MECHANICAL ENGINEERING

CATEGORY L T P CREDIT
MET386 INDUSTRIAL ENGINEERING
VAC 3 1 0 4

Preamble: This course helps an engineering student to understand the functions and
techniques of Industrial Engineering. It addresses economic aspects of the business decision
and the concepts of human factors in design. The course involves productivity improvement
methods, Work study, Method study and Time study. Industrial Engineering Tools and
Techniques for Plant management including Plant layout and Material handling are also
covered in this course. The students also will able understand Production Planning and
Control process, and procedures. The other focus areas of Industrial Engineering, Quality
practices, Project Management and Replacement technique are also part of this course.

Prerequisite: NIL

Course Outcomes: After the completion of the course the student will be able to

CO 1 Understand the functions of Industrial Engineering, Economic aspects of business

and Human factors in design

CO 2 Apply Principles of Work study, Method study and Work measurement techniques.

CO 3 Develop layout for a manufacturing/service system and apply plant management and
Material handling techniques.

CO 4 Evaluate Production Planning and Control techniques and Inventory control

CO 5 Analyse Quality practices, and Apply Project Management and Replacement

techniques.

Mapping of course outcomes with program outcomes

PO 1 PO 2 PO 3 PO 4 PO 5 PO 6 PO 7 PO 8 PO 9 PO 10 PO 11 PO 12
CO 1 2 3 3 3
CO 2 3 3 3
CO 3 3 3 3
CO 4 3 3 3 3 3
CO 5 3 3 3 3 3 3
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Assessment Pattern

Bloom’s Category Continuous Assessment End Semester Examination

Tests
1 2
Remember 10 10 10
Understand 20 20 20
Apply 20 20 70
Analyse
Evaluate
Create

Mark distribution

Total CIE ESE ESE

Marks Duration
150 50 100 3 hours

Continuous Internal Evaluation Pattern:

Attendance : 10 marks

Continuous Assessment Test (2 numbers) : 25 marks

Assignment/Quiz/Course project : 15 marks

End Semester Examination Pattern: There will be two parts; Part A and Part B. Part A
contain 10 questions with 2 questions from each module, having 3 marks for each question.
Students should answer all questions. Part B contains 2 questions from each module of which
student should answer any one. Each question can have maximum 2 sub-divisions and carry
14 marks.

Course Level Assessment Questions

Course Outcome 1 (CO1):

1. State functions of an Industrial Engineer which will lead to improvement in productivity?.

2. How the productivity of s system can be improved? List factors affecting productivity that
can be controlled.
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3. Asian industries specialize in the manufacture of small capacity motors. The cost structure
of the motor is as under

Material Rs 50/-

Labour Rs 80/-

Variable overhead 75% of labour cost

Fixed cost of the company amount 2,40,000 Rs/annum

The sales price of the motor is Rs 230/- each

Determine the number of motors to be manufactured to break even

How many motors are to be sold to make a profit of Rs 1 Lakh

If the sale price is reduced by Rs. 15/- how many motors are to sold to break even

Course Outcome 2 (CO2)

1. What is the concept of work content? What are reasons for excess of work content?

2. Differentiate between Two hand process chart and Multiple Activity chart.

3. The following data refers to the study conducted for an operation. The table shows the
actual time for elements in minutes.

Cycle 1 2 3 4 5
elements

1 2.5 2.6 2.4 2.5 2.5

2 6.0 6.2 6.1 5.9 6.0

3 2.3 2.1 2.4 2.2 2.3

4 2.4 2.5 2.6 2.8 2.5

i) Element 3 is machine elements

ii)Take performance rating as 110

Take following personal allowance of 30 minutes in shift of 8 hours, fatigue allowance 15%,
contingency allowance 2%. Estimate the standard time for the operation and production per 8
hour shift.
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Course Outcome 3(CO3):

1. List the different types of layout. Differentiate between Product and process layout based
any five parameters.

2. Consider the following assembly network relationships of a product. The number of shifts
per day is two and the number of working hours per shift is 8. The company aims to produce
80 units of the product per day. Group the activities into work stations using Ranking
Positional Weight method and compute balancing efficiency.

