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VALLIAMMAI ENGINEERING COLLEGE

DEPARTMENT OF MECHANICAL ENGINEERING


SEMESTER: I / M.E CAD/CAM
SUBJECT CODE: CM 7201
SUBJECT NAME: COMPETITIVE MANUFACTURING SYSTEMS

UNIT I
MANUFACTURING IN A COMPETITIVE ENVIRONMENT
PART A
1. Interpret the word mechanization with examples.(BT-2)
2. Define automation. (BT-1)
3. Compare hard automation with soft automation (BT-5)
4. Compare CNC and DNC. (BT-4)
5. Classify industrial robots based on its configuration. (BT-4)
6. Differentiate open loop and closed loop control circuits. (BT-2)
7. Explain the principle of numerical control of machines. (BT-4)
8. Illustrate different types of joints in robots.(BT-3)
9. Classify the material handling systems based on the principle of operation.(BT-3)
10. Show the work volume of Cartesian coordinate robot. (BT-3)
11. Summarize the advantages of CNC over DNC.(BT-2)
12. Describe the principle of adaptive control. (BT-2)
13. Distinguish between internal and external sensors.(BT-2)
14. Express the degrees of freedom of wrist in terms of joints. (BT-2)
15. Define flexible fixture. (BT-1)
16. List out the purpose of adaptive control.(BT-1)
17. Name the different types of material transport equipment. (BT-1)
18. List out the applications of AGV.(BT-1)
19. List the types of flexible fixtures. (BT-1)
20. Describe the design for assembly.(BT-1)

PART B

1. a) Describe the differences between mechanization and automation. Give some specific
examples.(BT-1)
b) Label and explain the work envelope of various robot configurations. (BT-1)
2. a) Tabulate the differences between direct numerical control and computer numerical
control. (BT-1)
b) List out the advantages of various numerical control systems. (BT-1)
3. a) Describe the principle and purpose of adaptive controls. (BT-1)
b) Quote the different material handling techniques used in automatic manufacturing
system. Explain each. (BT-1)
4. a) Summarize the major classifications of the sensors used in industrial robots with their
applications. (BT-2)
b) Discuss about any two position sensors. (BT-2)
5. a) Interpret the factors that should be considered in choosing suitable material handling
systems for a particular manufacturing facility. (BT-2)
b) Summarize the activities in manufacturing operations that cannot be automated.
(BT-2)
6. a) Illustrate the various features of an industrial robot using a block diagram. (BT-3)
b) Show the necessity of these features. (BT-3)
7. a) Analyse the design for assembly and disassembly. Discuss its design consideration.
(BT-4)
b) Classify robots according to their functions. Give examples. (BT-4)
8. Describe the principle and purpose of adaptive controls. Give some example of present
application in manufacturing and others that you think can be implemented. (BT-2)
9. Criticize the factors that led to the development of automated guided vehicles? Do they
have any disadvantages? Explain your answers. (BT-5)
10. a) Integrate adaptive control with present application in manufacturing. (BT-6)
b) Formulate the concept of design of assembly. (BT-6)
11. a) Evaluate the importance of design of assembly in manufacturing. (BT-5)
b) Criticize the possibility of partial automation in assembly. (BT-5)
12. a) Explain the principle of any two types of sensors used in robots. (BT-4)
b) Describe the impact of industrial robots used in the shop floor. (BT-2)
13. a) Discuss about flexible fixtures with examples. (BT-2)
b) Summarize the advantages of flexible fixtures in production. (BT-2)

14. a) Explain the classification and applications of adaptive control system with example.
(BT-5)
b) List out the applications of industrial robots. (BT-1)
PART C
1. Compose a case study on Manufacturing in a competitive environment. (BT-6)
2. Explain briefly about automation of manufacturing process, Numerical control &
Adaptive control. (BT-5)
3. Discuss material handling and movement in a CMS. (BT-2)
4. Demonstrate the practical application of Industrial robots & Sensor technology. (BT-3)

