain production system in detail?
   Ans: Production:-
 Production is the method of turning raw material into finished
good product in manufacturing process.
Production system:-
 The production system is a part of a larger system – the business
firm.
 The production system can be viewed as a framework or skeleton
of activities within which the creation of value can occur.
 At one end of the production system are the inputs and at the other
end are outputs.
 Connection the inputs and outputs are a series of operations or
processes, storage and inspections.
 The concept of production system is applicable to both production
of component and production of service as well.
 The production of any component or service can be viewed in
terms of a production system.

2. Define productivity? Which factor affecting productivity?

Ans:  Productivity:-
 Productivity is a measure of economic performance that compare
the amount of good and service output with the amount of inputs
used to produced those good and service.

 Factor affecting productivity:-

a. Factors affecting national productivity:-

 Human resources.
 Technology and capital investment.
 Government regulation.
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b. Factors affecting productivity in manufacturing and service:-

 Product or system design.

 Machinery and equipment.
 The skill and effectiveness of the workers.
 Production volume.

3. How the different kind of productivity to be measured?

Ans:   Kind of productivity measures:-

1.  Labour productivity:-
          
 The resource inputs are aggregates in term of labour hours.  This
index is relatively free of changes caused by wage rates and labour
mix.
2.  Direct labour cost productivity:-
 The resource inputs are aggregates in terms of direct labour costs.
This index will reflect the effect of both wage rates and changes in
the labour mix.

3.  Capital productivity:-
 Several formulations are possible. In one the resource inputs may
be changes during the period to depreciation in another the inputs
may be the book value of capital investment.

4.  Direct cost productivity:-

 In this formulation all items of direct cost associated with resource
used are aggregated on a monetary value basis.
5.  Energy productivity:-
 In this formulation the only resource considered is the amount of
energy consumed. 
6.  Raw material productivity:-
 In this formulation the numerators are usually weight of product
the denominators are the weight of raw material consumed. 
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4. Define the terms:

 Cost.
 Accounting.
 Cost accounting.
 Cost control.
Ans: 
 Cost:-
 Cost may be defined as the amount of expenditure incurred on or
attributable to a given thing.

 The word cost is rarely used independently it is always related to a

particular thing e. g number of good produced etc.

 Accounting:-
 Accounting may be defined as the are and science of recording
business transactions in  methodical manner so as to show.

 The true state of affairs of a business at a particular instant of time.

 The deficiency or surplus which as accrued during a specific time

period.
 Cost accounting:-
 Costing is frequently looked upon as the operation of calculating
the cost of an article as a basis to fix its selling price. 
 Costing implies the techniques and process of ascertaining costs of
given thing or items.
 Costing or cost accounting deals with the internal affairs of a
business it attempts to show the results of the operation carried out
and emphasizes throughout the measurement and achievement of
efficiency.

 Cost control:-
 Cost accounting helps control of expenditure or cost.
 Cost control leads to efficiency in use of material machinery and
labour.
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 The profit making capacity of a business is guided by the efficiency

with which various costs are controlled.
 Cost control provides a basis for minimizing the cost or cost-
reduction.

5. What are the main elements of cost for industrial enterprise?

Ans:   - The costs of an industrial enterprise  divided into
three               
principle elements:-  
1. Material.
2. Labour.
3. Expense.
    

 Material cost:-

a. Direct material cost:-

  A direct material is one which goes into a salable product or its use
is directly essential for the completion of that product.
 The amount paid for or the money spent  on direct materials is
known as direct material cost.

b. Indirect material cost:-

 An indirect material is one which is necessary in the production
process but is not directly used in the product itself, it does not
become an integral part f the product e. g cotton waste, greases,
oils, sandpaper etc.
 The costs associated with indirect materials is called indirect
material cost.

 Labour cost:-

a. Direct labour cost:-

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 The direct labour cost is the cost of labour that can be identified
directly with the manufacture of the product and allocated to cost
centers or coat units.
 A direct labourer is one who coverts the direct material into salable
product the wages etc of such employees constitute  direct labour
cost.
 The wages of a welder fabricating a structure from a part of the
total direct labour cost.
b. Indirect labour cost:-
 It is that labour cost which cannot be allocated but which can be
appointed to or absorbed by cost centers or cost units.
 This is the cost of the labour that does not alter the construction,
conformation, composition or condition of the direct material but is
necessary for the progressive movement and handling of the
product to the point of dispatch.

 Expense:-
 It is a collective title which refers to all charges other than those
incurred as direct result of employing workers or obtaining
material.
a. Direct expense:-
 These are the expense which can be identified with and allocated to
cost centers or cost units .
 Layout, design or drawing are totally consumed on the job.
 Though they can be used again but there are hardly any chances of
their being used again.
b. Indirect expense:-
 These are the expenses which cannot be allocated but which can be
apportioned to or absorbed by cost centers or cost units.
 Fixed expense are those costs that tend to remain relatively constant
regardless of the volume of production.

