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MS-5   june-2008

MS-5 : MANAGEMENT OF MACHINES AND MATERIALS

1,(a) Explain the Management Systems concept with the help of an exarnple. what are the major distinctions between a production organisation and a service organisation ?

(b) Product A consists of three B type sub-assemblies and one C type sub-assembly. The sub-assembly B consists of one D sub-assembly, one E sub-assembly, and one F sub-assembly. The sub-assembly E consists of a D and a K. The sub-assembly C consists of a G and an F.

(i) Prepare a product tree.

(ii) Prepare the Bill of Materials.

iii)Determine the number of each sub-assembly/components required to prepaffe fifty units of item A.

2. a) Discuss briefly with suitable examples, each of the following :

(i) a long-range capacity decision

(ii) an intermediate-range capacity decision

(iii) a short-range capacity decision

b) A small firm intends to increase the capacity of a bottleneck operation by adding a new machine. Two alternatives A and B have been identified, and the

associated costs and revenues have been estimated. Annual fixed costs would be Rs. 40,000 for A, and Rs. 30,000 for B; variable costs per unit would be Rs. 10 for A and Rs. L2 for B; and revenu e per unit would be Rs. 15 for A and Rs. 16 for B.

1. (i)Determine the break- even point, in units, for each alternative.
2. (ii)At what volume of output would the two alternatives yield the same profit ?
3. (iii)If expected annual demand is 12,000 units, which alternative would yield a higher profit ?

3. (a) Why are new facilities built on sites that are far away from the companies'

present sites ? Justify your answer with suitable examples'

(b) The time following observations have been taken in a study experiment :

Determine

(i) the observed time,

(ii) the norrnal time, and

(iii) the standard time,

using a performance rating of 0.95 and a percent allowance of 8 percent

4- (a) Define value analysis. Differentiate between the traditional reduction technique and value analysis.

(b) A group of six jobs are to be processed through a two-step operation. The first operation involves leaning and the second involves painting . Determine a sequence that will minimize the total completion time for this group of jobs. Also, calculate the idle times for both machines.

5. (a) why is R&D a key factor in productivity improvement ? Name some ways in which R&D contributes to productivity improvements.

(b) A local distributor for a national tyre company expects to sale approximately 9600 steel belted radial tyres of a certain size and tread design next year . annual carrying costs are rs 16 per tyre and ordering costs are rs75 . the distributor operates 288 days a year

(i) What is the EOQ ?

(ii) Howmanytimesperyeardoesthestore reorder ?

(iii) What is the length of an order cycle ?

6 The R&D Department is planning to bid on a large project for the development

of a new communication system for commercial planes. The accompanying table shows the activities, times, and sequences required.

(a) Draw the Network Diagram.

(b) What is the critical path ?

(c) Suppose you want to shorten the completion time as much as possible,

and have the option of shortening any or all of B, c, D and G, each two weeks. Which would you shorten ?

1. (b)What is the new critical path and earliest completion time ?

7 . Write short notes on any four of the following :

(a) Cost of Quality

(b) CIM

(c) Standardization and Codification

(d) Buffer Stock

(e) Zero defects

(f) Taxonomy of waste

MS-5   june-2009

MS-5 : MANAGEMENT OF MACHINES AND MATERIALS

1. (a) Define a 'system'. Use this concept in explaining a production system. Briefly

indicate the relationship of production systems to operations management.

(b) Discuss how life cycle approach to product and systems can help decision making. Use examples.

2. (a) Why is there a need for maintenance ? Discuss different types of maintenance as used in manufacturing type of organisations.

(b) Draw a flow process chart of changing tyre of your motor cycle or car. Assume all necessary data.

3. (a) Def ine " Value Engineering" . Discuss different phases of value engineering

approach. Use examples.

(b) Diffeierrtiate continuous flow processes from intermittent flow processes. Give exarnpies.

4(a) Why are service organisations usually provided with  higher capacities than the

requirement ? Explain with some examples.

(b) Why are control charts used ? Differentiate between control charts for variables and control charts for attributes. Give examples.

5(a) In a situation of 2 jobs and 'm' machines. How doer do we determine the optimal sequence of these jobs to minimise the total processing time using graphical method ? Elaborate the method using following problem.

1. (b)Discuss the objectives of maintenance how is failure analysis done Explain

6.What is the significance of assembly lines ? Discuss different types of assembly lines and respective advantages and disadvantages.

