IE6605 Production Planning and Control question Bank

Question Bank

Sub. Code/Name: IE6605 – PRODUCTION PLANNING AND CONTROL

Year/Sem: IV/VIII

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Production Planning and Control question April/May 2015

Unit-I (Introduction)

Part-A (Two marks)

 1.Define production planning and control.

2.List the objectives of PPC.

3.What are the phases of production planning and control?

4.List various functions of PPC.

 5.What is production system?

 6.List the types of production system

7.What are the objectives of product analysis?

8.List the various factors that influence the product design.

9.What is meant by standardization?

 10.What is meant by simplification?

Part-B (16 marks)

 1.What do you understand by production planning and control? Discuss its main elements. (16)

2. Enumerates the activities involved in the production planning and control function under the Convenient points. (16)

 3.Explain different types of production systems. Differentiate between them. (16)

 4.Explain the functional and operational aspects of product design. (16)

5.Explain in detail the production aspects of product design. (16)

Unit –II (Work study)

Part-A (Two marks)

1.What is meant by work study?

2.List the objectives of work study?

3.Define method study?

4.List the objectives of method study.

5.What is a Process chart?

6.List the types of process chart.

7.What is flow diagram?

8.What is meant by work measurement?

9.What is meant by work sampling?

Part-B (16 marks)

1.Explain briefly the various steps involved in conducting the work study. (16)

2.State and explain in brief the steps involved in conducting the method study procedure. (16)

3.Briefly explain the various techniques of work measurement. (16)

4.Define time study. List down the various steps in conducting a stopwatch time study. (16)

 5.Explain the following terms a) Work sampling (6) b) Synthetic data (6) c) PMTS (4)

Unit-III (Product planning and process planning)

Part-A (Two marks)

1.What are steps involved in a product planning process?

2.Define value analysis.

3.List the types of economic value.

4.Define Process planning.

5.What are the different steps or specific activities involved in process planning?

6.Write the general approaches to process planning.

7.What is machine loading?

8.What is balancing?

9.What are the factors affecting process planning?

10.What are steps involved in the value analysis?

PART-B (16 marks)

1. What is value analysis? Describe the basic steps involved in the value analysis. (16)

2.Explain the importance of process planning with reference to production control. Discuss the activities in process planning (16)

3.Compare and contrast the manual process planning with CAPP. (16)

 4.What is meant by machine loading? Also enumerate the various methods to the cycle time to a minimum. (16)

5. What do you mean by machine balancing? Also explain the effect of balancing on number of machines required with an illustration. (16)

6. Write short notes on analysis of process capacities in a multiproduct system. (16)

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Production Planning and Control question April/May 2015

Unit-IV (Production scheduling)

Part-A (Two marks)

1.What is Scheduling?

2.List out types of scheduling techniques.

 3.Define master scheduling.

 4.What are basic scheduling problems?

 5.Define  Line of balance.

 6.Write out various charts used in LOB .

7.Define Material requirements planning.

8.Define dispatching. 9.Define Expediting.

10.Define Priority sequencing.

Part-B (16 marks)

 1. Explain the procedure by which scheduling 2 jobs in m machines can be done with suitable example

2. Write short notes on: a) Aggregate run-out method of batch scheduling. (8) b) Line of balance method

 3. Discuss the concepts, inputs, characteristics, working, outputs, and benefits of MRP

4. What are the functions of dispatching? Explain the various documents raised (16) .

 5. What is progressing? Explain its function? Also write short notes on ‘recording progresses’. (16)

Unit –V

(Inventory control and Recent trends in PPC)

Part-A (Two marks)

 1.Define Inventory control.

 2.What are the types of inventory?

 3.What are the main cost associated with inventory?

 4.What are the types of inventory system?

5.What is meant by selective inventory control?

 6.What is JIT?

 7.List out any six selective inventory control techniques.

 8.What is ERP?

9.What is MRP II?

10.Differentiate between pull system and push system.

Part-B (16 marks)

1.What do you understand by inventory control? Explain the purpose of maintaining inventory in any production unit.

2.What is EOQ? Derive the expression for EOQ when the demand of the item is uniform, the production rate is infinite and no stock-outs are allowed.

3.a) Explain the terms: lead time, stock out, buffer stock, inventory carrying cost. (8) b) Distinguish between in-process inventory, safety stock inventory and seasonal inventory (8)

 4.Describe the fixed period quantity inventory model? Also compare and contrast P-system with Q- System. (16)

 5.What is selective control of inventory and explain various selective control techniques.(16)

 6.What is ABC analysis? Explain its significance in the inventory control with suitable example


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Production Planning and Control question April/May 2015

Ultrasonic welding PPT

CONTENTS

üWhat is advanced welding process?

üWhat is Ultrasonic Welding?

üComponents

üProcess

üApplications

What is advanced welding process?

—Non traditional welding processes.

— Automation can be obtained.

— Some process are done without the use of electrode.