6. What is breakeven analysis explain its concept, importance

and scope in detail?
Ans: Concept of break even analysis:-                      
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 Revenue and cost can be studied by directing attention to total

revenue and total cost.
 Breakeven  analysis implies that at some point in the operations,
total revenue equals total cost.
 The breakeven point is therefore the volume of output at which
neither a profit is made nor a loss is incurred.
 The breakeven analysis can be carried out algebraically or
graphically.
 Importance and scope of breakeven analysis:-
  Breakeven analysis helps solving the following types of problems:
 What volume of sales will be necessary to cover.
 Computing costs and revenue for all possible volume of output to
fix budgeted sales.
 To find the price of an articles to give the desired profit.
 To determine variable cost per unit.
 To compare a number of business enterprise by arranging their
earning in order of magnitude.

7. What is breakeven chart explain its limitation in details?

Ans: Breakeven chart:-
 It was one of the first synthetic tools that become available to
production management and management accountancy.
 Modifications of the breakeven chart that introduce risk make it an
even more useful tool for the synthetic of the production
management field.
 Limitation of breakeven chart:
 The breakeven points is difficult to determine in many instances
because of the difficulty in properly classifying costs as either fixed
or variable and because market condition may not remain constant
over the range of projected capacity.
 The breakeven chart is a tool for short run analysis it cannot be
used for 8 or 10 year projections because of the difficulty of
indicating variables in each of the costs line on the chart.
 The total cost line representing the variables costs added to fixes
costs need not be straight line, in actual fact, costs do not usually
vary in direct proportion.
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 The straight line which represent sales revenue may also

misrepresent the true facts.
 The broken chart represent a static picture whereas business
operations are far from static.  

ASSIGNMENT - 2

Que.
1. What is concept and factor governing the plant location?
  Ans: Concept:-
 A plant is place, where men, materials, money, equipment,
machinery, etc are brought together for manufacturing pro- ducts.
 The problem  of plant location arises when starting a new concern
or during the expansion of the existing plant.
 Plant location means deciding a suitable location, area, place, etc
where the plant or factory will start functioning.
 Plant location involves two major activities, first to select a proper
geographic region and second, selecting a specific site within the
region.
 Factors:-
 Nearness to raw material:-

 It will reduce the cost of transporting raw material from the

vendor’s end to the plant.
 Especially those, plants, which consume raw material in bulk or
raw material located close to the source of raw material.  
 Transport facilities:-
 A lot of money is spent both in transporting the raw material and
the finished goods.
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 Depend upon the size of raw material and finished goods a suitable
method of transportation like roads, rails, water or air is selected
and accordingly the plant location is decided.
 Nearness to markets:-
 It reduces the cost of transportation as well as the chances of the
finished product getting damaged and spoiled in the way.
 Moreover a plant being near, to the market can catch a big share of
the market and can render quick service to the customers.
 Availability of fuel and power:-
 Because of the wide spread use of electric power in most cases fuel
has not remained a deciding factor for plant location.
 Steel industries are located near source of fuel (coal) to cut down
the fuel transportation costs.
 Availability of water:-
 Water is used for processing, as in paper and chemical industries
and is also required for drinking and sanitary purpose.
 The nature of plant Water should be available in adequate quantity
and should be of proper quality.
 Climatic condition:-
 With the development in the field of heating ventilating and
conditioning, climatic of the region does not present much problem,
of course, control of climatic need money.
 Community attitude:-
 Success of an industry depends very much on the attitude of the
local people and whether they want work or not. 

2. What is location economics?

   Ans: Location economics:-
 An ideal plant location is one which result in lowest production
cost and least distribution cost per unit.
 The various costs which decided the locational economy are those
of:
a. Land.
b.  Building/Rent.
c. Equipment and machinery.
d. Labour.
e. Water, power and fuel.
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f. Freight.
I. In- coming.
II. Out-going.
g. Raw material.
h. Taxes. 

 The economic aspects of locations are considered or an economic

analysis is carried out to decide as to which of the possible two or
more preliminary selected locations is the overall best location.

3. What is the advantages and disadvantages of selecting the

plant site in a city(urban site)?
  Ans: 
Advantages
A city is very well connected by
rail, road, air.
It provides a good market also.
Right labour force is available.
Power and water is easily
available.
It has good hospital, marketing
centers, school, bank, recreation
clubs, etc
The factory can be set up in an
existing available building.
Disadvantages
Land available for the building
is limited in area.
Cost of land and building
construction is high.
Expansion of the industry is
seldom possible.
Local taxes etc, are high.
Labour salaries are high.
Union problems are more;
employer relation are not so
good.

