Operations Management 1st Edition P. B. Mahapatra - Solutions

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4. In a machine shop two identical machines process the same product. The average time between two consecutive products arriving for machining is 10 minutes. The average machining time is 15 minutes per product. The arrival pattern of products has Poisson distribution and the machining time is
3. The time between two consecutive arrivals of customers at a telephone booth has the following distribution:Time between 3 4 5 6 7 8 arrivals (min.)Probability 0.10 0.22 0.30 0.23 0.10 0.05 The time for a telephone call has the following distribution:Time (min.) 1 2 3 4 5 6 Probability 0.13 0.20
2. The demand for newspapers by a newsagent has the following distribution:Demand 30 35 40 45 50 55 60 70 Probability 0.03 0.07 0.10 0.20 0.25 0.18 0.13 0.04 His purchase price is Rs 2.00 and the selling price Rs 2.50 per paper. He disposes of unsold papers as scrap at Re. 0.30 per paper. Simulate
1. Find by simulation, the probability of having three heads when a coin is tossed five times.
6. Experiments reveal that the weekly demand for a product has a Poisson distribution with a given mean. How will you simulate the demand using a table of random numbers?
5. Explain the multiplicative congruence method for generation of random numbers.
4. Suppose you are simulating the inventory position of a product. How will you determine the length of the simulation run?
3. Can you use simulation to obtain the optimal solution to an industrial problem? How?
2. List the advantages of simulation over mathematical models.
1. Distinguish between a mathematical model and a simulation model.
6. What is meant by Design of Experiments? Describe its role in Improve Stage of a Six Sigma Project.
5. Describe the following tools and explain how these are used during Analyze stage of a Six Sigma Project(a) FMEA(b) Root Cause Analysis(c) Hypothesis Testing(d) Regression Analysis
4. How will you decide on the sample size to estimate statistical parameters of the population.
3. Define the following parameters of a measuring instrument(a) Accuracy(b) Precision(c) Reliability
2. Define the role of QFD as an effective tool for use in the Define Stage of a Six Sigma Project.
1. What is process capacity? How can it be quantitatively measured.
14. What are Taguchi’s orthogonal arrays? How are they useful for design of experiments?
13. Describe the role of design of experiments for product design.
12. Distinguish between online and off-line control of quality.
11. Describe how you would use the following for control of quality.(a) Histogram(b) Cause–effect diagram
10. List the steps suggested by Juran to solve chronic quality problems.
9. Distinguish between the management controlled and the operator controlled quality problems.
8. Distinguish between a sporadic and chronic quality problem.
7. Describe Juran’s quality trilogy.
6. Describe Deming’s PDCA cycle.
5. A company plans to monitor the number of defectives produced by workers and give an incentive to those whose performance is significantly better than the average. What will be the impact of the above on the psychology of the workers?
4. TQM culture will not develop in an industry if fear is not driven out from the minds of the employees. Why?
3. Deming suggests not to depend upon inspection to improve quality. Why?
2. Why is management’s direct involvement essential for success of TQM?
1. Describe Taguchi’s concept of the costs associated with quality.
12. Lots are subjected to sampling inspection by the plan given in Problem 10. If the fraction defective in the incoming lots is 5 per cent, what will be the average fraction defective in the outgoing lots?
11. Lots are subjected to sampling by the double sampling plan given in Problem 10. If the average fraction defective in the incoming lots is 0.04, what is the probability that a second sample will be required before a decision is taken either to accept or to reject the lot?
10. In a double sampling plan, a first sample of 100 is subjected to inspection and the lot is accepted if it contains 2 or less defectives and rejected if it contains more than 6 defectives. If the number of defectives is more than 2 but less than 7, a second sample of 100 is inspected and the
9. Lots of 1500 with average fraction defective of 6 per cent are subjected to inspection by the sampling plan given in Problem 7. All rejected lots are subjected to 100 per cent inspection and all defective units are replaced by acceptable units. What is the average inspection required?
8. Draw the AOQ curve for the plan given in Problem 7. What is the average outgoing quality limit (AOQL)?
7. A sampling plan calls for taking a sample of 200 from a lot of 1500 and accepts the lot if the number of defectives in the sample does not exceed 6. Draw the OC curve for the plan.