What is Ultrasonic Welding?

üUltrasonic welding is an industrial technique whereby two pieces of plastic or metal are joined together seamlessly through high-frequency acoustic vibrations.

üOne component to be welded is placed upon a fixed anvil, with the second component being placed on top. 

Process:

When bonding material through ultrasonic welding, the energy required comes in the form of mechanical vibrations.

—The welding tool (sonotrode) couples to the part to be welded and moves it in longitudinal direction. 

—Sonotrode Tip is usually made of High Speed Tool Steels for welding,

ü Soft Materials

ü Aluminum

ü Copper

ü Iron

ü Low Carbon Steel

üThe part to be welded on remains static. Now the parts to be bonded are simultaneously pressed together.

üThe simultaneous action of static and dynamic forces causes fusion of the parts without having to use additional material.

—The acoustic energy is converted into heat energy by friction, and the parts are welded together in less than a second.

—Thus, saves on manufacturing costs and creates  unnoticeable seams in products where appearance is important.

Merits:

 ØNo heat is applied and no melting occurs.

ØPermits welding of thin to thick sections.

ØWelding can be made through some surface coatings.

ØPressures used are lower, welding times are shorter, and the thickness of deformed regions are thinner than for cold welding.

Demerits :

üThe thickness of the component adjacent to the sonotrode tip must not exceed relatively thin gages because of power limitations of the equipment.

üProcess is limited to lap joints.

üButt welds can not be made because there is no means of supporting the work pieces and applying clamping force.

Applications:

üAssembling of electronic components such as diodes and semiconductors.

üUsed in the assembly of large plastic components and electrical components such as instrument panels, door panels, lamps, air ducts, steering wheels.

üMany everyday items are either created or packaged using ultrasonic welding techniques. 

Types of gearbox notes PPT/PDF

GEARBOX

Gearbox is a speed and torque changing device.

It changes speed and torque between engine  and driving wheels.

The mechanism through which the driving torque of the engine is transmitted to the driving wheel is the gearbox.

PURPOSES/ FUNCTIONS OF GEAR BOX

It helps the engine to disconnect from driving wheels.

It helps the running engine to be connected to the driving wheel smoothly and without shock.

It provides the leverage between engine and driving wheels to be varied.

It helps the driving wheel to be driven at different speeds.

It gives the relative movement between engine and driving wheels due to flexing of the road springs.

TRACTIVE EFFORT

The torque available on the wheel produces a driving force which is parallel to the road known as “Tractive effort”.

TYPES OF GEARBOX

1.            Manual transmission

                i) sliding mesh gearbox

                ii) Constant mesh gearbox

                iii) Synchromesh gearbox

2.            Automatic transmission

                i) Hydromantic gearbox

                ii) Torque converter gearbox

3.            Epicyclical gearbox

SLIDING MESH GEAR BOX

Simple in construction, Simplest type of gearbox.

In this gearbox, spur gears are used.

It consist of following parts.

                1. output shaft 

                2.Low and reverse sliding gear 

                3. Second sliding gear

                4. clutch

                5. Input shaft

                 6. Clutch gear

                  7. Counter shaft drive gear

                8. Counter shaft

                9.Low speed gear

                10. Second gear

                11. reverse gear

                12. Reverse idler gear

                13. Gear shift fork

There are three gears (1,6 and 5) attached on the main shaft and four gears (2,3,4 and 7) are on the lay shaft.

The two gears on the main shaft (6 and 5) can be slide by a shifting yoke and mesh with the gears (3 and 4) on lay shaft.

Therefore it is called “sliding mesh gearbox”. A separated idler gear (8) is mounted on the idler shaft.

GEARS IN NEUTRAL

When the engine is running and the clutch is engaged, the counter shaft is driven by the clutch gear.

The clutch gear rotates in opposite direction to the counter shaft.

The low speed and high speed gears that are fitted on the transmission main shaft or gearbox shaft do not rotate because they are not engaged with any driving gears.

Therefore there is no motion transmitted from clutch to output shaft.

Hence the vehicle is stationary.

CONSTANT MESH GEARBOX

All gears are constantly mesh and dog clutches are used for engaging and disengaging the gears.

Helical and double helical gear teeth can be used for the gears.

This type gears having less damaging during meshing because the gear diameter are smaller with few numbers of teeth.

So this type has more defects when compared o synchronous type.

ADVANTAGES OF CONSTANT MESH GEARBOX OVER SLIDING MESH GEARBOX

Quicker gearing can be achieved

Only damage occurs on dog clutch teeth not teeth of gear wheels.

Synchronizing devices can be used for smooth engagement of gears.

Once the dog clutches are engaged there is no motion between their teeth but the power is transmitted through the sliding action on teeth on one wheel on those of other when the gear teeth are engaged.

To transmit the motion properly, the teeth are suitably shaped.

