Dr. B.R.

Ambedkar National Institute Of Technology

Jalandhar Punjab

INDUSTRIAL ENGINEERING

Submitted To: Submitted By:

Dr. L.P Singh Vikash Gupta (21126052)
IPE DEPARTMENT Electrical Engineering
 ASSIGNMENT 2

Q.1 What are the various symbols used for making process charts?
Differentiate between the outline process chart and flow process chart
with a suitable example.
Symbols Used for Process Charts:

Operation: Represented by a circle; it indicates any operation or work being done.

Inspection: Represented by a square; it shows where an inspection occurs.

Transport: Represented by an arrow; it denotes movement of materials or equipment.

Storage: Represented by an inverted triangle; it indicates storage or inventory.

Delay: Represented by a 'D' shaped symbol; it shows waiting or delay in the process.

Symbols:
Difference Between Outline Process Chart and Flow Process Chart:

• Outline Process Chart: This chart provides a bird’s-eye view of the overall process,
listing only the main operations and inspections. It is more macro-level and used for
initial assessments.
➢ Example: In manufacturing a shirt, an outline process chart might simply show
major steps like cutting fabric, sewing pieces, and inspecting the finished shirts.
• Flow Process Chart: This chart is more detailed compared to the outline process
chart and includes all activities involved, such as operations, inspections, delays,
and storage, along with the flow of materials. It is used for more in-depth analysis to
identify inefficiencies.
➢ Example: For the same shirt manufacturing, a flow process chart would detail each
step like laying out fabric, cutting specific parts, transporting cut pieces to sewing,
sewing each part, and every inspection and delay between these steps.

Q.2 Make a two-handed process chart for the assembly of i) nut, bolt and
washer ii) nut, bolt and two washers as shown in fig below.
A general format for how a two-handed process chart could be structured for assembling a
nut, bolt, and washer(s):

Assembly of Nut, Bolt, and Washer:

Serial Hand Description

No.
1 Left Hand (LH) Picks up bolt
2 Right Hand (RH) Picks up washer
3 LH Holds bolt
4 RH Places washer on bolt
5 RH Picks up nut
6 LH Threads nut onto bolt

Assembly of Nut, Bolt, and Two Washers:

Serial Hand Description

No.
1 LH Picks up bolt.
 2 RH Picks up the first washer.
3 LH Holds bolt
4 RH Slides first washer onto bolt
5 RH Picks up second washer
6 LH Holds bolt with first washer.
7 RH Slides second washer onto bolt
8 RH Picks up nut
9 LH+RH Threads nut onto bolt

Q.3 What is the use of multiple activity chart? A researcher is engaged in

collecting physiological data of 3 subjects (A, B, C) in Ergonomics
laboratory. The data with respect to setting time, recording time and
unloading time is given in the table below. Make a multiple activity chart
so that all the three workers are checked on each machine.
i.) Calculate the idle time for i0 the researcher,

ii.) all the 3 machines

iii.) waiting time for each subject.
Use of Multiple Activity Chart: A multiple activity chart is a graphical representation that
shows the relationships and timing between different activities occurring simultaneously
within a process. It is used to optimize the use of resources, reduce idle times, and
improve overall efficiency, particularly in complex environments where multiple entities
are interacting.

Given,

• HRV – Heart Rate Variability

• BERA - brainstem evoked response audiometry
• Spirometry

Now by preparing a Multiple Activity Chart, we get,

1) The idle time for i0 the researcher= 5 minutes.

2) The idle time for all 3 machines is: -
a) The idle time for HRV= 32 minutes.
b) The idle time for BERA= 74 minutes.
c) The idle time for Spirometry= 52 minutes.
 3) The waiting time for each subject is: -
a) Subject A= 2 minutes
b) Subject B= 34 minutes
c) Subject C= 57 minutes

Q.4 Differentiate between a product and a project, what factors will you
consider for SWOT analysis for a new startup?
Difference Between a Product and a Project:

PRODUCT PROJECT
A product is a tangible or intangible item A project is a temporary endeavor
that results from a process and is intended undertaken to create a unique product,
to be delivered to a customer. service, or result.
A product has a potentially indefinite A project has a finite duration, with a
lifespan. It can undergo continuous defined start and end date. Once the
improvement, updates, and modifications project's objectives are achieved, it is
even after it has been initially delivered to considered complete.
the customer.
Products are the result of completed Projects are focused on delivering specific
projects but are not necessarily focused outcomes or deliverables within a set
solely on deliverables. Products timeframe and budget. These deliverables
encompass the entire offering, including contribute to the creation of the final
ongoing maintenance, support, and product, service, or result.
enhancements, beyond the initial project
phase.