Operation Immediate Duration (Min)

Number predecessor
1 - 7
2 1 2
3 1 2
4 1 5
5 2,3 8
6 3,4 3
7 5 4
8 5,6 7
9 4,6 9
10 7,8,9 8

3. The initial cost of an equipment is Rs 21000/- expected salvage value Rs 1000 and
expected useful life of 10 years. Calculate the depreciation and book value after 1 year and 9
years using sinking fund method and straight line method. Take interest rate as 6%

Course Outcome 4 (CO4):

1. Explain the steps of Production planning Process,

2. Describe the importance Product Life cycle in Product development and Management

3. A manufacturer has to supply his customer a 2400 units of his products per year. Shortages
are not permitted. Inventory carrying cost amounts to Rs. 0.8/- per unit per annum. The setup
cost per run is Rs 60/- . Find

i. EOQ

ii. Optimum number of order per annum

 MECHANICAL ENGINEERING
iii. Average annual inventory cost(min)

iv. Optimum period of supply per order

Course Outcome 5 (CO5):

1. Explain the Procedure of X and R chart .

2. The mortality rate are given in the table below for certain type of electric bulb. There are
2000 bulb in use and it costs Rs 12/- to replace an individual bulb that has burnt. If all the
bulbs are replaced simultaneously, it would cost Rs. 4/- per bulb. It is proposed to replace all
the bulbs in fixed intervals, whether or not they have burnt out and to continue replacing
burnt bulbs out bulbs if they fail. At what intervals should all the bulbs be replaced?

Week 1 2 3 4 5 6
Probability
0.05 0.2 0.25 0.3 0.15 0.05
of failure

Model Question paper

APJ ABDUL KALAM TECHNOLOGICAL UNIVERSITY

SIXTH SEMESTER B.TECH DEGREE EXAMINATION
Course Code : MET386
Course Name : INDUSTRIAL ENGINEERING

Max. Marks : 100 Duration : 3 Hours

Part A

(ANSWER ALL QUESTIONS, EACH QUESTION CARRIES 3 MARKS)

1. What are the factors influencing productivity?
2. Explain the role ergonomics plays in environmental man-machine interface

3. What is micro motion study? What are the steps involved?

4. Explain flow diagram with example

5. Explain REL Chart
6. Explain the criteria for selecting Material handling equipment
7. How order promising is done during Production planning
8. Briefly explain any three selective inventory control techniques
 MECHANICAL ENGINEERING
9. Explain the significance of Bathtub curve
10. Briefly explain the stages of TQM implementation

Part B

(ANSWER ONE FULL QUESTION FROM EACH MODULE)

Module 1

11. a) Explain the factors affecting make or buy decisions. (7marks)

b) ABC company plans to sell an article at local market. The articles are purchased at Rs 5
on the condition that all unsold items shall be returned. The rent for the space Rs 2000. The
article will be sold at Rs 9 . Determine the number of articles which must be sold to i) to
break even ii) to earn Rs 400 profit iii)if the company sells 750 articles . Calculate the margin
of Safety (7 marks)

12. a) Explain the principles in the application of Anthropometric data. How it can be used in
work place design? (8 marks)
b) Explain the functions of Industrial Engineering (6 Marks)

Module 2

13. a) Explain the use recording techniques in method study. Differentiate between
Operations Process chart and Flow process chart. (7 Marks)

b) The observed time and the performance rating for five elements are given. Compute the
standard time assuming rest and personal allowance as 15% and contingency as 2% of basic
time.

Element 1 2 3 4 5
Observed
0.2 0.08 0.50 0.12 0.10
time
Performance
85 80 90 85 80
rating
(7 Marks)

14 a) Explain the different techniques used for work measurement. (7 Marks)

 MECHANICAL ENGINEERING
b) The following data refers to the study conducted for an operation. The table shows the
actual time for elements in minutes.

Cycle 1 2 3 4 5
elements
1 2.5 2.6 2.4 2.5 2.5
2 6.0 6.2 6.1 5.9 6.0
3 2.3 2.1 2.4 2.2 2.3
4 2.4 2.5 2.6 2.8 2.5

i) Element 3 is machine elements

ii)Take performance rating as 110

Take following personal allowance of 30 minutes in shift of 8 hours, fatigue allowance 15%,
contingency allowance 2%. Estimate the standard time for the operation and production per 8
hour shift. (7 Marks)

Module 3

15. a) Explain Systematic Layout planning with the help of block diagram. (6 Marks)

b) Consider the following assembly network relationship of a product. The number of shifts
per day is two and the number of working hours per shift is 12. The company aims to produce
100 units of the product per day. Group the activities into work stations using Rank Positional
Weight Method and compute balancing efficiency.

