Module No 4

Industrial Engineering and Entrprise Resources Planning
Chapter 4.1 INVENTORY CONTROL

1. Define Inventory and Inventory Control? INVENTORY Inventory is detailed list of those movable items which are necessary to manufacture a product and maintain the equipment and machinery in good working order. INVENTORY CONTROL 1. Inventory CONTROL is the techniques of maintain the size of the inventory at some desired level keeping in the view the best economic interest off an organization. 2. It may be defined as the systematic location, storage and recording of goods in such a way that desired degree of service can be made to the operating shop at minimum ultimate cost. 2. State the need of INVENTORY CONTROL? Ans :- NEED OF INVENTORY CONTROL 1. For smooth and uninterrupted production. 2. For efficient utilization of work, capital. 3. For minimizing loss due to damage, deterioration. 4. For eliminating the possibilities of duplicated purchasing. 5. Economy purchasing. Ans: - INVENTORY and INVENTORY CONTROL
Module No 04 1
Vaibhav Vithoba Naik
3. List down the various types of inventories used in industry? Ans:-COMPONENTS OF INVENTORIES Inventory consist of the following 1. Raw material Raw material is the basic input get converted into output. Example: Wood is the basic material for furniture for furniture making. 2. Bough out parts/Purchased parts These are finished part or sub assemblies purchased from outside suppliers Example: Compressor is bought parts in AC 3. IN PROCESS INVENTORIES OR SEMI FINISHED GOODS OR WORK IN PROGRESS These refer to the items or material which is partially completed. Example: the stage of book before binding. 4. FINISHED GOOD INVENTORY These include manufactured or processed item which are ready for dispatch. Example: Ball bearing, Screw and nuts. 4. State the objective of INVENTORY CONTROL? Ans:-OBJECTIVES OF INVENTORY CONTROL 1. To ensure adequate supply of product to customer. 2. To make sure that the investment in the inventories is minimum. 3. To maintain stock within desired limits 4. To take correct and timely decision fro replenishment. 5. To maintain timely records of inventory of all items
Module No 04 2
5. What do you know about the Inventory cost relationship? Ans:- INVENTORY COST RELATIONSHIP There are two types of major cost related to the inventory 1. Cost associated with inventory. 2. Inventory carrying holding cost A. COST ASSOCIATED WITH INVENTORY 1. Purchase price It is a very important cost which is expressed in the terms of unit price. It is a very useful when price discount are offered. 2. Procurement cost Procurement cost involves money spent to give order. The cost of placing an order varies from company to company. 3. Clerical and administration cost It is associated with purchasing like inviting tenders through advertisement, placing follow up through medias like personal visits, telephone fax,etc. 4. Inspection accounting This involves cost of incoming raw material, inspection and maintains record s of the receipts. 5. Transportation cost This involves cost associated with checking of each order and maintaining records of purchase.
Module No 04 3
B. INVENTORY CARRYING HOLDING COST 1. These are cost associated with holding given level of inventory. 2. This cost varies in direct proportion to the amount of holding period of holding stock in the store. 3. The holding cost include a. Storage cost in terms of rent, heating and lighting system. b. Deprecation, deterioration and obsolesce cost. c. Cost of record keeping d. Taxes and insurance. e. Handling, maintenance, repair and operating cost. f. Spoilage, breakage, loss due to fire.
6. List the benefits of Inventory Control? Ans: - BENEFITS OF INVENTORY CONTROL It is an established fact that through the practice of scientific inventory control, the stocks can be reduced anywhere between 10% to 40%. The benefits of inventory control are 1. Improvement in customer relationship because of the timely delivery off goods and services. 2. Smooth and uninterrupted production and hence no stock out. 3. Efficient utilization of working capital. 4. Helps in minimizing loss due to deterioration, obsolescenece,damage and preliferage. 5. Economy in purchasing. 6. Eliminates the possibility of duplicate ordering.
Module No 04 4
7. Explain some Quality standards of Inventory Control Ans: -QUALITY STANDARDS OF INVENTORY CONTROL
Figure: Quality standards of Inventory Control 1. Maximum level of inventory It represents the upper limit beyond which the quantity of any item is not normally allowed to rise. To ensure that un-necessary working capital is not blocked in stores. Maximum Stock =recorder level + recorder quantity minimum consumption 2. Minimum stock level (safety stock) It represents the lower limit below which the stock of any item is not normally allowed to fall. To protect against stock out of a particular item. Minimum stock= Reorder level- (normal usage per periods x average delivery time) 3. Standard order It is the quantity to be purchased any time amount of standard order should be adjusted to situation. The same value should not be used for long period.
Module No 04 5
4. Recorder level Re-order level is fixed between the minimum and maximum level. It represents the level or point at which the replenishment action is initiated. Reorder level = lead time +safety stock
5. Lead time a. It is the time gap between of an order and time of actual supply b. It is composed of three component Lead time = servicing time +delivery time +receiving time
Module No 04 6
8. List the Inventory control terminology? Ans: - INVENTORY CONTROL TERMINOLOGY 1. Demand It is the number of items (products) required per unit of time. The demand may be either deterministic or probabilistic in nature. 2. Order cycle The time period between the two successive orders is called order cycle. 3. Lead time The length of time between placing an order and receipt of items is called lead time. 4. Safety stock It is also called buffer stock or minimum stock. It is tock or inventory needed to account for delays in material supply and account for sudden increase in demand due to rush order. 5. Inventory turnover If the company maintains the inventory equal to 3 month consumption. It means that inventory turnover is 4 times a year i.e. the entire inventory is used up and replaced 4 times a year. 6. Re-order level (ROL) It is the point at which the replenishment action is initiated. When the stock level reaches the R.O.L, the order is placed for the item.
Module No 04 7
7. Re-order quantity This is the quantity of material (items) to be ordered at the reorder level. Normally this quantity equals to the economic order quantity.
Module No 04 8
8. Write down the formula of EOQ for model with uniform demand. Explain the meaning of each term used there in? State the assumption made for deriving the formulas? Ans:- ECONOMIC ORDER QUANTITY (EOQ) 1) It is the quantity which permits low cost per unit. 2) It is an important strategic factor in inventory control and indicates the quantities, which can be reasonable ordered economically at a time. Formula for ECONOMIC ORDER QUANTITY (EOQ)
where u = annual usage p=procurement cost associated with one order c= cost per unit. I = cost of carrying inventory in percentage per period including insurances, obsolescence taxes.
Module No 04 9
9. Explain EOQ with example? Ans: ECONOMIC ORDER QUANTITY (EOQ)
EOQ is explained by the following example Let q = economic lot size or EOQ c = cost for 1 item i= cost of carrying inventory in % per period. p=procurement cost associated with one order. u= total quality used per period.
a. Total procurement cost= No of purchased order placed in a pear x cost involved in one purchase
Module No 04 10
b. Average annual inventory=q/2 Inventory carrying cost =average inventory x cost per item x cost of carrying inventory per period
To minimize the total cost, differentiate t with respect to q ,
Module No 04 11
9: -Derive the relation for ECONOMIC ORDER QUANTITY EOQ? Ans: - ECONOMIC ORDER QUANTITY EOQ
ECONOMIC ORDER QUANTITY, EOQ is that order which will minimize the total variable cost of managing inventory. METHODS OF CALCULATING OF EOQ Assuming that the inventory decreases at a constant rate from the order quality q to zero and then replenished by another quantity.
Symbols used: Let, S =annual consumption of the product (units) C0 = Cost of placing an order. Cu = Unit cost of an item (unit price Rs) q = order quantity (units) I Now, The total variable cost of managing the inventory per year= Annual ordering cost+ Annual cost of carrying Inventory = E = interests rate charged pr unit per year
Module No 04 12
To determine Economic Order quantity (qO) that minimized the total cost of managing the inventory, we must differentiate E with respect to decision variable q and set the first derivative to zero i.e for minimum
Module No 04 13
Q.10: -Inventory is a necessary evil Comment? Ans:-Inventory Control: Inventory control means making the desired item of required quantity available to various departments when needed. Too much inventory created a problem of their storage, huge investment and the maintenance of stored items from deterioration, pilferage, damage etc. However .low inventory leads o chance of stoppage of production increase in overheads and disruption in production schedules and delivery promises. Therefore, optimum amount of inventory should be maintained in stores. Every firm must maintain adequate stock of inventories for the following reasons: 7. To ensure against delays in Deliveries: When an order is places for fresh stock, the materials are not immediately available but sometime elapses before it arrives. This period between the time of placing the order and time of stock arrival is often subjected to variations. A firm must therefore hold some reverse stock to low production operations to continue it delay in procurement occurs. 8. To ensure against delays in Deliveries: Change in manufacturing programme may occur because of the variation in the demand. To meet the increased demand of the finished goods, the company should have enough stock or inventories so as to allow production without interference. 9. To ensure against delays in Deliveries: When a company has little inventory and run out of stock, stock out of essential material means interruption in production which raises the cost of production.
Module No 04 14
10. To keep better Customer relations : Stock out means stoppage or interruptions in production, therefore it may delay re delivery of finished goods to the customer. After a few such delays even a most patient customer will start looking for supplier who will give him better services. 11. To take advantage of Quantity Discounts: Material and components may be cheaper when purchased in large quantities owing to larger discounts and lower transportation costs. Furthermore, paper work and inspection of incoming material are also simplified when larger quantities. 12. To have a better utilization of men and machinery : If there is a stock out of materials the men and machine will remain idle. Therefore the company should keep enough stock of inventories to have better utilization of men and machinery. ADVANTGES OF INVENTORY CONTROL 1. There is no shortage of materials at any stage of production. 2. Materials are made available at most economical rates. 3. Exact and accurate delivery dates can be forecast. 4. Production schedules and delivery dates are maintained. 5. There is an increase in overall efficiency/productivity of the company.
Module No 04 15
Q.11: -Describe the various order launching inventory control systems?
1. Ans: A problem which always remains is that how much material may be ordered
at aimed.An economic order quantity is one which permits the lowest cost per unit and is most advantageous. 2. Figure shows different quantity standards.
3. Starting from an instant which inventory OA is in the stores. It (Inventory)

