pera ; | Malays ; PAHANG eps feet comy, FINAL EXAMINATION COURSE : LEAN MANUFACTURING SYSTEM COURSE CODE : BIM3713 COURSE COORDINATOR : NORAINI MOHD RAZALI DATE 7 03 FEBRUARY 2021 DURATION : 3 HOURS SESSION/SEMESTER i SESSION 2020/2021 SEMESTER I This examination paper consists of FOUR (4) questions. Answer ALL questions, All answers to a new question should starts on a new page. All the calculations and assumptions must be clearly stated. APN Candidates are not allowed to bring any materials other than those allowed by the invigilator into the examination room. EXAMINATION REOUIREMENTS: 1. NIL APPENDIX: 1. NIL —DOROT TORN THISPAGE UNTIL YOUARE TOLD TO DOSO—— This examination paper consists of FIVE (5) printed pages including the front page.CONFIDENTIAL, 20211/BTM3713 QUESTION 1 [25 MARKS] @ () (©) @ Explain the terms MUDA, MURA and MURI. [6 Marks} {CO1, PO1, C4] Explain the MUDA seven types of wastes with your own example. [10 Marks} ICO, PO1, C4] Differentiate between the “push” and “pull” methods of material flow. [4 Marks] ICO1, POI, C4) Discuss the various type of pull signal available in the manufacturing industry to create the pull system in a production plant. [5 Marks} {CO1, PO1, C4] QUESTION 2 [25 MARKS] @ 0) Explain TWO (2) pillars of Total Productive Maintenance (TPM) as a modem tool for maintenance activity related with Lean, [4 Marks] [CO1, PO1, C4] Overall Equipment Effectiveness (OEE) is one of the key measures of TPM which indicates how effectively the machinery and equipment is being run, OEE is calculated by ‘measuring the availability, performance and quality losses. Describe each of them. [6 marks] {CO1, PO1, C4]CONFIDENTIAL 2021BTM3713 © @ One of the main targets with TPM and OEE program is to reduce and/or eliminate what is called the "Six Big Losses". Explain the Six Big Losses with your own example. [9 Marks] [Co1, PO1, C4] ‘A factory runs a singlé shift of 8 hours. There are three breaks, one of 30 minutes and two other breaks of 10 minutes each. During the shift in question, downtime of 50 minutes is recorded. The machine being studied has a stated production rate of 1 part every 20 seconds G per minute). In this particular shift 957 parts are produced. The number of defects produced during this shift is measured as 97 parts which must be scrapped. Determine OEE for the machine, [6 Marks] [CO1, PO1, C4] QUESTION 3 [25 MARKS] (@) Explain the difference between “Takt Time”, “Cycle Time” and “Lead Time”. [6 Marks} [CO2, PO2, C6] (b) Explain two (2) reason to balance the assembly line. [4 Marks} [C02, PO2, C6) (©) Table 1 shows the assembly Task and Times to build the Model Z Bicycle. The company expects 480 bicycles daily, and the line producing the bicycles is scheduled to work for 420 minutes daily.CONFIDENTIAL 2021/BTM3713 Table 1 Task Task Time | Preceding Task (seconds) 50 16 14 35, 20 17 17 17 17 1B FGHI 14 7 >] aifalalol + co) A |] a] of |] Of o} we] > i) Construct the precedence diagram for the Model Z bicycle assembly line [4 Marks] ii) Determine the required workstation cycle time (takt time). [3 Marks] iii) Determine the theoretical minimum number of workstations. [3 Marks} iv) Balance the line and evaluate the efficiency of the line. [5 Marks] [C02, PO2, C6] QUESTION 4 [25 MARKS] (@)__Jidoka is providing machines and operators the ability to detect when an abnormal condition has occurred and immediately stop work. Jidoka is often translate as “built in quality at source”. Explain the three rules of Jidoka, 16 Marks] {C02, PO2, C6]CONFIDENTIAL 2021/BTM3713 ) © @ Explain how implementation of Andon system can support Jidoka in the production floor. [6 Marks} [C02, PO2,C6} SPOTWELD Sdn. Bhd. is one of the car chassis vendor for automotive company in Malaysia. The company found a problem in the process of spot welding at welding shop, where weld nugget slip off specification which count as defects when workers occasionally forget to change tips. This issue need to be solved using one of the lean tools knows as “mistake proofing” technique. What is the Japanese term for this tool and describe the purpose of the tool {5 Marks} [c02, PO2, C6] In a manufacturing plant, tooling and equipment set up are necessary activities to produce different kind of products from the same production line. Set up time however are non- value added activities that must be reduced in order to reduce waste. Single Minute Exchange of Die (SMED) is a techniques used to reduce the amount of time required for equipment set up, including the exchange of tools and dies, or changeover. Explain the stages required to reduce the set up time of a typical production line. [8 Marks} [Co2, P02, C6] END OF QUESTION PAPER.