MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
Q. Sub Marking
Answer
No. Q.N Scheme

10
Q.1 Attempt any FIVE of the following:
Marks
a State the need of inspection.
Ans
• To ensure that part, material or a component confirms to the established standard
• To meet the interchangeability of manufacture 1/2 Marks
• To maintain the customer relation by ensuring that no faulty product reaches the for each
customer point
• Provide the means of finding out shortcomings in manufacture
• It also helps to co-ordinate the functions of quality control, production, purchasing (Any four
and other departments of the organization Points)
• To take decision on the defective parts i.e. the possibility of making some of these
parts acceptable after minor repairs

b Define Fatigue: 02 Mark

for
Ans Definition definition
it is the state of the worker by which the capacity and willingness for doing the work is
reduced.
It is negative drive state corresponding to the need of the rest
c Define method study. State its objectives. Definition
1mark
Ans Definition Any two
Method study is the technique of systematic recording and critical examination of existing objective
and proposed ways of doing work and developing an easier and economical method (1/2x2)
Objectives of Method Study

1 Improvement of manufacturing processes and procedures.

2. Improvement of working conditions.
3. Improvement of plant layout and work place layout.
4. Reducing the human effort and fatigue.
5. Reducing material handling
6. Improvement of plant and equipment design.
7. Improvement in the utility of material, machines and manpower.
8. Standardization of method.
9. Improvement in safety standard.
d Define process planning.
02 Mark
Ans Definition for
Process planning is defined as the subsystem responsible for the conversion of design definition
data to work instruction.

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
OR
Process planning is that function within a manufacturing facility which establishes the
process and process parameters to be used (as well as those machines capable of performing
these processes) in order to convert a piece-part from its initial form to a final form that is
predetermined on a detailed engineering drawing
e Name the various control charts in SQC.
Ans
Xbar chart ½ mark for
R chart each
C – chart Any four
P – chart
N – chart
NP – chart
f State any two symbols used in a process chart
Ans

01 Mark
for each
symbol

g Enlist various QC tools

Ans
1. Histogram.
2. Check Sheet.
1/2 Marks
3. Pareto Diagram. for each
tool
4. Brainstorming.
5. Cause & Effect Diagram (ishikawa/fishbone diagram)
6. Control Charts.
7. Scatter Diagram.

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
12
Q.2 Attempt any THREE of the following:
Marks
a Explain the concept of line balancing. State its objectives
Ans
Line balancing means the balancing the (assembly/production) line. Suppose there are three
machines (workstations) A, B and C which can process 5, 10 and 15 pieces per unit time
respectively and the pieces flow from A to B to C (precedence constraint). Since A has
minimum capacity i.e. of processing only 5 pieces per unit time naturally work station
(machine) B will remain idle for 50% of its time and machine C for 66.66% of its time. It shows
that the line is unbalanced. One way to partially balance the line is to have three machines of
type A, 2 of type B, with every machined of type C. Another approach to balance the line will
be to give some other task to machines B and C so that they do not remain idle. The main
objective of line balancing will be distributing task evenly over the work stations so that idle
time of men and machines is minimized
02 Marks
explanati
Objectives of Line Balancing (four objectives for 2marks)
on and
1. To equalize the workload among the workers:
02 marks
Workload should be distributed equally at each stage of assembly line with respect to overall
for
assembly time.
objective
2. To identify the bottleneck operation:
s (any
Identify the bottleneck operation and improve the stage by doing some modifications or
four)
corrections.
3. To establish the speed of production line:
To divide the work properly with respect to worker’s movements. Sometime, combine the
operations for improvement the speed of production line.
4. To determine the number of workstations:
Industrial Engineer should do the time study of each stage and as per sequence of assembly
determine the number of workstations for completing all assembly operations.
5. To determine the percentage workload of each operator:
Workload at each stage should be distributed equally in terms of percentage too.
6. To assist in plant layout:
Line balancing can be done in such a way that it should utilize the minimum space in a factory.
Therefore, space saving can be possible.

b Explain man-machine relationship in terms of ergonomics.

Ans Man–machine system is a system in which the functions of a human operator (or a group of
operators) and a machine are integrated. This term can also be used to emphasize the view of
such a system as a single entity that interacts with external environment. Human factors are a
system concerned with the relationship among human beings, work place or work environment 04 Marks
and machines. The proper integration of man and machine, which is beneficial for human
operator and enhances the overall system performance, is a primary aim of the ergonomics
discipline. For eg. A manual system consists of hand tools and other aids which are coupled by
a human operator who controls the operation. Operators of such systems use their own physical
energy as the power source. The system could range from a person with a hammer to a person
with a super-strength giving exoskeleton.