consumes gradually in quantity from A along AD at uniform rate. It is preknown that it take L number of days between initiating order and receiving the required inventory.Therfore, as the quantity reaches point B purchase requisition in initiated which takes from B to C, that is time R.From C to D is the inventory procurement time P.At the point D when only reserve stock is left, the ordered material is supposed to reach and again the total quantity shoots to its maximum value i.e. .the point A (A=A).
4. Maximum quantity OA is upper or maximum limit to which the inventory can be

kept in the stores at time.
5. Minimum quantity OE is lower or minimum limit to which the inventory can be

kept in the stores at time. 6. Standard order (AD) is the difference between maximum and minimum quantity and it is known as economical purchase inventory size. 7. Recorder point (B) indicates that it is high time to initiate a purchase order if not done so the inventory may exhaust and even reserve stock is utilized before the new material arrives.
8. From B to D it is an lead time and it may calculated on the basis of past

experience.
Module No 04 16
Q.11: -State the reason for keeping the Inventories? Solution: REASONS FOR KEEPING INVENTORIES
1. To stabilize production: The demand for an item fluctuates because of the number of factors, e.g., seasonality, production schedule etc. The inventories (raw materials and components) should be made available to the production as per the demand failing which results in stock out and the production stoppage takes place for want of materials. Hence, the inventory is kept to take care of this fluctuation so that the production is smooth.
2. To take advantage of price discounts: Usually the manufacturers offer discount for bulk buying and to gain this price advantage the materials is bought in bulk even though it is not required immediately. Thus, inventory is maintained to gain economy in purchasing.
3. To meet the demand during the replenishment period: The lead time for procurement of materials depends upon many factors like location of the source, demand supply condition, etc. So inventory is maintained to meet the demand during the procurement (replenishment) period.
4. To prevent loss of orders (sales): In this competitive scenario, one has to meet the delivery schedules at 100 per cent service level, means they cannot afford to miss the delivery schedule which may result in loss of sales. To avoid the organizations have to maintain inventory.
Module No 04 17
5. To keep pace with changing market conditions: The organizations have to anticipate the changing market sentiments and they have to stock materials in anticipation of non-availability of materials or sudden increase in prices. Sometimes the organizations have to stock materials due to other reasons like suppliers minimum quantity condition, seasonal availability of materials or sudden increase in prices.
Module No 04 18
Q.11: -Explain the techniques of Inventory Control? Solution: TECHNIQUES OF INVENTORY CONTROL
In any organization, depending on the type of business, inventory is maintained. When the number of items in inventory is large and then large amount of money is needed to create such inventory, it becomes the concern of the management to have a proper control over its ordering, procurement, maintenance and consumption. The control can be for order quality and order frequency. The different techniques of inventory control are: 1. ABC analysis, 2. HML analysis, 3. VED analysis, 4. FSN analysis, 5. SDE analysis, 6. GOLF analysis and 7. SOS analysis.
The most widely used method of inventory control is known as ABC analysis. In this technique, the total inventory is categorized into three sub-heads and then proper exercise is exercised for each sub-heads.
Module No 04 19
1. ABC analysis: a. In this analysis, the classification of existing inventory is based on annual consumption and the annual value of the items. b. Hence we obtain the quantity of inventory item consumed during the year and multiply it by unit cost to obtain annual usage cost. c. The items are then arranged in the descending order of such annual usage cost. d. The analysis is carried out by drawing a graph based on the cumulative number of items and cumulative usage of consumption cost. Classification is done as follows:
Category
Percentage of items
Percentage of annual consumption value
A B C
1020 2030 6070
7080 1025 515
Module No 04 20
The classification of ABC analysis is shown by the graph given as follows
Once ABC classification has been achieved, the policy control can be formulated as follows: A-Item: Very tight control, the items being of high value. The control need be exercised at higher level of authority. B-Item: Moderate control, the items being of moderate value. The control need be exercised at middle level of authority. C-Item: The items being of low value, the control can be exercised at gross root level of authority, i.e., by respective user department managers.
Module No 04 21
Chapter No 4.2
Facility planning
1) Short notes a. layout design techniques b. Computer packages for layout analysis. c. Plant layout
Module No 04 22
2) What is plant layout? Discuss the different types of layout?10m 3) Differentiate between the product and process layout?4m 4) Compare the different types of plant layout?10m 5) Explain the different quantitivae technique of layout design8m 6) Explain the concept of cellular group layout?6m 7) State the different types of layout. What are different facilities of lacition?Discuss the techniques of layout design of process and product layout?10m
1. Define Plant layout? What are different types of layout used in industry? Give suitable example of each? Ans: - PLANT LAYOUT Plant layout is defined as techniques of locating different machines and facilities like person, storage space, material handling equipment and all other supporting services within in the factory so as to get maximum output with desired quality at lowest possible cost. TYPES OF PLANT LAYOUT IN INDUSTRY The various plant layout are used in the industry are
Module No 04 23
1. Product layout Example: Sugar plant, bottling Industry 2. Process layout Example: Chemical Industry 3. Fixed position layout Example: Ship Building Industry, Air craft production.
2. Give the main objectives of Plant Layout? Ans: OBJECTIVES OF PLANT LAYOUT A good layout is one which provides maximum satisfaction to employees, management and consumers. The main objectives of good plant layout are 1. Streamline the flow of material through the plant. 2. Effective utilization of men, machines and available space. 3. Easy supervision and better production control.
Module No 04 24
4. Provide workman safety, convenience and comfort. 5. Minimization of material handling and manufacturing cycle time.
3. State the symptoms of Bad Plant Layout? Ans: - Symptoms of Bad plant layout The symptom of bad plant layout are as follows: 1. Long transportation lines 2. Poor utilization of space. 3. Mental or physical stain in the workers. 4. More frequent accident 5. Difficult to supervise and control. 6. Over-crowding of men, material, machine and equipment. 7. Scrap or wastage of material is more. 8. The amount of the work in process is large.
4. Explain the Muther principle of Good Plant Layout? Ans: Muther principle of Good Plant Layout According to Muther, there are six basic principles to design best plant layout These are 1. Principles of overall integration A good layout is one that integrates men, materials, machines, services in such a way that the best comprise is obtained. 2. Principles of minimum distance or moment
Module No 04 25
A good layout is one in which the total distance travelled by men and material is minimum. Straight line movements are preferred. 3. Principles of flow A good layout is one that makes the material moves only in forward direction towards the completion stage without backtracking. 4. Principles of cubic space A good layout is one that make effective utilization of available space in three dimension i.e. length, breadth and height. 5. Principle of satisfaction and safety This principle considers workers safety and satisfaction and protecting the plant and machinery against the fire, theft etc. 6. Principles of flexibility. The plant must be flexible to absorb necessary changes whenever required without consuming much cost and time.
5. What are the techniques used in Plant Layout? Explain any two OR State the plant layout techniques used in and explain any one of them? Ans: TOOLS AND TECHNIQUES USED IN PLANT LAYOUT The various tools and techniques used in plant layout planning are 1. Operational process chart. 2. Flow process chart. 3. Flow diagrams. 4. Machine data cards.
Module No 04 26
5. Templates 6. Three dimensional models. 7. Relationship chart (REL)
Relationship chart (REL) 1. The relationship chart is developed by ROBER MUTHER. 2. The relationship and interdependence of one department to another is shown by REL chart rather than exact flows and related costs. 3. This chart shows how close on workstation is one to another. This closeness is expressed on a scale. 4. After checking, the degree of closeness suitable placing of department and machine is possible. Figure shows REL chart
Module No 04 27
5. Each block in the chart shoes the relationship between the two workstations and rating is given in the adjacent tables.
Value
A E I O U X
Closeness
Absolute Essential Essential Important Ordinary Un-important Not desirable
where 1, 25 are the depth or workstation
TRAVEL CHART 1. A travel chart is a tabular record for presenting quantitative data about the movement of the workers, material or equipment between any numbers of places over a given period of time. 2. It is quicker and more manageable techniques. 3. It records the distance and frequency of movement between the pairs of departments. 4. This chart is used to determine the degree of closeness between the departments. 5. It forms the basis of layout design that seeks to minimize the total material handling costs.
Module No 04 28
Advantages 1. It is a useful tool for movement analysis. 2. It is helpful to locate the activities and backtracking. 3. Useful for comparing alternative flows. 4. Can be easily computerized as quantitative data is involved. Procedure 1. Department or work centres are listed both row wise and columwise in the same sequence. 2. Each intersecting square or cells is used to records the data from department to another. 3. The entries in the chart are scattered on both sides of the diagonal. Three dimensional scaled model. 1. It is modification of the template model. Here in place of templates,3 dimensional scale models of workstation and other facilities are prepared and are placed on the factory plan at suitable places. 2. These models are made from wood ,plastic and metal.etc 3. This technique gives more realistic view of future plant layout like height and projection of machine parts, overhead structure,arrangment for safety ,ventilation etc.
