Question Bank

S.Y.B. B. A. (Semester – IV)

Subject: Production and Operation Management

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Unit 1: introduction to Production Management (15%)

❖ Answer following questions briefly: (2Marks)

1. Define production and production management
2. Give two examples of continuous production systems and intermittent production
systems.
❖ Long Questions:
1. Explain the importance of production management. (8M)
2. Briefly explain the scope of production management. (8M)
3. Explain different types of manufacturing systems with examples. (7M)
4. Explain intermittent production system with its advantages and disadvantages. (8M)

Unit 2: Plant Layout and Material handling (15%)

❖ Answer following questions briefly: (2Marks)

1. Define plant layout and mention different types of plant lay outs.
2. Define material handling and mention the functions of material handling.
3. Define fixed position layout and cellular manufacturing layout.
4. Explain the term: cellular layout with suitable examples.
5. Explain fixed position layout with suitable examples.
6. What is the difference between material handling and logistics?
7. Explain any two principles of material handling.
8. Explain why fixed path material handling equipments are more seen in continuous
systems and variable path equipments are more seen in intermittent systems.
9. Explain classification of material handling equipments as per source of power.
❖ Long Questions:
1. Compare process layout with product layout. (8M)
2. Compare and contrast Product Layout and Process Layout. (8M)
3. Discuss any eight factors affecting the design of plant layout. (8M)
4. Discuss various principles of material handling. (7M)
5. Describe various material handling equipments. (8M)

Unit 3: Inventory Control (25%)

❖ Answer following questions briefly: (2Marks)

1. Define inventory and inventory control.
2. Define order cost and mention the components of order cost.
3. Define inventory carrying cost and mention its components.
4. Define safety stock and mention the factors affecting safety stock.
 5. List any four components of material shortage cost.
6. Define ABC analysis.
7. Define VED analysis.
8. Give the traditional as well as modern definition of “lead time of purchasing”.
9. If ordering cost is Rs. 800 product price is Rs. 1920 per box of dozen, annualised
carrying cost is 10% of price and demand is 4800 units per month, find out EOQ.
10. Annual demand of one material is 120000kgs. Price of this material is Rs. 40 per kg.
Inventory carrying cost is counted at the rate of 20% of price on per unit, per year
basis. When EOQ is ordered, only six orders are placed in a year. What should be
cost of placing one order to justify this EOQ?
11. Monthly requirements of one chemical is 10000 litres. When EOQ is ordered, one
order is placed every two months. The price of this material is Rs. 40 per litre.
Inventory carrying cost is to be counted at the rate of 15% of price on per unit, per
year basis. What should be the cost of placing one order?
12. If ordering cost is Rs. 1600, product price is Rs. 1920 per box of dozen, annualised
carrying cost is 20% of price and demand is 4800 units per month, find out time gap
between two orders if EOQ is the order quantity.
❖ Long Questions:
1. Describe various costs associated with inventory control by including their
components. (8M)
2. Derive EOQ formula for basic model, giving assumptions and limitations. (8M)
3. Write a detailed note on ordering cost and inventory carrying cost. (7M)
4. Write a detailed note on ABC analysis. (7M)
❖ Numerical:
1. For a given item of constant demand rate of 60000 units per year, the price is Rs. 60
per unit. Order cost is Rs. 600 per order. The inventory carrying cost is 30% of average
inventory on annual basis. Therefore, find EOQ. Should company accept 5% discount
for minimum order quantity of 20000 units? (8M)
2. An auto industry purchases spark plugs at the rate of Rs. 25 per unit. The annual
consumption of spark plugs is 18000 nos. If the cost of ordering is Rs. 250 per order
and the inventory carrying cost 25% of annual average inventory; what should be
EOQ? Should the company accept 5% price discount for minimum order quantity of
3000 units? (8M)
3. A factory uses 24000 units annually of raw material which costs Rs. 1.25 per unit. The
cost of placing an order is Rs. 25 per order. The inventory carrying cost is 6% of cost
of average inventory on annual basis. Therefore, find EOQ and total inventory cost
including the cost of raw material.
If the factory works for 320 days in a year, procurement lead time is 10 days and
safety stock is 10% of EOQ; find safety stock, reorder level, minimum level, maximum
level and average inventory level. (8M)
 Unit 4: Production Planning (25%)
❖ Define the following terms: (1Mark)
1. MPS
2. MRP
3. CRP
4. BOM

❖ Answer following questions briefly: (2Marks)

1. Convert following assignment problem into a balanced minimization format.
Job 1 Job 2 Job 3 Job 4 Job 5
Worker 1 12 27 16 13 14
Worker 2 10 24 20 10 18
Worker 3 Not 28 12 30 20
Possible
(Figures are profit in thousands of rupees for combinations of jobs and workers)
2. Define term: operation scheduling.