SWOT Analysis Factors for a New Startup:

• Strengths: Unique value proposition, expertise of the founding team, innovative

technology.
• Weaknesses: Limited resources, brand recognition, dependence on external
funding.
• Opportunities: Market gaps, emerging technology trends, potential strategic
partnerships.
• Threats: Competitive pressures, economic downturns, changing regulations.
Q.5 What is KAN BAN system, how it works and helps for effective
material flow at the shop floor.
KAN BAN System: The Kanban system is a visual and signaling system used in lean
manufacturing to regulate the flow of materials and work in progress. It operates under the
principles of just-in-time (JIT) production, where production is based on customer demand
rather than traditional forecasting.

How It Works:

Visual Signals: Kanban uses cards or digital signals that represent the need for items in
production or inventory. Each card or signal corresponds to a specific amount of product
that must be produced or a specific quantity of materials to be replenished.

Pull System: Instead of pushing production based on forecasts, production and supply are
"pulled" through the system based on actual demand. When a product is consumed, a
Kanban signal is sent to start the production or replenishment of that product.

Limits Work in Progress: By limiting the number of Kanban signals in circulation, the
system inherently limits the amount of work in progress (WIP) and inventory at any point in
the process. This helps to reduce waste and inefficiencies.

Benefits for Effective Material Flow:

Reduces Inventory Costs: By producing only what is needed when it is needed, Kanban
reduces excess inventory and associated costs.

Increases Efficiency: Minimizing work-in-progress and optimizing the flow of goods

reduces waiting times and potential bottlenecks, increasing overall efficiency.

Enhances Flexibility: The system's responsiveness to actual demand makes it easier to

adapt to changes in customer needs or production capacity.

Improves Ǫuality: With a more focused approach to production, defects and errors are
less likely, improving the overall quality of output.

The Kanban system aligns with lean manufacturing goals by streamlining operations,
reducing waste, and enhancing productivity, making it a vital tool for effective material flow
on the shop floor.

Q.6 What is selective inventory management (SIM), describe in brief

the various techniques.
Selective Inventory Management (SIM): Selective Inventory Management is a strategy
that categorizes inventory based on its importance to the business, allowing companies to
prioritize resources and management efforts according to the value of different items.

Techniques in SIM:

ABC Analysis:

• ABC analysis categorizes inventory items into three categories (A, B, and C) based
on their annual consumption value.
• Category A items have the highest consumption value and typically represent a
smaller percentage of the total items but contribute the most to inventory costs.
• Category B items have moderate consumption value.
• Category C items have the lowest consumption value.
• This analysis helps prioritize inventory management efforts and resources, focusing
more attention on high-value items.

VED Analysis:

• VED analysis categorizes inventory items based on their criticality in terms of

importance for operations, essentiality, and ease of availability.
• V items are vital items that are crucial for operations, and their unavailability could
lead to significant disruption.
• E items are essential items that are necessary for operations but not as critical as
vital items.
• D items are desirable items that are optional and whose unavailability would not
significantly affect operations.
• This analysis helps in prioritizing inventory control measures and resources based
on the criticality of items.

FSN Analysis:

• FSN analysis categorizes inventory items based on their rate of consumption or

movement.
• F items are fast-moving items that are consumed or used frequently.
• S items are slow-moving items that are consumed or used less frequently.
• N items are non-moving items that are rarely consumed or used.
• This analysis helps in adjusting reorder levels, lead times, and stocking strategies
based on the velocity of item consumption.
Q.7 Collect annual consumption data of glossary/vegetables/fruits
etc. from the hostel mess and perform ABC/FSN/VED analysis.