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
c Differentiate inspection and quality control
Ans Sr. Inspection Quality Control
1 Quality control is a broad term, it involves
Inspection is a part of quality
inspection at particular stages, but more
Control.
inspection does not mean quality control
2 Quality control is an effective system for
Inspection is an act of checking integrating quality development, quality
components, products at various maintenance and quality improvement
stages in manufacturing and efforts of various groups in an
sorting out the defective items organization to enable the production to
from good items. be carried out at most economical level
and to achieve satisfaction of customers.
01 Mark
3 Inspection uses precision Quality control uses devices such as
for
measuring instruments such as statistics, control charts, acceptance
Vernier calipers, micrometers, sampling ,process capability, quality one point
profile projectors etc. audits etc.
4 Quality control concerned with quality of
Inspection is concerned with the
Future production. e.g. Take a sample,
quality of past production to
inspect it, if it is defective find out the
judge conformance and sorting
reasons and take corrective action, so
out defective items from good
that such type of defects will not occur in
items
Future.
5 Everybody working in an organization is
Inspection is mainly the
responsible for quality of products
Responsibility of the inspectors.
Produced.

d Sate Merits and demerits of Acceptance Sampling: 02 Marks

Ans
for
Merits of Acceptance Sampling: 02
(i) The method is applicable in those industries where there is mass production and the Merits
industries follow a set production procedure. and 02
(ii) The method is economical and easy to understand. Marks
(iii) Causes less fatigue boredom. for
(iv) Computation work involved is comparatively very small. 02
(v) The people involved in inspection can be easily imparted training. demerits
(vi) Products of destructive nature during inspection can be easily inspected by sampling.
(vii) Due to quick inspection process, scheduling and delivery times are improved.
Demerits of Acceptance Sampling:
It does not give 100% assurance for the confirmation of specifications so there is always some
likelihood/risk of drawing wrong inference about the quality of the batch/lot.
(ii) Success of the system is dependent on, sampling randomness, quality characteristics to be
tested, batch size and criteria of acceptance of lot.

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
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(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
12
Q.3 Attempt any THREE of the following:
Marks
a Why allowances are considered while calculating standard time?
Ans
Standard time = Normal time + Allowances
Allowances are considered while calculating standard time because; 01 Mark
• Method study investigation tries to minimize the energy expended by the worker in for
performing the operation.
• However, the job will still require the expenditure of human effort. one point
• Therefore, a worker is not able to work throughout the day continuously. Therefore he
requires sometime for recovery from fatigue and for relaxation.
• He also requires some additional time for his personal needs and other reasons.
• This additional time other than basic time is known as allowance.
b Explain Producer’s Risk and Consumer’s Risk
Ans
Producer’s Risk:-Sometimes it happen that in spite of good quality, the sample taken may
show defective units as such the lot will be rejected. In spite of good quality the lot is rejected,
such a type of risk of rejection is known as producer’s risk. In other words, the probability of
rejecting a lot which has actually been satisfactory by the producer. According to acceptable
quality level is known as producer’s risk. Thus, the risk of rejecting a lot of good items is known 2 +2
as producer’s risk. Producer’s risk is designated as the alpha(α) risk. Marks

Consumer’s Risk:- Sometimes it may happen that the quality of the lot is not good but the
sample results show good quality units as such the consumer has to accept a defective lot. Such
a risk is known as consumer’s risk. In other words, the probability of accepting a lot which has
actually been satisfactory by the consumer according to a predetermined standard is known as
consumer’s risk. Consumer’s risk is designated as the Beta (β) risk.
c Explain cost of quality
Ans Cost of quality is a method for calculating the costs that companies incur ensuring that products 1 Mark
meet quality standards, as well as the costs of producing goods that fail to meet quality meaning
standards. and
Cost of quality includes
3 Marks
Market research cost
for
Product research and development cost
explanati
Design cost
on
Cost of manufacturing
Cost of inspection
Cost of quality assurance
d Apply principles of ergonomics for designing of lever for hand press machine
Following ergonomics principle should be considered while designing lever for hand press
Ans

• Neutral Posture to be maintain while handling machine handle

01 Mark
• Reduce Excessive Force for
• Keep it Easy to Reach one point
• Work in Power or Comfort Zone .The power zone refers to the zone where interacting
with objects has the least amount of effort spent, it is also known as “hand shake zone”.
• Reduce Excessive Motion

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(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
• Reduce Static Load
• Minimize Pressure Points
• Provide Clearance
• Enable Movement and Stretching
• Reduce Excessive Vibration
12
Q.4 Attempt any THREE of the following:
Marks
a State the principles of TQM
Ans
1. Focus on Customers
2. Full Employee Commitment:
3. Strategic and Systematic Approach
4. Adherence to Process ½x8=4
marks
5. Fact-based Decision Making:
6. Effective Communication.
7. Continual improvement:
8. Integrated Systems:

b Construct two handed process chart for an activity of replacing old battery of mobile
handset.
Ans

3 Marks
for chart
and 1
mark for
summary

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________

c Write advantages and limitations of ISO 9000.(Four each)