4. What is the advantages and disadvantages of selecting the

plant site in small town(Rural area)?
Ans: 
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Advantage
Plenty of land is available for
building construction and
expansion propose.
Unskilled labour is available which Rail, road and air links may
can be trained to suit the
requirement of the concern.
Employee-employer relation are
good; no union problem.
Undesirable manufacturing
neighbour’s are not likely to be
present.
Municipal and other regulation
and taxes are seldom burdensome.
Government gives inducements as
it wants to develop the
underdeveloped areas.
Disadvantage
Skilled labour is not
available.
not be there at all or may not
be adequate.
Power is not available.
Rural areas are far from
selling markets.
Hospitals, education and
amusement centers are not
available.
High grade executives may
not like to live in rural areas.

5. Explain current Indian government policies for relaxation in

backward area?
Ans: 

6. What are the objective of plant layout?

Ans:   Objective: 
 Material handling and transportation is minimized and efficiency
controlled.
 Work station are designed suitably and properly.
 Suitable spaces are allocated to production centers and service
centers.
 The movement made by the workers are minimized.
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 Waiting time of the semi-finished product is minimized.

 Working conditions are safer, better and improved.
 There is increased flexibility for changes is product design and for
future expansion.
 There is the utilization of cubic space.
 There is increased productivity and better product quality with
reduced capital cost. 

7. What are the principle of plan layout?

Ans: Principle of plant layout:-
 Integration it means the integration of production centers facilities
like workers machinery raw material etc.
 Minimum movement and material handling. The number of
movements of workers and materials should be minimized.
 Smooth and continuous flow bottlenecks, congestion points and
back tracking should be removed by proper line balancing
techniques.

 Safe and improved environment. Working places-safe well

ventilated and free from dust noise fumes and other hazardous
conditions decidedly increase the operating efficiency of the
workers and improve their morale.

8. What are types of plant layout?

Ans: Types of plant layout:-      
 Process layout:-
 It is also known as functional layout and is characterized by
keeping similar machines or similar operations at one location.
 In other word all lathes will be at one place all milling at another as
so on that is machines have been arranged according to their
function.
 Product layout:-
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 It is also known as line layout. It implies that various on raw

material are performed in a sequence and the machines are placed
along the product flow line.
 Machines are arranged in the sequence in which the raw material
will be operated upon.
 Combination layout:-
 A combination of process and product layouts combines the
advantages of the both types of layouts.
 Moreover these days pure product or process layouts are rare.
 The manufacturing sections are arranged in process layout with
manufacturing lines occurring here and there wherever the
conditions permit.
 Fixed position layout:-
 Layout by fixed positions of the product is inherent in ship
building, aircraft manufacture and big pressure vessels fabrication.
 In other types of layouts discussed earlier the product moves past
stationary production equipment whereas in this case the reverse
applied men and equipment are moved to the material which
remains at one place and the product is completed at that placed
where the material lies.

9. Draw and explain with advantage/disadvantage for different

types of plant layout?
Ans. Some of the important types of plant layout are: A. Product or
line layout, B. Process or functional layout, C. Layout by stationary
material!

(A) Product or Line Layout:

Product or Line Layout is the arrangement of machines in a line
(not always straight) or a sequence in which they would be used in
the process of manufacture of the product. This type of layout is
most appropriate in case of continuous type of industries where
raw materials is fed at one end and taken out as finished product at
the other end. For each type of product a separate line of
production will have to be maintained.

ADVERTISEMENTS:
Sahil Purohit 160450119007

This type of layout is most suitable in case of metal extraction

industry, chemical industry, soap manufacturing industry, sugar
industry and electric industry. It should be noted that this method
is most suitable in case of mass production industries.

Following diagram clearly explains product layout:

In the above diagram there are two products A and B for which
separate lines of production have been maintained. Kimbaii and
Kimbaii jr. have given a simple diagram to explain this type of
layout in the book “Principles of Industrial organisation”.

ADVERTISEMENTS:

According to Shubin and Madeheim, product layout is suitable

where:

(i) large quantity of standardized products are produced;

(ii) the standardized products are to be processed repetitively or

continuously on the given production facilities;

(iii) there must be sufficient volume of goods processed to keep the

production line actively occupied,

ADVERTISEMENTS:

(iv) there should be greater interchangeability of the parts; and (v)

to maintain good equipment balance each work station must
employ machines or equipment’s of approximately equal capacities.
Similarly to maintain good labour balance, each work station must
require an equal amount of work to be performed.

Advantages of Product Layout:

(1) Removal of obstacles in production:
Product layout ensures unrestricted and continuous production
thereby minimising bottlenecks in the process of production, this is
because work stoppages are minimum under this method.

(2) Economies in material handling:

ADVERTISEMENTS:
Sahil Purohit 160450119007

Under this method there are direct channels for the flow of
materials requiring lesser time which considerably eliminate back-
tracking of materials. On account of this, cost of material handling
is considerably reduced. This is greatly helpful in achieving desired
quality of the end product.

(3) Lesser manufacturing time:

Under this method (as already pointed), backward and forward
handling of materials is not involved, it leads to considerable
saving in manufacturing time.

(4) Lesser work in progress:

ADVERTISEMENTS:

On account of continuous uninterrupted mass production, there is

lesser accumulation of work in progress or semi-finished goods.