Module No 04 29
6. Short notes on Types of Plant Layout? Explain any two Ans: - PLANT LAYOUT Plant layout is defined as techniques of locating different machines and facilities like person, storage space, material handling equipment and all other supporting services within in the factory so as to get maximum output with desired quality at lowest possible cost. TYPES OF PLANT LAYOUT IN INDUSTRY The various plant layout are used in the industry are 1. Product layout Example: Sugar plant, bottling Industry 2. Process layout Example: Chemical Industry
Module No 04 30
3. Fixed position layout Example: Ship Building Industry, Air craft production.
1. Product layout a. It is also known as line layout. It is used in mass production. b. In this layout, all necessary machinery and equipment are set out in same are in the sequence of manufacturing process. c. This layout is used when there is high demand of one or several product. Example: Sugar plant, bottling Industry, Automobile and TV sets.
Figure: Product Layout Advantage
Module No 04 31
a. Low cost per unit b. Better use of cubic space. c. Work in a process is high. d. It needs less skilled workers. e. Production cycle per unit time is low. Disadvantage a. Machines are not used to full capacity. b. Less flexibility. c. High capital investment due to SPM. d. Same kind of work makes the worker feel boredom and montous. e. For expansion purpose is not possible to add machines
2. Process Layout. a. It is also called functional layout. It is suitable for volume production. b. In process layout, the machines of similar category are grouped together and one not is arranged according to particular sequence of operation. c. It is suitable when the product is non standard and there is major variation in processing time of individual operations.
Figure: Process Layout Advantage
Module No 04 32
a. Process layout makes the best use of man and machines. b. Lot of flexibility. c. Low capital investment due to GPM. d. Variety of job makes the job challenging and interesting for workers. e. For expansion purpose, it is possible to add more machines. Disadvantage a. High cost per unit. b. Poor use of available space c. Work in process is low. d. It needs specially skilled workers. e. Production cycle time is per unit is more.
3. Fixed Position layout a. It is used for the products which are very massive. b. It is very inconvenient or it is not desirable to move them c. In fixed position layout, the works remains in fixed positions. d. The machines, material, equipment and workers are needed for productions are brought to the site of the workers.
Module No 04 33
Figure: Fixed Position Layout Example: Ship Building Industry, Air craft production, Assembly operation Industry, Advantage a. Capital investment in the plant layout is minimum. b. Higher flexibility. c. Effective used of skilled workers. d. It is easy to measure the progress of work e. The worker identify themselves with a product in which they took interest and pride in doing job..
7. Describe the procedural step involved in making a plant layout? Ans: - PLANT LAYOUT PRCOEDURE A step by step procedure for planning or designing a plant layout is given below. 1. Collect the data regarding the product, process etc and record the data systematically.
Module No 04 34
2. Analyze the data using the various techniques of analysis. 3. Determine the machinery and equipment recorded. 4. Select the material handling equipment. 5. Draw the plan of site. 6. Design the individual workstation. 7. Fit the individual layout into total layout. 8. Determine the storage space required also make floor diagram. 9. Plan and locate service areas. 10. Check the final layout and prepare master layout. 11. Present the layout to management and get approval. 12. Install the approved layout. 13. Follow up. 8. List the factor to be considered while designing layout? Ans: - The factors considered while designing layout are 1. Types of Industry 2. Nature of product 3. Production system 4. Production capacity 5. Types of layouts 6. Arrangements of material handling system 7. Types of building 8. Total space available: Machines and equipment should not be fixed very close each other. Sufficient space should be provided between them to work conveniently. 9. Name and describe the various techniques used for layout planning? Ans: -The various techniques used in layout planning 1. Operation process chart It represents the basic activities involves in product.
Module No 04 35
It gives the information regarding distance moved and time required for various activities. 2. Flow process chart It is the graphical representation of all production activity occurring on the floor of the plant. 3. Flow diagram The flow diagram is the plan of the work area. It is drawn to the scale. It indicated backtracking, cross traffic, obstacles in the way of the product. 4. Templates Templates are pieces of cardboard or paper representing the equipment of a shop at smaller scale. Templates show the visual picture of desired layout. The templates are so arranged so as to give best layout. 5. Machine data cards. These are cards prepared for each machine showing its capacity, space and other requirements, handling needs and corresponding activities.
10. Compare the product layout and Process Layout Ans: No Product layout Process layout
Module No 04 36
Product oriented layout 1 2 3 4 Less flexible Better use of space
Process oriented layout More flexible Poor use of space
Work stations are arranged as per Work stations are arranged sequence of product operations. according to the function. Low capital investment is needed.
High capital investment is needed.
Applicable to the mass production.
Applicable to the job or batch production. Work in process is low Volume of production is low Production cycle time per unit is more. Per unit cost is more
7 8
Work in process is high. Volume of production is high. Production cycle time per unit is
9 10
less. Per unit cost is less.
11. Explain the need for good facilities planning Ans: - THE NEED FOR GOOD FACILITIES PLANNING The need for good facilities planning 1. Plant facilities influence the costs of operating and therefore profits. 2. Planning allows facilities to comply with laws ad/or regulations. 3. Facilities involve high capital-cost expenditures. 4. Facilities are fixed investments, not readily convertible to money or resale.
Module No 04 37
5. Facilities are inflexible (i.e. physically fixed and have limited opportunities to be changed). 6. Facilities are long term commitments with protracted periods of financial return. 7. Facilities planning, design and construction require long lead times. 8. Sound plans for implementation can avoid disruptions in production, and discontinuities for shipping or delivery. 9. Operations often produce detrimental wastes that affect entire communities. 10. The safety, convenience, appearance, and comfort of industrial facilities influence the attitudes of and the ability to attract suitable employees. 11. Industrial facilities must be planned to meet anticipated future requirements yet compete profitably today. 12. Facilities need to be planned for an appropriate degree of flexibility, expandability, versatility 13. Good planning buys time for making commitments; it minimizes being taken by surprise. 14. If plans are made, managements can react faster and take advantage of business opportunities that arise. 15. Good planning, especially if presented well visually, is an aid to obtain financing monies. 16. The single most important cause of high materials handling costs is ad hoc expansion of plant facilities in the absence of a strategic sitedevelopment plan.
Module No 04 38
Chapter No 4.3
STATISTICAL QUALITY CONTROL
1. Cost of quality 2. Quality specification
Module No 04 39
3. Need of SQC 4. Concept of variation 5. Central tendency theorem 6. Acceptance Sampling 7. Control chart for variable 8. Control chart for attributes 9. TQM
SQC 1. Short note a. b. c. d. e. f. g. Cost of quality **** Quality of design Quality of conformance AQL AOQ LTPD Process capability ** 5 m
Module No 04 40 Vaibhav Vithoba Naik
2. Differentiate between the defect and defectives ?5m** 3. What do you understand by process capability with suitable example.explian the concept of the process capability?8m 4. Explain process capability 10 m 5. What is the process chart? Explain the various types ?10m 6. Explain the different quality standard in brief? 7. Discuss the ISO QUALITY standard .state its at least of 10 clauses? 8. Define quality standard.Disccuss the various quality standard in details with its causes?10m 9. Define control chart? Diffrent between the variable control chart and attribute control chart in details with example? 10. Explain the different type of control chart in SQC 11. Comment on control chart and control limit? Different between the variable control chart and attribute control chart ? 12. What do you mean by quality standard 5m 13. Write a note on TQM policy and objectives?4m
Q.1: -Short notes on Cost of Quality? Solution: COST OF QUALTIY The expenditure incurred to improve the quality of the product is generally termed as Cost of Quality. The cost of carrying out the companys quality function i.e meeting the quality needs of the customers are known as Cost of Quality.
Module No 04 41
These includes 1. Market research cost. 2. The product R and D costs. 3. Cost of inspection and tests 4. Cost defects prevention. 5. Cost of scrap, quality failure. 6. Cost of QA (Quality assurances) 7. Cost of field service. 8. Design Costs.
Objectives of the Evaluation of the COST OF THE QUALITY 1. To identify the major opportunities for cost reductions. 2. To identify the opportunities for reducing cost reduction. 3. To expand the budgetary and cost control. 4. To collect the quality data which is affecting in the poor quality of the product.
Quality specification
1) The concept of designing a component means finalizing the dimension of give jobs by considering the stress calculation. 2) When after calcaulations,the design conclusion are explains on papers ,called as Quality specification. 3) The specification contains the list of essential characteristics and their tolerances. 4) The quality specification include
Module No 04 42
Material specification Process specification Method of testing Criteria of acceptance and rejection. Method of use.
5) One specification may or may not be sufficient to describe the product. 6) The specification are classified as
a. The standard specification :

