Scheme —l

Programme Name: Mechanical Engineering

Programme Code: ME
22657
Semester : Sixth
Course Title : Industrial Engineering and Quality Control
Marks: 70 Times: 3 Hrs.

Instructions:
I. All questions are compulsory.
2. Illustrate your answers with neat sketches wherever necessary.
3. Figures to the right indicate full marks.
4. Preferably, write the answers in sequential order.

Q.l) Attempt any FIVE or the following. (10 Marks)

a) Denne Method Study. State its objectives.
"Method study is the systematic recording and critical examination Ofexisting and proposed
ways of doing work. as a means of developing and applying easier and more effective
methods and reducing costs."

Objectives or Method Study

To improve work methods and procedures.
To detennirr the best sequence of doing work.
3. To material flow with minimum of back tracking ami to improve layout.
4, To improve the working conditions and hence to improve labour efficiency.

b) State the factors or production

Iliey are the inputs for the vyocessof production.They the starting p«Åntof tir vroduction
process. Factors of production are the parameters which affect ttr (AJtBJtof production.
I. Land 3. Capital
2. Labour 4. Entrepreneur
e) Enlist various QC tools
For solving quality problems following seven QC tools are required
Pareto Diagram 5. Check Sheets
2. Cause & Effect Diagram 6. Scatter Diagrams
3. Histogram 7. Graphs (Not for •r Scheme)
4. Control Charts (Not for •t• Scheme)

d) Name the various control charts in SQC

Histogram 4. Process capability study
2. Bar Chart S. Various control charts
3. Frequency polygon

e) State the types and ___location or

1) VISUAL DISPLAYS
a) Qualitative Displays Ex. Red. ON-OFF. Traffic signals etc
b) Quantitative Displays Ex. Voltmeters. Ammeters. Speedonrters. Watches.
energy Meters etc

2) AUDITORY DLSPLAYS
a) These devicesare suitableas warningdevtecs

Location of display• Place the top linc of the screen at or slightly (0-30 degrees) below eye
level.

State the characteristics ot Quality

Quality charactenstics can be defined as. "Any physical or chemical property such
as dimension. temperature, pressure. taste, od«nrr or other requirement
used to define the nature of product and service."
 For Ex:- In case of a hollow metallic pipe. its quality can be defined by stating the
quality characteristics. such as external and internal diameters. length. type of material
used etc.

Classification quality characterbtics

l. According to analysis
Direct Measureable like Weight. specific gravity. length. diameter, thickness etc
Non-Measurable like rejection due to flaws. cracks, breakages etc
2. According to type
Quality characteristics may be defined in terms 01 parameters which may be of the following

Technical parameters (Structural type) —l.,ength.Viscosity.Tenyvrature. Diameteretc.

• Psychological parameters (look Type) —Taste. Beauty.
Time parameters —Speed, Life span, Reliability, Maintaimåyility,etc.
Contractual parameters - Safety. Guarantee. Warranty etc.
Ethical parameters —Honesty. Integrity. Nature. etc.

g) State the merits of acceptance sampling.

It is usually less expensive there is less insrrction
2. There is less handling of products, hence reduced damage,
3. It is applicable to destructive testing also.
4. Fewer rx•rsonnel involved in inspection activity.

Q.2) Attempt any THREE of the following. (12 Marks)

a) Explain in brier different "Recording Techniques" used in Method study
The recording techniques are designed to simplify and standardise the recording work. For
this purpose charts and diagrams are used.

1. Outline ProcessChart
• It is also called Operation Process Chart.
• Outline process chart is helpful to:
a) Visualise the complete sequence of the operations and inspections in the process.
b) Know where the operation selected for detailed study fits into the entire pmcess.
 c) In operation pnvess chart. the graphic representation of the points at which materials
are introduced into the process and what operations and inspections are carried on
them are shown.