UNIT II
GROUP TECHNOLOGY & FLEXIBLE MANUFACTURING SYSTEMS
PART A
1. List the various types of coding systems widely used. (BT-1)
2. Define group technology. (BT-1)
3. Describe the concept of part family. (BT-1)
4. Name the various criteria used for cell design. (BT-1)
5. Where the mono-code can be used? (BT-1)
6. List the various components of FMS. (BT-1)
7. Distinguish between MICLASS and DCLASS systems.(BT-2)
8. Summarize the applications of FMS. (BT-2)
9. Distinguish between poly-code and mixed-code.(BT-2)
10. Contrast FMS with FMC. (BT-2)
11. Differentiate dedicated FMS from random-order FMS. (BT-2)
12. Summarize the advantages of FMS. (BT-5)
13. Illustrate the cellular manufacturing system with a sketch. (BT-3)
14. Relate the principle of AGV in flexible manufacturing system. (BT-3)
15. Point out any two functions of the material handling systems in a FMS. (BT-4)
16. Explain the DCLASS system. (BT-4)
17. Assess the bottleneck elements in cellular manufacturing. (BT-5)
18. Summarize the applications of cell design. (BT-5)
19. Explain the principle of AGV. (BT-5)

20. Combine the exceptional elements and bottleneck machines. (BT-6)


PART B
1. a) Discuss the various benefits of implementing a GT in a firm. (BT-2)
b) Summarize the advantages and limitations of using group technology. (BT-2)
2. a) Illustrate and explain the concept of part families. (BT-3)
b) Demonstrate the opitz classification system used in group technology. (BT-3)
3. a) Compare and contrast DCLASS and CODE classification systems. (BT-4)
b) Point out the functions of the material handling systems. (BT-4)
4. a) Explain production flow analysis. (BT-5)
b) Order the steps involved in carrying out PFA. (BT-4)
5. Give short notes about i) Mono-code, ii) Poly-code and iii) Mixed code with example for
each. (BT-2)
6. a) Compare Mono-code with Poly-code and Poly-code with Mixed-code. (BT-4)
b) Classify part families and explain with example. (BT-4)
7. a) Explain cellular manufacturing in detail. (BT-5)
b) Explain in detail, single-linkage clustering algorithm used for cell formation. (BT-5)
8. a) Describe flexible manufacturing system. (BT-1)
b) Illustrate various FMS layout configuration with suitable sketches. (BT-3)
9. a) Differentiate Group technology from cellular manufacturing system. (BT-2)
b) Discuss about primary digits of opitz coding system with examples. (BT-2)
10. a) Explain the various components of FMS with an example. (BT-4)
b) Analyze the need of FMS in Today's Competitive Environment. (BT-4)
11. a) Point out the various functions that are performed by FMS computer control systems.
(BT-4)
b) Discuss the factors to be considered for designing a machine cell. (BT-2)
12. a) Discuss about the planning, scheduling and control of FMS. (BT-2)
b) Explain in detail about knowledge based scheduling. (BT-4)
13. Generalize the hierarchy of computer control? If one of the modules does not function,
how its compensated? (BT-6)
14. a) Give a short note on supervisory computer. (BT-2)

b) Explain briefly about multi class system. (BT-4)


PART C
1. Formulate a Case Study On Group Technology & Flexible Manufacturing Systems.
(BT-6)
2. Describe Part families - classification and coding with a block diagram. List out their
benefits. (BT-1)
3. Discuss the components of FMS - Application work stations Computer control and
functions. (BT-2)
4. Describe the practicality of Planning, scheduling and control of FMS and Knowledge
based scheduling. (BT-1)

