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Code No: K0321

R07

Set No. 1

IV B.Tech. II Semester Regular Examinations, April, 2011

PRODUCTION PLANNING AND CONTROL (Mechanical Engineering)

Time: 3 Hours Max Marks: 80 Answer any FIVE Questions All Questions carry equal marks ******* 1. a) Define Production Planning & Control (PPC). b)Production Planning & Control System is factorys nervous system. Justify the statement with logical explanation. 2. a) Give your observations pertaining to the exponential smoothing constant () b) Forecast the production for next two years when the production quantity for last ten years is as follows: 200, 225, 235, 240, 255, 260, 265, 275, 270, 271 Use the following methods to compute the forecast and comment on results i) Moving average ( 5 years) ii) Exponential smoothing for =0.3 3. Ten items kept in inventory are listed below. Which items should be classified as A, B and C . What percentage of items is in each class? What percentage of total annual value is in each class? Item no Annual use Price

T N
1 200 40 2 100 360

W U
3 2000 0.2 4 400 20

R O
0.8 100

D L
8 2000 0.7

5 6 7 6000 1200 120 0.04

9 1000 1.00

10 80 400

4. a) Explain various steps involved in MRP system. b) Explain the JIT Kanban working principle. 5. a) What is route sheet? What is the information it contains? Explain it by drawing a route sheet. b) What is the significance of loading? Explain with the help of machine load record. 1 of 2

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Code No: K0321

R07

Set No. 1

6.

Andy Arthurson is an independent computer software consultant. After completing his most recent project, he had five jobs awaiting completion. Following are the estimated work times required to complete each job and due dates requested by customers

Job A B C D E

Processing time 12 16 8 20 6

Due date(days from present) 52 37 28 57 31

a) Construct job sequences using the Critical ratio rule, and Slack Time Remaining rule and b) Compute the average flow time, and average number of jobs in the system. 7. The Basic Block Company needs to produce 4000 boxes of blocks per 40 hour week to meet upcoming holiday demand. The process of making blocks can be broken down into six work elements. The precedence and time requirements for each element are as follows. a) Draw precedence diagram for the production process b) Determine minimum number of work stations and c) balance efficiency.

Work element A B C D E F

T N

W U
Precedence

R O

D L

A A C,D B,E

Performance time(min) 0.1 0.4 0.5 0.2 0.6 0.4

8. a) Explain various activities of dispatcher. b) List out various forms raised by dispatcher? Explain any three with neat sketch.

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Code No: K0321

R07
(Mechanical Engineering)

Set No. 2

IV B.Tech. II Semester Regular Examinations, April, 2011

PRODUCTION PLANNING AND CONTROL

Time: 3 Hours Max Marks: 80 Answer any FIVE Questions All Questions carry equal marks ******* 1. a) State the objectives for which PPC department is established in a factory system. b) Explain the characteristics of various types of production systems.

2. The sales particular of a company a for 13 years of operation is furnished below Year 1 2 Sales 96 116 a) b) 3 119 4 127

Fit simple regression for the above data Forecast the sales for the 14th year of operation.

3. a) Derive the Wilson EOQ formula. What are the practical limitations of the EOQ formula ? b) A company requires 10000 units of an item per annum. The cost of ordering is Rs.100 per order. The inventory carrying cost is 20%. The unit price of the item is Rs.10. Calculate i) the economic order quantity ii) Optimal total annual cost iii) time between the orders.

T N

W U

5 146

6 145

R O
7 153 8 158

D L
10 165 11 177

9 160

12 190

13 205

4. a) Explain Enterprise Resource Planning (ERP) logic in detail. b) With respect to LOB, explain with examples the following i) Objective chart ii) Program plan 1 of 2

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Code No: K0321

R07

Set No. 2

5. a) State the important factors that affecting routing procedure. b) Explain the importance of bills of material in production control. How does it help in assembly production? 6. a) Explain the characteristics of various scheduling policies. b) Three jobs go over three machines M1, M2 and M3 in that order. From the data given below, find the sequence that minimizes the total elapsed time and find the minimum time Jobs Machines M1 M2 M3 A 1 6 5 B 2 2 6 C 3 3 2

7. A company makes a special type of pipe wrench. The marketing department has estimated the demand for this product during the next six months to be as follows: Month Demand January 370 February 430 March 380 April 450 May 520 June 440 With its current labour force, the company can make approximately 420 pipe wrenches per month at a cost of Rs.40 per wrench using regular time production. An additional 80 wrenches per month can be made using overtime production but then the cost per wrench is Rs.45. Wrenches can be made in one month and held in inventory for later shipment at a cost of Rs.3 per month per wrench. The monthly demand for wrenches must be satisfied every month. At the end of December, the company has 10 wrenches in inventory. The company wants to plan its production including overtime and inventory for the next six months so as to minimize cost while satisfying demand a) Formulate the company problem as a transportation model and b) Develop an aggregate plan for the next six months. 8. a) What is follow up? Explain its significance in production? b) Explain the applications of computer in Production Planning & Control.