(5) Proper use of floor space:

This method facilitates proper and optimum use of available floor
space. This is due to non- accumulation of work in progress and
overstocking of raw materials.

(6) Economy in inspection:

ADVERTISEMENTS:

Inspection can be easily and conveniently undertaken under this

method and any defect in production operations can be easily
located in production operations. The need for inspection under
this method is much less and can be confined at some crucial points
only.

(7) Lesser manufacturing cost:

On account of lesser material handling, inspection costs and fullest
utilisation of available space, production costs are considerably
reduced under this method.

(8) Lesser labour costs:

ADVERTISEMENTS:
Sahil Purohit 160450119007

Due to specialisation and simplification of operations and use of

automatic simple machines, employment of unskilled and semi-
skilled workers can carry on the work. The workers are required to
carry routine tasks under this method. This leads to lesser labour
costs.

(9) Introduction of effective production control:

Effective production control on account of simple operation of this
method can be employed successfully. Production control refers to
the adoption of measures to achieve production planning.

Disadvantages of Product Layout:

(1) Lesser flexibility:
As work is carried in sequence and process arranged in a line, it is
very difficult to make adjustments in production of operations.
Sometimes, certain changes under this method become very costly
and impractical. On account of this drawback, this method is not
suitable in the production of goods which are subject to quick style
and design changes.

(2) Large investment:
ADVERTISEMENTS:

Under this method, machines are not arranged in accordance with

functions as such similar type of machines and equipment is fixed
at various lines of production. This leads to unavoidable machinery
duplication resulting in idle capacity and large capital investment
on the part of the entrepreneur.

(3) Higher overhead charges:

Higher capital investment leads to higher overheads (fixed
overheads) under this method. This leads to excessive financial
burden.

(4) Interruption due to breakdown:

If one machine in the sequence stops on account of breakdown,
other machines cannot operate and work will be stopped. The work
stoppage may also take place on account of irregular supply of
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material, poor production scheduling and employee absenteeism

etc.

(5) Difficulties in expanding production:

ADVERTISEMENTS:

Production cannot be expanded beyond certain limits under this

method.

(6) Lack of specialisation in supervision:

Supervision of different production jobs becomes difficult under
this method as there is absence of specialised supervision as the
work is carried on in one line having different processes and not on
the basis of different departments for different specialised jobs.
Under this method a supervisor is supposed to have detailed
knowledge of all the machines and processes which leads to
absence of specialisation in the process of supervision.

(7) Under-utilisation of machines:
As has already been pointed out, separate set of one type of
machines is fixed at different lines of production. Usually, these
machines are not properly and fully utilised and there remains idle
capacity in the form of under utilised equipment.

(B) Functional or Process Layout:

It is just the reverse of product layout. There is a functional division
of work under this method. For example, lathes are fixed in one
department and welding activities are carried in another
department of the factory. The salient features of this type of layout
are based on Frederick W. Taylor’s concept of ‘functional
organisation’.

ADVERTISEMENTS:

This method is generally adopted for producing different varieties

of unlike products. This is particularly adopted tor job order
industries like engineering, ship building and printing etc. The
following diagram shows that raw material travels through various
process or departments from lathes passing through mills, grinders,
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drills, welding, inspection, finishing, and assembly and to finished

product.

Advantages of Process Layout:

(1) Maximum utilisation of machines:
This method ensures fuller and effective utilisation of machines and
consequently investment in equipment and machines becomes
economical.

(2) Greater flexibility:
Changes in the sequence of machines and operations can be made
without much difficulty. This is because the machines are arranged
in different departments in accordance with the nature of functions
performed by them.

ADVERTISEMENTS:

(3) Scope for expansion:

Production can be increased by installing additional machines
without much difficulty.

(4) Specialisation:
As has already been pointed out that under this method, specialised
machines are used for performing different production operations.
This leads to specialisation.

(5) Effective utilisation of workers:

Specialised workers are appointed to carry different type of work in
different departments. This leads to effective and efficient use of
their talent and capabilities.

ADVERTISEMENTS:

(6) More effective supervision:

As the machines are arranged on the basis of functions, performed
by them, the specialised and effective supervision is ensured by the
specialised knowledge of supervisors. Each supervisor can perform
his task of supervision effectively as he has to supervise limited
number machines operating in his department.
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(7) Lesser work stoppages:

Unlike the product method, if a machine fails, it does not lead to
complete work stoppage and production schedules are not
seriously affected. Due to breakdown in one machine, the work can
be easily transferred to the other machines.

Disadvantages of Process Layout:

(1) Coverage of more floor area:
Under this method, more floor space is needed for the same
quantum of work as compared to product layout.

(2) Higher cost of material handling:

Material moves from one department to another under this method,
leading to the higher cost of material handling. The mechanical
devices of material handling cannot be conveniently employed
under this method on account of functional division of work.
Material has to be carried by applying other methods from one
department to another, resulting into higher cost of material
handling.

