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IEQ Model Ans

The document provides model answers and marking schemes for the Summer 2022 examination on Industrial Engineering and Quality Control, detailing instructions for examiners and sample questions with corresponding answers. It emphasizes the importance of assessing candidates' understanding rather than exact wording, and includes various topics such as inspection, ergonomics, line balancing, and quality control. The document serves as a guideline for evaluating student responses in a technical education context.

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100% found this document useful (1 vote)

1K views75 pages

IEQ Model Ans

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MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
SUMMER – 2022 EXAMINATION
Subject Name: Industrial Engineering and Quality Control Model Answer Subject Code: 22657
XXXXX
Important Instructions to examiners:
1) The answers should be examined by key words and not as word-to-word as given in the model answer scheme.
2) The model answer and the answer written by candidate may vary but the examiner may try to assess the
understanding level of the candidate.
3) The language errors such as grammatical, spelling errors should not be given more Importance (Not applicable for
subject English and Communication Skills.
4) While assessing figures, examiner may give credit for principal components indicated in the figure. The figures
drawn by candidate and model answer may vary. The examiner may give credit for any equivalent figure drawn.
5) Credits may be given step wise for numerical problems. In some cases, the assumed constant values may vary and
there may be some difference in the candidate’s answers and model answer.
6) In case of some questions credit may be given by judgement on part of examiner of relevant answer based on
candidate’s understanding.
7) For programming language papers, credit may be given to any other program based on equivalent concept.
8) As per the policy decision of Maharashtra State Government, teaching in English/Marathi and Bilingual (English +
Marathi) medium is introduced at first year of AICTE diploma Programme from academic year 2021-2022. Hence if
the students in first year (first and second semesters) write answers in Marathi or bilingual language (English
+Marathi), the Examiner shall consider the same and assess the answer based on matching of concepts with
model answer.

Q. Sub Marking
Answer
No. Q. N. Scheme

Q.1 Attempt any FIVE of the following: 10 Marks

a. State the need of inspection.

Ans: • To ensure that part, material or a component conforms to the established standard

• To meet the interchangeability of manufacture

• To maintain the customer relation by ensuring that no faulty product reaches the 1/2 Marks
customer for each
point
• Provide the means of finding out shortcomings in manufacture
Any four
• It also helps to co-ordinate the functions of quality control, production, purchasing points
and other departments of the organization

• To take decision on the defective parts i.e. the possibility of making some of these
parts acceptable after minor repairs

b. Define ergonomics.

Ans: Ergonomics (or human factors) is the scientific discipline concerned with the 02 Mark
understanding of interactions among humans and other elements of a system, and the for
profession that applies theory, principles, data and methods to design in order to definition
optimize human well-being and overall system performance.

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Ans: i) Transport loaded 01 Mark

ii) Search
01 Mark

d. Define process planning. (Correct Definition 2m)

Ans: Process planning is defined as the subsystem responsible for the conversion of design
data to work instruction.
02 Mark
OR for
definition
Process planning is that function within a manufacturing facility which establishes the
process and process parameters to be used (as well as those machines capable of
performing these processes) in order to convert a piece-part from its initial form to a
final form that is predetermined on a detailed engineering drawing.

e. State different SQC tools. (1m for each tool) (any two)

Ans: 1. Histogram.
2. Check Sheet. 1/2 Marks
3. Pareto Diagram. for each
tool
4. Brainstorming.
5. Cause & Effect Diagram (ishikawa/fishbone diagram)
6. Control Charts.
7. Scatter Diagram.
f. State any two symbols used in a process chart. (1m for each symbol with its meaning)
(any two)
Ans:
Sr. No. Symbol Meaning

1 Operation

2 Inspection
01 Mark
3 Transport for each
symbol
4 Delay or Temporary storage

5 Storage

6 Operation and inspection

7 Operation cum transportation

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Ans: 1. Reliability: means that it should give efficient and consistent performance
2. Suitability: suitability for a specific application.
3. Durability: means it should have desired life.
4. Affordability: It should be economical.
5. Maintainability: It should be easy to maintain.
6. Aesthetic look: It should look attractive. ½ Mark for
each point
7. Satisfaction to customers: It should satisfy the customer’s requirements.
8. Safe and foolproof workability.
9. Versatility: It should be used or serve a number of purposes.
10. Economical: It should have a reasonable price.
Q.2 Attempt any THREE of the following: 12 Marks

a. Explain the concept of line balancing. (Explanation with an proper example)

Ans: Line balancing means the balancing the (assembly/production) line. Suppose there are
three machines (workstations) A, B and C which can process 5, 10 and 15 pieces per unit
time respectively and the pieces flow from A to B to C (precedence constraint). Since A
has minimum capacity i.e. of processing only 5 pieces per unit time naturally work 04 Marks
station (machine) B will remain idle for 50% of its time and machine C for 66.66% of its
time. It shows that the line is unbalanced. One way to partially balance the line is to
have three machines of type A, 2 of type B, with every machined of type C.

Another approach to balance the line will be to give some other task to machines B and
C so that they do not remain idle. The main objective of line balancing will be
distributing task evenly over the work stations so that idle time of men and machines is
minimized.

b. Explain man-machine relationship in terms of ergonomics.

Ans: Man–machine system is a system in which the functions of a human operator (or a
group of operators) and a machine are integrated. This term can also be used to
emphasize the view of such a system as a single entity that interacts with external
environment.
Human factors are a system concerned with the relationship among human beings,
work place or work environment and machines. The proper integration of man and 04 Marks
machine, which is beneficial for human operator and enhances the overall system
performance, is a primary aim of the ergonomics discipline.
For eg. A manual system consists of hand tools and other aids which are coupled by a
human operator who controls the operation. Operators of such systems use their own
physical energy as the power source. The system could range from a person with a
hammer to a person with a super-strength giving exoskeleton.

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Ans: Sr. No. Acceptance Sampling 100% inspection

1 Cost of inspection is less Cost of inspection is high

2 Subjected to sampling error Subjected to fatigue error

3 Magnitude of sampling error can be Magnitude of fatigue error cannot 01 Mark

estimated estimated for each
point
4 Only recourse for inspection in case of Not feasible when inspection involves
destructive tests. destructive tests

5 Time of inspection if less Time of inspection is more

6 Gathered data is not more suitable for Gathered data is more suitable for
further analysis by quantitative further analysis by quantitative
techniques. techniques.

d. Explain relation between ‘cost of quality’ and ‘value of quality’ with a graph.

Ans: The balance between the cost of quality and value of quality gives optimum quality of
design. The quality of design must fulfill the needs and expectations of customers, while
the production cost should be low as possible so as to earn maximum profit. The graph
shown represents cost and value of quality.

02 Mark
for graph

If we want to improve the quality of design from point 1 to 2, the cost of quality will
increase by amount A, where as the value of quality will increase by amount B.
02 Mark
Here B>A and therefore, improvement in quality at this level will yield more income. for
But, when the quality is to be improved from 2 to 3, we find here that D<C, i.e. rise in explanatio
value of quality is less than cost of quality. Hence, the quality level at point 2 is optimum n
quality of design,

Below this, the profit that can be earned is not maximized and above this it is not
economical to improve the quality of design.
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MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
Q. 3 Attempt any THREE of the following 12 Marks

a) Enlist the allowances consider while calculating standard time and explain any one.

1. Personal Allowance.
2. Relaxation or Fatigue Allowance.
3. Delay Allowance. 01 Mark for
4. Contingency Allowance. Enlist
5. Policy Allowance.
6. Machine Interference Allowance.
1. Personal Allowance:-A worker cannot work continuously like a machine and hence
such allowances are provided to him in order to satisfy his personal needs and to
recover from the physiological and psychological effects of energy spent while
performing an operation under existing working conditions. This allowance is present in 02 Marks
any work environment. In order to satisfy personal needs, the allowance provided is for
personal allowance.5% addition to basic time are used to allow for personal needs. explanation
of any one
e.g. Drinking water, washing hands, going to washroom etc.

2. Relaxation or Fatigue Allowance:-Rest allowance is a relaxation allowance to a

worker to overcome fatigue incurred during working. Excessive fatigue affects badly the
performance of a worker. Relaxation or fatigue allowances may vary from 5% to 20% (or
even more) of the normal time from light to heavy works. 01 Mark for
example
e.g. unhealthy working conditions, physical exertion, inconvenient postures,
concentration, etc.

3. Delay Allowance:- During the working, many interruptions to the work cycle occurs.
These are the delays which may not be compensated in any way .Delay allowances may
vary from 1 to 5 % to the basic time.
e.g. Waiting for parts, materials or tools, receiving instructions from supervisors, waiting
for a crane to clear work area, answering co-workers questions etc.

4. 4. Contingency Allowance: This is a small allowance of time given to compensate such

delay as tool breakage involving removal of tool from the holder or power failures for
small duration. This allowance provides for small unavoidable delays as well as for
occasional minor extra work. This allowance should never be more than 5%.
e.g. Tool breakage involving removal of tool from the holder and all other activities to
insert new tool into the tool holder. Power failures of small duration.
5. Policy Allowance:- The policy allowance is an increment, other than bonus increment,
applied to a standard time , to provide a satisfactory level of earnings for a specified
level of performance under exceptional circumstances.The usual reason for making the
policy allowance is to line up standard times with requirements of wage agreement
between employers and trade unions.Policy allowances should be used with utmost
care and only in clearly defined circumstances.
e.g., work content

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MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
6. Machine Interference Allowance: -Machine interference allowances are provided
when a worker is looking after two or more machines and one or more of them stop (at
random or cyclically) while he is attending to another (machine). The result, of machine
stoppages or machine interference, is loss in production or total output. Thus, for no
fault of his own, the worker suffers because of low output. Interference allowance
compensates these aspects. Machine stoppage may be cyclic or random and thus ‘cycle
interference allowances’ or ‘random interference allowances’ are specified. Cycle
interference allowances are generally given to a worker handling more than one
automatic machine which has different automatic cycle times. If the worker is attending
machine B and the automatic cycle time of machine A is over, naturally machine A will
stop and the worker is not in a position to attend the same until he makes machine B to
start. ‘Random interference allowances’ are given on machines which stop or have to be
stopped due to certain causes occurring at random.
e.g. when a yarn breaks in winding.
b) Draw OC curve and explain the producer’s risk and consumer’s risk.

