MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
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WINTER – 2022 EXAMINATION
Model Answer

Subject Name: Industrial Engg. & Quality Control Subject Code: 22657
Important Instructions to examiners: XXXXX
1) The answers should be examined by key words and not as word-to-word as given in the model answer
scheme.
2) The model answer and the answer written by candidate may vary but the examiner may try to assess the
understanding level of the candidate.
3) The language errors such as grammatical, spelling errors should not be given more Importance (Not
applicable for subject English and Communication Skills.
4) While assessing figures, examiner may give credit for principal components indicated in the figure. The
figures drawn by candidate and model answer may vary. The examiner may give credit for any equivalent
figure drawn.
5) Credits may be given step wise for numerical problems. In some cases, the assumed constant values
may vary and there may be some difference in the candidate’s answers and model answer.
6) In case of some questions credit may be given by judgement on part of examiner of relevant answer
based on candidate’s understanding.
7) For programming language papers, credit may be given to any other program based on equivalent
concept.
8) As per the policy decision of Maharashtra State Government, teaching in English/Marathi and Bilingual
(English + Marathi) medium is introduced at first year of AICTE diploma Programme from academic year
2021-2022. Hence if the students in first year (first and second semesters) write answers in Marathi or
bilingual language (English +Marathi), the Examiner shall consider the same and assess the answer
based on matching of concepts with model answer.

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Que.1 Attempt any FIVE of the following 10 Marks

a) Define work study. Name the various steps involved in it.

Sol. Work study: Work study investigates the work done in an organization and aims at
finding the best and the most effective way of utilizing the available resources (Men,
material, money and machinery) to achieve best possible quality work which involves
least possible time and causes least possible fatigue to the worker.
Or 01 Mark
Work study is a term used to embrace the techniques of method study and work
measurement, which are employed to ensure the best possible use of human and
material resources in carrying out a specified activity.
Steps: 1. Select the task to be studied.
2. Record the facts
3. Examine / analyze the facts 01 Mark
4. Develop new method/ measure the task
5. Install new method / compile standard time
6. Maintain new method.

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b) State the important functions of process Engineering.

Sol. (i) Selection of machines

(ii) Determining sequence of operation
½ mark
(iii) Combining operations wherever possible for each
(iv) Specifying inspection stages function
(v) Specifying tools, jigs, fixtures required for process.

c) Draw a scatter diagram showing negative correlation between two variables.

Sol.

02 Mark
for
diagram

d) Name the various control charts used in Statistical Quality Control.

Sol. - R chart
- σ chart ½ mark
C – chart for each
P – chart
e) With the help of block diagram show the basic structure of cause and effect diagram.

Sol.

02 Mark

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f) List out the various factors affecting quality of product.

1. Raw material used.
Sol.
2. Skill of operator.
3. Environmental conditions ½ mark
4. Machines used for production. for each
5. Calibration of instruments.
6. Proper methods of using an instrument.
g) Why 100% inspection is generally not preferred in the industry for mass production.
1. Cost required is more for 100% inspection.
Sol.
2. Time consuming process.
3. Fatigue to the operator. ½ mark
4. More staff is required for inspection. for each
5. More material handling so more chances of material damage.

Q.2 Attempt any THREE of the following: 12 Marks

a) Explain in brief different “Recording Techniques” used in method study.

Sol. The success of procedure depends upon the accuracy with which the facts are recorded
because they will provide the basis of both the critical examination and the development of
the improved method. All the facts relating to selected jobs are recorded in forms, charts
and diagrams.
(a) Charts: Indicating process sequence
(i) Outline process chart (Records only main events)
01 Mark
(ii) Flow process chart (Records all events)
1. Man Type
2. Material type 01 Mark
3.Machine / Equipment type
(b) Charts: Using a time scale
01 Mark
(i) Multiple activity chart
(ii) SIMO Chart
(c) Models and diagrams: Indicating movements
01 Mark
(i) Flow diagram
(ii) String diagram
(iii) Cycle graph
(iv) Chrono cycle graph
(v) Two-three dimentional models

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b) Explain “Part Print Analysis’. Which information does the process Engineer seeks from it.

Sol. Preliminary part print analysis is the first step in process planning. The product design
is conveyed by design department to process engineer in the form of part print. It is also 01 Mark
called as part drawings or blue prints. The part drawing consists of a variety of information
which helps in planning the process.
The detailed study or interpretation of part drawing under consideration for the
manufacturing of the part is called as part print analysis. Part print consists of following
information:
 Part geometry
 Dimensions and associated tolerances 01 Mark

 Geometrical tolerances
 Surface finish specifications
 Material specifications
 Quantity of parts required
Preliminary analysis is done in order to get a general visualization of the complete
manufacturing of the part.
General characteristics of the workpiece
The process engineering department tries to determine following requirements from the
detailed study of part print. These are:
01 Mark
1. The general description of the part.
2. The general configuration of part.
3. The material from which the part is made.
4. Originating operation of part.
5. Recording of changes in design.
6. Protection of workpiece during manufacture.
Working drawing:
 Working drawing is referred to all those drawings are reference drawings from
which, the parts are manufactured.
 These drawings includes part drawings of individual component and sub assembly 01 Mark
drawing and final assembly drawing
 Working drawing consists of conventions of process, tolerances, surface finish,
machining symbols etc.
 Working drawings are also referred as production drawings. The drawings represent
details of product, its size, shape, material, processes, and tools equipment.
• The operator is completely guided by the working drawings during the manufacturing
of the product. These are the legal and authentic documents of the company.