7.a) Discuss different functions of stores and detail how stores should be organised.

b) Discuss ABC system of inventory control.

8. write a short notes any two of the following.

(a) Waste management

(b) Materials Requirement Planning

(c) Control Charts for attributes

(d) Standardisation and codification

MS-5   june-2010

MS-5 : MANAGEMENT OF MACHINES AND MATERIALS

1. a) Why does the "proper" operations strategy keep changing for companies that are world-class competitors ?

(b) Some suggest that customer expectation is the key to service success. Give an example from your own experience to support or refute this assertion.

2.(a) "You don't inspect quality into a product; you have to build it in". Discuss the implications of this statement.

(b) Find the economic order quantity and the reorder point, given the following data :

Annual demand (D) = 1000 units. Ordering cost (S) = Rs. 50 per order. Holding cost (H) = Rs. 12.50 per unit per year Cost per unit (C) = Rs. 125.00. Lead time (L) = 5 days. Assume 250 working days in a year.

3. (a) Why are work measurement and time study activities still necessary today ?

(b) A company that produces pleasure boats has decided to expand one of its lines. Current facilities are insufficient to handle the increased workload, so the company is considering three alternatives, A (new location), B (subcontract), and C (expand existing facilities). Alternative A would involve substantial fixed costs but relatively low variable costs : fixed costs would be Rs. 25,000,00 per year, and variable costs would be Rs. 5000

per boat.

Subcontracting would involve a cost per boat of Rs. 25,000 and expansion would require an annual fixed cost of Rs. 5,00,000 and a variable cost of Rs. 10,000 per boat. For what range of output would each alternative yield the lowest total cost ? Which alternate would yield the lowest total cost for an expected annual volume of 150 boats ?

(a) How does the role of a project manager differ from that of a traditional functional

manager ?

(b) An industrial engineer conducts a time study on an operator and determine that a specific task takes about two minutes to complete. The engineer estimates that the particular operator that she is observing is working about 20 percent faster than normal. The company has an allowance factor of 15 percent of job time for personal needs, delays, and fatigue. Calculate the standard time for this task.

5(a) Explain value engineering giving its area of application in some industry which you are aware of.

(b) There are seven jobs that must be processed in two operations. A and B. All seven jobs must go through A and B in that sequence A first, then B.

( i ) Determine the optimal order in which the jobs should be sequenced through the process using these times.

ii) Draw a graph similar to the solved problems showing the sequence of jobs.

iii) What is the total completion time for all seven jobs

6. The following activities are part of a project to be scheduled using CPM :

a) Draw the network

b) What is the critical path ?

c) How many weeks will it take to complete the project ?

d) How much slack does activity B have ?

7. Write short notes on any four of the following :

a) Preventive Maintenance

b) Automated storage/retrieval

c) CAD/CAM

d) ABC Analysis

e) Tero Technology

f) LIFO system

MS-5   june-2011

MS-5 : MANAGEMENT OF MACHINES AND MATERIALS

1. (a) How is value added to any entity using operations function ? Explain the conceptual model of a 'Operations System'.

(b) Discuss life cycle approach in Operations Management. Use examples to elaborate.

2. (a) What is Product Design ? How does it influence the Process Design ? Explain with examples.

(b) What type of layout would you suggest in designing a big hospital ? Discuss.

3. (a) How is computerized layout planning is done ? Discuss its benefits and different

softwares used for this purpose.

(b) Define capacity. Explain the process used for capacity planning. Take example of any organization of your choice.

4. (a) Why is material handling important ? Discuss its classification.

(b) What are common classification systems of materials ? Explain importance of

codification and standardization of materials.

5. (a) What are different forms used by purchase department ? Discuss different criteria

employed for evaluating purchasing system.

(b) Discuss importance of Value Engineering. Also list its various phases.

6. (a) What is acceptance sampling ? Explain different types of sampling plans. Explain

Operating Characteristic Curve.

(b) Why are control charts used ? Discuss mean and R type of control chart. Give its importance.

7. (a) Where do we use work sampling ? Explain its step as used for standard time determination.

(b) Discuss ABC system of Inventory Control. Give its variants as used in Industry.

8. Write short notes on any two of the following

(a) Methods Study

(b) Programme Evaluation and Review Technique.