The standard bodies formulate the specification for standardization of the components. Example specification by BIS.
b. Consumer specification:
When BIS specifications are not available or not suitable for the particular customer need, then consumer specification are used.
c. Company specifications :
When a company which manufacture produce its own specification ,called as company specifications.
Q.1 Describe Different Quality Specification? Solution:Quality Specification 1. Quality Specification is the process to define the requirement of quality characteristics 2. Quality Specification contains a list of essential characteristics and tolerances 3. It may includes
Module No 04 43
a. Material specification b. Process specification c. Method of testing d. Criteria of acceptance and rejection. e. Method of use. f. Programmes.
Need of Specification 1. Helps the manufacturing department to decide what exactly is to be produced. 2. To decide the raw material, process equipment, skill required to produce the product of designed quality. 3. Top differentiate between defectives and non defective parts. 4. To decide the inspection and testing standards required. 5. To judge the various requirement of the buyer. 6. To plan the various manufacturing facilities.
Types of Specification 1. Standard specifications. 2. Consumer Specifications. 3. Company Specifications. 4. Process Specifications 5. Test Specifications.
1. Standard specifications.
a. Most of the countries have their own standard bodies. b. These standard bodies formulate the specification for a variety of product. c. In India, BIS is Nations Standard Body. 2. Consumer Specifications.
Module No 04 44
a. When the BIS specifications are not available or suitable for particular customer needs, then the manufacture manufactures the product according to the customer needs and specifications. b. These specifications are called Consumer Specifications. 3. Company Specifications. a. When the manufacture the product according own specifications to suit the customer needs, they are called as the company specification. 4. Process Specifications a. It is essential to specify the process to manufacture the particular product with specified quality. b. The process specification fulfillment is fulfillment of the product quality. c. It includes Specifications identifications. Material requirement. Sequence of operation. Process sheet Process condition (temp,pressure and humidity) Inspection and testing standards.
5. Test Specifications.
The test specifications includes a. The various specifications about the testing methods. b. Instrument and testing equipment required for testing with specification. c. Method of selection the testing method and the preparation of sample specimens. d. Testing procedure. Q.1.Explain Quality of Design? Solution:Quality of Design 1. The quality of design is related with the tightness of the specification which are used for manufacturing of a product.
Module No 04 45
2. If the specification required for product is according to the national and international standards, then the product is said to have good quality of design. 3. A product having work tolerance of 0.01 mm is having better quality than the product having work tolerance of 0.001mm. Factor affecting /controlling the Quality of Design 1. Types of customers in the market. 2. Performance of product expected. 3. Profit considerations. 4. Changing needs. 5. Economic Considerations. 6. Feasibility. Q.2.Explain Quality of Confirmation? Solution:Quality of Confirmation 1. The quality of conformance is concerned with how well the manufactured product conforms the quality of design. 2. All the products should be conformed to the designed specifications. 3. The product which is fulfilling the designed specifications and providing a good quality then it is said to have a good quality of conformance. Factor affecting /controlling the Quality of Conformance 1. Adequate quality of raw material, machineries, tools and equipment, inspection and testing equipments. 2. Proper process and adequate process control. 3. Quality of operators in regards to their skill and experience. 4. Inspections stages and frequency of inspections. 5. Proper storage and finished product. Q.3.Short notes on Quality of Performance? Solution:Quality of Performance 1. Quality of performance is concerned with how well a manufactured product gives its performance.
Module No 04 46
2. It depends on Quality of design and Quality of performance. Example: If a centrifugal pump lifts the water to the desired height then we say the quality of performance of centrifugal pump is good. 3. The quality of design can be very good but if proper quality control is not there, quality of conformance is poor, This will result into poor quality of performance also as the product will fail to satisfy customer. 4. Also if the quality of design is poor then the quality of performance will be affected still the quality of performance is good. 5. Thus for a good quality of performance, both quality of design and quality of conformance should be good.
Q.3.What is Quality Characteristics? Explain any one of them? OR What are the main elements of Quality Function? Solution:Main Elements of Quality Function
Module No 04 47
The three main elements of the quality function 1. Acceptance function 2. Prevention function 3. Assurance function 1. Acceptance function a. This is the day to day job of measuring the product, judging the performance, making disposition and recoding the data. b. It cam include the incidental function as mainting, measuring equipment storage, salvage. c. This function is related to the acceptability of the product with regard to the set quality of programme. 2. Prevention function a. This function includes the quality control in its various aspects, economic studies, process capability studies, design of experiments, design of sampling plans. b. In this function, the different measure is taken to control the quality of products by minimizing the defects. 3. Assurance functions a. This is high level job of preparing the executive type information on quality presenting it to the various interested supervisory levels.
Q4. Define SQC & State its benefits. Ans:Statistical quality control: A quality Control system is called SQC, when statistical techniques are employed to control the quality or to solve quality problems.
Module No 04 48
It is based on law of large numbers & Mathematical theory of probabilities. Modern techniques of SQC & acceptance sampling have an important role in improvement of quality, enhancement of productivity, creation of consumer confidence & development of industrial economy of country. Advantages/Benefits of SQC: 1) Efficiency & Cost reduction 2) Reduction of scrap:- It enables to forecast troubles before rejection occur & reduce the amount of spoiled work. 3) More effective pressure. 4) Easy detection of faults. 5) Easy application. 6) Reduction in consumer complaints. 7) Quality awareness creation in employees. 8) Improves productivity. 9) Reduce wastage of men & machines hours.
Q.4: -Define SQC? Define in short the practical devices used as a tools in statistical control in industry Ans: Statistical Quality Control SQC
Module No 04 49
SQC is defined as the techniques of applying statistical methods based on theory of probability to established quality standards and to maintain in the most economical manner. It is a data driven approach and is applicable to outgoing products like during shipping. Practical devices used as tool in SQC 1. Histogram It is a representation of disturbtion of variable data represented by a series and equal width columns of varying height. It is used for visual communication about the process and for helping in making decision about where to focus the effort of improvements. 2. Control Chart These are basically line graph with control limits that record the number defects for each period (shift, weak etc).these are used to monitor the performance or ongoing process and to get a working in advance to prevent the manufacturing of defective parts. 3. Scatter Diagram It is a graphical technique for studying relationship between two sets associated data. 4. Pareto Chart It is a technique of arranging data according to priority or importance and using it in the problem solving framework. This helps to find out important few from many trivial. 5. Cause and Effect Diagrams It represents a relationship between a given effect and its potential cause and is used as tool for problem solving. It is used to identify the potential root cause of the problems. Q.5. Why statistics is important in Quality Control? State the benefits of SQC? Solution:-
Module No 04 50
STATISTICAL QUALITY CONTROL: 1) It is the branch of quality control which deals with collection, problem analysis and interpretation of data to solve the problem. 2) Statistical quality control applies the law of statistics to solve quality control problem. 3) It is based on the law of application to large number and theory of probability. IMPORTANCE OF STATISTICAL QUALITY CONTROL 1. Less amount of inspection Due to SQC, less amount of inspection is required which saves the lot of man hour of the production 2. Reduction in scrap and reworking Due to SQC techniques of production, production is possible with minimum chances of scraps and reworks. 3. Fault fining and corrective action Due to SQC, the fault finding is easy and the corrective action can be easily taken 4. Efficiency and cost reduction Due to SQC, there is increase in efficiency and reduction in cost is easily possible. 5. Better customer relation The good customer relations can be maintained by the proper use of SQC.
Advantage /Benefits of SQC 1. Efficiency and cost reductions
Module No 04 51
2. Easy detection of fault. 3. Easy application 4. Reduction of scrap. 5. Reduction in consumer complaints. 6. Reduction of men and machine hours. Q.6. Distinguish between Variables and Attributes Solution:No 1 Variables Attributes When the measurement is carried out to When a record shows only the number of find the quality characteristics of articles confirm and non confirming to components, the quality is said to be any special requirement it is said to be 2 3 4 Ex: expressed in varbles. attribute data It is done with the help of precision It is recorded with the help of laid down measurement. standard. Data obtained is called the continuous Data obtained is called discrete data data. The value cannot be fractions Dimension of a parts measured Weight in kg The value cannot be fractions No of defects found in sample Cracks in sheet by spot weld.
Q.7. What is Variation/Variability? What are possible causes of variation? Solution:VARIATION/VARIABILITY
No production process can produce all items exactly alike.
Module No 04 52
Production process consists of combination of men, materials and machine. Each of these elements of combination has some inherent or natural variability, the causes of which cannot be isolated.
Reason for variation 1) Poor raw material 2) Machine vibration 3) Tool wear 4) Improper work setting 5) Faulty work holding device Two types of Variation 1) Chance variation /random variation 2) Assignable variation
Q.8. Differentiate between the Chance causes and Assignable causes? Solution:No 1 Chance cause This cause occurs by chance. Assignable causes This cause occurs due to individual
Module No 04 53
2 3 4
There is a minute amount of variations. They are difficult to trace and un economical to eliminate. With the random variation ,the process is stable to use the sampling procedure These causes flows the statistical laws of variation.
error. There is a small and large amount of variations. They are easy to trace/detect and un economical to eliminate. With the assignable variation ,the process is not stable to use the sampling procedure These causes do not follows any statistical laws of variations.
5.
6 Example a. vibration in machine b. variation in material Example a) Faulty set up b) Fault jigs and fixtures
Q.9:-Define Solution : -
frequency
distribution.
Describe
various
ways
of
graphical
representation of frequency distribution. FREQUENCY DISTRIBUTION: -
Module No 04 54
1. When the measured sizes of all the products are plotted against the frequency of occurrences of each size in the form of graph, it is known as frequency distribution. 2. The height of curve at any point is proportional to the frequency of occurrence of that particular size. APPLICATION OF FREQUENCY DISTRIBUTION 1. For producing entire lot character from sample. 2. For determining process capabilities. 3. For comparing inspection results for two machines 4. For analysis effective of tool wear. GRAPHICAL REPRESENTATION OF FREQUENCY DISTRIBUTION 1. Frequency Histogram 2. Bar chart 3. Frequency Polygon 4. Cumulative Frequency Distribution
Frequency distribution can be represented graphically by following ways.
Module No 04 55
1. Frequency Histogram: 1) In the graph the sides of column represents the upper & lower cell boundaries & heights are proportional to the frequencies of occurrences within the cells. 2) In drawing a histogram, It is assumed that the frequency is centered at the mid value of cell or class.
3) Simplicity of construction & inspection of histogram makes it an effective tool.
4) A random sample is taken from the lot under consideration & measurements
are made for selected quality characteristic. 5) When there is a large amount of highly variable data, then it may be grouped into cell. 6) As a general rule, at least 50 measurements are taken to provide sufficient data to plot the histogram.
2. Bar Chart: -
Module No 04 56
1) Bar chart is a graphical representation of the frequency distribution, in which the bars are centered at the midpoint of the cells. 2) The heights of bars are proportional to the frequencies in the respective cells.
3.
Frequency Polygon: 1) Frequency Polygon is a graphical representation of frequency distribution in which series of lines joining the points are platted at cell midpoints at the height shown for frequency. 2) It consists of a series of straight line joining points which are plotted at all mid points with a height proportional to the frequency. 3) The advantage of frequency polygon is that frequency polygon of several distributions may be plot on the same axis, those by making certain comparisons possible.
4. OGIVE CURVE
Module No 04 57
1) Ogive curve are used to plot cumulative frequencies of value less than or greater than respective cell bounded. 2) Less than Ogive: Upper class boundary and less than cumulative frequency. 3) More than Ogive : Lower class boundary and more than cumulative frequency
Q.10: - Define
Module No 04 58
1. Grouped Frequency 2. Relative Frequency 3. Cell 4. Universe. Solution: -
1) Cell : While grouping the data into a frequency distribution, the cell boundaries should be chosen half way between two possible observations and cell intervals should be equal. The interval along the scale of measurement of each ordered class is termed cell.
2) Grouped frequency: It is an arrangement, which shows the frequency of occurrence of values in ordered classes.
3) Relative frequency: The relative frequency of any cell is the frequency for that cell divided by total numbers of observations.
4) Unit: Unit is one of a number of similar items, objects etc.
5) Universe or population: The universe may be thought of as a common source, from which the total collection of unit is obtained. Statistical methods are based on the concept of a distribution of exceeding larger number of observations, termed as Infinite Universe or Population. . Q.11: -Define central tendency
OR Define 1. Mean 2. Median 3. Mode 4. Range Solution: Central Tendency: When accurately measured, the dimensions of most of the components tend to concentrate close to middle of the two extremes. This is called as Central Tendency.
1. Arithmetic Mean: -
The arithmetic mean is the average of all the values of the variable in the sample. If X1,X2,X3,.,Xn are the n values of the variables X in the sample, then their arithmetic mean is given by,
X1 + X2 + X3 +.................+ Xn n
X=
i.e. X = 2. Median:
When all the observations are arranged in ascending or descending order, then the median is the magnitude of middle case. Case 1:If n is odd, the observations are arranged in ascending order, then median is given by, ( Case 2:If n is even, then the median is taken as, Average of ( ) th value or ( value.
n 2 n + 1) 2
th
n +1 th ) 2
value.
3. Mode: -
Module No 04 60
Mode is the value that occurs most frequently in a frequency histogram or frequency polygon. It is the observed value corresponding to the high point of the graph. For Example, The recorded observations are, 2,3,2,4,5,2,7,6,2,4,2 Here, 2 occurs most frequently, hence mode = 2
Module No 04 61
Q.12:- Define dispersion. How will you measure dispersion? Solution:DISPERSION: The extent to which data is scattered about the zone of central tendency is known as dispersion. Common measure of Dispersion 1. Range 2. Standard deviation 3. Variance The various measures of dispersion are, 1) Range (R): Range is the difference between largest observed value & smallest observed value. It is the simplest measure of dispersion in a sample. It is particularly used in the control chart. Range = largest observed value smallest observed value.
2) Standard Deviation: - (RMS value)