2. now ProcessChart
• Flow process chart gives the sequence of flow of work of a pnxluct or any part of it
through work centre or the ikpanment recording the events using appnvriate
symbols. It is the arnplificationof the outline process chart in which operati€ms•.
inspection, storage. delay and transportation are
• However. How process charts ate of three types:
l. Man performed by the man.
Material type—Which shows the events that occur to materials.
3. Equipment type—How equipment is used.

3. Two Handed Process Chart

A two handed (operatorprocess is the most detailed type of now chart in which
activities Of the workers hands are recorded in relati'*t to one another. TIE two haruled
process chart is normally confined to work carried out at a single workplxe. This also gives
synchronised and graphical representation of the sequetK•eof manual activities of the worker.
The of this charts are:

To visualise the complete sequence of activities in a repetitive task.

To study the work station layout.
4. Multiple Activity Olart
It is a chart where activities of more than subject (worker or equipment) are each recordedon
a common time scale to show their inter-relationship Multiple activity chart is m*k:
• TOstudyidle time Ofthe man and
• TOdetermine Ofmachineshandledby opennor.
• TOdetermirr numberOfoperatorsrequiredin teamworkto givenjob
S. mow Diagram
Flowdiagramis a drawing.Ofthe workingarea.showing I(X'ationOf vari«asXtivities
i'kntified by their numberedsymbolsand are asqx•iatedwithparticularnow chart
either man type or rnachinctype.
6. String Diagram
The stringdiagramis a scalelayoutdrawingon which.lengthof a string is used to the
extent as wellas the patternOfmovementOfa workerworkingwithina limitedarea a
CertainperiodOftime
7. TherbligsSymbols
S. Sinu:•Chart
Simultaneousmotioncycle Chart(SIMO is a rec«ding techniqtr for micro-m«ion
study. A SIMO chart is a chart based on the film analysis. used to record simultatxously a
common time scalethe Tlrrbjigs or a group Of Frfornrd by different Ofthe
IV)dyOfone or more operatews.
9. TravelChart
The chart Whichgives an estimate about the anunint or materialsharxllingl*tween
workstationsis knownas The aim in construction of Travel
is to
decidesucha layoutwhereoverallmaterialshandlingfunctionis Ffformed a minimum
e) Explain Ergonomic considerations applied to types and ___location at display
1. TYPESOF DISPLAYS
a) VISUAL DISPLAYS
i) Qualitative Displays
Qualitative displays indicate only the condition or state without giving any value.
Ex. Re'LON-OFF,Trafficsigna1setc

ii) Quantitative Displays

Quantitative Displays gives numerical information about the equipment or
tnachine. as required by operator.
Ex. Voltmeters. Ammeters. Srx•edometers. Watches. energy Meters etc

b) AUDITORYDISPLAYS
Auditory displays can make "K'nitonng performance suFt•ior. Therefore. these
devices are suitable as warning devices.
Ergonomic considerations in Design of Displays
a) The scale on the dial indicator should be divided in suitable linear progresston such
as 0-10-20-30.
b) Number of subdivisions between divisions should be nunimum.
c) Vertical figures should tx•used for stationary dials and radially onented figures
should be used for rotating dials.
d) The height of letters or numbers on display should be greater or equal to reading
distance 1200.
e) The pointer should have knife edge with a mirror to minimize parallax error.
f) The numtrring should increase in cl€x•kwisedirection on circular scale. nghtward
on a horizontal scale and upwards on vertical scale.

2. LOCATIONOF DISPLAY
The positioning of a visual display is of key importance in determining its
effectiveness.
Location of a display that is of the main field of view or requinng bead body
movements

Ergonomic considerations in Location Displays

a) Place the top line of the screen at or slightly (0-30 degrees) below eye level.
 b) It should be I«ate near to observer that no fatigue on operater.
c) The display unit and the control should be in the same plane
d) The correct Symbols or icons must tv specified at appropriate pl;se wherever

d) Differentiate between Jnssm•tion & quality control

SR.NO. PARAMETERS INSPECTION ALITY CONTROL

QC is a term. it involves
It is a patt of qualitycontrol inspection at particular stages.
inspection not oran quality
control
Effective system for integrating
Checking Of material. product or
quality development. quality
component at various stages. with
matntenance and quality improvement
reference to certain pre-
2 Definition efforts or vanous grenaps an
deterttuned factors and detecting
organisation to enable production
and sorting out the faulty or
to be carried (hit at most economical
defective items.
level.
Starts before and along with
3 Production Starts after prvxluction