02 Mark for
OC curve

Producer’s Risk:-Sometimes it happen that in spite of good quality, the sample taken
may show defective units as such the lot will be rejected. In spite of good quality the lot
is rejected, such a type of risk of rejection is known as producer’s risk. In other words, 01 Mark
the probability of rejecting a lot which has actually been satisfactory by the producer
according to acceptable quality level is known as producer’s risk. Thus, the risk of
rejecting a lot of good items is known as producer’s risk. Producer’s risk is designated
as the alpha(α) risk.

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MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
Consumer’s Risk:- Sometimes it may happen that the quality of the lot is not good but
the sample results show good quality units as such the consumer has to accept a
defective lot. Such a risk is known as consumer’s risk. In other words, the probability of 01 Mark
accepting a lot which has actually been satisfactory by the consumer according to a
predetermined standard is known as consumer’s risk. Consumer’s risk is designated as
the Beta (β) risk.
The α risk at the AQL level and the β risk at the LTPD level establish two points from
which the sample size and acceptance number are determined.
c) Differentiate inspection and quality control.(Four points)

Sr.
N Inspection Quality Control
o

Inspection is a part of quality Quality control is a broad term, it involves

1 control inspection at particular stages, but more
inspection does not mean quality control.

Inspection is an act of checking Quality control is an effective system for

components, products at various integrating quality development, quality
stages in manufacturing and maintenance and quality improvement
2 sorting out the defective items efforts of various groups in an
from good items. organization to enable the production to
be carried out at most economical level
and to achieve satisfaction of customers.

Inspection uses precision Quality control uses devices such as 01 Mark for
measuring instruments such as statistics, control charts, acceptance one point
3
Vernier calipers, micrometers, sampling ,process capability, quality
profile projectors etc. audits etc.

Inspection is concerned with the Quality control concerned with quality of

quality of past production to judge future production. e.g. Take a sample,
conformance and sorting out inspect it, if it is defective find out the
4
defective items from good items. reasons and take corrective action, so
that such type of defects will not occur in
future.

Inspection is mainly the Everybody working in an organization is

5 responsibility of the inspectors. responsible for quality of products
produced.

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MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
d) Apply principles of Ergonomics for design of control members like push button and
knobs.

Push button:-
A push button may be push-on or push-off type.They should be reasonably small. The
design of push buttons has the following distinguished features :

(a) Surface should be slightly concave, so that the finger force may be transmitted more
effectively.
(b) Diameter should be able to accommodate the fingertip without slipping.
(c) Recommended design range is as follows : Diameter : 12-15 mm ,Movement : 3-10 02 Marks
mm Resistance : 200-500 grams
(d) It is to be made of such a material which is easily distinguishable and preferably can
shine even in the dark (luminescent color may be used) so that there should be no
problem in locating it.

Knobs:-
These are rotary controls that can be operated freely by gripping it on both sides with
the fingers of one hand. They are available in different shapes such as circular, bar-
shaped, pointed and so forth.

The general design guidelines for these products are given below.

(a) The shape should be in such a manner that must be easy to feel and provide a
reliable 02 Marks
grip.
(b) Any movement required must be clearly visible.
(c) They may be used for making fine adjustment when loads are light .
(d) Thicker knob allows two or three fingers for more grip and more ease.
(e) The gear ratio should be such that it should minimize the force required to operate.
(f) Protection of scale against scratching is essential. An arc of 120 degrees can be
obtained on a single rotation. For greater angle grasps have to be changed but this
should be avoided.
(g) When several knobs are attached to an instrument panel, pointed knobs are
preferable as the adjusted position readily obtained.
Q. 4 Attempt any THREE of the following 12 Marks

a) Explain importance of TQM.

TQM is concerned with the integration of all the efforts in the organization towards
quality improvement, quality development and quality maintenance to meet full
customer satisfaction at economical levels. TQM enhance quality of work and employee
04 marks
satisfaction through participation and involvement and consequently the image of for
explanation
organization. TQM develops participative culture where each employee can directly
participate in areas relating to his work and decisions concerning his works. It is very
important for supplier as well as customer.
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MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
TQM results:
1. Lower cost of manufacturing.
2. Lower inventory investment.
3. Reduction in product development time.
4. Shorter throughput time.
5. Lower the cost of inspection.
6. More training and improvement in skill of employees.
7. Improve business and development of good work culture.
b) Construct two handed process chart for assembly of nut, bolt and washer.

Job :- Assembly of nut, bolt and washer

Chart Begins:- Both hands free before assembly
Chart Ends:- Both hands free after assembly
Chart:- Existing/Proposed Date:- 13/06/2022
Operator:-XYZ Chart No.1

Left HandRight Hand

Sr. Description of the Symbol Sr. Description of the Symbol

activities activities
No No

1 To the bolt tray 1 To the washer tray

2 Picks up one bolt 2 Picks up one washer

04 Marks
3 Returns to original 3 Returns to initial for
position position Complete
Assembles washer over chart
4 Holding the bolt
4 bolt
5 Idle
5 To the nut tray
6 Idle
6 Picks up one nut
7 Idle
7 Returns to initial
8 Idle position
9 To the assembly tray Assemble nut to the
8
bolt
10 Puts the assembly in the
tray Idle
9
Returns to the original Idle
11 10
position
11 Idle

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MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
c) Write any two advantages and limitations of ISO 9000.
Advantages of ISO 9000:-
1. ISO 9000 gives international recognition of ability, credibility and expertise, thereby
increasing the number of customers.
2. ISO 9000 provides a competitive edge in the domestic and global markets.
3. It motivates the employees and develops pride in them for achieving excellence in
quality. It helps to enhance quality image of the company.
4. It provides a climate for consistent improvement in quality.
5. It creates a more effective and efficient operation. 02 Marks
6. It helps to increase the level of customer satisfaction and relation. for
7. It reduces audits.
8. It helps in the improvement of the marketing process. 02
9. Enhance the motivation of employees as well as awareness and morale. advantages
10. It promotes international trade.
11.Helps in increasing the profit
12. It helps in the reduction of wastage and increase productivity.
13. It is a common tool for standardization.
14. Improvement in productivity.
15. Effective Maintenance of quality system.
Limitations of ISO 9000:-
1.Owners and managers do not have an adequate understanding of ISO 9000.
2. Most of companies have less funding available, therefore companies are finding
Difficulties to adopt ISO system.
3. ISO 9000 registration need heavy document workload.
02 Marks
4. ISO 9000 registration process require long time.
for
5. Implementation of this system is very demanding of resources.
6. Work culture need to be changed/improved. 02
Limitation

d) Differentiate between variable control chart and attribute control chart based on any
four parameters.
Parameters Variable Control Chart Attribute Control Chart

Characteristics Actual Measurements of Determining the presence of

quality characteristics quality characteristics

Data Continuous Discrete

Time More Less 01 mark for

each
Inspection High Less Parameter
Cost

Measurement Length, Temp. etc. Defective, Non -Defective.

Instruments Vernier calipers, Micrometer Gauges like Go and NOGO.

Examples X-Bar and R chart P, C, np Chart

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MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
e) Prepare operation process sheet and sequence of operation for step turning
operation on lathe machine.

All dimensions are in mm

Operation Process Sheet:-
Part Name: ABC Material:-MS

Part No. 1234 Blank Size:- Φ53 x 105

Feed Speed
Sr. Description of Tools/ DOC
Machine Gauges mm/re m/mi
No Operation Fixtures mm
v n
Clamp the blank in
chuck projected Center 3 jaw
01 -- -- -- --
105 mm outside Lathe chuck 04 Marks
Facing operation 3 jaw for
chuck complete
Center Operation
02 HSS,RHS -- 0.05 30 0.5
Lathe Process
t
ol Sheet
Turn diameter to 3 jaw
50 mm for 100 chuck HSS
Center Vernier
03 mm length R.H. 0.05 40 0.5
Lathe caliper
Turning
tool
Turn diameter to 3 jaw
35 mm for 50 mm chuck HSS
Center Vernier
04 length R.H. 0.05 40 0.5
Lathe caliper
Turning
tool
Turn diameter to 3 jaw
20 mm for 20 mm chuck HSS
05 length Center Vernier
R.H. 0.025 30 0.25
Lathe caliper
Turning
tool
Cutting Speed, Feed and Depth of Cut values are assume approximately.
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MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
05 Attempt any TWO of the following: 12 Marks

a State and explain in brief any six ergonomics consideration in design of machine
element.

Ergonomics is the science of work which removes barriers to quality and designs and
develops new systems to ensure human comfort and safety with maximum efficiency.
The following are the ergonomic considerations in design of machine element: Any six
1. Vibrations: considerati
 Vibrations are unwanted frequencies resulted from unwanted frequencies. ons
Vibrations are undesirable factor. required
 While designing of a machine, care should be taken of designing such that
minimum vibrations are generated.
 To control them, vibration absorbers, vibration dampers should be used.
2. Noise:
 Noise is also an undesirable factor considering human health.
 It should be noted that the designed machine should have minimum possible 01 Mark for
vibrations so as to maintain peace in the work environment. each
3. 3. Display: considerati
i. Displays are the device which presents the information about the state of the system. on
ii. Various machines have visual displays fitted upon them. These displays should be
located accordingly such that it becomes easy foe the operator to read and note
down the display readings.
iii. Displays should highlight the measured values without overlapping of pointing
arrow.
4. Work factor: (Factor of Safety)
 While designing of any machine which would have certain applications of loads and
forces on it, should consider appropriate stress factor, failure factors.
 It is important to conclude design safe in order to ensure safety of the operator.
5. Handles and Levers:
 The hand levers provided for the operation on the machine should have efficient
control.
 They should be located at appropriate locations so that it would be easy for an
operator to operate to operate them.
6. Location of Display and Controls:
 The various displays and controls provided for functioning of the machine should
be located at proper positions considering human body dimensions.
 E.g.: A foot lever should be so provided that it could function by standing and
sitting of the operator.

