Here’s a detailed explanation and answers to the questions from **Industrial Engineering** and

**Quality Control**:

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### **1. Industrial Engineering:**

#### **Work Study and Time Motion Study**

- **Define work study. Explain its significance in improving productivity.**

- **Work study** is the systematic study of work processes to improve efficiency and productivity.
It involves techniques like **method study** and **time study** to analyze and optimize
workflows, eliminate inefficiencies, and improve the use of resources.

- **Significance**: Work study helps in increasing productivity by reducing wasted time, improving
work methods, standardizing tasks, and enhancing worker safety.

- **What is the difference between time study and motion study? Explain the methods used in
each.**

- **Time Study**: Involves measuring the time taken to perform specific tasks. It helps determine
the standard time required for performing a task. Methods include stopwatch time study, work
sampling.

- **Motion Study**: Focuses on analyzing movements made by a worker while performing a task to
eliminate unnecessary motions and improve efficiency. Methods include the use of **Therbligs**
(basic hand motions), and **micromotion analysis**.

- **Describe the procedure of conducting a time study for a manufacturing operation.**

1. **Select the task** to be studied.

2. Break the task into smaller operations.

3. **Observe the task** being performed and record the time taken for each operation using a
stopwatch.

4. Take multiple observations to improve accuracy.

5. **Calculate the average time** for each operation.

6. Add **allowances** (for rest, delays) to the observed time to calculate **standard time**.
- **Explain the concept of standard time. How do you calculate it?**

- **Standard time** is the time required for a qualified worker to perform a task, including
allowances for rest and other delays.

- **Formula**:

\[ \text{Standard Time} = \text{Observed Time} \times (1 + \text{Allowance Factor}) \]

- **Discuss the methods for analyzing work processes and reducing unnecessary motions.**

- Methods include:

- **Motion study**: Breaking down tasks into Therbligs (basic motions).

- **Process flow charts**: Mapping tasks and identifying inefficiencies.

- **Work sampling**: Observing and recording random samples of work performance.

#### **Production Planning and Control (PPC)**

- **Explain the role of production planning and control in manufacturing.**

- **PPC** ensures efficient management of production activities to meet demand while minimizing
costs. It involves planning, scheduling, and controlling the manufacturing processes to optimize
resource use, reduce downtime, and ensure timely delivery.

- **What is aggregate planning? Discuss the strategies for aggregate production planning.**

- **Aggregate planning** involves determining the overall production output, workforce, and
inventory levels for a medium-term period (usually 6-12 months).

- **Strategies**:

- **Chase demand strategy**: Adjusts production and workforce to match changing demand.

- **Level production strategy**: Maintains a steady production rate and uses inventory to buffer
demand fluctuations.

- **Hybrid strategy**: Combines both approaches.

- **Define scheduling. Explain the different types of scheduling techniques used in industries.**

- **Scheduling** is the process of planning the start and end times of tasks or operations.

- **Techniques**:

- **Gantt Charts**: Visual representation of project timelines.

- **Critical Path Method (CPM)**: Identifies the longest path of dependent tasks in a project.
 - **Program Evaluation and Review Technique (PERT)**: Estimates project completion times
based on probabilistic task durations.

- **What are the differences between push and pull production systems?**

- **Push system**: Production is based on forecasted demand, where items are pushed through
the system.

- **Pull system**: Production is based on actual customer demand, reducing inventory and
overproduction.

- **Discuss the concept of Just-in-Time (JIT) manufacturing and its advantages.**

- **JIT** is a production strategy that aims to produce only what is needed, when it is needed, and
in the amount needed, minimizing inventory and reducing waste.

- **Advantages**: Reduces inventory costs, improves product quality, and increases production
efficiency.

#### **Inventory Management**

- **What are the different types of inventory control systems? Explain the EOQ (Economic Order
Quantity) model.**

- **Types of Inventory Control Systems**:

- **Periodic system**: Inventory is counted at specific intervals.

- **Perpetual system**: Inventory is continuously updated as transactions occur.

- **EOQ Model**: Determines the optimal order quantity that minimizes total costs of ordering
and holding inventory.