SYNCHROMESH GEARBOX

To simplify the operations of changing gears without the occurrence of clashes and their consequent damage, a synchromesh gearbox is used in different type of motor vehicles.

Helical gears are used

It has synchromesh unit instead of dog clutch.

The synchronizer helps to synchronize the speeds of two gears to be engaged.

ADVANTAGES

Gear changing is very much simplified

Less wear in gears

Quiet

DISADVANTAGES:

Design is very much complex

Initial cost is high

Quick change of gears occurs due to noise of crashing

TORQUE CONVERTER

Constructional features are similar to fluid flywheel.

The only difference is that it has an ordinary stationary member called “stator or reaction member”.

All the members have blades or vanes of specified shape.

But the operation is not similar.

In fluid flywheel same torque is transmitted as given by the engine shaft.

But the torque converter increases the torque in the ratio of about 2:1 to 3:1

Fluid Flywheel notes PPT

FLUID FLYWHEEL:

DEFINE:

 A fluid coupling or hydraulic coupling is a hydrodynamic device used to transmit rotating mechanical power.

  It has been used in automobile transmissions as an alternative to a mechanical clutch.

    It also has widespread application in marine and industrial machine drives, where variable speed operation and controlled start-up without shock loading of the power transmission system is essential.

It is also known as fluid clutch or fluid coupling which couples the driving member with driven member through a medium of fluid.

It consists of two members in which one is driving member and other one is driven member.

Among them the driving member is connected with the engine flywheel and the driven member is connected to the driven member is connected with the transmission shaft.

ž         These two members are not made to contact with each other.

ž      The driven member is free to slide on splines provided on the transmission shaft.

ž      The two rotors are filled with fluid of require viscosity.

ž      Radial ribs are provided to form a number of passages to avoid the formation of eddies.

ž      They also guide the fluid to flow in the desired direction. 

WORKING:

  žWhen the engine is started, the driving member called “impeller” starts to move inside the house containing    oil.

ž  Pockets of moving driving member are completely filled with oil.

ž  Due to this, centrifugal force forces the oil outward radials.

  žThe pockets are designed in such a way that the splashed oil will strike the pockets or vanes of the driven member.

ž Hence it is forced to move in the same direction.

 žWhen the engine speed increases the oil which is coming out from the pocket of the driving member strikes the pockets of the driven member with great force.

 žThus it tends the driven member to rotate at the same speed.

ADVANTAGES:

žGives smoother power take up than the centrifugal type

when the engine is accelerated.

žNo need of separate pedal or lever to operate.

žThere is no wear on moving parts.

žNo need of adjustment is required.

žNo maintenance is necessary, except maintaining oil level.

žSimple in design

žThere is no jerk on transmission when the gear engages.

žNo skills required to operate

DIS ADVANTAGES:

1.  There is a drag on the gearbox shaft even the slip is 100%

2.  Gear changing is difficult in ordinary crash type gearbox. By using epicyclical gearbox to avoids this difficulty.

APPLICATIONS:

1.  Industrial
2.  Rail Transportation
3.  Automotive
4.  Aviation

Over drive notes PPT

 This post gives the basic idea about an over drive. The  over drive is one of the main transmission system used in automobiles. Now discuss about an Over drive below.

OVER DRIVE:

1. ž Over drive is a device which is used to set up the gear ratio in the vehicle. It is mounted in between transmission and propeller shaft.
2. ž  It provides a high cruising speed with comparatively low engine speed (up to about 20-25% less) on long journeys.
3. ž  It is generally fixed at the top gear only.

OPERATION

ž  

 1.  The shift to overdrive can be obtained when the car is running above a predetermined cut in speed from 32-51 km/hr by lifting the foot momentarily from the accelerator.

ž  

 2.  The action of the overdrive is controlled by a centrifugally operated switch.

ž  3.  As the car slows down below another predetermined speed (slightly lower than cut in speed), it is returned to third speed automatically in most designs.

ž 4. Greater power and acceleration are needed through the overdrive gear ratio when a car runs on the road.

ž  5.  So the car is shifted back to direct gear when an overdrive is depressed by the accelerator to the full throttle position.

HOW AN OVER DRIVE UNIT WORKS:

ž  The overdrive consists of an electrically or hydraulically operated epicyclic gear train bolted behind the transmission unit.

ž  

    It can either couple the input drive shaft directly to the output shaft (propeller shaft) (1:1), or increase the output speed so that it turns faster than the input shaft (1:1 + n).

ž    Thus the output shaft may be "overdriven" relative to the input shaft.

ž    In newer transmissions, the overdrive speed(s) are typically as a result of combinations of planetary/epicyclic gear sets which are integrated in the transmission.

ADVANTAGES:

ž  1. Saves fuel

ž  2. It allows a lower engine speed to maintain the car at highway speed.

ž  3. Wear on the engine and accessories are reduced.

ž  4. It does not require as much as power to keep it moving.

  5.Therefore, the engine can turn more slowly, produce less power and still maintain vehicle speed.