Mass Production - Engineering Management - Exam, Exams of Business Management and Analysis

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CORK INSTITUTE OF TECHNOLOGY

INSTITIÚID TEICNEOLAÍOCHTA CHORCAÍ

Semester 1 Examinations 2011/

Module Title: Engineering Management

Module Code: MANU

School: Mechanical & Process Engineering

Programme Title: BEng Honours in Sustainable Energy Technology BEng in Mechanical Engineering (Part time)

Programme Code: ESENT_8_Y EMECN_7_Y

External Examiner(s): Mr Paul Kenny, Mr Conor Buckley Internal Examiner(s): Ms Sally Bryan

Instructions: Answer any 3 questions

Duration: 2 hours

Sitting: Winter 2011

Requirements for this examination:

Note to Candidates: Please check the Programme Title and the Module Title to ensure that you are attempting the correct examination. If in doubt please contact an Invigilator.

1. a) Manufacturing is continually evolving. State the main characteristics of the following manufacturing eras: i. Craft Production ii. Mass Production iii. Lean Production (6 marks) b) State how product improvement is generally measured in the service sector. (5 marks) c) Discuss the influence of batch size in a typical batch manufacturing environment. In particular, make reference to non-value activities. (10 marks) d) Design ‘evaluation and improvement’ is a very important step in the design and development process. Why is it important? What tools are used to make the step more effective? (12 marks)
2. a) The following design methods can be used to improve the reliability of a product. Describe and give an example of each method. i. Fail-safe ii. Redundancy iii. Derating (9 marks) b) The following are different types of benchmarking. Briefly describe and differentiate between the categories. Use examples to illustrate your answer. i. Internal ii. External iii. Non-competitive iv. Strategic. (12 marks) c) What is the reliability of the system in figure Q2 at 300hrs if R 1 is approximated by the exponential distribution with a failure rate of 0.0025/hr and R 2 is approximated by the normal distribution with mean of 900hrs and standard deviation of 300hrs. (12 marks)

Figure Q

R 1

R 2

3. a) Explain how inventory is used to make operations independent of each other in a batch manufacturing environment. (6 marks) b) A local distributor for a national tyre company expects to sell 9600 steel belted radial tyres of a certain size and thread next year. Annual carrying cost is €16 per tyre and the ordering cost is €75. The distributor operates 288 days per year. i. Calculate the Economic Order Quantity (EOQ) ii. How many times per year does the store reorder? iii. What is the length of the order cycle? iv. What is the total annual cost if the EOQ quantity is ordered? (16 marks) c) Material Resource Planning (MRP) requires information from the Bill of Materials, the Inventory Record File and the Master Production Schedule. Briefly describe these three inputs and the information they provide to the MRP system. (11 marks)
4. a) Summarise the duties of the employer in regard to the safety, health and welfare of their employees. (5 marks) b) What is the difference between writing in ‘first person’ and ‘third person’? State a situation when ‘first person’ is more appropriate. (6 marks) c) Construct a network activity diagram using the information below and highlight the critical path. (12 marks) Activity Predecessor Duration (days) A - 2 B - 1 C A 5 D B 2 E D 2 F C,E 4 G F 3 d) The topic of ethics is a very important and far reaching term. List ten aspects of ethics. Choose your examples to illustrate the wide scope of the general topic of ethics. (10 marks)