7. Thermal Conductivity:
The machine should have appropriate thermal conductivity rate in accordance with
human body temperature in order to lessen the health problems caused through
severe hot or cold conditions of machine.
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MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
8. The controls on machine should be easily accessible and properly positioned.
9. The control operation should involve minimum motions.
10. Height of machine should be matched with the worker for operation.
11. Machine should make less noise during operation.
12. Force & power capacity required in turning the wheel as per operation or human
being can apply normally.
13. Should get the required accuracy in operation.

b Explain critical path method with suitable example and write its applications. ½ Mark

1. CPM, also known as Critical Path Method is a method used for determining the
critical path amongst the available path to reach the output. ½ Mark
2. It is showcased using a Network Diagram showing the various paths available to
complete an activity, including the time required for completion of particular
½ Mark
activity.
3. The critical path is demonstrated using a Network Diagram comprising of Network,
Events and Activity. ½ Mark
4. Network: It is a graphical representation of activities, events and time required to ½ Mark
complete the task in a logical sequence.
5. Activity: It is the time taken to complete two consecutive activities in the Critical ½ Mark
Path.
Event: These are the start and end points of an activity.

Example:

15 01 Mark for
B
C 5 example
5
D

A
3

6
E G
F 1
4

Fig.: Network Diagram for CPM

i) In above example, Event A is the start event and Event D resembles as End Event.
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MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
ii) The network diagram shows two possible paths to complete the task assigned or to
reach till “D”.
iii) Path 1: A-B-C-D and Path 2: A-E-F-G-D
iv) Now the time required for both paths are:
Path 1: 5 + 15 + 5 = 25 minutes
Path 2: 6 + 4 + 1 + 3 =14 minutes
v) The time required for Path 1 is highest among both the paths and thus it is the
Critical Path to reach event D.

Applications:
Project Management by Project Managers, to calculate critical path in constructional 02 Mark for
application
fields, CPM is applicable to both large and small projects, taking from space
programmes to wedding or horse show. It is widely recognized and is most versatile and
potent management planning technique. CPM is a technique, used for planning and
controlling the most logical and economic sequence of operations for accomplishing a
project.

C In a manufacturing process following observations are recorded. Draw appropriate

control chart and conclude.

Sample No. Defective found out of 50

1 4

2 5

3 0

4 3

5 2

6 5

7 1

8 6

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Number of jobs
Sr. Defectives % defectives
inspected
No. d (d/n x 100)
n
1 50 4 8
2 50 5 10
3 50 0 0 01 Mark
4 50 3 6
5 50 2 4
6 50 5 10
7 50 1 2
8 50 6 12
Tota Ʃn = 400 Ʃd = 26
l

1/2 Mark
= X 100 = X 100 = 6.5 %

n= = = 50 1/2 Mark

Control Limits for P-Chart are:

UCL – P= +3X
1/2 Mark
= 0.065 + 3 X
= 0.1695
= 0.1695 X 100
= 16.95%

LCL – P = -3X

= 0.065 - 3 X 1/2 Mark

= - 0.0395

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01 Mark for
graph

01Mark
Conclusion: The process is within control.

06 Attempt any TWO of the following: 12 Marks

06 a Prepare outline process chart for replacement of four wheeler tyre with use of jack.

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05 Mark for
Chart

SUMMARY:

SYMBOL

01 Mark for
FREQUENCY 8 2 Summary

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Soln: 1. ‘5S Technique’ is a Japanese technique used by Japanese industries to keep the
workplace in a systematic way.
2. It is related with keeping workplace clean, items sorted, proper places, and make it has
a habit.
3. The 5S are:
i. Seiri (Sort): Indicates sorting, items kept near workplace to be sorted according to set
parameters (i.e. sort out necessary and not necessary).
ii. Seiton (Set in Order): Seiton means setting in proper sequence. The workplace items to
be located in proper allocated place, so that it would be easy to access them (i.e.
searching time should be zero). 01 mark
iii. Seiso (Shine): Indicating cleaning the workplace daily to make it shine using regular for each
cleaning. So that we regularly monitor workplace. “S”
iv. Seiketsu (Standardize): Standardization to be done by following daily practices. Use meaning
standard operating procedure (SOP).
v. Shitsuke (Sustain): Indicates to maintain and follow the above techniques regularly
and consistently.
Example:
1. Application of 5S in academic excellence.
2. Application in Food Industry.
Application of 5S in Food in Industry:

a) Seiri: Describes sorting of available raw material according of parameters like

variety, quality, etc. 01 Mark
for
b) Seiton: To set in order required material to locate them in order of their sequence
example
of operation.
c) Seiso: Maintaining workplace clean.
d) Seiketsu: Standardization of process. Use standard operating procedure (SOP).
e) Shitsuke: To sustain and maintain 5S technique in order to achieve quality and
overall efficiency consistently.
c Following are the inspection result of casting for a shift. Draw appropriate control chart
and write your conclusion.
Given
A2 = 0.58, d3 = 0, d4 = 2.11
Time 7 to 8 8 to 9 9 to 10 10 to 11 to 12 to 1 1 to 2 2 to 3
(hrs) am am am 11 am 12 pm pm pm pm
No. of
defects 08 07 09 06 04 05 04 06
casting
Casting
300 350 400 400 350 350 350 320
inspected

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Soln: 1. The problem is of P-chart. 01 Mark
2.
Sr. Fraction defectives
Jobs Inspected (n) Defectives (d)
No. (d/n)

1 300 08 0.0267
2 350 07 0.02
3 400 09 0.0225
4 400 06 0.015 01 Mark
5 350 04 0.0114
6 350 05 0.0142
7 350 04 0.0114
8 320 06 0.0187
Total Ʃn = 2820 Ʃd = 49

1/2 Mark
n= = = 352.5

1/2 Mark
= = = 0.0173

Control Limits for P-Chart are:

UCL – P = + 3 X
1/2 Mark
= 0.0173 + 3 X

= 0.038

LCL – P = - 3X
1/2 Mark
= 0.0173 - 3 X
= - 0.0035

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01 Mark
for graph

01Mark
Conclusion: The process is within control.
END

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WINTER – 2023 EXAMINATION
-
Subject Name: Industrial Engineering & Quality Control
Subject Code: IEQ
22657
Important Instructions to examiners:
1) The answers should be examined by key words and not as word-to-word as given in the model answer scheme.
2) The model answer and the answer written by candidate may vary but the examiner may try to assess the
understanding level of the candidate.
3) The language errors such as grammatical, spelling errors should not be given more Importance (Not applicable for
subject English and Communication Skills.
4) While assessing figures, examiner may give credit for principal components indicated in the figure. The figures
drawn by candidate and model answer may vary. The examiner may give credit for any equivalent figure drawn.
5) Credits may be given step wise for numerical problems. In some cases, the assumed constant values may vary and
there may be some difference in the candidate’s answers and model answer.
6) In case of some questions credit may be given by judgement on part of examiner of relevant answer based on
candidate’s understanding.
7) For programming language papers, credit may be given to any other program based on equivalent concept.
8) As per the policy decision of Maharashtra State Government, teaching in English/Marathi and Bilingual (English +
Marathi) medium is introduced at first year of AICTE diploma Programme from academic year 2021-2022. Hence if
the students write answers in Marathi or bilingual language (English +Marathi), the Examiner shall consider the
same and assess the answer based on matching of concepts with model answer.

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Q. Sub Marking
Answer
No. Q.N Scheme

10
Q.1 Attempt any FIVE of the following:
Marks
a State the need of inspection.
Ans
• To ensure that part, material or a component confirms to the established standard
• To meet the interchangeability of manufacture 1/2 Marks
• To maintain the customer relation by ensuring that no faulty product reaches the for each
customer point
• Provide the means of finding out shortcomings in manufacture
• It also helps to co-ordinate the functions of quality control, production, purchasing (Any four
and other departments of the organization Points)
• To take decision on the defective parts i.e. the possibility of making some of these
parts acceptable after minor repairs

b Define Fatigue: 02 Mark

for
Ans Definition definition
it is the state of the worker by which the capacity and willingness for doing the work is
reduced.
It is negative drive state corresponding to the need of the rest
c Define method study. State its objectives. Definition
1mark
Ans Definition Any two
Method study is the technique of systematic recording and critical examination of existing objective
and proposed ways of doing work and developing an easier and economical method (1/2x2)
Objectives of Method Study

1 Improvement of manufacturing processes and procedures.

2. Improvement of working conditions.
3. Improvement of plant layout and work place layout.
4. Reducing the human effort and fatigue.
5. Reducing material handling
6. Improvement of plant and equipment design.
7. Improvement in the utility of material, machines and manpower.
8. Standardization of method.
9. Improvement in safety standard.
d Define process planning.
02 Mark
Ans Definition for
Process planning is defined as the subsystem responsible for the conversion of design definition
data to work instruction.

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OR
Process planning is that function within a manufacturing facility which establishes the
process and process parameters to be used (as well as those machines capable of performing
these processes) in order to convert a piece-part from its initial form to a final form that is
predetermined on a detailed engineering drawing
e Name the various control charts in SQC.
Ans
Xbar chart ½ mark for
R chart each
C – chart Any four
P – chart
N – chart
NP – chart
f State any two symbols used in a process chart
Ans

01 Mark
for each
symbol

g Enlist various QC tools

Ans
1. Histogram.
2. Check Sheet.
1/2 Marks
3. Pareto Diagram. for each
tool
4. Brainstorming.
5. Cause & Effect Diagram (ishikawa/fishbone diagram)
6. Control Charts.
7. Scatter Diagram.

