SRM VALLIAMMAI ENGINEERING

COLLEGE
SRM Nagar, Kattankulathur – 603 203

DEPARTMENT OF
MECHANICAL ENGINEERING

QUESTION BANK

VSEMESTER
OPEN ELECTIVE

OIM552 / LEAN MANUFACTURING

Regulation – 2017

Academic Year 2019 – 20

Prepared by

Mr.R.Ramkumar, Assistant Professor/Mechanical

 SRM VALLIAMMAI ENGINEERING COLLEGE
SRM Nagar, Kattankulathur

DEPARTMENT OF MECHANICAL ENGINEERING

QUESTION BANK
SUBJECT : OIM552 / LEAN MANUFACTURING

SEM / YEAR: V / III

UNIT-I-INTRODUCTION TO LEAN MANUFACTURING

SYLLABUS

Conventional Manufacturing versus Lean Manufacturing- principles of Lean Manufacturing – Basic

elements of lean manufacturing – Introduction to LM Tools
PART-A (2 Marks)
Q.No Questions BT Level Competence
1 Define lean production. BTL-1 Remembering
2 Classify the manufacturing activities based on the value they BTL-1 Remembering
contribute to a part or product.
3 Define product variety. BTL-1 Remembering
4 Distinguish between Lean production and mass production. BTL-1 Remembering
5 Define Kanban. BTL-1 Remembering
6 Mention the objectives of JIT. BTL-1 Remembering
7 Compare auxillary activitiy with value adding activity. BTL-2 Understanding
8 Define JIT. BTL-2 Understanding
9 Classify Kanban. BTL-1 Remembering
10 State the implications of over production and excess BTL-2 Understanding
inventory in industry.
11 Point out the conditions for successful implementation of BTL-3 Applying
JIT.
12 Define muda. BTL-3 Applying
13 State the concept of Jidoka. BTL-1 Remembering
14 Relate product variety with product volume. BTL-3 Applying
15 Define Kaizen. BTL-1 Understanding
16 List the objectives of standardized work procedure. BTL-3 Applying
17 Expand the term 5S. BTL-2 Understanding
18 Differentiate cycle time and takt time. BTL-5 Evaluating

19 Express the benefits of production leveling. BTL-1 Remembering

20 State the elements of standardized work. BTL-6 Creating
 PART-B (13 Marks)
Q.No. Questions BT Level Competence
1 Explain the activities associated with the lean production. BTL-1 Remembering
2 Recognize the elements of JIT, Worker involvement and BTL-1 Remembering
Autonomation in Lean production.
3 Enumerate Ohno’s seven forms of waste. BTL-2 Understanding
4 Indicate the reasons for the people and material to move BTL-3 Applying
unnecessarily in the manufacturing plant.
5 Discuss the pull based system of production control. BTL-5 Evaluating
6 Explain the ways to reduce the work in process inventory in BTL-2 Understanding
a manufacturing firm.
7 Describe the effects of production leveling and work force in BTL-5 Evaluating
the implementation of JIT.
8 Explain the functioning of Jidoka with suitable illustrations.
BTL-4 Analysing
9 Discuss the various techniques for mistake proofing process.
BTL-4 Analysing
10 Explain the concept of Kaizen. BTL-4 Analysing
11 Write short notes on standardized work procedures in lean BTL-3 Applying
manufacturing.
12 (i) Calculate the number of Kanbans needed at the ABC BTL-6 Creating
company for the following two products, produced in a
factory that works 8 hours per day, 5 days per week. (7)
(ii) Explain the various steps involved in the 5S. (6)

13 (i) ABB Refrigeration, Inc., is trying to reduce inventory and BTL-5 Evaluating
wants to install a Kanban system for compressors one of its
assembly lines. Determine the size of containers and number
of Kanban cards (number of containers) needed, given the
following data: Setup cost = $10 Annual holding cost per
compressor = $100 Daily production = 200 compressors
Annual usage = 25,000 (50 weeks x 5 days each x daily
usage of 100 compressor) Lead time = 3 days Safety stock =
1/2 day's production of compressors. (7)

(ii) The monthly demand for a certain parts is 10000 units.