Operation number Immediate preceding Tasks Duration (Min)

1 - 7
2 1 2
3 1 2
4 1 5
5 2,3 8
6 3,4 3
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7 5 4
8 5,6 7
9 4,6 9
10 7,8,9 8
(8 Marks)

16 a) The initial cost of an equipment is Rs 21000/- expected salvage value Rs 1000 and
expected useful life of 10 years. Calculate the depreciation and book value after 1 year and 9
years using sinking fund method and straight line method. Take interest rate as 6%. (6 Marks)

b)The price of an office equipment is Rs 2.5 lakhs the salvage value at the end of 10 years is
Rs 25,000/ Calculate the amortised value after 5 years by using i) sinking fund method ii)
declining balance method. (8 Marks)

Module 4

17 a) What are the different types of Production system, explain (7 Marks)

b)Consider the following 3 machine and 5 jobs flow shop problem. Check whether Johnson’s
can be extended to this problem. What is the optimal schedule for this problem and
corresponding makespan? Draw the Gantt chart.

Job Machine 1 Machine 2 Machine 3

1 11 10 12
2 13 8 20
3 15 6 15
4 12 7 19
5 20 9 7
(7 Marks)

18 a) Explain the Product Life cycle and its importance in Product management. (7 Marks)
 MECHANICAL ENGINEERING
b) ABC industry needs 15,000 units/year of a bought out component which will be used in its
main product. The ordering cost is Rs. 125 per order and holding cost per unit per year is
20% of the purchase price per unit which is Rs. 75.

i. Find economic order quantity

ii. Number of order per year

iii. Time between successive orders

The activities involved in ABC manufacturing company are listed below with their time
estimates. Draw the network for the given activities and carry out critical path calculations.

(7 Marks)

Module 5

19 a) Differentiate between PERT and CPM, Specify the difference in application (6 Marks)

b) Consider the following data of the project

Duration (Weeks)
Activity Predecessor a m b
A _ 3 5 8
B _ 6 7 9
C A 4 5 9
D B 3 5 8
E A 4 6 9
F C,D 5 8 11
G C,D,E 3 6 9
H F 1 2 9

i. Construct the project network

ii. Find expected duration and variance of each activity

iii. What is the probability of completing the project in 30 weeks?

(8 Marks)

20 a) What is Process Capability? Explain the significance Process capability Index

(7 Marks)
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b)The cost of a machine is Rs. 60,000/-. The salvage value and the running costs of a machine
are shown in the table. Depreciation is cumulative. Find the most economical replacement age of
the machine. (7 marks)

Year 1 2 3 4 5 6
Running 12050 14100 16375 18875 20500 24550
cost in Rs.
Resale 40000 30000 25000 15000 10500 7000
value in Rs

Syllabus

Module 1

Introduction to Industrial Engineering - Evolution of modern Concepts in Industrial Engineering -

Functions of Industrial Engineering.
Productivity- productivity measures- dynamics of productivity change- Techniques for improving
productivity.
Production costs concepts – Manufacturing Vs Purchase- problems- Economic aspects- C-V-P
analysis – simple problems..
Ergonomics Man-Machine systems-Anthropometry Work place design and ergonomics - Value
Engineering.

Module 2
Work study-procedure-concept of work content- techniques to reduce work content.
Method Study-steps-recording techniques-operation process chart-flow process chart-two hand
process chart-multiple activity chart. Diagrams- Flow diagrams-String diagrams. Micro-motion
study-SIMO chart- critical examination. Principle of motion economy.
Work measurement- techniques of work measurement - Time Study- - Steps in time study-
calculation of standard time (problems)- allowances.