Standard Deviation is defined as the root mean square of the deviations from the arithmetic mean. If X1, X2, X3 Xn are n number of observations, Then, X = arithmetic mean, X X + X X ) +..........( X X ) = ( ) ( n
1
3) Variance: It is the sum of squares of deviations from the arithmetic mean divided by number of observations. In other words, Variance is the square of standard deviation i.e. 2.
Module No 04 62
Q.13: - What is N.D. curve. Give characteristics & applications of N.D. Curve. Solution:Normal Distribution Curve In the frequency distribution, if the number of observations is increased and if only the chance causes of variation are present in the quality characteristics measured, the frequency polygon assumes a bell-shape and approximates to normal distribution curve.
Characteristics 1. Normal distribution curve is bell shaped & symmetrical about the mean.
2. The curve is fully defined by X & . 3. Theoretically N.D. curve extends from -3 to +3. However for all practical
purposes, we can consider normal curve extending only 3 values to the left and 3 values to right of mean. I.e. X 3 .
4. The most coated limits in connection with the curve are as follows
Specification Limits X X 2 X 3 Percent Of Total Area 68.26% 95.46% 99.73%
When we select 3 limits, we are 99.73% sure that the observations will lie within these limits.
Module No 04 63
Applications of N.D.curve: -
1. The frequency of occurrence of the parts are plotted against their respective
classes are sizes. If the curve is approximates to N.D. Curves, it means no assignable causes of variation are present i.e. chance causes are present. 2. It is useful in process capability study to find whether the process is capable of meeting the specified tolerance or not. 3. The area under the curve between two limits represents the total percents of production that will fall either these limits. Q.14: - Define Control Chart. State its purposes?What are its objectives? Solution: Control Chart: 1) It is a graphical representation of the collected information. 2) The information may pertain to measure quality characteristic (e.g. length, diameter, thickness etc.). 3) Control chart is a device for specifying state of statistical control & for attaining quality control. 4) It is a tool to judge whether a state of statistical control has attended. Purpose of Control Chart: 1) To find out the changes in the quality of product; so that rectification can be equally made to correct the process before large quantity of defectives (or scrap) are produced. i.e. the chart gives warning of change in trend of production towards the increasing number of defective articles. 2) To determine whether the given process can meet the existing specification without a fundamental change in production process. 3) To secure information to be used in establishing or changing production procedure. 4) To give a feedback of information, which can be used for planning & control purposes. 5) To ensure product quality level.
Module No 04 64
Objectives of different control charts:The commonly used control charts are,
1. X Chart: - It shows variation in average of variation of samples i.e. it shows

centering of process
2. R Chart: - It shows uniformity or consistency of process i.e. it shows

variations ranges of samples.
3. Charts: - It shows variation of the process.
& R or X & Charts are used in combination to control the process.
TYPES OF CONTROL CHARTS:-
CONTROL CHART
X- R chart (For measurable quality characteristics available)
1) P chart & 2) C chart (For attribute data)
Module No 04 65
Q.15: -Describe the method of constructing X & R charts & explain how these charts help in determining lack of controls. Solution: Step I Calculate the average X & range for each sample: A good number of samples of items manufactured are collected randomly at different intervals of time & their quality characteristics (e.g. diameter, thickness, wt., etc.) are measured. For Examples: If a sample contains five items, whose dimensions are X1, X2, X3, X4 & X5, then
X= X1 + X2 + X3 + X4 + X5 5
& R = largest value smallest value. Step II Calculate grand average X & average range R . It is obtained by dividing the sum of X value by number of samples i.e. subgroups,
i.e. X =
X , Where N= Number of samples, and R = R

N
N
Step III Calculation of 3 limits for X chart, The control limits are given by, Upper control limit X = UCL X = X + 3 . X Lower control limit X = LCL X = X - 3 . X Step-IV Calculation of 3 limits for R chart, UCL R = D4 R UCL R = D3 R
where the values of various factors A, A1, A2, D1, D2, D3, D4 are based on normal distribution & can be found from standard tables for a particular sample size. Step V Plot X & R chart: For X chart, the central line on X chart should be drawn as solid horizontal line as X . The upper & lower control limits should be drawn as dotted horizontal lines at the calculated value. For R chart, central line will be indicates R & control limits are shown by dotted horizontal lines. Step VI Plot the average of samples in X chart in the order collected & points outside the control limits are indicated by cross. Plot the ranges in R chart & points outside the control limits are indicated by circles. Step VII Interpretation/preliminary conclusions from the control charts. The lack of control is indicated by points falling outside control limits on either X & R chart. When all the points fall inside, it means the process is in control. 1 out of 35 or 2 out of 100 points can be tolerated & process is said to be in control.
Q.16: -Differentiate between a defect & defective. Solution: A. Defective: 1. An item is said to be defective if it fails to conform to the specifications in any of the quality characteristics. B. Defect: -
1. Each characteristic that does not meet with the specifications is called as defect.
2. An item is said to be defective if it contains at least one defect.
Module No 04 67
3. For e.g. if a casting contains undesirable hard spots, blowholes, cracks etc., the casting is defective and hard spots, blowholes, cracks are called as defects. Q.17: Define Fraction Defective. How will you draw P chart? Solution: FRACTION DEFECTIVE: It is defined as the ratio of number of defective articles to the total number of articles actually inspected. It is always expressed as decimal fraction. P- Chart It is an attribute control chart i.e. for quality characteristics that can be classified as either conforming or non-conforming to the specifications. For e.g. dimensions checked by GO & NO - GO gauges.
Step to draw P Chart: 1) Record the data for each subgroup on no. of articles inspected and no. of defectives 2) Compute P (fraction defective) for each subgroup
P=
No. Of defectives in subgroup No. of articles inspected in subgroup
3) Compute P =average fraction defective P= Total No. Of defectives in a period Total No. of articles inspected in a period
4) Compute Control limits
UCLP = P + LCLP = P
P + (1 P) n P + (1 P) n
5) Plot each point as obtained, plot control limits as calculated. The points falling outside control limits are identified, (If any). 6) If the points fall outside the control limits, there may be two reasons. a) Assignable causes of variation may be present.
Module No 04 68
b) Quality level is different for assumed standard P. . Q18. Short Note on P- Chart? Solution: P- Chart It is an attribute control chart i.e. for quality characteristics that can be classified as either conforming or non-conforming to the specifications. For e.g. dimensions checked by GO & NO - GO gauges. 7) Record the data for each subgroup on no. of articles inspected and no. of defectives 8) Compute P (fraction defective) for each subgroup Step to draw P Chart: -
P=
No. Of defectives in subgroup No. of articles inspected in subgroup
9) Compute P =average fraction defective P= Total No. Of defectives in a period Total No. of articles inspected in a period
10) Compute Control limits
UCLP = P + LCLP = P
P + (1 P) n P + (1 P) n
11) Plot each point as obtained, plot control limits as calculated. The points falling outside control limits are identified, (If any). 12) If the points fall outside the control limits, there may be two reasons. c) Assignable causes of variation may be present. d) Quality level is different for assumed standard P.
Module No 04 69
Q.19: - What is the purpose of P-Chart? Solution Purpose of P-Chart Because of lower inspection & maintenance costs of p-chart, they usually have a greater area of economical applications than control charts for variable. 1. To discover avg. proportion of defective articles submitted for inspection, over a period of time. 2. In a sampling inspection of large lots. 3. To bring attention to management, any changes in average quality level. 4. To discovers identity & correct causes of bad quality. 5. Provides management with useful record of quality history.
6. To suggest where it is necessary to use X & R chart to diagnose quality problems.