There are 22 working days in the month. The plant operates
two shifts, each with an effective operating time of 440 min.
Determine the takt time for this part. (6)
 14 Write short notes on worker involvement. BTL-2 Understanding
PART-C (15 Marks)
Q.NO Questions BT Level Competence
1 Explain the basic elements and principle of lean BTL-3 Applying
manufacturing.
2 A two workstation cell uses a kanban system with a BTL-5 Evaluating
container size of 10 units. The workstation makes eight
different versions of the same product. Total annual demand
is 150,000 parts. The first workstation has a maximum
production rate of 250,000 parts per year, and the second
workstation could produce 325,000 parts per year working
full time. Internal setup is 0.0004 years at the first
workstation and 0.0003 years at the second. External setup
time is 0.0002 years per batch at each workstation. What
batch size would you used for this work center?
3 A stamping plant supplies sheet metal parts to a final BTL-6 Creating
assembly plant in the automotive industry. Annual demand
is 150,000 pc (for each part produced). Average cost per
piece is Rs 18 and holding cost is 20% of piece cost.
Changeover (setup) time for the presses is 5 hrs and cost of
downtime on any given press is Rs200/hr. Determine (a)
The economic batch size (b) total annual inventory cost for
the data. If the changeover time for the presses could be
reduced to 10 minutes, Determine (c) the economic batch
size and (d) total annual inventory cost.
4 Explain the three aspects of the autonomation with suitable BTL-4 Analysing
illustrations.
 UNIT II CELLULAR MANUFACTURING, JIT, TPM
SYLLABUS
Cellular Manufacturing - Types of Layout, Principles of Cell layout, Implementation. JIT –
Principles of JIT and Implementation of Kanban. TPM – Pillars of TPM, Principles and
implementation of TPM.
PART-A (2 Marks)
Q.No Questions BT Level Competence
1 Define cellular manufacturing. BTL-1 Remembering
2 List the objectives of cellular manufacturing. BTL-1 Remembering
3 Define composite part. BTL-1 Remembering
4 Define group technology. BTL-2 Understanding
5 Define part family. BTL-4 Analyzing
6 State the benefits of group technology. BTL-1 Remembering
7 Mention the various methods of converting parts into part BTL-1 Remembering
families.
8 Identify the reasons for using a coding system. BTL-1 Remembering
9 Mention the features of part classification and coding BTL-2 Understanding
system.
10 Differentiate between monocode and polycode. BTL-2 Understanding
11 Interpret the structures deployed in the parts classification BTL-3 Applying
and coding system.
12 Mention any 4 part design attributes. BTL-3 Applying
13 Mention any 4 design attributes. BTL-2 Understanding
14 List the various cell layouts. BTL-4 Analyzing
15 Define TPM. BTL-4 Analyzing
16 Differentiate between push based and pull based system. BTL-2 Understanding
17 Define utilization. BTL-3 Applying
18 Quote the expression of process yield. BTL-2 Understanding
19 Quote the expression of OEE. BTL-6 Creating
20 Compare preventive maintenance and predictive BTL-2 Understanding
maintenance.
PART-B (13 Marks)
Q.No Questions BT Level Competence
1 Explain the composite part concept with suitable sketches.
BTL-1 Remembering
2 Discuss the various factors influencing machine cell design.
BTL-1 Remembering
3 Describe the applications of group technology.
BTL-4 Analyzing
4 Five machines constitute a GT cell. The From/To data for
BTL-4 Analyzing
the machines are shown in the table below. (a) Determine
the most logical sequence of machines for this data and
construct the network flow diagram, showing where and
how many parts enter and exit the system. (b)Compute the
percentage of in-sequence moves, by passing moves and
backtracking moves in the solution.(c) Develop a feasible
layout plan for the cell based on the solution.
To
From 1 2 3 4 5
1 0 10 80 0 0
2 0 0 0 85 0
3 0 0 0 0 0
4 70 0 20 0 0
5 0 75 0 20 0
5 Suppose that four machines 1,2,3 and 4 belong to a GT
BTL-3 Applying
machine cell. An analysis of 50 parts processed on these
machines has been summarized in the From/To chart
shown in the table below. Additional information is that 50
parts enter the machine grouping at machine 3, 20 parts
leave after processing at machine 1 and 30 parts leave after
machine 4. Determine the most logical machine sequence
using the Holier method. Also compute the network flow
diagram and also determine (a) Percentage of in sequence
moves (b) percentage of bypassing moves (c) percentage of
back tracking moves.
TO
FROM 1 2 3 4
1 0 5 0 25
2 30 0 0 15
3 10 40 0 0
4 10 0 0 0
6 Four machines used to produce a family of parts are to be BTL-2 Understanding
arranged into a GT cell. The From / To data for the parts