Module 3
Plant location, plant layout and material handling- Type of layouts and characteristics –Tools
and techniques for plant layout- travel chart – REL chart- Computer algorithms for layout
design CRAFT-ALDEP (methods only)- Systematic layout planning -Line balancing–RPW
(problem).
Principles of material handling-selection and type of material handling equipment- Unit load
concept- Automated Material Handling Systems- AGVs.
Depreciation -Method of providing for depreciation- straight line method- Declining balance
method- Sinking fund methods (Problems)

Module 4
Production Planning and control -Types of Production systems.
Demand forecasting- Forecasting methods, Aggregate planning- methods- Master Production
Schedule-techniques-order promising- Material Requirement Planning-bill of material-
 MECHANICAL ENGINEERING
product structure diagram- MRP record processing- Shop floor control - Scheduling flow
shop and job shop scheduling methods, Johnson’s algorithm-dispatching rules - Gantt charts.
Introduction and need for a new product-product life cycle.
Inventory Control, Inventory models – Basic model -price discounts -problems –
determination of safety stock - Selective inventory control techniques

Module 5
Quality control - Statistical quality control –causes of variation in quality- control charts
for X and R (problems). Process Capability- process capability index- Reliability-causes
of failures- Bath tub curve.-System reliability. Introduction to concepts of, TQM, ISO,
Six Sigma and Quality circles.
Project management- Critical Path Method, PERT, crashing of networks
Determination of economic life -Replacement policy-- Methods of replacement analysis.

Text Books

1. Martand Telsang, Industrial Engineering & Production Management, S. Chand, Third revised
edition 2018.
2. B. Kumar, Industrial Engineering Khanna Publishers, Tenth Edition 2015
3. Thomas E Vollmann , William L Berry , D Clay Whybark, F Robert Jacobs,
Manufacturing Planning and Control for Supply Chain Management, McGraw Hill
Education (India) Private Limited, Fifth Edition 2017
4. M Mahajan, Industrial Engineering & Production Management, Dhanpat Rai, 2015
5. O. P. Khanna, Industrial Engineering and Management, Dhanpat Rai, 2018

Reference Books

1. E. S. Buffa, Modern Production management, John Wiley, 1983

2. Grant and Ieven Worth, Statistical Quality Control, McGraw Hill, 2000
3. Ralph M Barnes, Motion and Time Study, Wiley, 1980
4. Richard L. Francis, F. McGinnis Jr., John A. White, Facility Layout and Location: An
Analytical Approach, 2nd Edition,1991
 MECHANICAL ENGINEERING
Course Contents and Lecture Schedule

No. of
No Topic
Lectures
Introduction to Industrial Engineering - Evolution of modern Concepts in Industrial
Engineering - Functions of Industrial Engineering.
Productivity- productivity measures- dynamics of productivity change- Techniques for
improving productivity.
1 7-2-0
Production costs concepts – Manufacturing Vs Purchase- problems- Economic aspects-
C-V-P analysis – simple problems..
Ergonomics Man-Machine systems-Anthropometry Work place design and ergonomics -
Value Engineering
Work study-procedure-concept of work content- techniques to reduce work content.
Method Study-steps-recording techniques-operation process chart-flow process chart-two
hand process chart-multiple activity chart. Diagrams- Flow diagrams-String diagrams.
2 7-2-0
Micro-motion study-SIMO chart- critical examination. Principle of motion economy.
Work measurement- techniques of work measurement - Time Study- - Steps in time
study- calculation of standard time (problems)- allowances
Plant location, plant layout and material handling- Type of layouts and characteristics –
Tools and techniques for plant layout- travel chart – REL chart- Computer algorithms for
layout design CRAFT-ALDEP (methods only)- Systematic layout planning -Line
3 balancing–RPW (problem). 7-2-0
Principles of material handling-selection and type of material handling equipment- Unit
load concept- Automated Material Handling Systems- AGVs.
Depreciation -Method of providing for depreciation- straight line method- Declining
balance method- Sinking fund methods (Problems)
Production Planning and control -Types of Production systems.
Demand forecasting- Forecasting methods, Aggregate planning- methods- Master
Production Schedule-techniques-order promising- Material Requirement Planning-bill of
material-product structure diagram- MRP record processing- Shop floor control -
4 Scheduling flow shop and job shop scheduling methods, Johnson’s algorithm- 7-2-0
dispatching rules -- Gantt charts.
Introduction and need for a new product-product life cycle.
Inventory Control, Inventory models – Basic model -price discounts -problems –
determination of safety stock - Selective inventory control techniques
Quality control - Statistical quality control –causes of variation in quality- control charts
for X and R (problems). Process Capability- process capability index- Reliability-causes
of failures- Bath tub curve.-System reliability. Introduction to concepts of, TQM, ISO,
5 7-2-0
Six Sigma and Quality circles.
Project management- Critical Path Method, PERT, crashing of networks
Determination of economic life -Replacement policy-- Methods of replacement analysis.