(3) Higher labour costs:

As there is functional division of work, specialised workers are to
be appointed in different departments for carrying specialised
operations. The appointment of skilled worker leads to higher
labour costs.

(4) Longer production time:

Production takes longer time for completion under this method and
this leads to higher inventories of work-in-progress.

(5) Difficulties in production, planning and control:

Due to large variety of products and increased size of the plant,
there are practical difficulties in bringing about proper coordination
among various areas (departments) and processes of production.
The process of production, planning and control becomes more
complex and costly.

(6) Increased inspection costs:

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Under this type of layout more supervisors are needed and work is
to be checked after every operation which makes the process of
supervision costlier.

(C) Layout by Stationary Material:

This type of layout is undertaken for the manufacture of large parts
and assemblies. In this case, material remains fixed or stationary at
one place, men and equipment are taken to the site of material. This
is suitable in case of ship building, locomotives and heavy
machinery industries etc.

Advantages:
(a) Economies in transformation:
As the work is carried at one place and material is not taken from
one place to another, this leads to savings in transformation costs.

(b) Different jobs with same layout:

Different projects can be undertaken with the help of same layout.

(c) Production in accordance with specifications:

The jobs can be performed in accordance with the specifications
given by the customers.

(d) Scope for flexibility:

It provides maximum flexibility for various changes in production
processes and designs of the products.

Disadvantages:
(a) Immobility of material:
As material is fixed at one place, this leads to certain difficulties in
arranging specialised workers, machines and equipment for the job.

(b) Large investment:

This method is time consuming and costlier as compared to first
two methods.

(c) Unsuitable for small products:

This method is not suitable for producing and assembling small
products in large quantities. In actual practice, it has been observed
that a judicious combination of three types’ viz., product, process
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and stationary material layout is undertaken by different

organisations. This is done with the view to enjoy the advantages of
all the methods.

10. What is the symptoms of bad plant layout?

Ans. The symptoms of bad layout are listed below:

1. Poor utilization of space.

2. Long material flow lines.
3. Congestion for movement of materials and men.
4. Large amount work-in-progress.
5. Long production cycles.
6. More frequent accidents.
7. Difficult to supervise and control.
8. Spoilage of products during handling.
9. Production line bottlenecks.

11. Explain Group Technology?

Ans. Group technology or TZ is a manufacturing technique[1] in

which parts having similarities in geometry, manufacturing
process and/or functions are manufactured in one location using a
small number of machines or processes. Group technology is based
on a general principle that many problems are similar and by
grouping similar problems, a single solution can be found to a set of
problems, thus saving time and effort.
The group of similar parts is known as part family and the group
of machineries used to process an individual part family is known
as machine cell. It is not necessary for each part of a part family to
be processed by every machine of corresponding machine cell. This
type of manufacturing in which a part family is produced by a
machine cell is known as cellular manufacturing. The
manufacturing efficiencies are generally increased by employing
GT because the required operations may be confined to only a small
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cell and thus avoiding the need for transportation of in-process

parts.[2]
Group technology is an approach in which similar parts are
identified and grouped together in order to take advantage of the
similarities in design and production. Similarities among parts
permit them to be classified into part families.

12. What is the function and principles of Materrial Handling?

Ans. Material handling is the movement, protection, storage and

control of materials and products throughout manufacturing,
warehousing, distribution, consumption and disposal. As a process,
material handling incorporates a wide range of manual, semi-
automated and automated equipment and systems that support
logistics and make the supply chain work. Their application helps
with:

 Forecasting
 Resource allocation
 Production planning
 Flow and process management
 Inventory management and control
 Customer delivery
 After-sales support and service
A company’s material handling system and processes are put in
place to improve customer service, reduce inventory, shorten
delivery time, and lower overall handling costs in manufacturing,
distribution and transportation.

13. What factors should be consider for selecting a material

handling equipment?
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Ans. The following factors are to be taken into account while

selecting material handling equipment.
1. PROPERTIES OF THE MATERIAL
Whether it is solid, liquid or gas, and in what size, shape and
weight it is to be moved, are important considerations and can
already lead to a preliminary elimination from the range of
available equipment under review. Similarly, if the material is
fragile, corrosive or toxic this will imply that certain handling
methods and containers will be preferable to others.
2. LAYOUT AND CHARACTERISTICS OF THE BUILDING
Another restricting factor is the availability of space for handling. A
low-level ceiling may preclude the use of hoists or cranes, and the
presence of supporting columns in awkward places can limit the
size of the material-handling equipment. If the building is multi-
storied, chutes or ramps for industrial trucks may be used. The
layout itself will indicate the type of production operation
(continuous, intermittent, fixed position or group) and can indicate
some items of equipment that will be more suitable than others.
Floor capacity also helps in selecting the best material handling
equipment.
3. PRODUCTION FLOW
If the flow is fairly constant between two fixed positions that are
not likely to change, fixed equipment such as conveyors or chutes
can be successfully used. If, on the other hand, the flow is not
constant and the direction changes occasionally from one point to
another because several products are being produced
simultaneously, moving equipment such as trucks would be
preferable.
4. COST CONSIDERATIONS
This is one of the most important considerations. The above factors
can help to narrow the range of suitable equipment, while costing
can help in making a final decision. Several cost elements need to
be taken into consideration when comparisons are made between
various items of equipment that are all capable of handling the
same load. Initial investment and operating and maintenance costs
are the major cost to be considered. By calculating and comparing
the total cost for each of the items of equipment under
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consideration, a more rational decision can be reached on the most

