Answer Scheme

13
SULIT UNIVERSITI TEKNIKAL MALAYSIA MELAKA UJIAN PERTENGAHAN SEMESTER I MID TERM TEST SEMESTER I SESI 2013 /2014 SESSION 2013/2014 FAKULTI KEJURUTERAAN PEMBUATAN KOD MATAPELAJARAN : BMFG 3113 SUBJECT CODE MATAPELAJARAN : PENGENALAN KEPADA SISTEM PEMBUATAN SUBJECT INTRODUCTION TO MANUFACTURING SYSTEMS PENYELARAS : DR ZUHRIAH EBRAHIM COORDINATOR KURSUS : BTMI dan BTMM COURSE MASA : 2 JAM TIME 2 HOURS TARIKH : 5 NOVEMBER 2013 DATE TEMPAT : BK8 dan BK9, FPTT VENUE ________________________________________________________________________________________ ARAHAN KEPADA CALON INSTRUCTION TO CANDIDATES 1. Kertas soalan ini mengandungi SEPULUH (10) soalan. This question paper consists of TEN (5) questions. 2. Jawab SEMUA soalan. Answer ALL questions. 3. Setiap soalan hendaklah dijawab pada ruang yang disediakan. Use given space for every question answered. KERTAS SOALAN INI TERDIRI DARIPADA (13) MUKA SURAT SAHAJA (TERMASUK MUKA SURAT HADAPAN) THIS QUESTION PAPER CONTAINS OF (13) PAGES INCLUSIVE OF FRONT PAGE SULIT

description

answer scheme

Transcript of Answer Scheme

SULIT

SULIT

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

UJIAN PERTENGAHAN SEMESTER I MID TERM TEST SEMESTER I

SESI 2013 /2014 SESSION 2013/2014

FAKULTI KEJURUTERAAN PEMBUATAN

KOD MATAPELAJARAN : BMFG 3113 SUBJECT CODE

MATAPELAJARAN : PENGENALAN KEPADA SISTEM PEMBUATAN SUBJECT INTRODUCTION TO MANUFACTURING SYSTEMS

PENYELARAS : DR ZUHRIAH EBRAHIM COORDINATOR

KURSUS : BTMI dan BTMM COURSE

MASA : 2 JAM TIME 2 HOURS

TARIKH : 5 NOVEMBER 2013 DATE

TEMPAT : BK8 dan BK9, FPTT VENUE

________________________________________________________________________________________

ARAHAN KEPADA CALON INSTRUCTION TO CANDIDATES

1. Kertas soalan ini mengandungi SEPULUH (10) soalan.

This question paper consists of TEN (5) questions.

2. Jawab SEMUA soalan.

Answer ALL questions.

3. Setiap soalan hendaklah dijawab pada ruang yang disediakan.

Use given space for every question answered.

KERTAS SOALAN INI TERDIRI DARIPADA (13) MUKA SURAT SAHAJA

(TERMASUK MUKA SURAT HADAPAN) THIS QUESTION PAPER CONTAINS OF (13) PAGES INCLUSIVE OF FRONT PAGE

SULIT

(BMFG 3113) SULIT

-English Version -

SULIT - 2 -

Answer ALL questions.

Chapter 1: Essential of Manufacturing

Q1 Differentiate between Production, Manufacturing, and Manufacturing Systems.

(10 marks)

PRODUCTION

“The transformation of raw materials into products by a series of energy

applications, each of which effects well defined changes in physical or

chemical characteristics of the materials”

[3 marks]

MANUFACTURING

[3 marks]

MANUFACTURING SYSTEMS

“An integrated combination of processes, machine systems, people,

organizational structures, information flows, control systems and computers

whose purpose is to achieve economic product manufacture and

internationally competitive performance”.

[4 marks]

(BMFG 3113) SULIT

-English Version -

SULIT - 3 -

Q2 (a) Describe the principle of manufacturing using a diagram.

(5 marks)

[ 2 marks]

Material flow – 1 mark

Information flow – 1 mark

Cost flow – 1 marks

(b) Explain briefly three categories of production quantity. Give one example for each

category.

(5 marks)

Three categories:

i. Low production (1 to 100 units per year), example: Aeroplane, ship.

ii. Medium production (100 to 10,000 units per year), example: Washing

machine, limited edition products.

iii. High production (more than 10,000 units per year) , example: Coca-cola,

mobile phone.