❖ Answer following questions briefly: (2Marks)

1. Explain how MRP is done for independent demand inventories.
2. Explain chronocyclegraph as a method study recording technique. How can we know
direction of movement in chronocyclegraph?

❖ Long Questions:
1. Write a short note on MPS. (8M)
2. Explain MPS methodology with a flow diagram and highlight relationship of MPS
with MRP and with CRP. (8M)
3. Write a short note on BOM. (8M)
4. Explain MRP Briefly. (8M)
5. Explain MRP process. Explain various inputs and outputs of MRP Process. Discuss
role of Bill of Material in MRP. Explain the term Explosion of bill of material. (8M)
6. Briefly describe various scheduling strategies. (8M)
7. Explain CRP Briefly. (8M)
8. Explain various priority sequencing rules. (8M)

❖ Numerical:
1. There are five subjects to be taught in a college. Six teachers are available for this
purpose. It is decided to assign only one subject to one teacher. In the following
matrix, numbers of students passing various subjects are mentioned for different
combinations of a teacher and a subject.

Teacher 1 Teacher 2 Teacher 3 Teacher 4 Teacher 5 Teacher 6

Subject 1 33 18 30 40 28 20
Subject 2 20 12 19 38 16 34
Subject 3 23 19 8 26 20 18
Subject 4 24 16 18 30 24 28
Subject 5 18 14 12 21 6 16
(a) Find the best combinations of subjects and teachers.
(b) Which teacher should be sacked?

2. There are five subjects to be taught in a college. Six teachers are available for this
purpose. It is decided to assign only one subject to one teacher. In the following
matrix, numbers of students passing various subjects are mentioned for different
combinations of a teacher and a subject.

S1 S2 S3 S4 S5
T1 60 80 140 40 60
T2 120 60 20 100 100
T3 140 60 160 100 120
T4 40 80 120 80 40
T5 100 120 180 140 100
T6 140 160 40 140 100
(c) Find the best combinations of subjects and teachers.
(d) Which teacher will sit idle?

3. There are 6 jobs which are to be processed on three machines in the order of
M1→M2→M3. Following are various processing timings. Find out the best order in
which these six jobs are to be processed. What shall be total minimum completion
time to complete all six jobs? (8M)
Job 1 Job 2 Job 3 Job 4 Job 5 Job 6
Machine 1 2 9 7 2 2 5
Machine 2 0 6 3 5 7 6
Machine 3 6 5 5 4 3 5

4. There are 6 jobs which are to be processed on four machines in the order of
M1→M2→M3→M4. Following are various processing timings. Find out the best order
in which these six jobs are to be processed. What shall be total minimum completion
time to complete all six jobs? (8M)
Job 1 Job 2 Job 3 Job 4 Job 5 Job 6
Machine 1 8 14 12 10 8 12
Machine 2 6 0 6 4 4 8
Machine 3 4 6 0 4 4 6
Machine 4 10 8 6 14 4 6
(Time in Minutes)
5. There are 6 jobs which are to be processed on three machines in the order of
M1→M2→M3. Following are various processing timings. Find out the best order in
which these six jobs are to be processed. What shall be total minimum completion
time to complete all six jobs? (8M)
Job 1 Job 2 Job 3 Job 4 Job 5 Job 6
Machine 1 4 18 14 4 4 10
Machine 2 0 12 6 10 14 12
Machine 3 12 10 10 8 6 10
(Time in hours)
6. There are 7 jobs which are to be processed on three machines in the order of
M1→M2→M3. Following are various processing timings. Find out the best order in
 which these seven jobs are to be processed. What shall be total minimum completion
time to complete all seven jobs? (8M)
Job 1 Job 2 Job 3 Job 4 Job 5 Job 6 Job 7
Machine 1 6 2 0 1 3 7 2
Machine 2 1 0 3 4 2 1 4
Machine 3 4 6 4 5 5 6 5
(Time in hours)
7. A scheduler has four jobs which can be assigned on any of the four machines. The
time required for each job on each machine is as shown in the table. Therefore, find
the assignment of jobs which will result in minimum total machine hours to complete
all the jobs. Will all the job completed in 10 hours after starting all jobs at a time.(8M)
Machines
Job
M1 M2 M3 M4
A 5 6 8 7
B 10 12 11 7
C 10 8 13 6
D 8 7 4 3
(Time in Hours)
8. A workshop has 8 jobs to be sequentially processed through the three work centres
M1, M2 and M3. The following table shows the processing times for jobs on
corresponding machines. Therefore, find the sequence of jobs which minimizes the
elapsed time. What is this time? Show your result by Gantt chart. (8M)
Jobs A B C D E F G H
M1 8 16 10 18 6 8 18 12
M2 12 8 14 2 8 4 10 4
M3 16 14 18 14 18 16 18 14