appropriate choice.
5. NATURE OF OPERATIONS
The selection of equipment also depends on the nature of
operations like whether handling is temporary or permanent,
whether the flow is continuous or intermittent and material flow
pattern-vertical or horizontal.
6. ENGINEERING FACTORS
The selection of equipment also depends on engineering factors like
door and ceiling dimensions, floor space, floor conditions, and
structural strength.
7. EQUIPMENT RELIABILITY
The reliability of the equipment and supplier reputation and the
after-sale service also plays an important role in selecting material
handling equipment.

14. Show the characteristics of material handling equipment?

1. Ans. Deliver within budget (88% extremely/very important; 11%

important/somewhat important)
2. Deliver on schedule (85% extremely/very important; 13%
important/somewhat important)
3. After installation support (83% extremely/very important; 14%
important/somewhat important)
4. Design/concepting expertise (80% extremely/very important; 18%
important/somewhat important)
5. Engineering expertise (80% extremely/very important; 19%
important/somewhat important)
6. Interface/integration issues (hardware and software) (80%
extremely/very important; 18% important/somewhat important)
7. Software functionality (80% extremely/very important; 18%
important/somewhat important)

15. Give the classification of material handling equipment?

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Ans. Material handling equipment usually falls under four main

categories: bulk handling material equipment, engineered systems,
storage and handling equipment and industrial trucks.

16. Give a short note on AGV (automated guided vehicle)?

Ans. An automatic guided vehicle system (AGVS) consists of one or

more computer-controlled, wheel-based load carriers (normally
battery powered) that runs on the plant or warehouse floor (or if
outdoors on a paved area) without the need for an on-board
operator or driver. (MHI)

The term "automated guided vehicle" (AGV) is a general one that

encompasses all transport systems capable of functioning without
driver operation. The term "driverless" is often used in the context
of automatic guided vehicles to describe industrial trucks, used
primarily in manufacturing and distribution settings that would
conventionally have been driver-operated

The vehicle is the machine that provides material movement there

can be a single vehicle or as many as 100 or more in a system
Vehicle types include: – Misted vehicles – forked, clamp, single-
double – Unit load - lift deck, conveyor – Tow or taggers – Carts –
Custom.
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Assignment – 3

1. Define Process planning?

Ans. Process planning is the relation between design and

manufacturing. Process planning consists in defining the sequence
of the steps that should be taken to make the product. Process
planning is referring to the engineering and technological issues of
how to make it.

2. What information required to do process planning?

Ans.

1. Preparation of Working Drawing

2. Make or Buy Decision
3. Process Selection
4. Machine Capacity
5. Process and Equipment Selection Procedure
6. Selection of Material, Jigs, etc.
7. Preparation of Documents
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3. Show the procedure for process planning?

Ans. 1] Recognizing Need for Action.

2] Setting Objectives.

3] Developing Premises.

4] Identifying Alternatives.

5] Examining Alternate Course of Action.

6] Selecting the Alternative.

7] Formulating Supporting Plan

4. What factors affected process planning?

Ans. There are several factors which may affect the type of
planning application you need to submit and the outcome of your
planning application.
Local planning policies
Nature, wildlife and biodiversity
Bats
Building regulations
Design
Design and access statement
Sustainability
Environmental Health
Trees and hedgerows
Your neighbours
Lighting
Conservation Areas
Listed Buildings
Access / highways
Traffic
Parking
Flooding
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Covenants
Historical remains
Affordable housing
Sewer adoption and connection

5. Define term: sequencing, scheduling?

Ans. Sequencing

Process sequencing is a part of process planning that generate the

sequence of processes need to manufacture part. Process
sequencing is performed with a goal to minimize time and/or cost
of manufacturing.

Scheduling

Scheduling is the process of arranging, controlling and optimizing

work and workloads in a production process or manufacturing
process. Scheduling is used to allocate plant and machinery
resources, plan human resources, plan production processes and
purchase materials.

Assignment 4
 
1. what is 4 Production Planning and
Control ?

Ans:-  Production planning and control is a predetermined process

which includes the use of human resource, raw materials, machines
etc. PPC is the technique to plan each and every step in a long series
of separate operation

2.  Define:
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      (a) Routing
      (b) Sequencing
      (c) Scheduling
      (d) Dispatching

Ans:-(a) The routing decides the path and sequence of operations

to be performed on the job from one machine to another. The
purpose of routing is to establish the optimum sequence of
operations so that the manufacture of the finished item is
performed at the lowest cost and the fastest time.

