Birla Institute of Technology & Science, Pilani Work-Integrated Learning Programmes Division First Semester 2014-2015 Comprehensive Examination (EC-3 Regular) Course No. : ET ZC413 Course Title ENGINEERING DESIGN Nature of Exam ‘Open Book Weightage 150% Duration £3. Hours Date of Exam 09/11/2014 (AN) Note: 1, Please follow all the Instructions fo Candidates given on the cover page ofthe answer book. 2. Ail parts of a question should be answered consecutively. Each answer should start from a fresh page. 3.__Assumptions made if any, should be stated clearly atthe beginning of your answer. Q.1. Find the missing dimension AB and its tolerance (5) a | fr 4g | ea Q2. Rank-order the following materials for use as an automobile radiator: copper, stainless steel, brass, aluminum, ABS, galvanized steel. 5] Q3. A manufacturing process to make a product consists of 10 separate processes. A mistake ‘occurs in each, process on average of once every 10,000 part produced. What is the product defect rate, expressed in parts per million (ppm)? 5] Q4. A reliability block diagram for an engineering system is given below. Determine the overall system reliability. 5) [= 0095 092 y= ETZC43 (EC-3 Regular) First Semester 2014-2015 Page I of 2ET ZC413 (EC-3 Regular) First Semester 2014-2015 Page 2 Q5. ‘The type of tooling to make for a manufacturing process depends on the expected total quantity of parts. Tooling made from standard components and less wear-resistant materials (soft tooling) can be made more quickly and cheaply than conveitional tooling made from hardened steel (hard tooling). Use the concept of break-even point to determine the production quantity for which soft tooling can be justified. The total production run is expected to be 5000 units. Parts are made in batches of 500The following cost data applies: [10] ‘Soft Tooling | Hard Tooling | Tooling cost | Cs $600 (Cy $7500 ‘Setup cost. Ss $100 Sy $60 [Unit part cost [Cys $3.40 [Cur $0.80 Q6. ABC Electric agreed by fax on Monday to buy 100 fractional-horsepower motors for $3000 from Amalgamated Electric. On Wednesday the purchasing agent from ABC calls ‘and says he is canceling the order. Amalgamated says the motors have already been shipped and they want their money. 1 (@) What is the legal responsibility of ABC Electric in this transaction? (b) Would it have been any different if the motors had not already been shipped? Q7. Assume that a focus group of college students was convened to show them an innovative thumb drive memory unit and to ask what characteristics they wanted it to have. The comments were as follows: (3) © Itneeds to have enough memory to meet student needs. © Itshould interface with any computer a student would encounter. ‘© Itmust have a relisbility of near 100%. © Itshould have some way to signal that it is working. Translate these customer requirements into engineering characteristics of the product. Findout some more requirements which are not mentioned here which will work as “delighters". Q8. This decision concerns whether to develop a microprocessor-controlled machine tool. The high-technology microprocessor-equipped machine costs $4 million to develop, and the low-technology machine costs $1.5 million to develop. The low-technology machine is, less likely to receive wide customer acclaim ( P = 0.3) versus P = 0.8 for the microprocessor-equipped machine. The expected payofis (present worth of all future profits) are as follows: (10) ‘Strong Markat Ascopiance Wivor Market Accopiance High technology P= 08 P=02 Pw= si6M Pw $10M Tow technology P= 03 P=? Pw 312M Pwo If the low-technology machine does not meet with strong market acceptance (there is'a chance its low cost will be more attractive than its capability), it can be upgraded with microprocessor control at a cost of $3.2 million. It will then have an 80 percent chance of strong market acceptance and will bring in a total retum of $10 million. The non- upgraded machine will have a net retum of $3 million. Draw the decision tree and decide what you would do on the basis of (a) net expected value and (b) net opportunity loss. Opportunity loss is the difference between the payoff and the cost for each strategy. senerenenen ET ZC413 (EC-3 Regular) First Semester 2014-2015 Page 2 of 2