processed by the machines are shown in the table below. (a)
Determine the logical sequence of the machine for this data.
(b) Construct the network diagram for the data, showing
 where and how many parts enter and exit the system. (c)
Compute the percentages of in sequence moves, by passing
moves and backtracking moves in the solution (d) Develop a
feasible layout plan for the cell.
TO
FROM 1 2 3 4
1 0 10 0 40
2 0 0 0 0
3 50 0 0 20
4 0 50 0 0
7 Write short notes on qualitative analysis in cellular
BTL-6 Creating
manufacturing.
8 (i) Explain the different types of maintenance . (7)
BTL-2 Understanding
(ii) Write short notes on OEE. (6)
9 Explain the stages in implementing the TPM. BTL-3 Applying
10 Enumerate the key aspects of implementing TPM. BTL-4 Analyzing
11 Explain the various steps involved in the production flow
BTL-2 Understanding
analysis.
12 Explain the principle of JIT.
BTL-2 Understanding
13 List out the difficulties faced in implementing the TPM.
BTL-3 Applying
14 Explain the pillars of TPM.
BTL-3 Applying
PART-C (15 Marks)
Q.No Questions BT Level Competence
1 Explain the different types of machine cell layouts with
BTL-6 Creating
suitable sketches.
2 Explain the six rules of kanban.
BTL-4 Analyzing
3 Enumerate the implementation of Total productive
BTL-5 Evaluating
maintenance with suitable illustrations.
4 Explain the pillars of TPM. BTL-6 Creating
 UNIT III SET UP TIME REDUCTION, TQM, 5S, VSM
SYLLABUS
Set up time reduction – Definition, philosophies and reduction approaches. TQM – Principles and
implementation - Principles and implementation – Value stream mapping _ Procedure ad principles.
PART-A (2 Marks)
Q.NO Questions BT Level Competence
1 Define setup time. BTL-1 Remembering
2 Expand SMED. BTL-1 Remembering
3 Mention any 2 benefits of reducing the setup time. BTL-2 Understanding
4 Define changeover time. BTL-1 Remembering
5 Mention the reasons for reduction in setup time reduction. BTL-1 Remembering
6 Distinguish between internal setup and external setup BTL-2 Understanding
activity.
7 List any 2 benefits of SMED. BTL-3 Applying
8 Define TQM. BTL-4 Analyzing
9 Mention the various approaches used in setup time reduction. BTL-3 Applying
10 Define Robust design. BTL-2 Understanding
11 Mention the significance of taguchi loss function.
BTL-3 Applying
12 Mention the three barriers of TQM implementation. BTL-3 Applying
13 State the four PI’s of TQM. BTL-3 Applying
14 Expand the term ‘5S’. BTL-4 Analyzing
15 Define Kaizen. BTL-1 Remembering
16 Mention the levels of mapping the value stream for a product BTL-4 Analyzing
family.
17 Define value stream mapping. BTL-1 Remembering
18 Mention the steps essential to bring out any new product. BTL-1 Remembering
19 List the uses of value stream mapping. BTL-1 Remembering
20 Sketch the value stream mapping symbol for work cell and BTL-6 Creating
customer/supplier icon.
PART-B (13 Marks)
Q.No Questions BT Level Competence
1 Explain the key steps for reducing the setup times.
BTL-2 Understanding
2 (i) List the benefits of reducing the setup time. (7)
BTL-3 Applying
(ii)Interpret the impact of setup reduction in a manufacturing
plant. (6)
3 (i)Describe the benefits of SMED. (7) BTL-4 Analyzing
 (ii)Explain the setup reduction methodology most
commonly used in industry. (6)
4 (i) Explain the benefits of employee involvement. (7) BTL-4 Analyzing
(ii) Point out the benefits of implementing 5S. (6)
5 Explain the implementation of TQM in manufacturing
BTL-2 Understanding
sector.
6 Enumerate on the implementation techniques in SMED with
BTL-3 Applying
illustrations.
7 Write short notes on 5S technique.
BTL-1 Remembering
8 Explain the implementation and strategies of TQM.
BTL-3 Applying
9 Write short notes on Juran Philosophy. BTL-5 Evaluating
10 (i) Sketch the flowchart of SMED process for a new change
over time. (7) BTL-5 Evaluating
(ii) Explain the five steps to quick change over. (6)
11 (i)Mention the benefits of 5S system. (7) BTL-5 Evaluating
(ii) Mention the objectives of SMED. (6)
12 Describe the guidelines to be followed when generating the
BTL-3 Applying
Future State Map for an improved manufacturing system.
13 Justify the reasons for using value stream mapping as an BTL-4 Analyzing
essential tool.
14 Explain the pros and cons of the value stream mapping. BTL-1 Remembering
PART-C (15 Marks)
Q.No Questions BT Level Competence
1 Explain the various stages of SMED.
BTL-6 Creating
2 Enumerate the basic strategies for reducing the downtime BTL-4 Analyzing
for the setups.
3 With a case study explain how SMED helps in reducing the BTL-4 Analyzing
setup time in garment manufacturing industry?
4 Explain the various steps of PDSA cycle. BTL-5 Evaluating
 UNIT IV SIX SIGMA