(c) Assembly line

(d) Planning and Control for job shop production

MS-5   Dec, 2007

MS-5 : MANAGEMENT OF MACHINES AND MATERIALS

l. (a) Explain how the system concept can be used in explaining the terms waste and waste management.

(b) A company is considering adding a new feature that will increase unit sales by !2 percent and product cost by 10 percent. Profit is expected to increase by 16 percent of the increased sales. Initially the product cost incurred by the company was 63 percent of the sales price. Should the new feature be added ? Justify your answer.

2. (a) Four different organisations are considering youl home town as a potential location for one of the following :

(i) A medical research centre

(ii) A softdrink producer

(iii) A steel plant

(iv) A software producer

Select any  one of the above four and systematically evaluate the relevant locational factors.

(b) A worker in an engineering corporation is expected to work for 420 minutes in a shift of 8 hours . the remaining time, i.e. 60 minutes is meant  for rest and personal needs etc.

Determine :

(i) Standard time per piece of a job whose normal time is 4 minutes.

(ii) If the operator produces 120 pieces in the shift, what is his efficiency ?

3. a)Explain different types of maintenance, giving suitable examples. Suggest an organisation structure for the maintenance department of a medium-sized company

   (b) A small manufacturing firm has three proposals for a product. Either it can be purchased from an outside vendor at Rs. 4 per unit or it can be manufactured in-plant. There are alternatives for in-plant-manufacturing. One option it that a fully

automatic unit is procured involving fixed cost of Rs. 30,000 and variable cost of Rs. 275 per unit. Alternatively, a semi-automatic unit would cost Rs. 20,000 as fixed cost and Rs. 3 per unit as variable cost.

Draw a break-even chart for these alternatives. Suggest range of production-volume suited for these alternatives.

4. a) Explain various factors that govern the design of any layout of a plant. Give suitable examples.

   b) 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.

Determine the sequence of jobs that will minimize the total time for completion of all the jobs.

5. (a) What do you understand by Quality ? What is the difference between inspection and quality ? Describe the concept of Total Quality Management. How is it different from inspection and quality control ?

b) A repair and maintenance company is engaged in providing service to a particular brand o[ popular vehicle. It uses 8000 units of a moving part per year as replacement of the old parts; each part cost Rs. 250. The set-up costs are estimated at Rs. 100 and the inventory carrying cost is the average of 20% of the inventory cost. Supply of the parts is at the rate of 80 per day.

Calculate the following :

(i) Optimal order quantity

(ii) Optimal number of set-ups

(iii) Total variable cost based on optimal policy

Assume 310 working days in a year

6. The R&D department is planning to bid on a large proiect for the development of a new communication system for commercial planes. The following table shows the activities, times, and sequences required

(a) Draw the network diagram.

(b) What is the critical path ?

(c) How many weeks will it take to complete the project ?

(d) Which activities have slack and how much ?

7 . Write short notes on any four of the following :

(a) Operating characteristic curve

(b) ABC Analysis

(c) Job Enrichment

(d) CAD/CAM

(e) Tero Technology

(f) Aggregate planning

MS-5   Dec, 2008

MS-5 : MANAGEMENT OF MACHINES AND MATERIALS

l. (a) Give two examples (with supporting details) for each of a service and manufacturing firm, of the impact of technology in service and product design.

(b) Data for a breal+even analysis revealed that total cost at volumes of 600 and 800 units were Rs. 8,00,000 and Rs. 9,60,000 respectively. Revenue is Rs. 1,440 per unit. Based upon this information, what are

(i) the variable cost per unit, and

(ii) the fixed cost ?

2. (a) How do the capacity considerations in a hospital, automobile service centre and a company making lawn mowers, differ ?

(b) Rocket Propulsion Company is considering the expansion of a solid-propelled manufacturing process by adding more l-ton-capacity curing furnaces. Each batch (1 ton) of propellant must undergo 30 minutes of fumace time, including load and unload operations. However, the furnace is used only 80 percent of the time due

to power restrictions in other parts of the system. The required output for the new layout is to be 16 tons per shift (8 hours). Plant (system) effici,ency is estimated at 50 percent of system capacity.

(i) Determine the number of furnaces required.

(ii) Estimate.the percentage of time the furnace will be idle.

3. (a) How does inventory contribute to the value-adding activities of a firm ? When should inventory be considered a symptom of waste ? Explain with suitable examples.