(B) Sequencing means grouping production operations into

production batches and arranging them by priority. Metal
industry casting operations are a great real-life example of this.
Typically, casting starts from the purest products and moves on
toward progressively more alloyed products.

(C) Product production scheduling is the process of assigning

different raw materials, resources or processes to different
products. It's meant to make your production process as efficient
and cost-effective as possible when it comes to materials and
people — all while delivering products on time.

(D) Dispatching is the routine of setting productive activities in

motion through the release of orders and necessary instructions
according to pre-planned times and sequence of operations
embodied in route sheets and loading schedules.

2.1. What is progressive control?

Ans:- Production control is the activity of monitoring

and controlling any particular production or operation.
Production control is often run from a specific control room or
operations room. With inventory control and quality control,
production control is one of the key functions of operations
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management.

2.2. justify Concept of Line balancing?

Ans:- Line balancing is a production strategy that involves

balancing operator and machine time to match the production
rate to the takt time.
Takt time is the rate at which parts or products must be produced
in order to meet customer demand.
For a given production line, if production time is exactly equal to
takt time, then the line is perfectly balanced. Otherwise, resources
should be reallocated or rearranged to remove bottlenecks or
excess capacity. In other words, the quantities of workers and
machines assigned to each task in the line should be rebalanced to
meet the optimal production rate.

Assignment 5(che 5)
1.What is work study?
Ans:- Work study is field used to finding ways of increasing on
job performance, optimum usage of plant and machinery,
standardization of work methods, etc. Therefore, objectives of
work study are as follows: Scientific and controlled analysis of
existing available methods of executing a task.
2.What is the importance of work study?
Ans:- It helps to achieve the smooth production flow with
minimum interruptions. It helps to reduce the cost of the product
by eliminating waste and unnecessary operations. Meets the
delivery commitment. Reduction in rejections and scrap and
higher utilization of resources of the organization.
3. What is the time and motion study?

Ans:- Time-and-motion study, in the evaluation of industrial

performance, analysis of the time spent in going through the
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different motions of a job or series of jobs.

4. What is the method study represent the stages of method
study?
Ans:-  Method study enables the industrial engineer to subject
each operation to systematic analysis. The main purpose of
method study is to eliminate the unnecessary operations and to
achieve the best method of performing the operation. Method
study is also called methods engineering or work design.
Method engineering is used to describe collection of analysis
techniques which focus on improving the effectiveness of men
and machines. According to British Standards Institution (BS
3138): “Method study is the systematic recording and critical
examination or existing and proposed ways or doing work as a means or
developing and applying easier and more effective methods and reducing
cost.”
Fundamentally method study involves the breakdown of an
operation or procedure into its component elements and their
systematic analysis. In carrying out the method study, the right
attitude of mind is important. The method study man should
have:
1. The desire and determination to produce results.
2. Ability to achieve results.
3. An understanding of the human factors involved.
Method study scope lies in improving work methods through
process and operation analysis, such as:
1. Manufacturing operations and their sequence.
2. Workmen.
3. Materials, tools and gauges.
4. Layout of physical facilities and work station design.
5. Movement of men and material handling.
6. Work environment.
Objectives of Method Study
Method study is essentially concerned with finding better ways of
doing things. It adds value and increases the efficiency by
eliminating unnecessary operations, avoidable delays and other
forms of waste. The improvement in efficiency is achieved
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through:
1. Improved layout and design of workplace.
2. Improved and efficient work procedures.
3. Effective utilization of men, machines and materials.
4. Improved design or specification of the final product.
The objectives of method study techniques are:
1. Present and analyze true facts concerning the situation.
2. To examine those facts critically.
3. To develop the best answer possible under given circumstances
based on critical examination of facts.
Scope of Method Study
The scope of method study is not restricted to only manufacturing
industries. Method study techniques can be applied effectively in
service sector as well. It can be applied in offices, hospitals, banks
and other service organizations. The areas to which method study
can be applied successfully in manufacturing are:
1. To improve work methods and procedures.
2. To determine the best sequence of doing work.
3. To smoothen material flow with minimum of back tracking and
to improve layout.
4. To improve the working conditions and hence to improve labor
efficiency.
5. To reduce monotony in the work.
6. To improve plant utilization and material utilization.
7. Elimination of waste and unproductive operations.
8. To reduce the manufacturing costs through reducing cycle time
of operations.
Steps or Procedure Involved in Methods Study
The basic approach to method study consists of the following
eight steps. The detailed procedure for conducting the method
study is shown in the following figure.
1. SELECT the work to be studied and define its boundaries.
2. RECORD  the relevant facts about the job by direct observation
and collect such additional data as may be needed from
appropriate sources.
3. EXAMINE the way the job is being performed and challenge its
purpose, place sequence and method of performance.
Method study procedure
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4. DEVELOP the most practical, economic and effective