- **Formula**: \(EOQ = \sqrt{\frac{2DS}{H}}\) where:

- D = Demand

- S = Ordering cost

- H = Holding cost

- **Describe the ABC analysis technique for inventory management.**

- **ABC analysis** categorizes inventory based on its value:

- **A items**: High-value, low quantity (critical items).

- **B items**: Moderate value, moderate quantity.

- **What is the purpose of safety stock? How is it determined?**

- **Safety stock** acts as a buffer against demand fluctuations or supply delays.

- **Determined** by analyzing demand variability and lead time variability.

- **Explain the concepts of inventory turnover ratio and its significance in production
management.**

- **Inventory turnover ratio** measures how often inventory is sold and replaced during a period.

- **Formula**: \( \text{Inventory Turnover} = \frac{\text{COGS}}{\text{Average Inventory}} \)

- **Significance**: A higher turnover indicates efficient inventory management.

- **Discuss the difference between perpetual and periodic inventory systems.**

- **Perpetual**: Continuously updated in real-time.

- **Periodic**: Updated at regular intervals, often requiring physical counts.

#### **Operations Research and Optimization**

- **What is Linear Programming? Formulate and solve a simple Linear Programming problem.**

- **Linear Programming** is a method to achieve the best outcome (e.g., maximum profit or
minimum cost) in a mathematical model subject to constraints.

- Example: Maximize \( Z = 4x + 3y \) subject to:

- \( x + y \leq 5 \)

- \( 2x + y \leq 6 \)

- \( x, y \geq 0 \)

- Solve graphically or using the simplex method.

- **Explain the difference between the simplex method and the graphical method of solving Linear
Programming problems.**

- **Simplex Method**: An algebraic method for solving LP problems with more than two variables.

- **Graphical Method**: A visual method for solving LP problems with two variables by plotting the
constraints and identifying the optimal solution.
- **What is the transportation problem? Explain the methods used to solve it.**

- **Transportation Problem**: Involves finding the most cost-effective way to transport goods
from multiple sources to multiple destinations.

- **Methods**: **Northwest Corner Rule**, **Least Cost Method**, and **Vogel’s Approximation
Method**.

- **Discuss the concept of the critical path method (CPM) and PERT. How are they used in project
management?**

- **CPM**: A technique for scheduling project tasks to ensure timely completion. It identifies the
longest sequence of dependent tasks.

- **PERT**: Focuses on probabilistic task duration to estimate project completion time. Both
methods are used for planning, scheduling, and controlling projects.

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### **2. Quality Control:**

#### **Basic Concepts of Quality Control**

- **What is quality control? Discuss the difference between quality assurance and quality control.**

- **Quality Control (QC)** is the process of ensuring products or services meet certain standards
through inspection and testing.

- **Quality Assurance (QA)** is a broader concept that focuses on preventing defects by improving
the processes used to create the product.

- **Define quality management. Explain the role of quality control in a manufacturing system.**

- **Quality Management** involves overseeing all activities to ensure the quality of

- **Role of QC**: Ensures products meet quality standards, monitors process consistency, and
reduces defects.

- **What is Total Quality Management (TQM)? Discuss its principles and significance.**
 - **TQM** is a comprehensive approach that involves all employees in continuously improving
product quality.

- **Principles**: Customer focus, continuous improvement, employee involvement, process

- **Significance**: Leads to better customer satisfaction, reduced waste, and improved efficiency.

- **Explain the concept of Six Sigma. What is the DMAIC methodology?**

- **Six Sigma** focuses on reducing defects to improve processes. It aims for less than 3.4 defects
per million opportunities.

- **DMAIC**: Define, Measure, Analyze, Improve, Control - a structured approach to process

- **What are the costs of quality? Explain prevention, appraisal, internal failure, and external failure
costs.**

- **Prevention costs**: Costs to prevent defects (training, quality planning).

- **Appraisal costs**: Costs to evaluate and test quality (inspection).

- **Internal failure costs**: Costs due to defects found before shipment (rework).

- **External failure costs**: Costs from defects found after shipment (warranty costs, customer
complaints).