4 Ensures that bad things will

Segregates Segregates goods and bads
Responsibility oi inspection
5 Concern Everybody's responsibility
Inspection determines the
QC determines the causes of
6 Variability acceptability companng with
variations.
limits of variabilit
7 Determination Inspecuon actually conducts QC 'k•termines what. when and how
exanunations of g€x»dsfor quality
Factor much to
characteristics.
Precision measuring instruments Statistical. control chart. acceTflance
such as. vernier caliper. sampling. rmx•ess capability study.
8 Device Used nucronEters. profile propctors quality audits etc.

Attempt any THREE of the following. (12 Marks)

a) Denne chart .draw the symbols used in process chart
"A chart on uhicb are graphically shown in sequencethe separate details that make
up a complete process (as or a particular job operation)"
Graphical method of recording was originated by in onkr to make ryesentati€g•
Of the facts clearly without any ambiguity and to enable to grasp them quickly and clearly. It
is useful to use symbols instead of written description.
Operation O

An operation occurs when an (+ject is intentionally changed in one or more of its

charactensties (physical or chemical). This indicates the majn steps in a process. method

o OPERATION
INSPECTION
TRANSPORTATION
D DELAY
v STORAGE
An operation always takes the object one stage ahead towards completion. Examples of
operation are:
• Tuming. drilling. milling. etc, Getting instructions frorn

A chemical reaction. supervisor.

• Welding. brazing and riveting. • Taking dictation.

• Lifting. loading, unloading.

INSPECTION
• An inspection occurs when an object is examined and compared with standard for quality
and quantity. The inspection examples are:
• Visual Observations for finish.
• Count of quantity of incoming material.
• Gleeking the dirnensions.

TRANSPORTATION
• A transport indicates the movement of workers. materials or equipment from one place to

Example: Movement of materials from one work station to another. Workers travelling to
bring tools.
 DELAY D: DELAY (TEMPORARY STORAGE)
• A delay occurs when the immediate rx•rformanceof the next planned thing docs not take
place
Example: Work waiting between consecutive operations. Workers waiting at t€K'Icribs.
Operators waiting for instructions from suFrvisot.

STORAGE
V
• Storage occurs when the object is kept in an authorised custody and is protected agamst
unauthorised removal.
• For example. materials kern in sures to be distributed to

OPERATION AND TRANSPORT

Operation is performed during transport.
• Example:- Assembly of parts when it is rtu»vingon conveyor.

OPERATION AND INSPECTION

• Inspection and operation done simultaneously.
• Example: Filling milk in and checking of leakage etc.

b) Prepare a two handed process chart for a or the pencil with

appropriate processchart symbol
TWO HANDED PROCESS CHART
Task: SharpeningThe Pencil
Chart Begins : Both hands free before task
Chart End : Both hands rr« aner task
Charted by•
Date Of charting•
LEVr HAND RIGHT HAND
Symbol Description Symbol
 Pick the pencil Delaye0Wait

Pick sharpener

Insert the pencil in

Rotate the pencil

Check for sharpness Delayed'Wait

Place
tir
Place the pencil
Q.4) Attempt any THREE or the following. (12 Marks)
a) Write different steps to be f(AIowedfor Ergonomic consideration in Machine design.
The different areas covered under the ergonomics are:
l. Communication the man (user) and the machine.
2. Working environment.
3. Ilurnan anatomy and posture while using the machine.
4. Energy expenditure in hand and foot operations,
j. Communicatk•n between man and machine
The machine has a display unit and a control unit.
A man (user) receives the information from the machine display through the sense organs.
He (or she) then takes the corrective action on the machine using the hands or feet.