Ans
Advantages of ISO 9000:-

1. ISO 9000 gives international recognition of ability, credibility and expertise, thereby
increasing the number of customers.
2. ISO 9000 provides a competitive edge in the domestic and global markets.
3. It motivates the employees and develops pride in them for achieving excellence in quality. It
helps to enhance quality image of the company.
4. It provides a climate for consistent improvement in quality.
5. It creates a more effective and efficient operation. 02 Marks
6. It helps to increase the level of customer satisfaction and relation. for
04
7. It reduces audits.
Advantage
8. It helps in the improvement of the marketing process. s and 02
9. Enhance the motivation of employees as well as awareness and morale. Marks
10. It promotes international trade. for
11.Helps in increasing the profit 04
limitations
12. It helps in the reduction of wastage and increase productivity.
13. It is a common tool for standardization.
Limitations of ISO 9000:-
1.Owners and managers do not have an adequate understanding of ISO 9000.
2. Most of companies have less funding available, therefore companies are finding Difficulties
to adopt ISO system.
3. ISO 9000 registration need heavy document workload.
4. ISO 9000 registration process require long time.
5. Implementation of this system is very demanding of resources.
6. Work culture need to be changed/improved.
d Compare variable measurement and attribute measurement
Ans
Parameters Variable measurement Attribute measurement

Characteristics Actual Measurements of Determining the presence of

quality characteristics quality characteristics
Data Continuous Discrete 01 Mark
for
Time More Less
one point
Inspection Cost High Less

Measurement Length, Temp. etc. Defective, Non -Defective.

Instruments Vernier calipers, Gauges like Go and NOGO.

Micrometer
Examples X-Bar and R chart P, C, np Chart

Page 8 of 16
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
e Prepare operation process sheet and sequence of operation for step turning
Operation on lathe machine.

Ans

1 mark
for figure
and 3
marks for
operation
sheet

12
Q.5 Attempt any TWO of the following
Marks
a Explain the types of display’s and sketch any two

Displays are devices which the man can receive the information from the machine Explanatio
Ans A good display device is one which allows proper combination of speed, accuracy and n 2 marks
and figure
sensitivity of display 2 marks
Following are the types of display each
1. Visual display
a. Qualitative display

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
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(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________

b. Quantitative display

2. Auditory displays

Page 10 of 16
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
b Explain the concept of supply chain management and state its functions
Ans

Supply chain management (SCM) refers to the management of operations that are involved in
the procurement of raw materials, their transformation into finished goods, and their distribution
to the end consumer.

The five functions of supply chain management include the following:

1. Purchasing
In the manufacturing process, raw materials are required to produce goods and products. It is
important that these materials are procured and delivered on time so that production can begin.
For this to occur, coordination with suppliers and delivery companies will be required to avoid
explanatio
any potential delays. n 2 mark
2. Operations and
Demand planning and forecasting are usually required before materials can be procured, as the function 1
mark each
demand market will dictate how many units to be produced and how much material is required (any four
for production. functions)
3. Logistics
Logistics is the part of supply chain management that coordinates all aspects of planning,
purchasing, production, warehousing, and transportation so that the products will reach the end-
consumer without any hindrances
4. Resource Management
Production consumes raw materials, technology, time, and labor. Resource management
ensures that the right resources are allocated to the right activities in an optimized manner..
5. Information Workflow
Information sharing and distribution is what keeps all of the other functions of supply chain
management on track. If the information workflow and communication are poor, it could break
apart the entire chain.

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__________________________________________________________________________________________________
c
Ans

1 mark

2mark

1 mark

1 mark

1 mark

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(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________

12
Q.6 Attempt any TWO of the following
Marks
a Outline an appropriate process chart for the activity “Replace old battery of car”

Ans

4 marks
for chart
and 2 mark
for
summary

b Draw and explain Histogram, Pareto chart and scatter diagram

HISTOGRAMS
• A histogram is a bar graph that shows frequency data.
• It is used to graphically summarize and display the distribution and variation of a process data
set
. • It provides the easiest way to evaluate the distribution of

Explanatio
n 1 mark
and figure
1 mark
each

data

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PARETO CHARTS
• The Pareto chart can be used to display categories of problems graphi ll ca y so they can
be properly prioritized.
• A Pareto chart or diagram indicates which problem to tackle first by showing the proportion
of the total problem that each of the smaller problem comprise
. • This is based on the Pareto Principle: 20% of the source cause 80% of the problem.

SCATTER DIAGRAM
• To identify the correlations that might exist between a quality characteristic and a factor
that might be driving it.
• A scatter diagram shows the correlation between two variables in a process. These
variables could be a Critical To Quality CTQ characteristic.

Page 14 of 16
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
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c 10 samples of size 5 have been collected with following observations.
Draw the appropriate control chart and state the process is in statistical control or not.

Calculatio
n 2 Mark

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Grap
h 03
Mark
s

Conclusion
01 Mark
Conclusion : As all observations are within control limits, process is under control