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12
Q.2 Attempt any THREE of the following:
Marks
a Explain the concept of line balancing. State its objectives
Ans
Line balancing means the balancing the (assembly/production) line. Suppose there are three
machines (workstations) A, B and C which can process 5, 10 and 15 pieces per unit time
respectively and the pieces flow from A to B to C (precedence constraint). Since A has
minimum capacity i.e. of processing only 5 pieces per unit time naturally work station
(machine) B will remain idle for 50% of its time and machine C for 66.66% of its time. It shows
that the line is unbalanced. One way to partially balance the line is to have three machines of
type A, 2 of type B, with every machined of type C. Another approach to balance the line will
be to give some other task to machines B and C so that they do not remain idle. The main
objective of line balancing will be distributing task evenly over the work stations so that idle
time of men and machines is minimized
02 Marks
explanati
Objectives of Line Balancing (four objectives for 2marks)
on and
1. To equalize the workload among the workers:
02 marks
Workload should be distributed equally at each stage of assembly line with respect to overall
for
assembly time.
objective
2. To identify the bottleneck operation:
s (any
Identify the bottleneck operation and improve the stage by doing some modifications or
four)
corrections.
3. To establish the speed of production line:
To divide the work properly with respect to worker’s movements. Sometime, combine the
operations for improvement the speed of production line.
4. To determine the number of workstations:
Industrial Engineer should do the time study of each stage and as per sequence of assembly
determine the number of workstations for completing all assembly operations.
5. To determine the percentage workload of each operator:
Workload at each stage should be distributed equally in terms of percentage too.
6. To assist in plant layout:
Line balancing can be done in such a way that it should utilize the minimum space in a factory.
Therefore, space saving can be possible.

b Explain man-machine relationship in terms of ergonomics.

Ans Man–machine system is a system in which the functions of a human operator (or a group of
operators) and a machine are integrated. This term can also be used to emphasize the view of
such a system as a single entity that interacts with external environment. Human factors are a
system concerned with the relationship among human beings, work place or work environment 04 Marks
and machines. The proper integration of man and machine, which is beneficial for human
operator and enhances the overall system performance, is a primary aim of the ergonomics
discipline. For eg. A manual system consists of hand tools and other aids which are coupled by
a human operator who controls the operation. Operators of such systems use their own physical
energy as the power source. The system could range from a person with a hammer to a person
with a super-strength giving exoskeleton.

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c Differentiate inspection and quality control
Ans Sr. Inspection Quality Control
1 Quality control is a broad term, it involves
Inspection is a part of quality
inspection at particular stages, but more
Control.
inspection does not mean quality control
2 Quality control is an effective system for
Inspection is an act of checking integrating quality development, quality
components, products at various maintenance and quality improvement
stages in manufacturing and efforts of various groups in an
sorting out the defective items organization to enable the production to
from good items. be carried out at most economical level
and to achieve satisfaction of customers.
01 Mark
3 Inspection uses precision Quality control uses devices such as
for
measuring instruments such as statistics, control charts, acceptance
Vernier calipers, micrometers, sampling ,process capability, quality one point
profile projectors etc. audits etc.
4 Quality control concerned with quality of
Inspection is concerned with the
Future production. e.g. Take a sample,
quality of past production to
inspect it, if it is defective find out the
judge conformance and sorting
reasons and take corrective action, so
out defective items from good
that such type of defects will not occur in
items
Future.
5 Everybody working in an organization is
Inspection is mainly the
responsible for quality of products
Responsibility of the inspectors.
Produced.

d Sate Merits and demerits of Acceptance Sampling: 02 Marks

Ans
for
Merits of Acceptance Sampling: 02
(i) The method is applicable in those industries where there is mass production and the Merits
industries follow a set production procedure. and 02
(ii) The method is economical and easy to understand. Marks
(iii) Causes less fatigue boredom. for
(iv) Computation work involved is comparatively very small. 02
(v) The people involved in inspection can be easily imparted training. demerits
(vi) Products of destructive nature during inspection can be easily inspected by sampling.
(vii) Due to quick inspection process, scheduling and delivery times are improved.
Demerits of Acceptance Sampling:
It does not give 100% assurance for the confirmation of specifications so there is always some
likelihood/risk of drawing wrong inference about the quality of the batch/lot.
(ii) Success of the system is dependent on, sampling randomness, quality characteristics to be
tested, batch size and criteria of acceptance of lot.

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Consumer’s Risk:- Sometimes it may happen that the quality of the lot is not good but the
sample results show good quality units as such the consumer has to accept a defective lot. Such
a risk is known as consumer’s risk. In other words, the probability of accepting a lot which has
actually been satisfactory by the consumer according to a predetermined standard is known as
consumer’s risk. Consumer’s risk is designated as the Beta (β) risk.
c Explain cost of quality
Ans Cost of quality is a method for calculating the costs that companies incur ensuring that products 1 Mark
meet quality standards, as well as the costs of producing goods that fail to meet quality meaning
standards. and
Cost of quality includes
3 Marks
Market research cost
for
Product research and development cost
explanati
Design cost
on
Cost of manufacturing
Cost of inspection
Cost of quality assurance
d Apply principles of ergonomics for designing of lever for hand press machine
Following ergonomics principle should be considered while designing lever for hand press
Ans

• Neutral Posture to be maintain while handling machine handle

01 Mark
• Reduce Excessive Force for
• Keep it Easy to Reach one point
• Work in Power or Comfort Zone .The power zone refers to the zone where interacting
with objects has the least amount of effort spent, it is also known as “hand shake zone”.
• Reduce Excessive Motion

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• Reduce Static Load
• Minimize Pressure Points
• Provide Clearance
• Enable Movement and Stretching
• Reduce Excessive Vibration
12
Q.4 Attempt any THREE of the following:
Marks
a State the principles of TQM
Ans
1. Focus on Customers
2. Full Employee Commitment:
3. Strategic and Systematic Approach
4. Adherence to Process ½x8=4
marks
5. Fact-based Decision Making:
6. Effective Communication.
7. Continual improvement:
8. Integrated Systems:

b Construct two handed process chart for an activity of replacing old battery of mobile
handset.
Ans

3 Marks
for chart
and 1
mark for
summary

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c Write advantages and limitations of ISO 9000.(Four each)

Ans
Advantages of ISO 9000:-

1. ISO 9000 gives international recognition of ability, credibility and expertise, thereby
increasing the number of customers.
2. ISO 9000 provides a competitive edge in the domestic and global markets.
3. It motivates the employees and develops pride in them for achieving excellence in quality. It
helps to enhance quality image of the company.
4. It provides a climate for consistent improvement in quality.
5. It creates a more effective and efficient operation. 02 Marks
6. It helps to increase the level of customer satisfaction and relation. for
04
7. It reduces audits.
Advantage
8. It helps in the improvement of the marketing process. s and 02
9. Enhance the motivation of employees as well as awareness and morale. Marks
10. It promotes international trade. for
11.Helps in increasing the profit 04
limitations
12. It helps in the reduction of wastage and increase productivity.
13. It is a common tool for standardization.
Limitations of ISO 9000:-
1.Owners and managers do not have an adequate understanding of ISO 9000.
2. Most of companies have less funding available, therefore companies are finding Difficulties
to adopt ISO system.
3. ISO 9000 registration need heavy document workload.
4. ISO 9000 registration process require long time.
5. Implementation of this system is very demanding of resources.
6. Work culture need to be changed/improved.
d Compare variable measurement and attribute measurement
Ans
Parameters Variable measurement Attribute measurement

Characteristics Actual Measurements of Determining the presence of

quality characteristics quality characteristics
Data Continuous Discrete 01 Mark
for
Time More Less
one point
Inspection Cost High Less

Measurement Length, Temp. etc. Defective, Non -Defective.

Instruments Vernier calipers, Gauges like Go and NOGO.

Micrometer
Examples X-Bar and R chart P, C, np Chart

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Ans

1 mark
for figure
and 3
marks for
operation
sheet

12
Q.5 Attempt any TWO of the following
Marks
a Explain the types of display’s and sketch any two

Displays are devices which the man can receive the information from the machine Explanatio
Ans A good display device is one which allows proper combination of speed, accuracy and n 2 marks
and figure
sensitivity of display 2 marks
Following are the types of display each
1. Visual display
a. Qualitative display

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b. Quantitative display

2. Auditory displays

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Supply chain management (SCM) refers to the management of operations that are involved in
the procurement of raw materials, their transformation into finished goods, and their distribution
to the end consumer.

The five functions of supply chain management include the following:

1. Purchasing
In the manufacturing process, raw materials are required to produce goods and products. It is
important that these materials are procured and delivered on time so that production can begin.
For this to occur, coordination with suppliers and delivery companies will be required to avoid
explanatio
any potential delays. n 2 mark
2. Operations and
Demand planning and forecasting are usually required before materials can be procured, as the function 1
mark each
demand market will dictate how many units to be produced and how much material is required (any four
for production. functions)
3. Logistics
Logistics is the part of supply chain management that coordinates all aspects of planning,
purchasing, production, warehousing, and transportation so that the products will reach the end-
consumer without any hindrances
4. Resource Management
Production consumes raw materials, technology, time, and labor. Resource management
ensures that the right resources are allocated to the right activities in an optimized manner..
5. Information Workflow
Information sharing and distribution is what keeps all of the other functions of supply chain
management on track. If the information workflow and communication are poor, it could break
apart the entire chain.

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c
Ans

1 mark

2mark

1 mark

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12
Q.6 Attempt any TWO of the following
Marks
a Outline an appropriate process chart for the activity “Replace old battery of car”

Ans

4 marks
for chart
and 2 mark
for
summary

b Draw and explain Histogram, Pareto chart and scatter diagram

HISTOGRAMS
• A histogram is a bar graph that shows frequency data.
• It is used to graphically summarize and display the distribution and variation of a process data
set
. • It provides the easiest way to evaluate the distribution of

Explanatio
n 1 mark
and figure
1 mark
each

data

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PARETO CHARTS
• The Pareto chart can be used to display categories of problems graphi ll ca y so they can
be properly prioritized.
• A Pareto chart or diagram indicates which problem to tackle first by showing the proportion
of the total problem that each of the smaller problem comprise
. • This is based on the Pareto Principle: 20% of the source cause 80% of the problem.