(b) A plastics moulding firm produces and uses 24,400 Teflon bearing inserts annually. The cost of setting up for production is Rs. 700 and the weekly production rate is 1000 units. If the production cost is Rs. 55 per unit and the anhual carrying cost is Rs. 15 per unit, how many units should the firm produce during each production run ? Assume a 52-week year.

4. (a) Should a firm always attempt to “meet demand" ? Why or why not ? Justify answer with suitable examples.

(b) Define Productivity. How do operations managers contribute in improving productivity ? Explain with examples.

5. (a) Discuss with suitable examples, the process of launching a new product in the market. Explain with the help of suitable examples.

(b) Use Johnson's rule to determine the sequence that results in the minimum flow time for the seven jobs listed below. Alljobs must follow the same sequence of machine first, and then polish.

a) What is the optimal sequence of jobs ?

b) What is the minimum time flow to finish these seven jobs

SECTION B

The following table shows the jobs of a project with their duration in days.

i) Draw the network diagram.

ii) Compute the earliest event time and latest event times

iii) Determine the critical path and total project duration

7 . Write short notes on any of the following :

(a) VED Analysis

(b) Consumer's risk

(c) Learning Curve

(d) Standardization and Codification

(e) Delphi Technique

(f) Bill of Material

MS-5   Dec, 2009

MS-5 : MANAGEMENT OF MACHINES AND MATERIALS

1(a) Explain with the help of a suitable diagram the framework of organising and control in a production system.

(b) On the basis of material flow classify production systems and give examples for each type.

2(a) List down different phases of value engineering approach as used for a product design.

(b) What layout design procedure would you adopt to develop a layout for any small toy unit manufacturing plastic toys at the rate of 5000/day ? Discuss.

3.(a) Why is facility location important ? Discuss different factors important for locating any bread manufacturing unit. Make relevant assumptions.

(b) Describe the commonly used control charts for variables and attributes in SQC.

4(a) Discuss in brief various environmental factors taken into consideration for job design.

(b) Discuss objectives of maintenance management. List different types of maintenance system prevalent in manufacturing companies.

5. (a) Consider a situation of; production of a simple product with continuous demand.

The setup cost per batch of size Q is given. Unit variable cost of productions is also known. Derive the equation for optimum batch size. Assume and list major parameters.

(b) Why is mass production preferred over in some types of products with large volume ?

Explain the key elements of mass production with some examples.

6. (a) Explain the major scheduling rules for job shops as being practiced in industry.

(b) Draw CPM network for the following :

   Activates                                                                       Duration (days)

     1 - 2                                                                                    5

     1 - 3                                                                                   3

     1 - 4                                                                                   3

     2 - 3                                                                                    7

     4 - 5                                                                                    6

     3 - 4                                                                                    8

Determine Critical Path.

7. (a) Discuss ABC system of inventory management with examples.

(b) Explain the importance of store location and layout.

8. Write short note on any two of the following :

a) Productivity and waste

b) Value engineering

(c) Materials Requirement Planning

(d) Control charts for variables.

Ms-5 Dec 2010 solved paper from ignou university you can buy this ms-5 book from this site

MS-5   Dec, 2011

MS-5 : MANAGEMENT OF MACHINES AND MATERIALS

1. (a) Discuss conceptual model of an operations   system. Explain some of the performance objectives in operations management.

(b) Explain the frame work of organising and   control in a production system.

2. (a) What are different types of process forms   in manufacturing system which are used to effect transformation of inputs into outputs ? Explain with examples.

(b) Choose a major facility of any organization   ( manufacturing) and develop a detailed

layout for the same.

3. (a) What are the different types of material   handling equipment used in large industries ? What type of material handling system would you recommend for a cement plant.

(b) Discuss advantages and disadvantages of "codification and 'Standardization' of

material." Use examples.

4. (a) Discuss purchase procedure with the help   of a schematic diagram.

(b) Explain common approaches for price determination.

5. (a) Discuss systems of vendors evaluation and   rating. Also give its importance.

(b) List different steps of value engineering   approach, used as a product design tool.

6. (a) Explain operating characteristic curve. With the help of the 0.0 curve explain simple sampling plan.

(b) Discuss objectives of maintenance management. List different types of maintenance systems prevalent in manufacturing organisations.

7. . (a)   List some of the major line Balancing methods. Explain any one of the method.