This man-machineclosed loop system in influenced by the working environmental factors

such as: lighting, noise. temperature. humidity. air circulation, etc. Working
Environment

consideration in control deign

I) The control should bc accessible and logically m•sitione€L

2) Ihe shape of control comrx'ncnt which come in contact with hands should be comfortable
With anatomy or hand.

3) Control should painted in red colour With grey background of machine tool for
attention.

4) The control operation should involve Minimum motions. Ergonomics consideration in

Display design:

5) scale on the dial indicator should be divided in suitable linear progression such as O-
10-20-30.

6) Number of subdivisions divisions should be minimum.

7) Vertical figures should be used for stationary dials and radially oriented figures should be
used for rotating dials.

8) •nie height of letters or numbers on display should be greater or equal to reading distance
'200.
9) TIE shouldhaveknifeedge witha mirrorto minimizeparallax
numtx•ringshould inctease in directi€gion circular scale. on a horizontal
scale and upwards on vertical scale.

Workingenvironment.

Ibe surounding area irx•ludingwalls. ceiling. floor and other should

bright and more coloredthan workplace.The light should match needs Of taskas
far as illumination is concerned.

Noise: Jf the noise level is too high, it can be stopped source by better maintenanceOf
equipment.placing vibration isolating material, plug in ears and providing insulating

Temperature: 10order to get efficietw•y to the task. operator neither

nor too cold but comfortable.

When the heavy work is done. tenFature should be lowered and office work
is it should be little higher. Humidityand Air circulation: IS) humidity may
discomfortthrough drying Of the nose and 16) Air humidity air vel€xity become
imp«tant at high temp. Because they influence the amount Of sweat. which can be
evaluated from EX)dy
surfaceto poxjuce cq»ling effect
d) Explainin detailOCcurveand following elenrnt on OCcurve.
i) ii)P.Riskiii)AOQ
1. PRODUCER'S RISK (a)
ProducersRisk: It is the probabilitythat a lot will be rejectedbythe sampling
plan. In someplans this risk is fixed at 0.03; in othersit varies fromabout0.01 to
0.10
It is denotedby
2. Risk (B)
Risk: It is prthabilityOf &fectivelegsbeing which
otirrwise wouldhavebeenreÉcted-
It by (B)

Rejectablequality level (RQL):•It is alsocalledas t&rance defective

(LTPD).It rqyesents Of •Electiveswhich consunEr
&finitely
unacceptable.
ASRQLis an unxceptablequalitylevelthe probabilityOfxceptaxe for an RQLlot
bc low.
4. Averageoutgoingquality (AOQ)
Average quality (AOQ) It representsthe averagetyrcentdefectivein the
outgoingproductsafter inspection.includingall xcepted and all rejectedJotswhich
havebeen 100 insr*ctedanddefectivesreplacedby non-defectives.
e) In a manufacturing process the number or defectives found in the inspection 10
lots or 400 items each are given below
lot Number 01 2 4 1 8 9 10

No. of defectives 2 o 14 18 6 o 3 6

Determine the trial control limits for nP chart.

Solution: Given data, Number of lot N=IO. lot size—400,
Steps to solve:
L Calculate total number or defectives
From the given data. we can calculate, total number of defectives in the following way

EnP-2+O+14+3+1+18+6+O+3+6-53

2. Calculate the total number or items inspected

Total number of items inspected can be calculated in the following way

E n = Numberof lot x Lot size = 10 x 400 = 4000

3. Calculate average fraction defective

We know that.
Enl' 53
4000
- 0.01325

4. Calculate central line of nP

We know that,
x 0.01325- 5.3

S. Calculate control limits for nPChart

We know that.

12.16
1.56
 6. Conclusion/ComnmüStatement
As UCL(nP) = 12.16. we find that. the lot numbers (3) and (6) containing number Of
defectiveas 14and 18respectivelywill fall out of contrd limits.
Therefore.it is conclu&d that. is not under control.

