Manufacturing System Design Question Paper

Manufacturing System Design

Course:Bachelor Of Science In Engineering

Institution: Kenyatta University question papers

Exam Year:2009

KENYATTA UNIVERSITY
UNIVERSITY EXAMINATIONS 2009/2010
FIRST SEMESTER EXAMINATION FOR THE DEGREE OF BACHELOR OF
SCIENCE (ENERGY ENGINEERING)

SET 508: MANUFACTURING SYSTEM DESIGN

DATE: Monday
28th December 2009

TIME: 8.00am – 10.00am

INSTRUCTIONS
1.
This paper consists of FIVE Questions, of equal marks
2.
Answer ONLY THREE Questions

QUESTION ONE
a)
Explain the meanings of the following terms and give example in each case
i)
Benchmarking
ii)
Reverse
engineering

iii)
Design for manufacture
iv)
Concurrent
engineering [4
marks]
b)
Joe Chris, owner of Jenchris Manufacturing, is considering whether to produce a

new product. He has considered the operations requirements for the product as

well as the market potential.
I)
Joe estimates the fixed cost per year to be $40,000 and variable costs for

each unit produced to be $50.

i)
If Joe sells the product at a prise of $70, how many units of product

does he have to sell in order to break even?

[2marks]

ii)
If Joe sell 3000 units at the product price of $70, what will be his
contribution
profit?
[3marks]

Page 1 of 5

II)
Joe chris, owner of Jenchris Manufacturing, had decided to produce the new

product. The product can be produced with the current equipment in place.

However, Hoe is considering the purchase of new equipment that would produce

the product more efficiently. Joe’s fixed cost would be raised to $60,000 per

year, but the variable cost would be reduced to $25 per unit. Joe still plans to sell

the product at $70 per unit.

i)
Should Joe produce the new product with the new or current equipment?

[3marks]

ii)
Specify the volume of demand for which you would choose each process.

[3marks]

iii)
Represent the information in break even analysis graph.
[5marks]

QUESTION TWO
a) Explain
Five major factors that affects process design.

[10marks]
b)
By the use of flow chart explain the following types of process design

i)
Product-focused process design

ii)
Process-focused process design
iii)
Group
technology
process
design
[6marks]
c)
Explain the differences between process flow chart and process analysis.

[2marks]
d)
State Two reasons why U shaped flow line process is preferred that straight line.

[2marks]

QUESTION THREE
a)
Explain the following main methods of organizing processing systems and state
two
characteristics in each case.
i)
Job
Approach
ii)
Batch
method
iii)
Flow
method
[6marks]
b)
Describe the stages of the product life cycle and state the demand characteristics
at
each
stage.
[8marks]

Page 2 of 5

c)
Explain Three ways that world class manufacturing will do in use of automation

to make their production systems more competitive in flexibility and cost.

[6marks]
QUESTION FOUR
a)
Explain the three benefits of computer-aided design (CAD) in manufacturing.

[6marks]
b)
i)
Explain Four benefits of Just in time (JIT) manufacturing system.

[4marks]
ii)
Explain
five
measures that are undertaken towards eliminating waste in

Just in Time (JIT) manufacturing systems.

[5marks]
c)
i)
Explain flexible manufacturing
systems.
[2marks]

ii)
State Three benefits of flexible manufacturing systems in production.

[3marks]
QUESTION FIVE
a)
i)
Explain the term line balancing as used in manufacturing systems design.

[2marks]

ii)
Explain Two major obstacles of attaining a perfectly balanced line.

[4marks]

iii)
What are the differences between products design and service design.

[3marks]
b)
Dashg manufacturing company crankshaft is designing a new manufacturing

system. The following information contained in Table 1.0 is available.

Task
Immediate follower
Task time (in Minutes)
a b
0.2
b e
0.2
c d
0.8
d f
0.6
e f
0.3
f g
1.0
g h
0.4
h end
0.3

Table 1.0
Page 3 of 5

You are requested to
i)
Draw
a
precedence
diagram
[2marks]
ii)
Assuming an eighth-hour workday, compute the cycle time needed to obtain an
output
of
400
units
per
day.
[2marks]
iii)
Calculate the minimum number of work station request.

[1mark]
iv)
Assign task to work stations and design the new manufacturing system.

[5marks]

Page 4 of 5

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