Unit 5: Work Study (20%)

❖ Define the following terms: (1Mark)
1. Work Study
2. Work Measurement
3. Therblings
4. Elements
5. Method Study
6. Cycle Time
7. Allowances
8. Performance Rating
❖ Answer following questions briefly: (2Marks)
1. Explain activity ‘Hold’ in relation to Two handed process Chart. What is its Symbol?

❖ Long Questions:
1. Explain the basic procedure (steps) for Method study. (8M)
2. Explain the basic procedure (steps) for work measurement. (8M)
3. Name various recording techniques of work study and explain any two of them. (8M)
 4. Explain stop watch method (Time study Method) of work measurement. (8M)
5. Write a short note on SIMO chart. List various Therbligs with abbreviations and
symbols (5M)
6. Explain man type flow process chart with explanation of five activities shown in the
chart. (5M)
7. Write a short note on “Two handed flow process chart” (6M)
8. Explain various types of time allowances that we may have to consider while
converting normal time to standard time during work measurement (Time study)
process. (8M)
9. Explain various ways to classify or to break an operation or a job into time elements
during work measurement process. (5M)
❖ Numerical:
1. For following manufacturing operation, Prepare man-machine chart after suggesting
all possible improvements. Also find out cycle time. (10M)
(1) Worker picks up raw material from tray 1 minute
(2) Worker loads raw material piece in machine 1 minute
(3) Worker start machine by using a lever 1 minute
(4) Machine runs automatically with auto stop at the end 5 minute
(5) Worker unloads finish piece 1 minute
(6) Machine throws waste automatically 2 minute
(7) Worker inspects finished piece 1 minute
(8) Worker packs finished piece in the box 2 minute
(9) Worker marks entry in the job card 1 minute
2. Prepare man-machine chart for most efficient situation for the work having following
elemental activities: (8M)
(1) Picks up raw material piece from crate 4 seconds
(2) Inspects raw material piece for surface finish 6 seconds
(3) Loads raw material piece on machine 8 seconds
(4) Starts machine by pressing the button 3 seconds
(5) Machine does milling automatically 25 seconds
(6) Unloads finish piece 5 seconds
(7) Machine throws out scrape-chips automatically 10 seconds
(8) Inspects finished piece 10 seconds
(9) Worker packs finish piece in the box 10 seconds
Find cycle time for this operation. Also find idle time for worker and machine.
3. Prepare man-machine chart for following manufacturing operation after suggesting
all possible improvements: (8M)
(1) Worker Picks up raw material from tray 5 seconds
(2) Worker checks length of raw material 5 seconds
(3) Worker Loads raw material in machine 5 seconds
(4) Worker Starts machine 5 seconds
(5) Machine runs automatically with auto stop at the end 30 seconds
(6) Worker Unloads finished piece from machine 10 seconds
(7) Worker Inspects finished piece 10 seconds
(9) Worker packs finished piece in a box 10 seconds
4. Prepare man-machine chart for most efficient situation for the work having following
elemental activities: (8M)
(1) Worker opens box of raw material 5 seconds
 (2) Worker checks lengths of raw material 10 seconds
(3) Worker loads raw material in machine 5 seconds
(4) Worker Starts machine by pressing lever 5 seconds
(5) Machine runs automatically with auto stop at the end 20 seconds
(6) Worker unloads finished piece 5 seconds
(7) Worker inspects finished piece 15 seconds
(8) Worker packs finished piece in the box 20 seconds
(9) Machine re-sets itself automatically for next cycle 25 seconds
(10) Worker marks entry on job card 5 seconds
Find cycle time for this operation. Also find idle time for worker and machine.
5. For following manufacturing operation, Prepare man-machine chart after suggesting
all possible improvements. Also find out cycle time. (10M)
(1) Worker picks up raw material from tray 0.5 minute
(2) Worker checks raw material piece 1 minute
(3) Worker loads raw material piece in machine 0.5 minute
(4) Worker start machine 0.5 minute
(5) Machine runs automatically with auto stop at the end 2 minute
(6) Worker unloads finish piece 1 minute
(7) Machine throws waste automatically 0.5 minute
(8) Worker inspects finished piece 2 minute
(9) Worker packs finished piece in the box 1 minute
(10) Machine automatically resets itself for next cycle 1 minute