Since I can manage to get a dataset for only one week of our MBH Mess groceries
Let us assume it as an average data (per week).
Data:
Sr. Particulars Quantity Rate (Unit price) Amount
No (per week)
1. ONION 150 23.2 3480.00
2. GINGER 3 99.8 299.40
3. GARLIC 4 123 492.00
4. LEMON 4 90 360.00
5. CHILLI 5 80 400.00
6. TOMATO 75 29.9 2242.50
7. CAPSICUM 20 66 1320.00
8. Potato (new) 100 12.5 1250.00
9. CORIANDER 3 20 60.00
10. CAULIFLOWER 75 24.9 1867.50
11. CUCUMBER 20 24.8 496.00
12. BEANS 20 47 940.00
13. CARROT 40 13.5 540.00
14. Lotus Stum 10 85 850.00
15. MUSHROOM 10 64.5 645.00
16. RADISH 25 15 375.00
17. MATER DANA 45 87.8 3951.00
18. BEET ROOT 5 34 170.00

Total 614 19738.00

ABC Analysis:

Calculate AUV of each item.

Sr. Particulars Rate (Unit price) Amount Amount (AUV) =

No Amount*52 (weeks)
1. ONION 23.2 3480.00 180960.00
2. GINGER 99.8 299.40 15568.80
3. GARLIC 123 492.00 25584.00
4. LEMON 90 360.00 18720.00
5. CHILLI 80 400.00 20800.00
6. TOMATO 29.9 2242.50 116610.00
7. CAPSICUM 66 1320.00 68640.00
 8. Potato (new) 12.5 1250.00 65000.00
9. CORIANDER 20 60.00 3120.00
10. CAULIFLOWER 24.9 1867.50 97110.00
11. CUCUMBER 24.8 496.00 25792.00
12. BEANS 47 940.00 48880.00
13. CARROT 13.5 540.00 28080.00
14. Lotus Stum 85 850.00 44200.00
15. MUSHROOM 64.5 645.00 33540.00
16. RADISH 15 375.00 19500.00
17. MATER DANA 87.8 3951.00 205452.00
18. BEET ROOT 34 170.00 8840.00

Total 19738.00 1026376.80

Arrange All items in descending order of AUV

Sr. Particulars Amount (AUV) Cumulative Cost %Cost
No
1 Mater Dana 2,05,452.00 2,05,452.00 20.01682
2 Onion 1,80,960.00 3,86,412.00 17.63061
3 Tomato 1,16,610.00 5,03,022.00 11.3611
4 Cauliflower 97,110.00 6,00,132.00 9.461253
5 Capsicum 68,640.00 6,68,772.00 6.687472
6 Potato 65,000.00 7,33,772.00 6.332833
(new)
7 Beans 48,880.00 7,82,652.00 4.762291
8 Lotus Stem 44,200.00 8,26,852.00 4.306327
9 Mushroom 33,540.00 8,60,392.00 3.267742
10 Carrot 28,080.00 8,88,472.00 2.735784
11 Cucumber 25,792.00 9,14,264.00 2.512868
12 Garlic 25,584.00 9,39,848.00 2.492603
13 Chilli 20,800.00 9,60,648.00 2.026507
14 Radish 19,500.00 9,80,148.00 1.89985
15 Lemon 18,720.00 9,98,868.00 1.823856
16 Ginger 15,568.80 10,14,436.80 1.51684
17 Beet Root 8,840.00 10,23,276.80 0.861265
18 Coriander 3,120.00 10,26,396.80 0.303976

Prepare Accumulative curve by Putting AUV on Y-axis:

Step-4: Sorting the items according to sharp changes in the curve.

A-Class Items are of 20% which comprises of 70-80% of total cost.

C-Class Items are of 60-70% which comprise of less than 10% of
total cost, And the rest Items are B-Class.

So, after all calculations we get the following results: -

A-Class Items B-Class Items C-Class Items

Mater Dana Potato (new) Garlic
Onion Beans Chilli
Tomato Lotus Stem Radish
Cauliflower Mushroom Lemon
Capsicum Carrot Ginger
Cucumber Beet Root
Coriander