Question 1 a) Define JIT and Lean Manufacturing and contrast the similarities and differences between the two. Discuss why the ‘Traditional approach’ is more intuitive and what approaches are needed to move toward a JIT scenario? (15 marks) b) Critically appraise five of the nine Just in Time (JIT) techniques e.g. reduction of set up time, TPM etc. highlighting what they are and how they would be implemented (15 marks) c) Describe a tool or technique which can be used to analyse and improve the performance of manufacturing systems e.g. Rank-order clustering, Ishikawa diagrams, Value Stream Mapping Root cause analysis, Pareto Analysis etc. Explain the basic principle behind the technique, how it would be applied and the potential benefits/inhibitors to implementation.

2. Draw the Force Circle Diagram superposed at the cutting edge of the Free-bodyDiagram of Chip-Tool-Work combination in single-point machining; and using thesetwo diagrams explain the following: (10 points) a. Hypothesis of Merchant-Ernst's first theory: b. Assumptions of this theory: c. Mathematical expression (equation) of this first theory: d. Weaknesses/Defects of this first theory: e. Assumptions of the second theory (by Merchant): f. Mathematical expression (equation) of this second theory: g. Advantages/Benefits of this second theory:

What is the difference between fixed costs and variable costs?

pt)Draw the micro-fabrication process (2D cross sectional view) for a SU-8 pattern on a silicon wafer (top view and side view are shown below). Include your photomask design and indicate the dark and transparent regions. Start your process from the spinning to the final development.

2. What is an alloy? What is a solid solution in the context of alloys? (2')

19) Meeting internal needs are a strategically higher priority than providing customer-defined value. T/F

3. What would be the closest size estimation of a Helium atom? А. 1 mm В. 1 um С. 1 nm P. 1Å Е. 1 pm

7) Lean Six Sigma implementation should be from the ground up. T/F

10. What is the difference between traditional ceramics and new ceramics? (2')

3. What are the two basic categories of cutting tools in machining? Give an example of machining operations that use each tooling type. (2')