SCATTER DIAGRAM
• To identify the correlations that might exist between a quality characteristic and a factor
that might be driving it.
• A scatter diagram shows the correlation between two variables in a process. These
variables could be a Critical To Quality CTQ characteristic.

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c 10 samples of size 5 have been collected with following observations.
Draw the appropriate control chart and state the process is in statistical control or not.

Calculatio
n 2 Mark

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Grap
h 03
Mark
s

Conclusion
01 Mark
Conclusion : As all observations are within control limits, process is under control

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Subject Name: Industrial Engineering & Quality Control Subject Code: 22657

XXXXX
Important Instructions to examiners:
1) The answers should be examined by key words and not as word-to-word as given in the model answer scheme.
2) The model answer and the answer written by candidate may vary but the examiner may try to assess the
understanding level of the candidate.
3) The language errors such as grammatical, spelling errors should not be given more Importance (Not applicable for
subject English and Communication Skills.
4) While assessing figures, examiner may give credit for principal components indicated in the figure. The figures
drawn by candidate and model answer may vary. The examiner may give credit for any equivalent figure drawn.
5) Credits may be given step wise for numerical problems. In some cases, the assumed constant values may vary and
there may be some difference in the candidate’s answers and model answer.
6) In case of some questions credit may be given by judgement on part of examiner of relevant answer based on
candidate’s understanding.
7) For programming language papers, credit may be given to any other program based on equivalent concept.
8) As per the policy decision of Maharashtra State Government, teaching in English/Marathi and Bilingual (English +
Marathi) medium is introduced at first year of AICTE diploma Programme from academic year 2021-2022. Hence if
the students write answers in Marathi or bilingual language (English +Marathi), the Examiner shall consider the
same and assess the answer based on matching of concepts with model answer.

Q. Sub Answer Marking

No. Q. N. Scheme
1 Attempt any FIVE of the following: (5x2=10)
a) rocedure of method study - 2m
1. Select the work to be analyzed.
2. Record all facts relating to the existing method.
3. Examine the recorded facts critically but impartially.
4. Develop the most economical method commensurate with plant requirements
5. Install the new method as standard practice.
b) 6. Maintainofthe
Objectives new method.
quality control (any four) - 2m (1/2
1. Improved Income mark each)
2. Cost Reduction
3. Interchangeability
4. Customer’s Satisfaction
5. Optimum Quality
6. Integration of Quality Effects
7. Quality Mindness.
c) Six sigma with an example - 2m (1m for
Six-sigma is defined as ‘a disciplined and systematic data drive approach for eliminating definition
defects in any process of manufacturing company or service industry’. and 1m for
example)

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For example: When number of observations are plotted in the form of frequency polygon
for any variable characteristic, such as, diameter of shafts produced, then frequency
polygon shows a smooth curve obtained by joining various points (observations) on the
graph (Normal distribution curve).
d) Consideration in Display Design - 2m (Any
Following consideration should be taken in the design of display four- 1/2
1. Environmental Conditions mark for
2. Worker’s Capacity each)
3. Safety
4. Nature of work
5. Biological factors
e) Supply chain management – 2m for
Supply chain management is the handling of the entire production flow of a good or service definition
to maximize quality, delivery, customer experience and profitability.
OR
Supply chain management (SCM) is the optimization of a product's creation and flow from
raw material sourcing to production, logistics and delivery to the final customer.
f) Variable and attribute measurement – 2m (1m
Variable measurement- ‘When measurements are carried out to find quality characteristic each)
of a component, the quality is said to be expressed by ‘variables’. For example length of
bar in mm.
Attribute measurement- ‘When a record shows only the numbers of work pieces/items or
products conforming and non-conforming to any specified requirement, it is said to be
attribute’. For example, GO and NO GO gauge.
g) Applications of P chart and C Chart- 2m (any two
Applications of P Chart- applications
(a) To find out average proportion of defective articles submitted for inspection, over a of each)
period of time.
(b) In a sampling inspection of large lots.
(c) To bring attention to management, any changes in average quality level.
(d) To identify and correct the causes of bad quality.
(e) Provides useful record of quality history management.
Applications of C Chart-
(a) Number of surface defects in an aircraft wing.
(b) Number of defects such as blowholes, cracks in a casting.
(c) Number of imperfections observed in a cloth of unit area.
(d) Number of surface defects in galvanized sheet.
(e) Number of small holes in glass bottles.
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__________________________________________________________________________________________________
2. Attempt any THREE of the following: (3x4=12)

a) Multiple activity chart with an example- 4m

It is a chart where activities of more than subject (worker or equipment) are recorded on a (Explanation
common time scale to show their inter-relationship. Multiple activity chart is made to 2m and
• Study idle time of the man and machines. example
• Determine number of machines handled by one operator 2m)
• Determine number of operators required in teamwork to perform the given job.
A Multiple activity chart consists of a series of bars (columns) placed against a common
time scale. Each subject is allocated one bar and the activities related to the subjects are
represented in this bar. The columns are placed against a common time scale which starts at
zero and ends at cycle time of the job. The task to be recorded is broken into smaller
elements and time for each element is measured with the help of a stop watch. The
activities are then recorded in the chart in their respective columns.
Multiple activity chart is extremely useful in organizing teams of operatives on mass
production work. This is also used in maintenance. It is used to determine the number of
machines which is operator can handle. It is useful in:
• Reducing idle time of machines and operators.
• Combine or eliminate some of the operations.
• It helps to explore ways to increase utilization of men and machines.
Example-

b) Criteria’s for selecting a manufacturing process- 4m (any

1. Quantity of the product eight)
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2. Cost for tooling, manufacturing machines and equipment 1/2 Mark
3. Time required for processing Each
4. Level of skilled labor required
5. Process supervision
6. Energy consumption
7. Availability of material and cost of material
8. Capabilities required to processes material
9. Product dimensions and size
10. Surface finish required
11. Design tolerances
12. Waste produced by the process
13. Maintenance costs
14. Other costs
c) Anthropometric data for designing an adult male as an operator to control a machine 4m
–
Anthropometric data be applied for in the following steps :
1. Identify the important dimensions which come in contact with machine.
2. Identify the user population using the machine.
3. Determine the principles to use. ( Either Extreme, average, adjustable)
4. Select the percentile range to accommodate. (5% or 95%)
5. Find relevant body dimensions from Anthropometric table.
6. Make modifications if required
7. Test critical dimensions with a mock-up, user testing, or a virtual model.
d Difference between process inspection and final inspection – 4m (any
Sr. No. Process Inspection Final Inspection four points)
1 Process inspection for Final inspections take place when
manufacturing refers to inspection production is complete.
at any point along the production
cycle.
2 This is done to check the The overall product is measured against
parameters within each section of engineering, customer requirements,
the process. and standards.
3 It is possible to stop the production It not possible to stop the production as
at the moment if rejection is it is the post inspection procedure.
identified.
4 This will help to isolate the faulty It may be necessary to perform the
semi-finished goods, before they functional test (finished product is run
enter for next operation. to see whether, it performs according to
its specifications or not?) to evaluate
the fitness of product.
5 Eg. Inspection of raw materials or Eg. Inspection of finished goods or
semi-finished products. products.
6 Wastage is minimized at early Wastage is not minimized if rejection
stage of production. takes place.

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Q. Su Answer Marking
No. b Scheme
Q
N

Q.3 Attempt any THREE of the following: ( 3x4=12) 12 Marks

3 a Differentiate between flow process chart and travel chart.

Sr.No. Parameter Flow Process Chart Travel Chart

1 Definition Flow Process Chart is defined as Travel Chart is defined

the process chart which sets out as the record of the 1 Mark
the sequence of the flow of a amount of travel by the for each
product through the various worker or material while point
departments by recording the going from machine to
event using the appropriate machine or from one
process chart symbols. department to another.

2 Type of Generally flow chart records a Travel chart records

movement simple and main movements. complex movements.
recorded

3 Form of Flow process chart uses symbols It uses a tabular format

representation for representation of movements for the representation of
movements.

4 Use It is used to identify the flow of It is used to identify the

man, machine and material frequency of
movements.

b Prepare a two handed process chart for a task of cutting glass tubes using appropriate
process chart symbol.

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Task : Cutting of glass tubes

Chart begins: Tube in Hand

Chart ends: Tube in Hand

Charted By: ABC Date: 10/02/22

Left-hand Left-hand symbol Right-hand symbol Right-hand

description description

Pick up the tube Idle

Hold the tube Idle

Hold the tube Pick up the cutter

Hold the tube Move the cutter

4 Marks
tightly toward the tube

Hold the tube Cut the tube

Hold the tube Place the cutter on

table

Place the tube on Idle

table

Symbol Left-Hand Right-Hand

2 3

Summary - 3

- 1

5 -

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1. Line Balancing means balancing the production or assembly line.

2. Line balancing is the arrangement of the individual processing and assembly tasks at the
workstation so that the total time required at each workstation is same and the flow of
production will be smooth.
3. The main objective of line balancing is to distribute task evenly over the workstations so
that idle time of man and machine is minimized..
4. Heuristic method involves two stages for line balancing
i. Drawing the precedence diagram which determines the priority order of element.
ii. Assignments of elements to the stations.
5. Task can be assigned in two ways:
i. Permutability of task: It means that any number of tasks or steps of the column can be
½ Mark
combined to make their total time closer to cycle time.
for each
ii. Transferability of task: For making the total time equal to the cycle time tasks or steps point
may be shifted laterally.
6. Consider an example: Suppose there are three machines (workstations) A, B and C
which can process 5, 10 and 15 pieces per unit time respectively and the pieces flow
from A to B to C (precedence constraint).

A B C
(5 pieces/min) (10 pieces/min) (15 pieces/min)

7. Since A has minimum capacity i.e. of processing only 5 pieces per unit time naturally
work station (machine) B will remain idle for 50% of its time and machine C for 66.66%
of its time.