Q.20: -Short Note on C chart Solution: C Chart (Control Chart for defects per unit ): 1. It is also another type of control chart for attribute. 2. It this chart, sample size remains constant. It finds no of defects per unit of production. Example of this includes Cloth manufacturing & Tube manufacturing. 3. It applies to number ff defects in a subgroup of constant size. Central line = C =
No. of defects in all subgroups No. of defects in all subgroups
Upper control limit UCL C = C + 3 C Lower control limit LCL C = C 3 C 4. Plot each point as obtained, plot control limits as calculated. 5. The points falling outside control limits are identified Applications of C chart. 1. Number of surface defect in aircraft wing. 2. Number of surface defect in galvanized sheet.
Module No 04 70
3. Number of small holes in glass bottles. 4. Number of defect such as blowholes, cracks in a casting. 5. Number of imperfections observed in a cloth of unit area. Q.21: -Differentiate between Variable & Attribute Chart OR Differentiate between X & R chart with C, P chart.
Variable Charts Attribute Charts Examples: - P, np, C, U charts. Examples: - X & R Data required is variable data (i.e. Data required is attribute measured quality characteristic) Field of Application: Control
data
(i.e.
conformance or non-conformance using laid down standard GO & NO gauges). of Field of application: - Control of proportion of defectives or defect in a sample of constant size or number of defects per unit. of Data required are often already available
individual quality characteristic. Provides maximum utilization
information available from data. form inspection records. Provides detailed information on process They do not provide detailed information for average & variation for control of control of individual dimension. individual dimension. They are not easily understood unless They are more simple as compared to X, R training is provided. charts, so can be easily understand They involve more time for measuring, They involve less cost & time. calculation & plotting. Sample size is small. Sample size is generally larger.
Module No 04 71
Q.22: - What is Process capability? Explain its role in achieving the Quality? OR How Process capability is useful in industry? Solution: PROCESS CAPABILITY It may be defined as the minimum spread of specific measurement variation, which will include 99.73% of the measurement from the given processes as shown by limits in the N-D curve. In other words, Process capability = 6, since 6 is taken as a measure of spread of process, which is also called natural tolerance. By this study, it becomes possible to know the % of products, which will be produced within 3 limits on either side of mean X . ROLE OF PROCESS CAPABILITY IN ACHIEVING QUALITY 1. The capacity of the process and available equipment can be utilized effectively and efficiently.
2. The job with tight tolerance can be assigned to the capable machines.
3. The tools designer can find out the places where tooling improvement can be done to maintain the process capability. 4. The capability study helps in maintenance schedule. 5. The machine settler can judge the efficiently of the machine. 6. The machine operators can take decision selecting the machines. USE OF PROCESS CAPABILITY STUDY 1. It determines the ability of the process meet standard and specifications. 2. It can be used to establish the new standard. 3. It measures the variability of the process. 4. It determines the causes of the inherent and actual variability. Applications of Process Capability study:1. To find whether the process is capable of meeting the specified tolerance limits.
Module No 04 72
2. Discover why the process capable is failing to meet the specifications. 3. The knowledge of process capability studies lead to improve equipment maintenance, improved operator training & reduce costs. Q.23: - Explain the steps involved in process capability? Give its applications. Solution: Procedure for doing Process Capability study Step 1. Calculate X and R for each sample. Step 2. Calculate Grand average X & average range R , this measures centering of process. Step 3. Calculate process capability = 6 = 6
R R 6x d2 d2
where d2 is a factor for particular sample size.
This measures the piece-to-piece variability of process. Step 4. Calculate specified tolerance.i.e. (Xmax Xmin). When a controlled process must meet two specification limits on individual values, upper & lower specification limits, the possible situations may be grouped into 3 general classes as described below.
1. When (Xmax Xmin) > 6

Where Xmax = Upper specification limit Xmin = Lower specification limit i.e. specified tolerance > natural tolerance Conclusions 1) With any position a,b or c practically all the products manufactured will meet the specifications
2) If (Xmax Xmin/6) ratio is considerably large, frequency of control chart may be

reduced.
Module No 04 73
2. When (Xmax Xmin) < 6 i.e. specified tolerance is < natural tolerance
Conclusion In this type of situation defectives will always be there. Remedy:-
a. Increase the tolerance.

b. Reduce the dispersion. c. Suffer and sort out the defectives if it economical to make the fundamental changes in process.
3. When (Xmax Xmin) = 6

Conclusion Spread of process is approximately equal to difference between upper & lower specification limits.
Remedy:a. It is necessary to maintain the centering of process.
Module No 04 74
b. Reduce dispersion if it is economical. c. Advisable to increase tolerance. Q.24: -What do you mean by Acceptance sampling? How does it help in Quality Control? Solution: ACCEPTANCE SAMPLING 1) Acceptance sampling is the process of evaluating a portion of the products in lot for the purpose of accepting or rejecting the lot on the basis of number of defective parts found in a random sample drawn from the lot. 2) If the number of defective items does not exceed the predefined level, the lot is accepted otherwise rejected. NEED OF ACCEPTANCE SAMPLING 1. To interprete the specification. 2. To measure the product. 3. To compare the specification and the product. 4. To provide the basis for constructing the sampling plans. TWO METHODS OF ACCEPTANCE SAMPLING /SAMPLING INSPECTION Inspection for acceptance purpose is carried out at many stages in manufacturing. There are generally two ways in which inspection is carried out. 1. 100% inspection. 2. Sampling inspection. A. 100% inspection 1) In 100% inspection, all the parts or products are subjected to inspection, where as in sampling inspection only a sample is drawn from the lot & inspected. B. Sampling inspection.
Module No 04 75
1) In sampling inspection, certain samples are selected from a lot and they are checked. 2) Decisions are made after inspecting the samples selected. Q.25: - Give the advantages and limitations of ACCEPTANCE SAMPLING? Solution: ADVANTAGES OF ACCEPTANCE SAMPLING 1. Cost and time required is less compared to 100% inspection. 2. Less manpower is required for the inspection 3. It takes less time and hence delivery time and hence delivery commitments can be easily met. 4. The error and fatigue observed in 100% inspection is not there. 5. The quality awareness is increases in the business organizations. DISADVANTAGES OF ACCEPTANCE SAMPLING 1. Proper selection of sampling plans, sampling size, proper acceptance and rejections number is important while doing. 2. There are risk of accepting bad lots and rejecting good lots. 3. The field of application is limited depending on the product. 4. The sampling provides less information than the 100% inspection.
Module No 04 76
Q.26: - Give the advantages and limitations of sampling inspection over 100% inspections. Solution: ADVANTAGES AND LIMITATIONS OF SAMPLING INSPECTION OVER 100% INSPECTIONS.
Advantages of Acceptance sampling: The advantages of sampling inspection over 100% inspections: 1) Cost & time read is quite less than 100% inspection. 2) Problems of inspection fatigue are eliminated. 3) Less damage to products because only few items are subjected to handling during inspection 4) The inspector error introduced by 100% error is minimized. 5) The lot is disposed off in shorter period, so that scheduling & dispatch dates are improved. 6) It exerts more effective pressure on quality improvement.
Limitations of Acceptance sampling: 1) Since only a part is inspected, the sample may not represent the exact picture of the entire lot; hence there is likelihood of risk of making wrong decisions about the lot. 2) The producer will pass on the cost of rejected loss on the consumer. 3) This method may not be suitable for tasking decision on acceptance or rejection of very costly items. 4) It is necessary to use random sampling, select proper sample size & acceptance criteria for accurate results.
Q.27: -State the factors on which success of sampling inspection depend? Solution: - Factors on which success of sampling inspection depends are :a) Random sampling. b) Proper sample size & lot size.
Module No 04 77
c) Acceptance criteria. d) Quality characteristic to be measured.
Q.28: - What is O.C. Curve? Sketch neatly actual O.C. curve?State its parameter? Solution: O.C. Curve (Operating Characteristic Curve) 1. The operating characteristic curve for an attribute-sampling plan is a graph of fraction defectives in a lot against the probability of acceptance. OR The operating characteristic curve for an attribute-sampling plan is a graph of probability of acceptance versus percentage defectives.
2. The percentage defectives are taken on X axis and the probability of acceptances is taken on Y axis on the graph. 3. It provides both the produces and consumer a graph showing risks each of them takes in term of good product being rejected and bad product is accepted. 4. The shape of O.C. curve depends upon following parameters. N = Lot size from which samples are drawn
Module No 04 78
n = Sample size c = Acceptance number
5. An O.C. curve can be divided into three regions. a. Acceptance quality region. b. Indifference quality region c. Objectionable quality region. Parameter of an OC curve 1. Producers risks 2. Consumers risks 3. Acceptable quality level. 4. Lot tolerance percentage defective. 5. Average outgoing quality. 6. Average outgoing quality level Q.29: - State the characteristic of an O. C. Curve. Solution: Characteristic of O.C.curve: 1) The O.C. curve of an acceptance-sampling plan shows the ability of plan to distinguish between good lots & bad lots. 2) Sampling acceptance plans with same % samples gives very different quality protection 3) For different values of n, N & c, the O.C. curve will differ.
4) But for fixed value of c & n1 the O.C. curve for different values of N are not
appreciable different i.e. it is the absolute size of sample i.e. important than its relative size compared to size of lot.
5) With fixed value N and c < n1 than if n value is larger, better will be
discrimination between good lots & bad lots. 6) With fixed value of C and n < N, than if n is larger, the slope of O.C. curve will be steeper. Q.30: - List the significance of an O. C. Curve. Solution: Significance of an O. C. Curve
Module No 04 79
1. It compares the performance over a range of possible quality level of submitted product. 2. It provides the means of evaluating the means of evaluating the sampling. 3. It depicts the varying conditions of incoming material. 4. It explains the risk inherent in sampling plan at each level of product quality. Q.31:- Explain the following terms. A. Producers risk B. Consumers risk C. Acceptance Quality Level (AQL) D. Lot tolerance percent defective (LTPD) E. Average outgoing quality (AOQ) F. Average outgoing quality level (AOQL) Solution: -
A. Producers risk: 2) The producers risk is the probability of rejecting a good for which otherwise would have been selected (accepted). 3) If the quality is good still from the sampling plan some lots are rejected, then it becomes the risk of producer and producer has to suffer. 4) Producer should not be affected by rejecting a good lot. 5) So producers should be protected against the rejection of relatively better products. 6) The producers can decrease risk by producing product at better quality level than specified AQL depending upon other economical conditions.
B. Consumers risk 1) Consumers risk is defined as the probability of accepting the defective lots which otherwise would have been rejected.
2) If the quality of the product is bad and still some lots are accepted then it
becomes the risk of consumers. 3) If the quality is bad still from the sampling plan, some lots are accepted, the consumers has to suffer.
Module No 04 80
4) Saying that Pa 0.1 = 2.5 means that the consumer dose not want a worse quality containing more than 2.5% defectives & he would at the most accept 10% of lots containing 2.5% defectives.
C. Acceptable Quality level (AQL): 1) It represents the max proportion of defectives, which the consumer finds definitely acceptable. 2) AQL can also be defined as maximum percent defectives that for the purpose of sampling inspection can be considered satisfactory as a process average. 3) As an AQL, is an acceptable quality level, the probability of acceptance for an AQL should be high. 4) In fact the producers safe point is termed as AQL
D. Lot Tolerance Percent Defective (LTPD): Lot tolerance percent defective. 1) It can be called as RQL i.e. Rejectionable Quality Level. 2) It is a definition of unsatisfactory quality.
3) It represents the proportion of defectives which consumer finds definitely