SYLLABUS
Six Sigma – Definition, statistical considerations, variability reduction, design of experiments- Six
Sigma implementation.
PART-A (2 Marks)
Q.NO Questions BT Level Competence
1 Define Six sigma. BTL-1 Remembering
2 List the advantages of six sigma. BTL-1 Remembering
3 Expand DMAIC. BTL-2 Understanding
4 Quote the expression for DPMO. BTL-3 Applying
5 Quote the expression for DUPM. BTL-2 Understanding
6 Define DOE. BTL-1 Remembering
7 Mention the objectives of DOE. BTL-4 Analyzing
8 Indicate the uses of experimental design in process BTL-2 Understanding
development.
9 Interpret the applications of DOE in engineering design. BTL-1 Remembering
10 Identify the attributes of good point estimators. BTL-4 Analyzing
11 Mention the methodologies used in six sigma. BTL-3 Applying
12 Distinguish between random variation and assignable BTL-3 Applying
variation.
13 Define process capability. BTL-4 Analyzing
14 Quote the expression for process capability. BTL-3 Applying
15 Define process capability index. BTL-4 Analyzing
16 Mention the objectives of statistical process control. BTL-2 Understanding
17 Point out the tools used in SPC. BTL-1 Remembering
18 Indicate the objective of variability reduction. BTL-4 Analyzing
19 Mention the uses of process capability. BTL-2 Understanding
20 List out the various phases of root cause analysis. BTL-2 Understanding
PART-B (13 Marks)
Q.NO Questions BT Level Competence
1 (i) List the goals of six sigma. (7) BTL-1 Remembering
(ii) Ten samples (m=10) of 20 parts each (n=20) have been
collected. In one sample there were no defects; in three
samples there was one defect; in five samples there were
two defects and in one sample there were three defects.
 Determine the center, lower control unit and upper control
limit for the p-chart. (6)
2 A refrigerator final assembly plant inspects its completed BTL-5 Evaluating
products for 37 features that are considered critical-to-
quality(CTQ). During the previous three month period,
31,487 refrigerators were produced, among which 1690 had
defects of the 37 CTQ features and 902 refrigerators had one
or more defects. Determine (a) the defects per million
opportunities and corresponding sigma level (b) the defects
per million and corresponding sigma level and (c) the
defective units per million and corresponding sigma level.
3 Explain the various phases of root cause analysis. BTL-2 Understanding
4 Write short notes on the impact of six sigma on Ford and BTL-2 Understanding
GE.
5 Give a detailed report on how six sigma is related to TQM. BTL-2 Understanding
6 Give a detailed report on how six sigma is related to lean BTL-5 Evaluating
manufacturing.
7 Enumerate the benefits of using six sigma. BTL-4 Analyzing
8 Give a detailed report on how six sigma is related to Process BTL-4 Analyzing
tolerance.
9 A garment manufacturer produces 22 different coat styles BTL-3 Applying
and every year new coat styles are introduced and old styles
are discarded. The final inspection department checks each
coat, regardless of its style, before it leaves the factory for
nine features that are considered critical-to-quality (CTQ)
characteristics for customer satisfaction. The inspection
report for last month indicated that a total of 366
deficiencies of the nine features were found among 8240
coats produced. Determine (a) defects per million
opportunities and (b) sigma level for the manufacturer’s
production performance.
10 Explain how six sigma uses the design of experiments? BTL-4 Analyzing
11 A producer of cell phones checks each phone prior to BTL-3 Applying
packaging using seven critical-to-quality (CTQ)
characteristics that are deemed important to customers. Last
year, out of 205,438 phones produced by the company, a
total of 578 phones had at least one defect and the total
 number of defects among the 578 phones was 1692.
Determine (a) the number of defects per million
opportunities and corresponding six sigma level (b) number
of defects per million and corresponding six sigma level (c)
the number of defective units per million and corresponding
sigma level.
12 Suppose eight samples (m=8) of size 5 (n=5) have been BTL-3 Applying
collected from a manufacturing process that is in statistical
control and the dimension of interest has been measured for
each part. It is desired to determine the values of the center,
LCL and UCL to construct the value of x and R for each
sample are given here (measured values in centimeters),
S 1 2 3 4 5 6 7 8
X 2.008 1.998 1.993 2.002 2.001 1.995 2.004 1.999
r 0.027 0.011 0.017 0.009 0.014 0.020 0.024 0.018

