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D. E. I.

TECHNICAL COLLEGE, DAYALBAGH, AGRA


Diploma in Mechanical Engineering, Session 2010 – 2011
QUESTION BANK
PRODUCTION AUTOMATION & COMPUTER INTEGRATED MANUFACTURING
Course No.: DME – 605

UNIT – I

1. What is production? Explain the input-output model of production.


2. What are the different types of production? Mention salient features of each type of
production.
3. Differentiate between discrete manufacturing and continuous or processing industries
with suitable examples.
4. What are primary, secondary and tertiary industries?
5. Describe in detail, the manufacturing support system
6. What is Automation? What are the technologies that are included in Automation?
7. What are the stages of Automation? What are the various reasons of automation?
8. What are the salient features of the following types of automation:
i) Fixed automation
ii) Programmable automation
iii) Flexible automation
9. What is plant layout? Explain
i) Fixed position layout.
ii) Process layout.
iii) Cellular type production layout
iv) Flow line production layout
How do these differ from production view point?
10. What do you mean by product design? What are the various steps of developing a
product? Explain briefly.
11. What is meant by Manufacturing Planning? What are the various techniques used in
Manufacturing Planning?
12. What is Manufacturing Control? When do you exercise Manufacturing Control? Explain
briefly the various techniques of Manufacturing Control.

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UNIT II

13. Explain different Automation strategies. Mention various effects of each automation
strategy.
14. What are various performance measures of manufacturing system? Why do we need to
measure the performance?
15. Explain Manufacturing Lead time. What are the various components of operation time?
16. A part is to be processed on six machines in a shop. The batch comprises of 100 parts.
The set-up time of machine is 2 hours and the non-operational time is 3 hours. If the
operation time is 4 minutes, find the manufacturing lead time (MLT).
17. A batch of 200 parts is made from six operations. Average operation time on each
machine is 5 minutes and non-operational time is 6 hours. Find the total Manufacturing
time of the batch if the shift is of 8 hrs./day.
18. What is meant by Production Rate? A part in a batch production of 200 parts is
processed through 6 machines. Set-up time and operation time of each machine is given
in the table below
Set-up Time Operating time
Machine
(Hrs.) (Minutes)
1 4 5.0
2 2 2.5
3 6 12.0
4 3 1.2
5 3 4.0
6 4 3.5

If the non-operating time is 12 hours per machine, then find


i) Manufacturing lead time (MLT)
ii) Rate of production for third machine
iii) Rate of production for fifth machine
19. What do you mean by Plant Capacity and Utilization?
20. In a batch of 25 pieces, each piece has to be processed through six machines. If there ten
machines in the factory and 20 new batches are made per week having total 70 working
hours per week. Find:
i) Manufacturing lead time
ii) Production Capacity
iii) Utilization
If the operation time is 6 minutes and the set-up time of each machine is 5 hours and the
non-operating time is 10 hours.

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21. What do you mean by WIP? Give suitable examples.
22. What is WIP ratio and TIP ratio? Describe its significance.
23. What are the various methods of evaluating Investment alternatives?
24. What is Depreciation cost? Explain various methods of finding depreciation.
25. (a) What is Present value of a future single payment?
(b) From the following information calculate the Net Present Value of the two projects
and suggest which of the project should be accepted assuming a discount rate of 10%.
Project X Project Y
Initial Investment Rs. 20,000 Rs. 30,000
Estimated Life 5 years 5 years
Scrap Value Rs. 1000 Rs. 2000
The profits before depreciation and after taxes are as follows:
Year Project X Project Y
1 5,000 20,000
2 10,000 10,000
3 10,000 5,000
4 3,000 3,000
5 2,000 2,000

26. Calculate the average rate of return for Project A and B from the following.
Project A Project B
Investment Rs. 20,000 Rs. 30,000
Expected Life 4 years 5 years
Projected net income after interest, depreciation and taxes are given below in the table:
YEAR PROJECT ‘A’ PROJECT ‘B’
I 2,000 3,000
II 1,500 3,000
III 1,500 2,000
IV 1,000 1,000
V – 1,000
Calculate the rate of return and also mention which project you will prefer accordingly.
27. What are the various components of costs considered in a manufacturing industry?
28. i) What is Break-even analysis?