unacceptable. 4) As RQL is unacceptable quality level, the probability of acceptance is very low. 5) In fact, the probability of accepting a lot at LTPD represents consumers risk.
E. IQL: - (Indifference quality level)

1) This is a quality level somewhat between AQL & LTPD 2) It is defined as quality level having probability of acceptance of 0.5 for a given sampling plan. F. Average Outgoing Quality (AOQ): 1) An average outgoing quality of a product is important to the customer.
2) The AOQ is the expected average quality going to a customer for the
specified incoming quality level.
Module No 04 81
3) It represents the average % defective in the outgoing products after inspection, including all accepted & all rejected lots, which have been100% inspected & defectives replaced by non-defectives. 4) So for a given fraction defectives, the lot accepted as a result of first sampling inspection will have a fraction defectives p the rejected lots are subjected to 100% inspection & rectification (defective particles are either replaced or corrected), therefore AQL will be less than p. G. Average Outgoing Quality Level (AOQL): 1) Average outgoing quality level is the maximum average percent defective in the outgoing product. 2) For any sample size & acceptance number, there is a max. value of AOQ beyond which the average fraction defectives passed forward will not rise, no matter how bad the quality of lots when they arrive at inspection. 3) Because, when incoming quality is good, AOQ must be good. 4) However, when incoming quality is bad, the sampling plan will causes all the lots to be rejected, 100% inspected & rectified. Therefore the outgoing quality will be good. 5) Therefore at either extreme incoming quality very good or very bad, the outgoing quality will tend to be very good. 6) Between these two lots, there will be a point at which the percent of defectives will reach its maximum. This point is known as average outgoing level (AOQL)
Q.32:-Explain Acceptance / Rejection scheme & Acceptance /Rectification scheme? Solution: Acceptance / Rejection scheme: 1) The lots are subjected to sampling inspection. 2) If the lot contains more than c defectives it is rejected otherwise it is accepted. 3) The AOQ will be equal to or more than the given fraction defectives. 4) O.C. curve is used to discriminate between good & bad lots. Acceptance /Rectification scheme :-
Module No 04 82
1) The lots are subjected to sampling inspection & of it contains defectives less than c than it is accepted. 2) It the lot contain more than c defectives, it is subjected to 100% inspection & defectives articles are either replaced or corrected before it is passed forward if for a given fraction defectives, the lot accepted as a result of first sampling plan will have fraction defected p, the rejected lots are subjected to 100% inspection & defective articles are replaced or corrected, If AQC will be less than p. Q.33: -What do you mean by Random Sampling? Solution: Random Sampling: -
1) Selecting a sample in such a way that each item in a lot has an equal chance of
being selected is called as Random Sampling. 2) Since a judgment about the lot is to be made on the basis of only a sample it is very important that the sample truly represents the universe (lot) from which it is drawn. 3) Therefore samples must be selected from all sides & different depths of container containing the lot of parts. 4) Also the sample size should be large enough.
Module No 04 83
Q.34: -State & explain the different sampling plans with respect to their acceptance criteria. Solution: Sampling plans may be grouped into three categories.
A. Single sampling plan: 1) When a decision rejection or acceptance of lot is made on the basis of only one sample, the acceptance plan is known as single sampling plan. 2) In this sampling plan, the decision to accept or reject of a lot is based on the inspection of single sample. 3) It the number of defective found is less than equal to the acceptance number, then the lot is accepted. 4) It the number of defective found is greater than equal to the acceptance number, then the lot or batch is rejected. 5) In this, there are three parameters. N = Lot sizes, n = sample size & C = acceptance number = Maximum number of allowable defectives.
Inspect A Sample Of n Pieces
If number of defectives
Does not exceed C
Exceed C
Accept the lot
Reject the lot
Module No 04 84
B. Double sampling plan: 1) When the decision is made on acceptance or rejection of the lots on the basis on two samples combined it is called as double sampling plan. 2) A lot may be accepted at once if the first sample is good enough and rejected at once if sample is bad enough. 3) If the first sample is neither good enough nor bad enough, the decision is based on the evidence of first & second sample combined. 4) Parameters: Let n1 = number of pieces in the first sample C1 = acceptance number for the first sample= max. number of defectives that will permit the acceptance of lot on the basis of first sample. n2 = number of pieces in the second sample. n1+n2 = number of pieces in the two samples combined. C2 = Acceptance number for the two samples combined = max number of defectives that will permit the acceptance of the lot on the basis of first & second sample combined. Inspect a sample of n1 pieces
If number of defectives
Does not exceed C1
C1 < def < C2
Exceed C2
Accept the lot

Reject the lot
Take second sample of n2 pieces
If number of defectives in the first & second sample combined
Dose not exceed C2
Exceed C2
Accept the lot
Reject the lot
C. Multiple sampling plans: 1) The multiple sampling is used when three or more samples of stated size are permitted. 2) The multiple sampling procedures can be represented on a table such as the following. Sample Number First Second Third Fourth Fifth Sample Size n1 n2 n3 n4 n5 Combined samples Size Acceptance n1 n1+n2 n1+n2+n3 n1+n2+n3+n4 n1+n2+n3+n4+n5 c1 c2 c3 c4 c5
Rejection r1 r2 r3 r4 C5+1
3) A first sample of n1 is drawn, the lot is accepted if there are defectives less than c1
& rejected if there are defectives more than r1
4) Otherwise if c1 < def < r1, a second sample of n2 is drawn, the lot is accepted if
there are defectives less than c2 in combined sample of n1+n2 whereas lot is rejected if there are defectives more than r2. 5) The procedure is continued in accordance with the above table.
Module No 04 86
6) If by the end of fourth sample, the lot is neither accepted nor rejected, a sample n5
is drawn.
7) The lot is accepted if the number of defectives in the combined sample of n1, n2, n3,
n4, n5 less than c5 & rejected if more than c5+1.
Q.35. Compare the three sampling plans. Solution: Single Sampling plan Generally largest Double sampling plan In between single & multiple Multiple sampling plan Lowest Less acceptable if Most acceptable (Gives IInd chance) In between single & multiple indecision is continued for a larger period Largest
Number
Feature Avg. number of
1.
pieces inspected per lot Acceptability to producer Cost of Administration Information available about prevailing quality level
Poor, it given only one chance of passing the lot. Lowest
2.
3.
4.
Largest
In between
Lowest
Module No 04 87
Q.36. What is the Product Reliability ? Solution: PRODUCT RELIABILITY 1) The reliability of a system or device is the probability that it will give satisfactory performance for a specified period of time under specified operating condition. 2) It is expressed as a mathematics probability. Parameter involved in the product reliability 1) The equipment and the performance required of it. 2) The conditions under which it is to operate. 3) The time interval/duration of operations. Cause or Failure / Unreliability 1) Design weakness 2) Manufacturing defects. 3) Misuse failure. 4) Environment stresses coming from temperature, humidity, atmospheric pressure, chemical content, radiation etc. 5) Operating stress coming due to voltage, current and frequency.
Module No 04 88
Q.37. What is the Reliability? What are the factors to be considers while designing a reliable product? Solution: Reliability Reliability can be defines as the degree of assurance or ability of the part to be function under specified conditions for specified time. FACTOR TO BE CONSIDERED WHILE DESIGNING RELIABILITY. The factors to be considered while designing reliability are 1. Simplicity of product : Less the number of produt,the more is reliability. 2. Derating Derating means providing safety margin. 3. Redundancy Redundancy means providing stand by component in event of failure of primary item. 4. Safe operation The part fails should not be sudden and damage should be less. 5. Parts should be protected from extreme temperature, pressure and vibrations etc. 6. The product should be easily maintainable and serviceable.
Module No 04 89
Q.38. Explain the term MTBF? Solution: Mean time between failure (MTBF) 1) MTBF is defined as the total measured operating time of a population of equipment divided by total number of failures, coupled with an assumption of an exponential distribution of intervals between the failure. 2) It is reciprocal of failure rate .
=failure rate is number of failure occurring per unit time.
Module No 04 90
TOTAL QUALITY MANAGEMENT TQM