(BMFG 3113) SULIT

-English Version -

SULIT - 4 -

Q3 (a) Compare between Cellular Manufacturing and Job Production in terms of material

flow.

(5 marks)

CELLULAR MANUFACTURING

JOB PRODUCTION

(BMFG 3113) SULIT

-English Version -

SULIT - 5 -

(b) Describe TWO techniques used for Productive Operation.

(5 marks)

1- Optimum Routing ---[1 mark]

…An operation route with least time (or cost).

…an optimum routing problem has a finite number of combinations.

…thus, the solution can be always obtained by calculating the total

production times (or costs) of all possible routes by trial and error.

[1.5 marks]

2- Line Balancing ---[1 mark]

…aims at optimum decision making in regard to:

3- c

ycle time

2- number of work station or production stages

3- grouping of work elements in a same workstation such that their

precedence order is assured.

[1.5 mark]

Chapter 2: Process Systems for Manufacturing

Q4 Explain briefly three methods that can be used to reduce the transportation time and cost

in material flow.

(10 marks)

1- Reduce transfer distance.---[1 mark]

…optimal plant layout…

…single stage of conversion activities…

…multiple functional machine tools…

[2 mark]

(BMFG 3113) SULIT

-English Version -

SULIT - 6 -

2- Decrease the number of transfer activities. ---[1 mark]

…handling materials/parts/components as a group with standard shape,

volume, weight, etc.

…using ‘unit-load’ method…

[3 marks]

3- Determine the optimal transfer route & speed ---[1 mark]

…constructing a straight continuous route with minimal crossings.

…zero/minimum WIP…

[2 marks]

Q5 (a) Given product in Figure 1, build the Bill of Materials for the product.

(6 marks)

Figure 1

(BMFG 3113) SULIT

-English Version -

SULIT - 7 -

[6 marks for the components with quantity]

(b) Find the optimal number of workstations for assembling a product with an assembly

sequence and operation times shown in Figure 2. The cycle time is given as 8minutes.

(Circle the workstations determined).

(4 marks)

Optimum no. of workstation = 4 ---[1 mark]

[1.5 mark for each circle]

(2) (1) (1) (1) (2)

(2)

(2)

(BMFG 3113) SULIT

-English Version -

SULIT - 8 -

OR

Optimum no. of workstation = 4 ---[1 mark]

[1 mark for each circle]

OR

Optimum no. of workstation = 4 ---[1 mark]

[1 mark for each circle]

(BMFG 3113) SULIT

-English Version -

SULIT - 9 -

Q6 Explain the difference between process type layout and group technology cell

layout. Include sketches of both layouts.

(10 marks)

Group tech layout

(BMFG 3113) SULIT

-English Version -

SULIT - 10 -

Q7 Propose a group technology layout based on the production information shown

in Table 1.

(10 marks)

Table 1

Machine

Job

M1 M2 M3 M4 M5

J1 P1 P3 P2

J2 P1 P2

J3 P2 P1

J4 P1 P2

J5 P1

M Machine

J Job

P Process

Machine

Job

M1 M2 M3 M4 M5

J1 P1 P3 P2

J3 P2 P1

J4 P1 P2

J2 P1 P2

J5 P1

Machine

Job

M1 M4 M3 M2 M5

J1 P1 P2 P3

J3 P1 P2

J4 P1 P2

J2 P1 P2

J5 P1

(BMFG 3113) SULIT

-English Version -

SULIT - 11 -

Q8 Explain five (5) strategies that can be used to address fluctuation in demand.

( 10 marks)

Capacity Options Demand Options

1. Use inventories to absorb changes

in demand

2. Accommodate changes by varying

workforce size

3. Use part-timers, overtime, or idle

time to absorb changes

4. Use subcontractors and maintain a

stable workforce

5. Change prices or other factors to

influence demand

6. Influencing demand

7. Back ordering during high-

demand periods

8. Counter seasonal product and

service mixing

(BMFG 3113) SULIT

-English Version -

SULIT - 12 -

Q9 Define and differentiate MRP and ERP.

(10 marks)

Q10 Explain the differences between process strategy options ( Make to order, Assemble

to order, and Stock to forecast) for Master Production Schedule (MPS) activity.

Name an example of product that is suitable for each strategy.

(10 marks)

(BMFG 3113) SULIT

-English Version -

SULIT - 13 -

***END OF TEST QUESTIONS***