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ii) If the sales of a product is Rs. 1,00,000/-; Profit is Rs. 10,000/- and variable cost is
70%, find
(a) P/V ratio
(b) Fixed cost
(c) Sales volume to earn a profit of Rs. 40,000/-.
29. From the following information, calculate the B. E. P in units and in sales value:
Output = 3,000
Selling price per unit = Rs. 30
Variable cost per unit = Rs. 20
Total Fixed cost = Rs. 20,000/-

UNIT III

30. What do you mean by ‘Assembly? What are the characteristics of assembly process?
31. What are the various methods of Assembly process? Explain briefly.
32. Differentiate between Manual and Automated Assembly.
33. What do you mean by Assembly system?
34. Explain single point Manual Assembly.
35. What is line assembly? Explain the features of Manual line Assembly.
36. What do you mean by line balancing? Why it is necessary?
37. The line is to be balanced for an annual demand of 100,000 units / year. The line will
operate 50 weeks / year, 5 shifts / week, and 7.5 hours / shift. Manning level is one
worker per station. Previous experience suggests that the uptime efficiency for the line
is 96% and the repositioning time lost per cycle is 0.08 minute. The table below lists the
standard time that has been established for each element as well as the precedence order
in which they must be performed. Draw the precedence diagram and determine:
(a) Total work content time,
(b) Hourly production rate to achieve annual demand,
(c) Cycle time,
(d) Theoretical minimum number of workers,
(e) Service time to which the line must be balanced. Use largest candidate rule
OR Ranked positional weight method to balance the line.
(f) Find Balancing efficiency.
Work element Table
Work
Must be
No. element Tek (min.)
preceded by
description
1 A 0.2 -
2 B 0.4 -
3 C 0.7 1
4 D 0.1 1,2
5 E 0.3 2

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6 F 0.11 3
7 G 0.32 3
8 H 0.6 3, 4
9 I 0.27 6, 7, 8
10 J 0.38 5, 8
11 K 0.5 9, 10
12 L 0.12 11

38. What are the factors to consider while designing an Automated Assembly system?
39. Write short note on:
i) Part feed devices
ii) Type of Automated Assembly system

UNIT IV

40. Define the term ‘Numeric Control’. Explain the various elements of Numeric Control.
41. Give a block diagram showing the general structure of NC machine tool.
42. What are the advantages and disadvantages of NC machine tools?
43. Explain various co-ordinate systems of Numeric Control. Describe with a suitable
example.
44. How the NC systems are classified? Explain in detail.
45. Write short note on:
i) Open loop system
ii) Closed loop system
46. Write short note on:
i) BCD coding system
ii) Decimal coding system
iii) Binary coding system
47. Write short note on:
i) Tape and Tape format
ii) Preparation of Tape
48. What are the different types of reader? Explain the working of any two types of readers.

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UNIT V

49. What is part programming? What are the languages that can be used for part
programming?
50. Write short note on:
i) DNC machine
ii) Adaptive control system
51. Define the term CAD and CAM. What are the different steps taken in CAD?
52. What is FMS? What are the advantages of FMS? What are the different components of
FMS?
53. What do you mean by tool offset? Assuming different shapes, Calculate the tool offset.
54. For the part shown in Figure 1 having 3 holes of 8mm diameter, write a programme for a
NC machine having PTP control facility and the following format – N3. G2. X3. Y3.
M2 EOB
55. Write the APT programme for a NC machine for the part Figure 2. having 5 holes.

10
2

30
1 3 25 Figure 1
10
10 70 10

(10, 80) (100, 90)


(60, 80)
START POINT
(35, 50)
Figure 2
(10, 20) (60, 20)

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