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CORK INSTITUTE OF TECHNOLOGY
INSTITIÚID TEICNEOLAÍOCHTA CHORCAÍ
Semester 1 Examinations 2009/
Manufacturing Systems
Module Code: MANU 8004
School: Mechanical & Process Engineering
Programme Title: BSc Process Plant Technology B Eng (Honours) Mechanical Engineering B Eng (Honours) Biomedical Engineering
Programme Code: EPPTE_8_Y EMECH_8_Y3, EMECH_8_Y EBIOM_8_Y
External Examiner(s): Mr. Ger Reilly, Mr. Pat Ryan Internal Examiner(s): Michael P O’Mahony
Instructions: Answer THREE Questions
Duration: 2 hours
Sitting: Semester 1 2010
Requirements for this examination:
Note to Candidates: Please check the Programme Title and the Module Title to ensure that you have received the correct examination paper. If in doubt please contact an Invigilator.
Q1.
(a) What are the objectives of a payment System (9 Marks)
(b) Explain what the meaning of Measured Day work and how does it differs from individual payment by results ie piece rates (7 Marks)
(c) What are the main reasons for the trend towards Group Payment by Results Schemes? (4 Marks) (d) List THREE headings under which Relaxation Allowances are applied in Work Measurement
(3 Marks)
(e) Activity sampling has been used to study the performance of a simple stamping machine. The data is shown in the table: Machine idle 8% Machine being setup 12% Machine operating 65% Machine being cleaned 10% Machine jammed 5% Using the work sampling approach estimate the number of samples which would have to be taken to achieve an accuracy of +/-5% on the “Machine Operating” figure at a 95% confidence interval. If 250 samples were actually taken, what accuracy would be achieve at a 95% confidence interval for each of the above figures (10 marks)
Q
(a) What are the assumptions made for calculating the economic batch quantity (6 Marks)
(b) The demand for a particular item is 10,000 units per annum. It costs €20 to create an order and it costs 20% of the value of the item for storage (i.e. i = 20%). The cost of the item is as follows:
C = €5/unit for 0 – 499units; €4-50/unit for 500 – 1000 and €3-90/unit for > 1000 units
What quantity should be ordered and associated cost (6 Marks)
c) What is the purpose of safety stock (3 Marks)
(d) Compare Qualitative to Quantitative Forecasting methods, explaining the advantages and limitations of each and why one method would be chosen over another. (12 Marks) (e) Explain how why the Product Life cycle needs to be taken into account when forecasting. (6 Marks)
Q
In the context of manufacturing, Define LEAN (5 marks) List the FIVE principles of LEAN (5 marks) Describe the process of Value Stream Mapping (7 marks) Explain the EIGHT Wastes (16 marks)