T N

W U

R O

D L

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Code No: K0321

R07

Set No. 3

IV B.Tech. II Semester Regular Examinations, April, 2011

PRODUCTION PLANNING AND CONTROL (Mechanical Engineering)

Max Marks: 80 Answer any FIVE Questions All Questions carry equal marks ******* 1. Explain various functions of production control department. Draw internal organization chart of Production planning department. 2. A local building products store has accumulated sales data for 2x 4 lumber and the number of building permits in its area for the past 10 quarters. Quarter 1 2 3 4 5 6 7 8 9 10 Building permits(X) 8 12 7 9 15 6 5 8 101 12 Time: 3 Hours

a) Develop a linear regression model for these data and determine the strength of the linear relationship using correlation b) If the model appears to be relatively strong , determine the forecast for lumber given ten building permits in the next quarter. 3. a) Define inventory? Explain various functions of inventory. b) Explain various costs associated with inventory. 4. a) What types of demand are formally considered in MRP. b) Explain the methodology of MRP system briefly. 1 of 2

T N

W U

R O

Lumber sales(Y) 12.6 16.3 9.3 11.5 18.1 7.6 6.2 14.2 15.0 17.8

D L

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Code No: K0321

R07

Set No. 3

5. Product X is made of two units Y and three of Z. Y is made of one unit of A and two units of B. Z is made of two units of A and four units of C. Lead time for X is one week; Y two weeks; Z three weeks; A, two weeks, B: one week and C:three weeks. a) Draw the bill of material b) If 100 units of X are needed in week 10, develop a planning schedule showing when each item should be ordered and in what quantity? 6. Bright Expressions, a house painting contractor has five houses to paint. Following are the estimated times required to paint each house and due date for completion. House Adams Bradley Chin Dalton Evans Estimated Time (days) 2.5 4.0 3.0 5.0 2.0

a) Use the Shortest Processing Time rule to sequence the five jobs Compute average flow time and average tardiness per job using this sequence b) Earliest due date rule to sequence the five jobs Compute average flow time and average tardiness per job using this sequence. 7. a) What is aggregate planning? Explain various objectives of aggregate planning. b) What is expediting? What are the duties of expediter? 8. List out various forms raised by dispatcher. Explain any three with neat sketch.

T N

W U

R O
Due date 8 10 7 14 16

D L

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Code No: K0321

R07

Set No. 4

IV B.Tech. II Semester Regular Examinations, April, 2011

PRODUCTION PLANNING AND CONTROL (Mechanical Engineering)

Time: 3 Hours Max Marks: 80 Answer any FIVE Questions All Questions carry equal marks ******* 1. a) List out the planning functions and controlling functions separately. b) What are differences between job shop, batch type and continuous production systems? 2. a) Explain the characteristics of various types of forecasting briefly. b) Alpha company has the following sales pattern during 1988 to 1996. Compute the sales forecast for 1997 Year 1988 Sales in lakhs 6 1989 8

3. An engine manufacturing company stocks the items as shown in the following table in its stores. The unit price, annual consumption quantity in terms of units/year are also given in the same table. Classify the items into A, B, and C categories and mention nature of control one has to exercise on each category. Component Code C001 C002 C003 C004 C005 C006 C007 C008 C009 C010

T N

W U
1990 11 500 4000 2000 3000 4000 500 500 1000 1500 500 1 of 2

1991 23

R O
1992 29 1993 34

D L
1994 40 1995 45 Unit/year 600 600 600 600 600 1200 600 1200 600 600

1996 56

Description Connecting rod Crank case Cylinder Cylinder head Crank shaft Cam Nozzle Valve set Fuel injection pump Exhaust pipe

Price /unit

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Code No: K0321

R07

Set No. 4

4. a) List out and explain any three various segments of ERP system. b) Define Line Of Balance (LOB)? State its objectives. 5. a) What are the reasons for scheduling? Explain how scheduling improves process production control significantly b) Distinguish between loading and scheduling. 6. a) List out various scheduling rules. Explain at least three of them. b) State the standard scheduling methods. Explain at least one in detail.

7. Professional Image Briefcases is an exclusive producer of handcrafted, stylish cases. The company assembles each case with care and attention to detail. This work requires the completion of the six primary work elements listed here. Work Element A B C D E F

a) b) c) d)

Draw precedence diagram for the production process. Determine minimum number of work stations to assembly 50 cases in a 40 hour week and Balance efficiency

T N

W U

Precedence A B C,D E

R O
Time (min) 30 15 10 5 10 10

D L

8. a) Describe advantages & disadvantages of dispatching jobs all at once and operation by operation. b) Explain the role of follow up men in production control.

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