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? 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 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.

9) ISO 9000 is a standard for addressing environmental management. T/F

6. A tensile specimen of 1020 annealed steel is loaded in tension until the total strain is 10%, at which point it has just reached its ultimate strength. Using the properties from the appendices of this book,and your knowledge of the tensile behavior of a TDM, (a) sketch a graph of the resulting stress-strain curve. (b) estimate the total energy per unit volume absorbed by the specimen. (c) Calculate the elastic energy per unit volume in the tensile specimen and express it as a percent of total energy. (d) What forms do the elastic and plastic energy exist in? Describe. Hint: What would happen if the specimen were suddenly unloaded when the total strain is 10%?

27) Administrative and pre planning tasks related to Kiazen event management, play a minimal role determining the success of the event itself. T/F

31) Create an X-bar control chart. Include all required elements of a control chart. Analyze the chart for processstability and special cause variation. Determine if the data suggest the process is stable or not. Use the mean +/-3-sigma test for stability. If the data suggest special cause variation exists in the process, identify all data points which fail the requested test for special causes. Label any failing data points. Be specific. No Minitab or Excel. Use the following sequential data set Calculate the mean, UCL, and LCL. Assume one standard deviation = 3.15.5.1, 4.9, 2.3, 2.3, 7.0, 4.0, 6.9, 8.0, 1.6, 7.0, 5.0, 11.0, 1.1, 13.2, 0.9, 0.6, 3.2, 1.1, 0.8, 4.8, 3.6, 4.2, 3.8, 2.9, 4.9

4. What is the difference between engineering stress and true stress in a tensile test? (2')

(a) What are the different types of furnaces used for casting processes? Briefly describe them. (b) A part resembling a connecting rod is cast in sand. Porosity is found in the shank and cavities in the heads. Show with appropriate design sketches a remedy for the head and two possible remedies for the shank. Explain in few sentences each. (c) What is allotropic transformation? What are the results of shrinkage in a casting?

A manufacturing industry using 50 servicing equipment similar to the equipment presented in figure 1. The servicing equipment is composed of five subsystems. The estimated reliability for each subsystem is: Subsystem A is 0.99 Subsystem B is 0.81 Subsystem C is 0.75 Subsystem D is 0.98 Subsystem E is 0.90 To estimate the related Annual Maintenance Cost, the servicing equipment have been tested. The record of breakdowns during the testing period is presented in the table below: The average cost of breakdown is estimated to 200KD. The manufacturer target is to improve the Annualized Maintenance Cost by 30%. So, they decide to contract out the preventive maintenance to a service company SERVISCO. The contract will include fixed fees of 50 KD and the cost of: Labor: 30KD Consumables: 5KD Before signing the contract, the manufacturer performed a trial period with SERVISCO company, the new record of breakdowns presented by this company is shown below: 1-Calculate the system reliability 2-Calculate the corrective maintenance cost per month 3-Calculate the new maintenance cost if the plant will contract out the preventive maintenance service 4-Calculate the expected Annualized Maintenance Cost before and after contracting the maintenance service Give the expected annual savings in maintenance cost 6-Will the firm contract out the preventive maintenance service with this company? To answer this question, you have to calculate the targeted budget.

20.18 (SI units) A turning operation is carried out on aluminum. Based on the specific energy values in Table 20.2, determine material removal rate and cutting power in the operation under the following sets of cutting conditions: (a) Cutting speed = 5.6 m/s, feed = 0.25 mm/rev, and depth of cut(b) cutting speed = 1.3 m/s, feed = 0.75 mm/rev, and depth = 4.0 mm.= 2.0 mm; and

Question 2 ‘Smoothtools’ manufacturing company want to enter the ‘woodworking tools’ market and one of the first products it has decided to manufacture is a general purpose smoothing plane. (See Figure Q2- parts view). After ‘reverse engineering’ the wood plane, the planning department have arrived at a build sequence and timings for each task which is shown in Table Q2(a). Furthermore, the marketing department at ‘Smoothtools’ have produced a sales forecast for the new planes which is given in Table Q2(b). The plant is expected to have a work pattern of 40 hours week, 48 weeks per year. Assuming a Product layout (Long thin) arrangement, determine the following information for the 1st quarter of production: a) The required cycle time and the theoretical minimum number of people required to assemble the products (5 Marks) b) The ‘line design’. (5 Marks) c) The actual number of people required to manufacture/assemble the product based on your design and what would be the balance loss and estimated output for this arrangement? (6 Marks) d) If a ‘short fat’ layout is used in the 1st quarter, how many people would be required to assemble the products? What is the balance loss and potential output for this arrangement? (6 Marks) e) Considering the two options. Which layout is best suited to meet the demand in 4th quarter and why? (12 Marks) f) What are the advantages and disadvantages of both ‘long thin’ and ‘short fat’ layouts? (16 Marks)