QS) Attempt any TWO of the following. (12 Marks)

a) Outline an for the activity "Replace old battery or car".
OUTLINE PROCESS CHART
Task: Replacenrnt of ear Battery
O•art Begins : Ol*ning the car bonnet
Chart End : (.l(hing the car bonnet
Charted by:.
Date or charting:
Symbol lhscription

Open the car bonnet

Rest it on the clamp

Loosen the nuts

Remove the plug

Replacethe battery

Put the plug in battery terminal

Tighten the nuts

Start the car

Close the car bonnet

c) ΙΟ Ot 5 beeo wllh tollowlng :

Sr.No. Ι 2 3 4 S 6 8 9 ΙΟ
2.011 1.998 Ι.Ψ)5 Ι.'"7 2ΙΙ)2 2.003
R ().0Ι7 0.(MN Ι).026 0.27 021 0014 (1017 0023 0.0Ι5
Given A2 O. 2.Ι 141)rawlhe Shart
Solution: Give Data: A2 0577.03 0.04 2.114. Draw ttv appropriatecontrol chart

Sr.No. 6 8 10
2.011 1.998 1.995 1.997 1.997 2.003
R 0.011 0.017 0.009 0.026 027 0.21 0.014 0.017 0.023 0.015

I. Identity appropriate or Suitable control chart

Since given in variable form. the appropriate control charts. to be drawn are and R

2. Mean ( Total Average or grand Average) for X bar O•art

(2.011 + 2.008 + 2.001 + 2.003 + 1.998 + 1.995 + 1.997 + 1.997 + 2.002 + 2.0031
10
—2.0015
3. Mean ( Total Average or grand Average) for R

ER Ri + R2+ RJ+...+Rn

10.011 + 0.017 + 0.009 + 0.026 + 0.27 + 0.21 + 0.014 + 0.017 + 0.023 + 0.0151
10
k - o.0612
4. Control limits for X bar Chart

As tir value of factor (AZ) is given as 0.557 for sample size (na5). therefore. control limits
for chart are calculated using the following formulae.

UCL* = + Aa.k = 2.0015+ (0.557x 0.0612)= 2.005031

LCL = N —Ark = 2.0015- (0.557x 0.0612)= 1.9979

5. Control limits for R Oart

As value or factor (DJ O) and (D, 2.114) are given. then ctmtrol limits for R chart
are calculated using following formulx.

UCLR - D,.k - 2.114x 0.0612 O.12937

UCLR- ox 0.0612
-O
Q.6) Attempt any TWO of the following. (12 Marks)
a) Write Draw the X —Rcontrol chart and explain the following terms on it
a. Extreme
b. Shift
c, Indication of trend.

Variation Pattern on the Control

A control chart can indicate an out-of-control condition even though no single rx»intpkgs
outside the control limits, if the pattern of the B)ints exhibits non-randornor
systematic behaviour.
tn many cases. the pattern of the plotted points on control charts will provide useful
diagnostic information on tik• process, and this information can be used to make prrress
modifications that reduce variability.
In order to make full use of the information. the problem somng team should have
expertise in both statistical principles of the control charts and ttr process.

Shift in Process Level:

• A shift in process level is illustrated in figure - These shifts may result from the
introduction of new workers, raw materials, or machine, a change in
inspection method or standards. or change in either tir skill. attentiveness.or motivation
of the operators.
Sometimes an improvement in the process performance is noted following introduction of
a control chart program. Simply because of motivational factors mnucnctng the worker

Shift —V4benthe data starts to center around a different mean or center line

UCL

LCL

Sample number
 A trend
• A trend, or continuentsmovement in one direction. is shown on the control ctngt in
Figure Trends are usually due to a gradual wearing out or deterioration of a or some
Other critical process components.
• They may be also caused by worker fatigue. of waste products. and
deterioration of environmental conditions.