8. It shows that the line is unbalanced

9. Line can be balanced by addition of one or more machine A which has the capacity of 5
pieces per unit.

A B C
( 10 pieces/min) (10 pieces/min) (15 pieces/min)

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(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
Q. Su Answer Marking
No. b Scheme
Q
N
d Explain compatibility in the design of Toggle switch and Push button.

1. Compatibility is central concept in the study of displays and controls and gives
relationship between signals, control responses and the expectations of the operator.

2. The most common two categories are as follows:

i. Spatial Compatibility: It refers to the physical arrangements of display and control

components.

ii. Movement Compatibility: It refers to the relationship between the movement of

control devices and display.

3. Compatibility in the design of toggle switch:

i. Toggle switch should be positioned on machine in such a way that it should be easily
accessible to operator.
1 Mark
ii. Toggle switch should confirm with the anatomy of the operator’s hand. for each
iii. Toggle switch should provide desired movement on display when it is operated. point

iv. e.g. if toggle switch is positioned upwards, display should indicate either open, on,
start, increase.

v. Toggle switch should be painted in either red or black colour to grasp the attention of
an operator.

4. Compatibility in the design of Push button

i. Push button should have concave surface, so that the finger force may be transmitted
more effectively.

ii. Push button is used for emergency purpose so it should be positioned on machine in
such a way that it should be easily accessible to the operator.

iii. Diameter of pushbutton should be able to accommodate the fingertip without sliding.

iv. Push button should give desired movements on controls of machine when it is
operated.

v. It should be made of such material which is easily distinguishable and preferably can
shine even in the dark so that there should no problem in locating it.

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a A project consists of 8 activities. Precedence relation and activity times are given. Draw the
network and compute the critical path.

Activity Immediate Predecessor Activity time( Weeks)

P - 12

Q - 20

R - 28

S R 12

T P,Q 28

U T,S 12

V S 8

W U,V 8

1) Network Diagram

1 Mark

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Path 1 = P-Q-R-S-V-W

= 12+20+28+12+8+8 1 Mark

Path 1 = 88

Path 2 = P-T-U-W

= 12+28+12+8

Path 2 = 60 1 Mark

Path 3 = P-Q-T-U-W

= 12+20+28+12+8

Path 3 = 80

Path 4 = P-Q-R-S-U-W

= 12+20+28+12+12+8 1 Mark

Path 4 = 92

Critical Path is P-Q-R-S-U-W as project duration is 92 Days.

b Apply ergonomics aspects for designing of Hand Wheel for driving a car.

1. Hand wheel is a device which provides controlling torque via both hands.

2. Hand wheel of car should be positioned in front of driver’s seat so that it can be easily
accessible .

3. Diameter of hand wheel should be such that driver’s hand can be comfortably
positioned.

4. Shape of hand wheel which comes in contact with the driver’s hand should confirm Any 04
with the anatomy of driver’s hand. aspects,

5. Surface of the hand wheel should be smooth and shiny and it should not harm driver’s 01 Mark
hand. for each

6. Hand wheel should transmit maximum torque at minimum efforts.

7. Hand wheel should provide sufficient grip.

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1. Display are the devices through which user (operator) can receive the information
from the machine.

2. Scale on the display should be divided into suitable linear divisions like 0-10-15 or 0-
10-20 and not 0-5-23-33.

3. The size of letter or number on indicator is given as Height of letter or number >/200.

4. The number of sub divisions between numbered divisions on display should be

minimum. Any 04
5. Vertical figures should be used for stationary dial, while radially oriented figures for Aspect,
rotating dials. 01 Mark
each
6. The pointer on display should have knife edge to avoid parallax error.

7. Numbering should increase in clockwise direction on circular scale, rightward on

horizontal scale and upward on vertical scale.

d Show the following elements on OC curve and explain it.

α = 0.10
AQL = 0.01
β = 0.05
LTPD = 0.25 Values of α and β in diagram are 0.05 and 0.01

2 Mark

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It is Producer’s Risk

Sometimes it happen that in spite of good quality, the sample taken may show defective units ½ Mark
as such the lot will be rejected. In spite of good quality the lot is rejected, such a type of risk of
rejection is known as producer’s risk. Thus, the risk of rejecting a lot of good items is known as
producer’s risk.

2. AQL = 0.01

AQL stands for Acceptable Quality Level ½ Mark

It indicates that maximum number of defectives that customer accepts.

Also, probability of acceptance For AQL is higher.

3. β = 0.05

It is Consumer’s Risk ½ Mark

Sometimes it may happen that the quality of the lot is not good but the sample results show
good quality units as such the consumer has to accept a defective lot. Such a risk is known as
consumer’s risk.

4. LTPD = 0.25 ½ Mark

LTPD stands for Lot Tolerance Percent Defective

It indicates unsatisfactory quality level and customer not accepts it due to high number of
defectives in the lot.
e The record of number of defectives on daily samples of size 300, for 24 days is given below.
Prepare a control chart for number of defectives (np) and establish revised control limits
(Assume 3 σ Limits)

Day 1 2 43 4 5 6 7 8 9 10 11 12

No. 10 5 10 12 11 9 22 4 12 24 21 15
of
defe
cts

Day 13 14 15 16 17 18 19 20 21 22 23 24

No. 8 14 4 10 11 11 26 13 10 9 13 12
of
defe
cts
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__________________________________________________________________________________________________
Q. Su Answer Marking
No. b Scheme
Q
N
Slo Lots = N = 24 Sample Size = 300
Sr.No. Lot size (n) No. of Defectives

1 300 10
2 300 5
3 300 10
4 300 12
5 300 11
6 300 9
7 300 22
8 300 4
9 300 12
10 300 24
11 300 21
12 300 15
13 300 8
14 300 14
15 300 4
16 300 10
17 300 11
18 300 11
19 300 26
20 300 13
21 300 10
22 300 9
23 300 13
24 300 12
Total 7200 jobs 296 defectives

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= 1 Mark

p̅ n = 12.33

p̅ = total number of defectives / total Jobs

p̅ = 0.0411
• Control Limits for np chart

Upper Control Limit = p̅n +3

= 12.33 + 3

Upper Control Limit = 22.64

1 Mark
Lower Control Limits = p̅n -3

= 12.33 - 3

Lower Control Limits = 2.01

1 Mark

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(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
Q. Su Answer Marking
No. b Scheme
Q
N
From the drawn np chart we observed that, there are huge variation in the defects. For
example point 24 of day 10 & point 26 of day 19 are out of control. It means that dispersion is
more. Therefore it is very essential to maintain centering of the process. It is suggested that 1 Mark
values of defects should lie in the range of 2.01 to 22.64
5 Attempt any Two of the following. (2x6=12) 12 Marks

a A Worker operating on a machine performs the following elements. The description of

element, their observed time and rating are given. Compute the standard time for the
component.

Element Description Observed Time Rating Relaxation

Allowance

A Position the Job 0.25 80% 10%

B Switch ‘ON’ and lower 0.09 100% 11%

drill

C Drill Hole 2.8 90% 12%

D Raise drill and switch 0.05 80% 10%

‘OFF’

E Remove job from jig 0.15 110% 11%

Element Observed Rating Relaxation Basic time (normal time ) Allowances Standard Time
Time Allowance = Normal
=
Time +
Allowances
A 0.25 80% 10% = 0.25X80/100 = 0.2 0.2 X 10/100 0.2 + 0.02
= 0.02 =0.22 02+02+02
B 0.09 100% 11% =0.09X100/100 = 0.09 0.09 X 11/100 0.09 +0.0099
=0.0099 =0.0999 = 06 Mark
C 2.8 90% 12% =2.8X 90/100 = 2.52 2.52 X12/100 2.52+0.3024
=0.3024 =2.8224
D 0.05 80% 10% = 0.05 X80 /100 = 0.04 0.04 X10/100 0.04 +0.004
=0.004 =0.044
E 0.15 110% 11% = 0.15 X 110/100 = 0.165 0.165 X11 /100 0.165+0.01815
= 0.01815 =0.1815
Standard Time 3.36

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__________________________________________________________________________________________________
Q. Su Answer Marking
No. b Scheme
Q
N
b Draw and explain histogram, scatter diagram and Pareto chart with suitable examples.

• Histogram: The most commonly used graph for showing frequency distributions, or
how often each different value in a set of data occurs.

02+02+02

= 06 Mark

• Pareto chart :
- The pareto chart is one of the too in 7 basic tools of quality management
- Pareto chart is a chart that contains bar and line graph which is also known as pareto
diagram or paraeto analysis.
- Bar graph shows number of defects in decending order and line graph shows
cumulative persentage of defects.
The purpose of pareto giagram is to highlight the higest occurring type of defects.

• Scatter diagram: Graphs pairs of numerical data, one variable on each axis, to look for a
relationship.
• It is a tool to get relationships between two variables. This is a graph where one
variable is plotted on the x-axis whereas the other is plotted on y-axis. It can be cause
and effect relation also you put on the respective axis.

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c The following tensile strength readings were taken from a line processing a heap of steel
after heat treatment :

Date 1 2 3 4 5 6 7 8 9

Reading 95.5 93.0 96.5 87.5 90.5 96.0 100.0 98.0 97.0

Date 10 11 12 13 14 15 16 17 18

Reading 96.0 93.5 98.0 90.0 94.0 89.5 96.5 92.0 98.5

Date 19 20 21 22 23

Reading 96.5 92.0 97.0 99.5 91.0

Construct a two days moving average and range chart for the data. Analysis the results.