method, drawing on the contributions of those concerned.
5. EVALUATE different alternatives to developing a new
improved method comparing the cost- effectiveness of the
selected new method with the current method with the
current method of performance.
6. DEFINE the new method, as a result, in a clear manner and
present it to those concerned, i.e., management, supervisors
and workers.
7. INSTALL the new method as a standard practice and train
the persons involved in applying it.
8. MAINTAIN the new method and introduce control
procedures to prevent a drifting back to the previous
method of work.
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5.Define Work measurement?
Ans:- Work measurement is the application of techniques which is
designed to establish the time for an average worker to carry out a
specified manufacturing task at a defined level of performance. It
is concerned with the duration of time it takes to complete a work
task assigned to a specific job.
6.Explain PMTS?
Ans:- A predetermined motion time system (PMTS) is frequently
used to perform Labor Minute Costing in order to set piece-rates,
wage-rates and/or incentives in labor (labour) oriented industries
by quantifying the amount of time required to perform specific
tasks under defined conditions.
7.What are the recording technique?
Ans:- Recording Techniques
1. Process Chart Symbols
Indicates the main steps in a process, method or procedure.
Usually the part, material or product concerned is modified or
changed during the operation temporary Storage or Delay
2. Outline Process Chart
An outline process chart is a process chart giving an overall
picture by recording in sequence only the main operations and
inspections.
3. Flow process charts
Flow process charts are graphic representations of the sequences
of operations, transportation, inspections, delays and storages
occurring during a process or a procedure and include
information considered for analysis such as, time required and
distance moved.
4. Material or product type flow process chart
Records what happens to the material or product i.e. the changes
the material or product undergoes in location or condition
(includes operation and transportation).
5. Two Hand Process Chart
Two-Handed Flow Process Chart, is a motion study where the
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study is done to analyse the motions used by the worker in

performing an activity. In this chart the activities of a worker’s
hands (or limbs) are recorded in their relationship to one another.
6. Multiple activity chart
A Chart in which the activities of more than one item are recorded
on a common time scale to show their inter-relationship. Man
machine chart is the type of multiple activity charts.
7. Multiple activity chart  A Multiple activity chart is a form of
process chart recording the related sequence of work of a number
of operators and/or machines on common time scale. 
 

Assignment 6(che 6)
1.Define Inventory
Ans:- Inventory is the raw materials, components and finished
goods a company sells or uses in production.

2. Inventory is the raw materials, components and finished goods

a company sells or uses in production.
Ans:- Inventory management follows the flow of goods to,
through and out of the warehouse. The supply chain includes
demand planning, procurement, production, quality, fulfillment,
warehousing and customer service—all of which require
inventory visibility.

3.What is MRP?
Ans:- Material requirements planning (MRP) is a production
planning and inventory control system used to manage
manufacturing processes. These systems are in place so that a
manufacturing facility will always have enough stock for the
manufacturing process.
4.What is MIR?
Ans:-  Maximum Information Rate (ATMF)
 
Assignment 7/8(che 7/8)
 
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1.Differentiate JIGS & FIXTURE.

Ans:- Jigs are the device which is used to holds, supports and
locate the workpiece and it guides the cutting tool for a specific
operation. Fixtures are the device which is used to hold, support
and locate the workpiece and they don't guide the cutting tool.
2.What is the principles of location?
Ans:- The 3-2-1 principle of location (six point location principle)
is used to constrain the movement of workpiece along the three
axes XX, YY, and ZZ. This is achieved by providing six locating
points, 3 pins in base plate, 2 pins in vertical plane and 1 pin in a
plane which is perpendicular to first two planes.
3.Give types of locators and clamping device?
Ans:- Quick-release clamps can also be known as one-handed
clamps and are designed with a mechanism which allows the user
to release a workpiece in one quick movement. There are different
types of quick-release clamps, including lever clamps, spring
clamps and trigger clamps.
 
4.What is the principles of jigs and fixture design?
Ans:- The workpiece position needs to be precise with the guiding
tool in the jig or setup pieces in the fixture. FOOLPROOF: A
foolproof design of jigs and fixtures does not permit a tool or
workpiece to be placed in any other way other than the intended
one.
5.Give types of Jigs and Fixtures?
Ans:- Jigs and Fixtures
4.1. Template Jig.
4.2. Plate Jig.
4.3. Channel Jig.
4.4. Diameter Jig.
4.5. Leaf Jig.
4.6. Ring Jig.
4.7. Box Jig.
6.What is JIT?
Ans:- Just in time (JIT) manufacturing is a workflow methodology
aimed at reducing flow times within production systems, as well
as response times from suppliers and to customers.
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7. What is push & pull manufacturing system?

Ans:- "Push type" means Make to Stock in which the production is
not based on actual demand. "Pull type" means Make To Order in
which the production is based on actual demand.