(b) What do you understand by scheduling ? Discuss various dispatching rules as used

in Industry

8. Write short note on any two of the following :

(a) Materials Requirement Planning

(b) Economic order Quantity

(c) Critical Path Method

(d) Job Design

MS-4 -   june-2007

MS-4 : ACCOUNTING AND FINANCE FOR MANAGERS

1. (a) Explain the Continuity concept and the Periodicity concept and discuss their significance.

(b) Explain the nature of accounting function and describe the role played by the Accountant in a business organisation.

2. The following items appear on the Trial Balance prepared from the books of Mr. Kamal Saxena as on 31st March 2006 after making necessary adjustments for depreciation on fixed assets, outstanding and accrued items and placing the difference under Suspense Account.

Machinery: 1,70,000

Furniture: 49,500

Sundry Debtors: 38,000

Drawings: 28,000

Travelling Expenses: 6,500

Insurance: 1,500

Audit Fees: 1,000

Salaries: 49,000

Rent: 5,000

Cash in hand: 7,800

Cash at Bank: 18,500

Stock in trade (1-4-2005): 80,000

Prepaid Insurance: 250

Miscellaneous expenses: 21,200

Suspense A/c (Dr.): 39,400

Sundry Creditors: 82,000

Capital Account: 2,45,750

Outstanding Expenses :

Salaries: 1,500

Printing: 600

Audit Fees: 1,000

Bank Interest (Cr.): 1,200

Discounts (Cr.): 1,800

Sales less Refurns): 6,80,00

Discount allowed: 1,200

Printing and Stationery: 1,500

Purchases (less Returns): 4,60,00

Depreciation :

Machinery: 30,000

Furniture: 5,500

On a subsequent scrutiny the following mistakes were noticed

(i) A new machinery was purchased for Rs. 50,000 but the amount was wrongly posted to Furniture Account as Rs. 5,000.

(ii) Cash received from Debtors Rs. 5,600 was omitted to be posted in the ledger.

(iii) Goods worth Rs. s,000 withdrawn by the proprietor for personal use, but no entry was passed.

You are further told that :

(a) Closing Stock amounted to Rs. 47,500.

(b) Depreciation on Machinery and Furniture has been provided @ 15% and 10% respectively On declining balance system. Full year's depreciation is provided on addition.

You are required to prepare a Trading and Profit and Loss Account for the year ended on 31st March 2006 and a Balance Sheet as on that date.

3. (a) Explain the concept of cost of capital as a device for establishing a cut-off point for capital investment proposals.

(b) Discuss the limiting factors in the reliability of capital budgeting techniques including the discounted cash flow techniques.

4. (a) What is optimum cash balance ? How can it be determined ? Explain.

(b) Distinguish between Cash Flow Statement and Funds Flow Statement." What purposes do they serve? How do you calculate Funds from Business Operations while preparing a Funds Flow Statement? Explain.

5. (a) Explain the three important control ratios that are used to compare the actual performance with the budgeted performance.

(b) Distinguish between Fixed Budget and Flexible Budget. When is a Flexible Budget considered desirable ? Explain.

6. A company produces a single product which is sold by it presently in the domestic market at Rs. 75 per unit. The present production and sales is 40,000 units per month representing 50% of the available capacity. The cost data of the product are as under:

Variable cost per unit Rs. 50.

Fixed cost per month Rs. 10 lakh.

To improve profitability, the management has 3 proposals on hand as under :

(a) To accept an export supply order For 30,000 units per Month at a reduced price of Rs. 60 per unit, incurring additional variable costs of Rs. 5 per unit towards export packing, duties etc.

(b) To increase the domestic market sales by selling to a domestic chain store 30,000 units at Rs. 55 per unit, retaining the existing sales at the existing price.

(c) To reduce the selling price for the increased domestic sales as advised by the sales department as under :

Prepare a table to present the results of the above proposals and give your comments and advice on the proposals.

7. Comment on the following statements :

(a) Operating cycle plays a decisive role in influencing the working capital needs.

(b) "Debt is a double-edged knife."

(c) Break -even analysis is not without limitations.

(d) Higher profit margin need not necessarily lead to higher rate of return on investment.

(e) A company's profitability is better judged by PBIT rather than by PAT.

8. Write short notes on the following :

(a) Absorption Costing

(b) Zero based Budgeting

(c) Direct Labour Variances

(d) Sunk Costs and Imputed Costs