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c) With the help of a block diagram show the sequence of activities for any quality characteristics.

Sol. Quality Characteristics:

 For the refrigerator, it is described by using colour of body, capacity of the refrigerator,
brand of the compressor, warranty, service conditions, etc. These are called as 'quality 01 Mark
characteristics'.
 The quality characteristics are grouped as:
a) Structural type: Length, height, diameter, viscosity, etc. 01 Mark
b) Look type: Test, colour, texture, appearance, etc.
c) Time oriented: Safety, reliability, service, failures, etc.
d) Commercial Cost, discount, warranty, packing, etc.
 If also above conditions are applicable for the 'quality of product', similar characteristics
are used for 'quality of service".
 For service sectors like banking, postal services, transportation, bus services, hospital 01 Mark
services, etc. In these all above service characteristics are also used
 In banking : satisfaction of consumers, transaction accuracy, prompt time to time
service, telephonic internet banking, clarity in transaction space – infrastructure of bank, 01 Mark
ATM services, opening hours of banks, interest/loan facility, reliability i.e. accuracy of
services, image, honesty, responsiveness of bank, etc.
d) What is the effect of various environment factors such as temperature, noise, light on the
efficiency of operator.
Sol. Environment factors:
Working conditions are those which surround the worker as he performs his task.
Working conditions affect his physical well-being and therefore his efficiency towards work. 01 Mark
Some of the working conditions are mentioned below.
1. Temperature:
It includes the temperature, humidity and air flow. Poor heat and humid conditions produce
thermal stresses in the worker which affect their efficiency, concentration and dexterity of
their members of body. 01 Mark
0
Working temperature of 60-65 F is considered as normal but it varies according to nature of
work. Humidity and heat are related to each other both affect comfort and tolerance of the
body to heat. The effect of heat can be minimized by shielding isolating best sources, by
installing and providing local ventilation by permitting breaks or rest pauses in cool or
extreme hot conditions.

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2. Noise:
Noise is defined as unwanted sound and it has been shown to have both short and long
term effects on performance. Noise is the cause of various problems like fatigue, imitation,
reduced productivity and accidents.
To reduce the noise:
1. Control the noise at source.
2. By proper machine lubrication maintenance, padding and by providing noise mufflers 01 Mark
3. Using noise absorbers
4. Provision of ear plugs
S. Improved workplace layout.

3. Light
Most of the time man depends upon sunlight as a natural source of light. But sometimes of
weather conditions and in nights.
When shop activities are carried out indoors or at night, it is necessary to provide artificial
light.
01 Mark
Visibility depends on size and colour of product, its distance from eyes, intensity of light,
contest of colour these factors must be studied precisely in case of accurate works, work in
dangerous environment or in case of poor working conditions.
The lighting system should provide:
1. Sufficient brightness
2. Uniform illumination
3. A contrast between brightness of the job and of background
4. No direct or reflected glare

Que.3 Attempt any THREE of the following 12 Marks

a) Define process chart, draw the various symbols used in process chart.

Sol. A chart representing process is called process chart

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Event Symbols
Operation

Storage

Delay or Temporary storage

Transport 01+03
Mark
Inspection

Operation cum –transportation

Inspection cum –operation

b) Define anthropometry and explain its importance.

Sol. Anthropometry is defined as , “ the branch of ergonomics, which deals with shape and size
of body”.

Anthropometry is defined as “The scientific study of measurement and proportions of the 02+02
human body, which involves the systematic measurement of dimensional description of
Mark
size and shape of human body”.

Anthropometry play an important role in industrial design , clothing design , ergonomics

and architecture , where statistical data about the distribution of body dimensions in the
population are used to optimize products.

c) Draw a two handed process chart to assemble a nut and bolt.