6. The observations of inspection of television sets on different dates are given below:Date 1 2 3 4 5 6 7 8 9 10 11 12 No. of TVs 6 4 3 6 5 2 6 4 2 6 5 5 Defects 13 12 7 19 14 9 18 13 6 24 15 15 Use the above data to construct a suitable control chart for future use.
5. The number of customer complaints received daily by an organization is given below:Day 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Complaints 2 3 0 1 9 2 0 0 4 2 0 7 0 2 4 Does it mean that the number of complaints is under statistical control? Establish a control chart for future use.
4. In a manufacturing concern producing transistors, lots of 250 items are inspected at a time. Considering the number of defectives in 20 lots as shown in the table below, draw a suitable control chart and write a brief report based on the evidence of the chart.Sample no. Sample size No. of
3. It is required to control the weight of a product. The table below gives the sample averages and the range of the weights of the product in samples of size 5. Construct X and R charts and examine if the process is under control.Sample number 1 2 3 4 5 6 7 8 9 10 Sample average 201 198 202 200
2. The length of a pin is normally distributed with a mean of 50.05 mm and a standard deviation of 0.01 mm. The X and R charts with a sample size of four are maintained to control the length of the pin. It is decided to take a sample of four pins after every four hours. Find X and R and plot the
1. It is required to set up X and R charts to control the diameter of the gear blanks produced by a machine. Every hour a random sample of four blanks is subjected to inspection. The table below gives the diameters of 40 gear blanks inspected in ten samples of four each. Use this data to draw the X
11. What is the average sample number (ASN) of a double sampling plan? How is the ASN related to the quality of incoming lots?
10. What is the average outgoing quality (AOQ) of a sampling plan? How is the AOQ related to the quality of incoming lots?
9. Does a double sampling necessarily reduce the amount of inspection compared to a single sampling plan?
8. Describe the risks associated with a sampling plan.
7. A p chart is used to control the quality of a process. The lower control limit for the chart currently in use is 0. It has been suggested that the chart be re-designed with a positive lower control limit? How can you do it?
6. The reliability of X and R charts will increase in case the sample size is increased. Why?
5. Describe the two types of errors associated with the maintenance of control charts.
4. Distinguish between chance and assignable causes of variation.
3. The diameter of a pin needs to be controlled. The pin is produced on a machine which, on the average, produces 5 per cent defective units. Analysis reveals that the distribution of the diameter is not normal even though the average percentage defective is not significantly different from 5 per
2. List the costs associated with maintaining the quality of a product.
1. Distinguish between the quality of design and the quality of conformance.
3. An electronic equipment comprises of 1000 resistors which require periodic replacement.S(i), the percentage of resistors surviving at the end of month i (0 i 6) is given below:Month 0 1 2 3 4 5 6 7 S(i) 100 95 87 77 62 42 22 0 The cost of replacing an individual resistor is Rs 12.00.
2. The cost of a machine is 10,00,000/-. The following table gives the annual operating cost, maintenance cost and salvage value at the end of the year. Find the techno-economic life of the machine if rate of interest is 14%.Year Annual Annual Salvage value operating Cost maintenance cost at the
1. The cost of a machine is Rs 400,000/-. The annual maintenance cost is Rs 40,000 in the first year and it increases by 10% in every subsequent year. The scrap value of the machine at the end of its techno-economic life is negligible. When will you recommend the replacement of the machine if rate
7. What is a group replacement policy? List its advantages.
6. What is Total Productive Maintenance?
5. What is System Reliability? How can you improve the reliability of a system?
4. What is meant by proactive maintenance?
3. Will you recommend the replacement of a part even when it is in working order? Justify your answer.
2. Distinguish between preventive maintenance and predictive maintenance.
1. What is breakdown maintenance? List the conditions under which breakdown maintenance may be justified.
2. Shortest Processing Time (SPT)
1. First Come First Served (FCFS)
5. Find the heuristic solution to Problem 3 by using the following rules for assigning priority to jobs.
4. Solve Problem 3 by branch and bounding.
3. Five jobs are required to be machined on three machines A, B and C, in that order. The processing durations of the jobs on different machines are as under:Job 1 2 3 4 5 Machine A 3 8 7 5 4 Machine B 4 5 1 2 3 Machine C 7 9 5 6 10 Find the optimal sequence to complete the jobs in minimum time.