Trend —"ben the process mean begins to gradually move in one direction

Trend in the process

b) The following table gives the no. of defects in alignment observed at the final insrrction
of a certain model of an aero plane. prepare a C-chart and comment on it.
Aeroplane 01 2 3 4 S 6 7 8 9 10 11 12 13
Number
No. of alignment 07 6 6 7 4 7 8 12 9 9
defect

Solution:Give Data: A2 0377.03 0.04 2.114. Draw the appropriate control chan
Aeroplane
Number
or alignment
defects
l. Identify appropriate or Suitable control chart
• Since data given with numtvr of defects. the appropnate control charts. to tv is
C Charts (i.e. Ik•fect Chart)

2. Central Line For 'C' Chart

• We have,
Total No.of Alignment Defects
Total No, of Aeroplane Inspected
17+6+6+7 +8 + 12 +9+9+8+5 + 5)
13
7.1538
3. Control limits for 'C' Chart

UCLC = C+ = 7.1538+ 3FäSiä = 15.1778

LCL c C— - 7.1538— - -0.8701
Hence. LCL ror 'C Chart Taking as Not Negative.
4. Plotting 'C' Chart

5. Conclusion
• From above chart. As all points fan inside the control limits. we can conclude
that, the process is under control.
 c) Two machines producing components are checked up for the statistical stability. Draw the
V chart for both machines and comment upon processes. Sample size for both
machines is 200.

No.

23 28 30 30 20 29 31 26 31 21
MEE* B:
S.E No. 10

08 22 12 21 10 15 10 02

Solution
Machine-A
Sample No. 1 2 3 4 5 6 7 8 9 10
Defective 25 28 30 30 20 29 31 26 31 27

l. Identify amyropriate control chart

Since number of defectives is given. P chart is to be applicable and sanr to be drawn.
2. Calculation ror Fraction Ikfective
Number of Defective machine found 25
Fraction Defective 125
Number of machine inspected 200
In the similar manner. we can calculate fraction defective of remaining 9 Samples.
These calculated fraction defectives can be shown in tabular format along with
corresp»nding lot number in following way.

Percentage Defectives
Sr.No. Lot Size Defectivß Fraction Defective

25 0.125 12-5
2 28 0.14
3 30 0.15 15
30 15
5 20 0.1 10
6 29 0.145 143
7 31 0.155
 26 013 13
9 31 o. 155
10 27 0135 133
Total 277
3. Central ror P
Total Number of Defective
LotSizeor Totalnumbero/ magnetinspected
Ed
— 277—0.1385 13.85%
—
En 2000
4. Aver•geNumi*r
Total Number o/ machine inspected in alt 10Samples
Total Noor observationsor Samples
2000
200
10
S. Contrd limitsfor P Chart
1385x (t - 0.1385)
UCLP —p +3 0.1385+ 3 —0.2117
200
UCLP 21.17%
0.1385 x (t —0.1385)
LCLp = p —3 0.1385—3 = 0.06522
200
LCLP 6.52%
6. H•nting P Chart (Draw graph of Percentage Defective(On Y•Axisl Vs Sample No.
(On X-Axbl)
 7.

From abovechart. As an pointsfall inskie the controlHts. we can conclude

that, the processis utuier contr«i.

Machine-B
Sample No. 1 2 3 4 5 6 8 9 10
Defective 11 08 22 15 12 27 10 15 10 02

l. Identifyaswropriatectmtrolchart
Since number of defectives is given. P chart is to tv applicable and same to tv drawn
2. Calculationfor FractionIkfectivø
Numbero/ Defective machinefound Il
Fraction Defective z = — = 0.055
Number of machine inspected 200
In the similar manner. we can calculate fraction defective of remain•ng 9 Sanwies.
Ttvse calculated frx•ti€n defectives can be shown in format along with
lot nurntrr in following way.

Sr.No. IAASize Defectives Fraction Defective PercentageDefectives

11 0.055
2 08 0.04 4
3 22 0.11
4 0.075 73
5 12 (106 6
6 27 0.135 133
7 10 0.05 5
8 15 0.075 75
9 10 0.05
10 02
Total 132
3. Centralline p
Total Number o/ Defective
LotSize or Total number of magnet inspected
Ed 132
0.066 6.6%
En 2000