13 Write short notes on histogram and paretochart. BTL-1 Remembering

14 Explain the ways of successful implementation of SPC. BTL-4 Analyzing
PART-C (15 Marks)
Q.NO Questions BT Level Competence
1 Enumerate on the six sigma DMAIC procedure. BTL-4 Analyzing
2 Explain the implementation of six sigma in various BTL-6 Creating
industries.
3 Describe the guidelines for designing the experiments. BTL-5 Evaluating
4 Discuss the various tools used in statistical process control. BTL-5 Evaluating
 UNIT V CASE STUDIES
SYLLABUS
Various case studies of implementation of lean manufacturing at industries.
PART-A (2 Marks)
Q.NO Questions BT Level Competence
1 Define lean production. BTL-1 Remembering
2 List the types of manufacturing. BTL-2 Understanding
3 Mention the drawbacks of mass production. BTL-3 Applying
4 Distinguish between mass production and lean production. BTL-1 Remembering
5 State the pillars of lean manufacturing system. BTL-1 Remembering
6 Point out the objectives of JIT. BTL-2 Understanding
7 Give some examples of pull based system. BTL-2 Understanding
8 Mention the industries implementing lean system. BTL-3 Applying
9 Compare agile manufacturing and lean manufacturing. BTL-2 Understanding
10 Interpret the objectives of lean manufacturing system. BTL-2 Understanding
11 Define muda BTL-3 Applying
12 Relate muda , muri and mura. BTL-4 Analyzing
13 Define autonomation. BTL-1 Remembering
14 Mention the forms of waste by lean system. BTL-1 Remembering
15 Define poka yoke. BTL-4 Analyzing
16 Define jidoka. BTL-5 Evaluating
17 List the uses of autonomation. BTL-2 Understanding
18 Mention the benefits of TPM. BTL-3 Applying
19 Define Kaizen. BTL-1 Remembering
20 Define kanban. BTL-1 Remembering
PART-B (13 Marks)
Q.No Questions BT Level Competence
1 With a case study explain how lean manufacturing helps an BTL-1 Remembering
automobile industry to increase its performance?
2 With a case study explain the challenges faced by a SME BTL-5 Evaluating
while implementing lean system.
3 Write short notes on the impact of lean manufacturing BTL-2 Understanding
system in process industries.
4 With the use of case study explain the characteristic of
BTL-2 Understanding
material flow, value time and VSM in a wood
manufacturing industry.
 5 Explain the improvement of manufacturing operations BTL-5 Evaluating
through a Lean Management in the Pharmaceutical Industry
using a case study.
6 With a case study explain how SMED reduces the set up
BTL-2 Understanding
time in a plastic moulding company.
7 Explain the difficulties faced while implementing 5S to an BTL-3 Applying
alloy making industry.
8 With a case study explain the challenges faced by the BTL-2 Understanding
printing industry while implementing lean system.
9 Explain the findings reported by the Boeing while BTL-1 Remembering
implementing the lean production system.
10 Describe the impact of lean production system in the coir BTL-5 Evaluating
product based industry.
11 With a case study explain how the lean production system BTL-6 Creating
address the quality issues in an automotive industry.
12 Explain the implementation of the lean manufacturing BTL-4 Analyzing
system in a plastic grain manufacturing industry.
13 Enumerate on the real time practical issues faced while BTL-3 Applying
implementing the JIT in the industry.
14 Explain the status of lean manufacturing principle in the BTL-3 Applying
context of Indian industry with examples.
PART-C (15 Marks)
Q.No Questions BT Level Competence
1 Develop a case study of lean manufacturing in a die casting BTL-6 Creating
manufacturing industry.
2 Develop a case study of lean manufacturing on sustainable BTL-4 Analyzing
environment.
3 Discuss the implementation issue faced by ship building BTL-5 Evaluating
firm while implementing lean system.
4 Develop a case study of leaning manufacturing while BTL-4 Analyzing
implementing kanban system.