Q.1: -Short notes on TOTAL QUALITY MANAGEMENT (TQM)? Solution: TOTAL QUALITY MANAGEMENT (TQM)
1. TQM is defines as control of all the transformation of an organization to satisfy

the customers needs in the most economical ways. 2. It is the way of managing to improve the effectiveness, flexibility and competitiveness of a business as whole. 3. It refers to total involvement of staff in an organization in bringing about quality satisfactions. 4. It is responsible for quality revolution in the industry. 5. Its function is to improve the quality of work of all the people at all functional areas of organization. 6. TQM uses a. Fundamental ideas of group activity. b. Participation of all the statistical and quality tools. c. Self development and creativity. ACTIVITY INVOLVED IN TQM 1. Team work. 2. Integration and co-ordination of all the activities of all department to attain the desired goals. 3. Satisfy the worker emotions. 4. Installing motivation system. 5. Maintain a sound quality system to perform the task. OBJECTIVES OF TQM TQM gives emphasis on
Module No 04 91
1. Training in problem diagnosis and solution. 2. The effective communication amongst all the department. 3. Developing all the essential and appropriate procedure. 4. Positive attitude of all the employees working in organization so that customer will get the quality product Q.2: -Briefly explain the procedure for TOTAL QUALITY MANAGEMENT (TQM) implementations? Solution: TQM IMPLEMENTATION We Deming explained PDCA cycle for implementation of the TQM in any organization
1. PLAN a. Lay down and plan all the policies and objectives of TQM. b. Plan method to achieve the objective of organization. 2. DO a. Provide educational and training to workers and managers to achieve the objectives b. Implementation TQM by introducing the newer things. 3. CHECK a. Check the result by observing them and find cause of the non conformation
Module No 04 92
b. Analyze the result.

4. ACT a. Try to act for preventing undesired effects. b. Measure the improvements and design for the future.
Explain the different quality standard in brief? Discuss the ISO QUALITY standard .state its at least of 10 clauses? Define quality standard.Disccuss the various quality standard in details with its causes?10m What do you mean by quality standard 5m
Module No 04 93
Chapter No 4.4
Waste management
Module No 04 94
Q.1: -Short notes on JIT? Ans: - JIT Manufacturing 1. JIT is a production methodology which aims to improve overall productivity through the elimination of waste and which leads to improved quality. 2. JIT provides for the cost efficient production in an organization and delivery of only the necessary parts in the right quantity at the right time and place while using the minimum of facilities. 3. JIT is a manufacturing system whose goals are to optimize process and procedure by continuously pursuing waste reduction. 4. JIT enables one to conceive design, implement and operate a manufacturing and supporting system, as an integrated whole based on the principles of continuous improvements and elimination of all kinds of wastes. Basic Elements of JIT The basic elements of the JIT are 1. Flow Layout: The physical layout of production facilitates are arranged, so that the process flow is streamlined i.e. for each component, the proportion of value added time should be more, there should be more, the should be minimum queuing and non value added times. 2. Smooth built up rate: The buildup rate should be smooth over a monthly cycle. To achieve this, under capacity scheduling is resorted to so that they can respond to demand changes.
Module No 04 95
3. Mixed model scheduling JIT objective is to match the production rate to demand as closely possible. One way of doing this is to increase the flexibility of production lines to allow concurrent assembly of different models on the same line. 4. Buffer stock removal Constant elimination of buffer stock is emphasized to highlight production problem scheduled by high inventory level. 5. Quality The achievement of high quality levels is prerequisite of successful JIT. Zero defects, Statistical process quality, process data collection and worker centered quality are commonly used quality programmes. 6. Product and process simplification This is achieved through a. Rationalization of product range. b. Simplification of methods of manufacture. c. Simplification through the component item standardization. 7. Standard containers JIT emphasize small standard containers. This simplifies the material movement and use of material handling equipment. 8. Preventive maintenance
Module No 04 96
JIT requires removal of cause of uncertainty and waste. Breakdown is a major cause of the uncertainty. Rigorous preventive maintenance attempts to remove the uncertainty. 9. Flexible work force Flexible work force is critical requirement of JIT. Flexible workforce is developed thorough croos functional training. It is necessary to match production rate and demand rate closely as possible. 10. Organization in modules or cells Many JIT factories are organized in small autonomous modules or cells, each cell being totally responsible for its own production and supply of adjacent module. The cells are designed so that material flow between cycle is minimized. 11. Continuous improvement JIT is not one time effort. It is a philosophy of continuous improvement .it seeks the involvement of everyone in the continuous improvements.
Module No 04 97
Benefits of JIT The most significant benefit of JIT is to improve the responsiveness of the form to the changes in the marketplace thus providing an advantage in competition. The benefits are 1. Production Cost: is greatly reduced due to reduction of manufacturing cycle time. Reduction of waste, inventories and elimination of non value added operations. 2. Quality: is improved because of continuous quality improvements programmes. 3. Design: Due to fast response to engineering change, alternative design can be quickly brought on the shop floor. 4. Productive improvement. 5. Higher productive system flexibility. 6. Administrative ease and simplicity.
Module No 04 98
SEVEN WASTES 12. Waste of overproduction : 13. Waste of waiting 14. Waste of transportation 15. Waste of processing itsel 16. Waste of stocks 17. Waste of motion 18. Waste of making defective products:
Module No 04 99

Module No 4

Încărcat de

Informații document

Descriere originală:

Titlu original

Drepturi de autor

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Module No 4

Încărcat de

Drepturi de autor:

Industrial Engineering and Entrprise Resources Planning

Chapter 4.1 INVENTORY CONTROL

Vaibhav Vithoba Naik

Industrial Engineering and Entrprise Resources Planning

Vaibhav Vithoba Naik

Industrial Engineering and Entrprise Resources Planning

Vaibhav Vithoba Naik

Industrial Engineering and Entrprise Resources Planning

Vaibhav Vithoba Naik

Industrial Engineering and Entrprise Resources Planning

Vaibhav Vithoba Naik

Industrial Engineering and Entrprise Resources Planning

Vaibhav Vithoba Naik

Industrial Engineering and Entrprise Resources Planning

Vaibhav Vithoba Naik

Industrial Engineering and Entrprise Resources Planning

Vaibhav Vithoba Naik

Industrial Engineering and Entrprise Resources Planning

Vaibhav Vithoba Naik

Industrial Engineering and Entrprise Resources Planning

9. Explain EOQ with example? Ans: ECONOMIC ORDER QUANTITY (EOQ)

Vaibhav Vithoba Naik

Industrial Engineering and Entrprise Resources Planning

To minimize the total cost, differentiate t with respect to q ,

Vaibhav Vithoba Naik

Industrial Engineering and Entrprise Resources Planning

Vaibhav Vithoba Naik

Industrial Engineering and Entrprise Resources Planning

Vaibhav Vithoba Naik

Industrial Engineering and Entrprise Resources Planning

Vaibhav Vithoba Naik

Industrial Engineering and Entrprise Resources Planning

Vaibhav Vithoba Naik

Industrial Engineering and Entrprise Resources Planning

Q.11: -Describe the various order launching inventory control systems?

3. Starting from an instant which inventory OA is in the stores. It (Inventory)

4. Maximum quantity OA is upper or maximum limit to which the inventory can be

5. Minimum quantity OE is lower or minimum limit to which the inventory can be

8. From B to D it is an lead time and it may calculated on the basis of past

Vaibhav Vithoba Naik

Industrial Engineering and Entrprise Resources Planning

Vaibhav Vithoba Naik

Industrial Engineering and Entrprise Resources Planning

Vaibhav Vithoba Naik

Industrial Engineering and Entrprise Resources Planning

Vaibhav Vithoba Naik

Industrial Engineering and Entrprise Resources Planning

Percentage of annual consumption value

1020 2030 6070

7080 1025 515

Vaibhav Vithoba Naik

Industrial Engineering and Entrprise Resources Planning

The classification of ABC analysis is shown by the graph given as follows

Vaibhav Vithoba Naik

Industrial Engineering and Entrprise Resources Planning

Vaibhav Vithoba Naik

Industrial Engineering and Entrprise Resources Planning

Vaibhav Vithoba Naik

Industrial Engineering and Entrprise Resources Planning

Vaibhav Vithoba Naik

Industrial Engineering and Entrprise Resources Planning

Vaibhav Vithoba Naik

Industrial Engineering and Entrprise Resources Planning

Vaibhav Vithoba Naik

Industrial Engineering and Entrprise Resources Planning