2. Find the sequence that will minimize the total time required to complete the following tasks on two machines M1 and M2, in that order.Task A B C D E F G H I Machine M1 2 5 4 9 6 8 7 5 4 Machine M2 6 8 7 4 3 9 3 8 11
1. There are seven jobs as under, each of which has to go through machines A and B in that order. The processing time is in hours.Job 1 2 3 4 5 6 7 Machine A 3 12 15 6 10 11 9 Machine B 8 10 10 6 12 1 3 Determine the sequence of jobs that will minimize the total time for completion of all the jobs.
6. Distinguish between static and dynamic slacks on a job. Describe heuristic rules for job shop scheduling based on static and dynamic slacks.
5. Describe the SPT (Shortest Processing Time) rule for shop scheduling. Why does this rule cause undue delay for some jobs? Describe how the rule may be modified to overcome this limitation.
4. Describe the role of branch and bounding to solve the problem of scheduling n jobs through M machines.
3. Describe the condition under which Johnson’s rule can be applied to solve the sequencing problem of n jobs through M machines.
2. Describe Johnson’s rule for sequencing n jobs through two machines. Give justification for the rule.
1. Describe the problem of job shop scheduling.
8. What sort of supply chain will you recommend for the following products. Justify your answer.(a) Books(b) Artificial jewellery(c) Branded readymade garments(d) Heavy earth moving machinery.
7. A factory is to produce machine tools. The products can be supplied to end user directly from the manufacturer or finished goods inventory may be stored by a distributor in five regional warehouses. How will you choose between the options.
6. What is bullwhip effect? What problems does it create in a supply chain?
5. What is a responsive supply chain? List the conditions under which it may be required to improve the responsiveness of a supply chain even at the cost of its efficiency.
4. What is meant by supply chain structure? How does supply chain structure affects its performance?
3. How will the supply chain for a retailer selling branded garments would be different from a local manufacturer dealing with garments made to order?
2. List some supply chains which operate globally.
1. Identify the supply chain partners for(a) An automobile Service Station(b) A real estate builder(c) A foundry(d) An educational Institute(e) A publisher publishing text books
10. List the conditions under which JIT manufacturing can be successfully implemented.
9. Why has JIT not been successful in a number of Indian industries?
8. What are the advantages of small batch size in manufacture. How can you reduce the batch size?
7. Do you think that successful implementation of JIT requires a thorough overhauling of organization structure. Justify your answer.
6. Explain the dual-card Kanban system and list its advantages.
5. Distinguish between a P-Kanban and C-Kanban.
4. List the advantagtes of Kanban-based scheduling.
3. What short of scheduling system does JIT manufacturing utilize—push system or pull system? Why?
2. How is JIT different from an efficient inventory management system?
1. What is JIT manufacturing. How does it differ from traditional manufacturing?
6. Suppose the production schedule that you have made in Problem 5, after it is in operation for four weeks, needs to be modified as the company has received a request to supply 40 more units of product X along with the earlier order. Is it possible to meet the request? If not, what is the earliest
5. A company has received orders for supplying 50 units of product X and 60 units of product Y, both to be supplied in 12 weeks. The product structures of these products are given in Figure 14.12. The number in parentheses against each component stands for the number of units of that component
4. The master production schedule calls for production of 20, 25 and 30 units of Product X in the third, fourth and fifth weeks. Each unit of Product X is fabricated by assembling two units of P and one unit of Q. The product structure is shown in Figure 14.11.Each of the products P and Q has a
3. Product P450 for which the MRP sheet is given in Problem 2 is fabricated by assembling one unit each of products P551 and P552. The lot sizes for products P551 and P552 are 350 and 400, respectively. The lead time for each of these products is 2 weeks. Prepare the MRP sheets for both these
2. Part of the MRP sheet for a product P450 is given next. The batch size for the product is 300 units and the lead time is two weeks.Weeks 1 2 3 4 5 6 7 8 9 10 11 12 Avl. 170 G. Req. 150 50 70 100 0 100 200 150 0 180 80 0 N. Req.S. Rec. 300 S. Rel 300 Complete the MRP sheet.
1. A finished product P503 is assembled by joining subassemblies S101 and S102 with the help of six screws (S1001). Subassembly S101 is made by assembling two units of component S205 and three units of S206. Subassembly S102 is made by assembling two units of S208 and four units of S210. Draw the

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Operations Management 1st Edition P. B. Mahapatra - Solutions

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