91-201 ENGINEERING MANAGEMENT AND GLOBALIZATION Fall 2009 Prof. Z.

Pasek

November 19, 2009

MID-TERM EXAM II
[WHITE]

THIS IS A CLOSED-BOOK & CLOSED-NOTES EXAM

First Name Last Name Student ID Honor Pledge: I have neither given nor received aid on this exam.
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My expected score on this exam:

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--------------------------- Do not write below this line ----------------------------Q1 Q2 Q3 Q4 Q5 Q6 Grand Q7 Q8 Q9 Q10 Q11 Q12 Q13 Q14 B1

91-201 F09 MIDTERM II

I. MULTIPLE CHOICE [ 5 PTS EACH]

Circle best choice 1. The first four steps of the rational approach to decision making are specifically designed to help a manager: a. follow the scientific method. b. devise a problem solution. c. evaluate alternative solutions. d. identify the problem. In the QFD approach, House of Quality #1 translates a. customer needs to a set of customer satisfaction metrics. b. customer needs to a set of functional product features. c. customer needs to a set of product design characteristics. d. customer needs to a set of alternative product designs. The roof room in the House of Quality is devoted to identifying: a. Benchmarks b. Correlations c. Conflicts d. Competitive comparison What manufacturing process can be carried out in the setup shown in the figure?

2.

3.

4.

a. Drilling b. Milling c. Turning d. Grinding e. Casting

5. Flexible manufacturing systems and cells are generally applied in production systems characterized by: a. high variety, low volume production, b. low variety c. low volume d. mass production e. medium volume, medium variety production 6. A manufacturing enterprise is productively efficient when: a. it is making its products at the lowest unit cost that it can, b. it is selling at the lowest price possible c. it has the highest labour productivity that it can d. it is making what its customers want

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91-201 F09 MIDTERM II

II. TRUE OF FALSE [3 PTS EACH]

Circle correct answer [T] = True and [F] = False 7. [T] [F] 8. [T] [F] Most organizational decisions are not made in a logical, rational manner. According to Axiomatic Design principles (axioms) good design maximizes the information content. A tool magazine on a machine tool stores information about tools and their uses. Batch manufacturing refers to production of parts in discrete runs or lots. EOQ inventory model assumes that production is constant and deterministic.

9. [T] [F] 10. [T] [F] 11. [T] [F]

BONUS QUESTION
B1. [5 pts] Fill in the blank boxes on the chart below.

Drivers/Enablers

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91-201 F09 MIDTERM II

III. SHORT ANSWERS

Keep your answers brief, but show your work. 12. [15 pts] Using the information contained in the matrix below, rank the alternative designs and identify the best alternative. Explain the process by which you have arrived at your conclusion.
Concept Requirements

1
D A T U M -

2
+ + + + S 4 1 1 1

3
+ S S S + 2 1 3 4

4
S + 1 4 1 6

5
+ + S S + 3 1 2 3

6
+ S + 2 3 1 5

7
+ + + + 4 2 0 2

Must have X Must do Y Must not do Z Must have D Must do E Must not do F Sum of + Sum of Sum of S RANK

Process: Count number of +, - and S ratings for each alternative Identify which alternative has the most +, then the least- and S In the alternative set from the table Concept #2 is ranked #1 (most + and least -)

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91-201 F09 MIDTERM II

13.

[20 pts] An automotive body manufacturer uses 10,000 metal blanks per week at the cost of $0.40 per piece. The set up cost is $50.00 and the holding costs are based on an annual interest rate of 15%. Economic Order Quantity model Economic Order Quantity; D c A h Total cost: Y(Q) = h(Q/2) + A(D/Q) demand rate (units per year) unit production cost, not counting setup or inventory costs ($ per unit) setup cost to place an order ($) if the holding cost consists of interest on money tied up in inventory, then h = ic where i is an annual interest rate. the unknown size of the order or lot size

Determine using EOQ model A. [15 pts] Number of blanks to order Q D = (10,000 per week)(52 weeks/year) = 520,000 units A = $50.00 h = ($0.40)(0.15) = $0.06 Q = 29,439 units 29,440 B. [5 pts] Total relevant cost Y Y = (0.06) (14,720) + (50) (520000/29440) = $ 1766.4

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91-201 F09 MIDTERM II

14. [20 pts] Consider a process of making a cup of tea. [10 pts] Write down process steps, starting with necessary ingredients (raw materials) and equipment, and ending with a cup of tea. [10 pts] Using standard symbols draw a flowchart for this process.
Start/End Activity/Step Decision Flow Line Storage Delay Inspection

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

Start Fill kettle with water Put kettle on (electric) stove Turn on stove Wait for water to boil Ready (y/n) Turn off stove Flush tea pot with hot water Put tea leaves (tea bag) into the pot Pour hot water into the pot Wait 3-4 minutes Pour tea into a cup Sugar (y/n) Add sugar Milk (y/n) Add milk Stir tea with spoon End (cup of tea ready)

1 2 3 4 5 n 6 y 7 8 9 10 11 12 n 13 y 14 n 15 y 16 16 18

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