Date Reading 2 days 2 days 2 days Combination X̅ R̅

moving moving moving for
total average range conventional
control chart
1 95.5
2 93.0 188.5 94.25 2.5
3 96.5 189.5 94.75 3.5 A 94.5 6.25
4 87.5 184 92 9 B 3.37 6.25
5 90.5 178 89 3 C 90.5 6.0 02+02+02
6 96.0 186.5 93.25 5.5 A
7 100 196 98 4 B = 06 Mark
8 98.0 198 99 2 C
9 97.0 195 97.5 1 A
10 96.0 193 96.5 1 B
11 93.5 189.5 94.75 2.5 C
12 98.0 191.5 95.75 4.5 A
13 90.0 188 94 8 B
14 94.0 184 92 4 C
15 89.5 183.5 91.75 4.5 A
16 96.5 186 93 7 B
17 92.0 188.5 94.25 4.5 C
18 98.5 190.5 95.25 6.5 A
19 96.5 195 97.5 2 B
20 92.0 188.5 94.25 4.5 C
21 97.0 189 94.5 5 A
22 99.5 196.5 98.25 2.5 B
23 91.0 190.5 95.25 8.5 C
ƩX̅ ƩR=95.5
=2084.75

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For Combination A

X̅ = 94.5 R̅ = 6.25 n= 3 , A2 = 1.03 D3= 0 D4 = 2.28

Control limits for X chart

UCL = X̅ + A2 R̅

= 94.5 + 1.03 X 6.25

= 100.93

LCL = X̅ - A2 R̅

= 94.5 - 1.03 X 6.25

=88.06

Control limits for R chart

UCL = D4 X R̅ = 2.28 X 6.25

= 14.25
LCL = D3 X R̅ = 0 X 6.25
=0

For combination A the process is not in control

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6 Attempt any Two of the following. (2x6=12) 12 Marks

a Apply 5 S for Automobile Service Station

Sr. 5S English Application in Automobile Service Station 2+2+2

No Word
1 SEIRI Sort Separate out unnecessary things (e.g Scrap parts , oil
etc. ) and eliminate them from working zone of
automobile service station.
The Service Station has to be divided into several
small zones such that every inch of space in the
company is included when all zones are combined.
Assign coordinators for each of these zones. The
zone will include garden, security cabins, toilets,
cafeteria, etc. also
2 SEITON Set in order Arrange the essential tools equipment, automobile
part in order , so that they can be easily accessed.
- Locate the items in the workplace according to their
frequency of use
-Place frequently used items near the place of use
-Store infrequently used items away from the place of
use
-Store items together if used together, and in sequence if
used in sequence.
-Make storage space larger than the item so that easy to
put back
3 SEISO Shine Clean the work place , everything without fail as per
schedule.
4 SEIKETSU Standardization Standardize the way of maintaining the cleanliness .
-Decide who is responsible for 3 S activities
-Integrate 3S duties into regular work duties
-Check on how well 3S conditions are being maintained
-Prevent unneeded items from accumulating
-Prevent things from having to be put back
5 SHITSUKE Sustain Practice 5S
Shitsuke means to make it a habit of properly maintaining
correct procedures.
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__________________________________________________________________________________________________
Q. S Answer Marking
No. Q Scheme

b The following details collected from 100 meter pieces of woolen cloth:

Purchaser’s 1 2 3 4 5 6 7 8 9
Inspection
no
No. of 15 5 1 4 3 0 3 1 6
defects
Purchaser’s 10 11 12 13 14 15 16 17 18
Inspection
no
No. of 1 3 5 7 4 10 5 0 1
defects
i) Compute the value of c̅ and its control limits

ii) Draw C chart

iii) Compute value of C̅ for the future production. If you deem it necessary.

1 Central line for C chart 2+2+2

C̅ = Number of Defects / Total Number of inspection.

C̅ = 74 / 18
C̅ = 4.11
2. Control limits for C chart

UCL = C̅+ 3√ C̅
= 4.11+3√ 4.11
= 10.191

LCL = C̅ - 3√ C̅
= 4.11+3√ 4.11
= -1.971 =0

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Process is not in control

Q. S Answer Marking
No. Q Scheme

c An Inspection results of 10 typical samples , for establishing a P chart are

Sample No. 1 2 3 4 5 6 7 8 9 10

No. of 10 12 8 9 11 8 10 11 9 12
Defectives

No. of 90 110 90 100 130 100 80 110 110 80

Inspected
defectives
(%)

Compute trial control limits. Plot P chart and establish the value of P̅ and control limits for
future production.

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Sample No No of Defectives No. of inspected Fraction % Fraction

defective (%) defective defective
1 10 90 0.111 11.1
2 12 110 0.109 10.9
3 8 90 0.088 .08.8
4 9 100 0.09 09.0 2+2+2
5 11 130 0.084 08.4
6 8 10 0.08 08.0
7 10 80 0.125 12.5
8 11 110 0.1 10.0
9 9 110 0.081 8.10
10 12 80 0.15 15.0
100 1000
Central Line = P̅ = Total No of defective / Total No of Inspection

= 100/1000
= 0.1
Average no of Defective = n = Total no of inspection/ Total no of sample

= 1000/10
= 100
Control Limits for P Charts

UCL P = P̅ + 3 √ P̅ (1-P̅)/n
UCL P = 0.1 + 3 √ 0.1 (1-0.1)/100 = 0.19

UCL P = P̅ - 3 √ P̅ (1-P̅)/n

UCL P = 01- 3 √ 0.1 (1-0.1)/100 = 0.01

Or
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__________________________________________________________________________________________________

Process is in control

--------------------------------------xx END XX------------------------------------

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Subject Name: Industrial Engg. & Quality Control Subject Code: 22657
Important Instructions to examiners: XXXXX
1) The answers should be examined by key words and not as word-to-word as given in the model answer
scheme.
2) The model answer and the answer written by candidate may vary but the examiner may try to assess the
understanding level of the candidate.
3) The language errors such as grammatical, spelling errors should not be given more Importance (Not
applicable for subject English and Communication Skills.
4) While assessing figures, examiner may give credit for principal components indicated in the figure. The
figures drawn by candidate and model answer may vary. The examiner may give credit for any equivalent
figure drawn.
5) Credits may be given step wise for numerical problems. In some cases, the assumed constant values
may vary and there may be some difference in the candidate’s answers and model answer.
6) In case of some questions credit may be given by judgement on part of examiner of relevant answer
based on candidate’s understanding.
7) For programming language papers, credit may be given to any other program based on equivalent
concept.
8) As per the policy decision of Maharashtra State Government, teaching in English/Marathi and Bilingual
(English + Marathi) medium is introduced at first year of AICTE diploma Programme from academic year
2021-2022. Hence if the students in first year (first and second semesters) write answers in Marathi or
bilingual language (English +Marathi), the Examiner shall consider the same and assess the answer
based on matching of concepts with model answer.

Sub
Q. Marking
Q. Answer
No. Scheme
N.
Que.1 Attempt any FIVE of the following 10 Marks

a) Define work study. Name the various steps involved in it.

Sol. Work study: Work study investigates the work done in an organization and aims at
finding the best and the most effective way of utilizing the available resources (Men,
material, money and machinery) to achieve best possible quality work which involves
least possible time and causes least possible fatigue to the worker.
Or 01 Mark
Work study is a term used to embrace the techniques of method study and work
measurement, which are employed to ensure the best possible use of human and
material resources in carrying out a specified activity.
Steps: 1. Select the task to be studied.
2. Record the facts
3. Examine / analyze the facts 01 Mark
4. Develop new method/ measure the task
5. Install new method / compile standard time
6. Maintain new method.

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b) State the important functions of process Engineering.

Sol. (i) Selection of machines

(ii) Determining sequence of operation
½ mark
(iii) Combining operations wherever possible for each
(iv) Specifying inspection stages function
(v) Specifying tools, jigs, fixtures required for process.

c) Draw a scatter diagram showing negative correlation between two variables.

Sol.

02 Mark
for
diagram

d) Name the various control charts used in Statistical Quality Control.

Sol. - R chart
- σ chart ½ mark
C – chart for each
P – chart
e) With the help of block diagram show the basic structure of cause and effect diagram.

Sol.

02 Mark

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f) List out the various factors affecting quality of product.

1. Raw material used.
Sol.
2. Skill of operator.
3. Environmental conditions ½ mark
4. Machines used for production. for each
5. Calibration of instruments.
6. Proper methods of using an instrument.
g) Why 100% inspection is generally not preferred in the industry for mass production.
1. Cost required is more for 100% inspection.
Sol.
2. Time consuming process.
3. Fatigue to the operator. ½ mark
4. More staff is required for inspection. for each
5. More material handling so more chances of material damage.

Q.2 Attempt any THREE of the following: 12 Marks

a) Explain in brief different “Recording Techniques” used in method study.

Sol. The success of procedure depends upon the accuracy with which the facts are recorded
because they will provide the basis of both the critical examination and the development of
the improved method. All the facts relating to selected jobs are recorded in forms, charts
and diagrams.
(a) Charts: Indicating process sequence
(i) Outline process chart (Records only main events)
01 Mark
(ii) Flow process chart (Records all events)
1. Man Type
2. Material type 01 Mark
3.Machine / Equipment type
(b) Charts: Using a time scale
01 Mark
(i) Multiple activity chart
(ii) SIMO Chart
(c) Models and diagrams: Indicating movements
01 Mark
(i) Flow diagram
(ii) String diagram
(iii) Cycle graph
(iv) Chrono cycle graph
(v) Two-three dimentional models

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MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
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__________________________________________________________________________________________________ ___________
Sub
Q. Marking
Q. Answer
No. Scheme
N.
b) Explain “Part Print Analysis’. Which information does the process Engineer seeks from it.