Sol.
Job: Assemble a nut and bolt

Left hand Symbols Symbols Right hand

L. S. R. H.
Pick up bolt Idle
03+01
Hold Pick up nut Marks

Hold To left hand

Hold Assemble (Screw up)

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Summary

Lift hand Right hand

01 02

03 00

00 01

00 01

d) Classify the man – machine system

Sol. a) Based on the importance of feedback

- Open loop system

- Closed loop system

b) Based on the type of processing

- Manual Systems

- Semi- automatic Systems

04 Mark
- Automatic Systems

c) Based on the number of men and machines

- One to one Man – Machine System

- Many to one type Man- Machine System

- One to many Man - Machine System

- Many to many Man – Machine system

Que.4 Attempt any THREE of the following 12 Marks

a) State any four advantages of Ergonomics (any 4)

Sol. 1. Higher productivity

2. More the human comfort, less the fatigue to operator.
3. Better deign to machine. 01 Mark
4. Increase the safety. for each
5. Better integration of man –machine system.
6. Reduced labour turnover

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Describe any two of the following in connecter with a man – machine system
b) i) Design of visual display
ii) Design of control
iii) Design of workplace
Sol. Design of visual display

- Display are the device, through which, the man can receive the information from the
machine.

- A good display is one, which allows proper combination of speed, accuracy and
sensitivity of display.

- Display provides primary and secondary information needed by operators in making

decisions and in effecting control responses.

- Information presented by display can be considered as dynamic or static

- Two broad categories of display are 1. Visual display 2. Auditory display

- Depending upon the type of information provided by visual display, Visual display can
be further classified into two subgroups.

i) Qualitative display – Indicating only the condition or state without giving any values.

ii) Quantitative Displays- Give numerical information about the equipment or machine Any two

Auditory display can make monitoring performance superior 02+02

Design of control

A control is a device which can transmit information to some machine, mechanism or a

system. Thus a control is selected based upon the nature of information desired to be
transmitted.

The performance efficiency of a human operator is affected by the nature/type of controls

provided with any machine. A proper design goes a long way in making the work of
operator easy. A proper control for any machine should be the optimum for the machine.

Factor Affecting the Selection of a Control Device:

1. Operational Functions of the Control
2. Need of control task.
3. Informational Need of operator
4. Space and layout requirement

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Design of workplace
Working environment is another very important factor which requires consideration in the
design of man-machine systems.
The environment in which a worker/operator performs his job has a big influence on the
following:
(i) The fatigue or the strain a worker acquires in performing his task.
(ii) The productivity of the system.
Even the optimum work methods would not help if the workplace layout or the working
environment where the operator work has.
Unbearable noise.
Insufficient light leading to poor visibility ‘smoke and fumes, and uncleanness etc.
Thus an operator’s performance and comport are dependent upon proper design of work
space. Our aim is to arrive at optimum location and arrangement of each component
essential for smooth working.
These components affecting workers task may be as follows:
1. Equipment’s.
2. Seating arrangement.
3. Displays.
4. Controls.
5. Materials.
6. Working space.
c) Enlist the benefits of kaizen.

Sol. Benefits of kaizen

1. Increased Productivity
2. Improve Quality Any Four
3. Reduced Cost 01 Mark
4. Faster Deliveries for each
5. Improve Safety
6. Process standardization
7. Waste reduction
d) What is meant by “5S” Explain each “S” in detail.

Sol. Japanese term English Explanation

Remove unnecessary items from each

1.Seiri (tidiness) Sort
area
Organize and identify storage for
2.Seiton (orderliness) Set In Order 04 Mark
efficient use
3.Seiso (cleanliness) Shine Clean and inspect each area regularly
4.Seiketsu Incorporate 5S into standard
Standardize
(standardization) operating procedures
Assign responsibility, track progress,
5.Shitsuke (discipline) Sustain
and continue the cycle

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Que.5 Attempt any TWO of the following 12 Marks

a) Critical Path

Network
Diag. 4m

C.P. 2m

b) Task- Replacement of punctured tyre.

Chart begins- Jack up the car.
Chart ends- Remove the jack.
Checked by- Mr. ABC
Date of charting- DD/MM/YYYY

6 Mark

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c)

01 Mark

02 Mark

02 Mark

01 Mark

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Que.6 Attempt any TWO of the following 12 Marks

a) Objectives of Line Balancing (six objectives for 6 marks)

1. To equalize the workload among the workers
Workload should be distributed equally at each stage of assembly line wrt overall
assembly time.
2. To identify the bottleneck operation
Identify the bottleneck operation and improve the stage by doing some modifications or
corrections.
3. To eatablish the speed of production line
To divide the work properly wrt worker’s movements. Sometime, combine the operations
01 Mark
for improvement the speed of production line.
for each
4. To deterine the number of workstations.
Industrial Engineer should do the time study of each stage and as per sequence of
assembly determine the number of workstations for completing all assembly operations.
5. To determine the percentage worklod of each operator
Workload at each stage should be distributed equally in terms of percentage too.
6. To assist in plant layout
Line balancing can be done in such a way that it should utilize the minimum space in a
factory. Therefore, space saving can be possible and effective plant layout should be
possible
b)

01 Mark

02 Mark

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02 Mark

01 Mark

c) Machine- A

01 Mark

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01 Mark

01 Mark

Machine- B

01 Mark

01 Mark

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01 Mark

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