Sol. Preliminary part print analysis is the first step in process planning. The product design
is conveyed by design department to process engineer in the form of part print. It is also 01 Mark
called as part drawings or blue prints. The part drawing consists of a variety of information
which helps in planning the process.
The detailed study or interpretation of part drawing under consideration for the
manufacturing of the part is called as part print analysis. Part print consists of following
information:
 Part geometry
 Dimensions and associated tolerances 01 Mark

 Geometrical tolerances
 Surface finish specifications
 Material specifications
 Quantity of parts required
Preliminary analysis is done in order to get a general visualization of the complete
manufacturing of the part.
General characteristics of the workpiece
The process engineering department tries to determine following requirements from the
detailed study of part print. These are:
01 Mark
1. The general description of the part.
2. The general configuration of part.
3. The material from which the part is made.
4. Originating operation of part.
5. Recording of changes in design.
6. Protection of workpiece during manufacture.
Working drawing:
 Working drawing is referred to all those drawings are reference drawings from
which, the parts are manufactured.
 These drawings includes part drawings of individual component and sub assembly 01 Mark
drawing and final assembly drawing
 Working drawing consists of conventions of process, tolerances, surface finish,
machining symbols etc.
 Working drawings are also referred as production drawings. The drawings represent
details of product, its size, shape, material, processes, and tools equipment.
• The operator is completely guided by the working drawings during the manufacturing
of the product. These are the legal and authentic documents of the company.

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__________________________________________________________________________________________________ ___________
Sub
Q. Marking
Q. Answer
No. Scheme
N.
c) With the help of a block diagram show the sequence of activities for any quality characteristics.

Sol. Quality Characteristics:

 For the refrigerator, it is described by using colour of body, capacity of the refrigerator,
brand of the compressor, warranty, service conditions, etc. These are called as 'quality 01 Mark
characteristics'.
 The quality characteristics are grouped as:
a) Structural type: Length, height, diameter, viscosity, etc. 01 Mark
b) Look type: Test, colour, texture, appearance, etc.
c) Time oriented: Safety, reliability, service, failures, etc.
d) Commercial Cost, discount, warranty, packing, etc.
 If also above conditions are applicable for the 'quality of product', similar characteristics
are used for 'quality of service".
 For service sectors like banking, postal services, transportation, bus services, hospital 01 Mark
services, etc. In these all above service characteristics are also used
 In banking : satisfaction of consumers, transaction accuracy, prompt time to time
service, telephonic internet banking, clarity in transaction space – infrastructure of bank, 01 Mark
ATM services, opening hours of banks, interest/loan facility, reliability i.e. accuracy of
services, image, honesty, responsiveness of bank, etc.
d) What is the effect of various environment factors such as temperature, noise, light on the
efficiency of operator.
Sol. Environment factors:
Working conditions are those which surround the worker as he performs his task.
Working conditions affect his physical well-being and therefore his efficiency towards work. 01 Mark
Some of the working conditions are mentioned below.
1. Temperature:
It includes the temperature, humidity and air flow. Poor heat and humid conditions produce
thermal stresses in the worker which affect their efficiency, concentration and dexterity of
their members of body. 01 Mark
0
Working temperature of 60-65 F is considered as normal but it varies according to nature of
work. Humidity and heat are related to each other both affect comfort and tolerance of the
body to heat. The effect of heat can be minimized by shielding isolating best sources, by
installing and providing local ventilation by permitting breaks or rest pauses in cool or
extreme hot conditions.

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2. Noise:
Noise is defined as unwanted sound and it has been shown to have both short and long
term effects on performance. Noise is the cause of various problems like fatigue, imitation,
reduced productivity and accidents.
To reduce the noise:
1. Control the noise at source.
2. By proper machine lubrication maintenance, padding and by providing noise mufflers 01 Mark
3. Using noise absorbers
4. Provision of ear plugs
S. Improved workplace layout.

3. Light
Most of the time man depends upon sunlight as a natural source of light. But sometimes of
weather conditions and in nights.
When shop activities are carried out indoors or at night, it is necessary to provide artificial
light.
01 Mark
Visibility depends on size and colour of product, its distance from eyes, intensity of light,
contest of colour these factors must be studied precisely in case of accurate works, work in
dangerous environment or in case of poor working conditions.
The lighting system should provide:
1. Sufficient brightness
2. Uniform illumination
3. A contrast between brightness of the job and of background
4. No direct or reflected glare

Que.3 Attempt any THREE of the following 12 Marks

a) Define process chart, draw the various symbols used in process chart.

Sol. A chart representing process is called process chart

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Event Symbols
Operation

Storage

Delay or Temporary storage

Transport 01+03
Mark
Inspection

Operation cum –transportation

Inspection cum –operation

b) Define anthropometry and explain its importance.

Sol. Anthropometry is defined as , “ the branch of ergonomics, which deals with shape and size
of body”.

Anthropometry is defined as “The scientific study of measurement and proportions of the 02+02
human body, which involves the systematic measurement of dimensional description of
Mark
size and shape of human body”.

Anthropometry play an important role in industrial design , clothing design , ergonomics

and architecture , where statistical data about the distribution of body dimensions in the
population are used to optimize products.

c) Draw a two handed process chart to assemble a nut and bolt.

Sol.
Job: Assemble a nut and bolt

Left hand Symbols Symbols Right hand

L. S. R. H.
Pick up bolt Idle
03+01
Hold Pick up nut Marks

Hold To left hand

Hold Assemble (Screw up)

Page No: ____/ N

Lift hand Right hand

01 02

03 00

00 01

d) Classify the man – machine system

Sol. a) Based on the importance of feedback

- Open loop system

- Closed loop system

b) Based on the type of processing

- Manual Systems

- Semi- automatic Systems

04 Mark
- Automatic Systems

c) Based on the number of men and machines

- One to one Man – Machine System

- Many to one type Man- Machine System

- One to many Man - Machine System

- Many to many Man – Machine system

Que.4 Attempt any THREE of the following 12 Marks

a) State any four advantages of Ergonomics (any 4)

Sol. 1. Higher productivity

2. More the human comfort, less the fatigue to operator.
3. Better deign to machine. 01 Mark
4. Increase the safety. for each
5. Better integration of man –machine system.
6. Reduced labour turnover

Page No: ____/ N

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________ ___________
Sub
Q. Marking
Q. Answer
No. Scheme
N.
Describe any two of the following in connecter with a man – machine system
b) i) Design of visual display
ii) Design of control
iii) Design of workplace
Sol. Design of visual display

- Display are the device, through which, the man can receive the information from the
machine.

- A good display is one, which allows proper combination of speed, accuracy and
sensitivity of display.

- Display provides primary and secondary information needed by operators in making

decisions and in effecting control responses.

- Information presented by display can be considered as dynamic or static

- Two broad categories of display are 1. Visual display 2. Auditory display

- Depending upon the type of information provided by visual display, Visual display can
be further classified into two subgroups.

i) Qualitative display – Indicating only the condition or state without giving any values.

ii) Quantitative Displays- Give numerical information about the equipment or machine Any two

Auditory display can make monitoring performance superior 02+02

Design of control

A control is a device which can transmit information to some machine, mechanism or a

system. Thus a control is selected based upon the nature of information desired to be
transmitted.

The performance efficiency of a human operator is affected by the nature/type of controls

provided with any machine. A proper design goes a long way in making the work of
operator easy. A proper control for any machine should be the optimum for the machine.

Factor Affecting the Selection of a Control Device:

1. Operational Functions of the Control
2. Need of control task.
3. Informational Need of operator
4. Space and layout requirement

Page No: ____/ N

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________ ___________
Sub
Q. Marking
Q. Answer
No. Scheme
N.
Design of workplace
Working environment is another very important factor which requires consideration in the
design of man-machine systems.
The environment in which a worker/operator performs his job has a big influence on the
following:
(i) The fatigue or the strain a worker acquires in performing his task.
(ii) The productivity of the system.
Even the optimum work methods would not help if the workplace layout or the working
environment where the operator work has.
Unbearable noise.
Insufficient light leading to poor visibility ‘smoke and fumes, and uncleanness etc.
Thus an operator’s performance and comport are dependent upon proper design of work
space. Our aim is to arrive at optimum location and arrangement of each component
essential for smooth working.
These components affecting workers task may be as follows:
1. Equipment’s.
2. Seating arrangement.
3. Displays.
4. Controls.
5. Materials.
6. Working space.
c) Enlist the benefits of kaizen.

Sol. Benefits of kaizen

1. Increased Productivity
2. Improve Quality Any Four
3. Reduced Cost 01 Mark
4. Faster Deliveries for each
5. Improve Safety
6. Process standardization
7. Waste reduction
d) What is meant by “5S” Explain each “S” in detail.

Sol. Japanese term English Explanation

Remove unnecessary items from each

1.Seiri (tidiness) Sort
area
Organize and identify storage for
2.Seiton (orderliness) Set In Order 04 Mark
efficient use
3.Seiso (cleanliness) Shine Clean and inspect each area regularly
4.Seiketsu Incorporate 5S into standard
Standardize
(standardization) operating procedures
Assign responsibility, track progress,
5.Shitsuke (discipline) Sustain
and continue the cycle

Page No: ____/ N

a) Critical Path

Network
Diag. 4m

C.P. 2m

b) Task- Replacement of punctured tyre.

Chart begins- Jack up the car.
Chart ends- Remove the jack.
Checked by- Mr. ABC
Date of charting- DD/MM/YYYY

6 Mark

Page No: ____/ N

01 Mark

02 Mark

01 Mark

Page No: ____/ N

a) Objectives of Line Balancing (six objectives for 6 marks)

1. To equalize the workload among the workers
Workload should be distributed equally at each stage of assembly line wrt overall
assembly time.
2. To identify the bottleneck operation
Identify the bottleneck operation and improve the stage by doing some modifications or
corrections.
3. To eatablish the speed of production line
To divide the work properly wrt worker’s movements. Sometime, combine the operations
01 Mark
for improvement the speed of production line.
for each
4. To deterine the number of workstations.
Industrial Engineer should do the time study of each stage and as per sequence of
assembly determine the number of workstations for completing all assembly operations.
5. To determine the percentage worklod of each operator
Workload at each stage should be distributed equally in terms of percentage too.
6. To assist in plant layout
Line balancing can be done in such a way that it should utilize the minimum space in a
factory. Therefore, space saving can be possible and effective plant layout should be
possible
b)

01 Mark

02 Mark

Page No: ____/ N

02 Mark

01 Mark

c) Machine- A

01 Mark

Page No: ____/ N

01 Mark

Machine- B

01 Mark

Page No: ____/ N

01 Mark

Page No: ____/ N

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