UNIT III
COMPUTER SOFTWARE, SIMULATION AND DATABASE OF FMS
PART A
1. Name the various factors influence the FMS design. (BT-1)
2. List the factors involved in product design. (BT-1)
3. Define sequential flow FMS. (BT-1)
4. Where the random flow system can be used? (BT-1)
5. Describe extrinsic functions in brief. (BT-1)
6. Give examples for extrinsic functions. (BT-2)
7. Discuss shortly about the software used in FMS. (BT-2)
8. Differentiate intrinsic function from extrinsic function. (BT-2)
9. Distinguish various types of flexible manufacturing system. (BT-2)
10. Show any one type of FMS with a simple sketch.(BT-3)
11. Relate software specification with FMS. (BT-3)
12. Classify various flow system with example. (BT-3)
13. Explain absolute specifications. (BT-4)
14. Analyze the advantages of system simulation. (BT-4)
15. Plan the systematic steps in which the simulation is carried out. (BT-6)
16. Point out the role of software in tool management systems. (BT-4)
17. Summarize the factors should be consider in tool management systems. (BT-5)
18. Compare knowledge-based systems with tool management systems. (BT-5)
19. Explain various trade-off issues. (BT-5)

20. Formulate the steps involved in the process of simulating a manufacturing systems.
(BT-6)
PART B
1. Select the software and hardware for the applications of manufacturing automation.
Justify your selection and discuss the types of software used in automation. (BT-4)
2. Explain the following terms: i) Sequential flow, ii) Single station and iii) Random flow.
(BT-4)
3. a) Invent the simulation requirement in CAD/CAM. (BT-6)
b) Explain the procedure involved in simulation of any one pressure valve component.
(BT-5)
4. a) List out the stages of FMS simulation. Discuss with example. (BT-1)
b) Describe, how the results are analysed. (BT-1)
5. a) Summarize the CAD/CAM considerations when planning for an FMS. (BT-2)
b) Discuss in detail about the planning of flexible manufacturing system with the help of
a block diagram. (BT-2)
6. a) Explain briefly the extrinsic and intrinsic functions. (BT-4)
b) Point out the factors that should be considered to implement FMS. (BT-4)
7. a) Analyze the various software design requirements in FMS. (BT-4)
b) Describe briefly about system issues. (BT-1)
8. Explain in detail the various CAD/CAM considerations to be considered in planning of
FMS database with your own example. (BT-5)
9. Formulate your own example to explain in detail, how data flow is carried out in a
manufacturing data system. (BT-6)
10. a) List out the various system issues in FMS. (BT-1)
b) Explain FMS system concepts in detail. (BT-5)
11. a) Distinguish the sequential flow from random flow. (BT-2)
b) Describe the various types of software in FMS. (BT-1)
12. a) Summarize the applications of simulation in CAD/CAM. (BT-2)
b) Invent the factors that are critical to database design and explain why. (BT-6)
13. a) Identify the reasons for the companies to need database. (BT-1)
b) Compare and contrast extrinsic and intrinsic functions. (BT-4)
14. a) Classify and explain the three types of simulations. (BT-4)

b) Explain the various techniques of simulations. (BT-5)


PART C
1. Compose a case Study On Computer Software, Simulation And Database Of FMS.
(BT-6)
2. Explain in detail about practical System issues - Types of software - specification and
selection of software for simulation. (BT-5)
3. Describe the practical Manufacturing data systems and data flow in detail. (BT-1)
4. Tabulate the various CAD/CAM considerations. Explain each. (BT-1)

UNIT IV
LEAN MANUFACTURING
PART A
1. List out the four principles of lean production. (BT-1)
2. Define Total Productive Maintenance. (BT-1)
3. Name the term opposite to standardization. Explain. (BT-1)
4. Describe the meaning of Standardization. (BT-1)
5. Name all the elements in 5S system. (BT-1)
6. Distinguish between Agile Manufacturing and FMS. (BT-2)
7. Summarize the benefits of lean manufacturing. (BT-2)
8. Give explanation for Poka-Yoke. (BT-2)
9. Illustrate the Deming circle or PDCA cycle. (BT-3)
10. Point out the four types of visual systems. (BT-4)
11. Demonstrate the quality circle activity. (BT-3)
12. Relate Andon with Lean Production Management. (BT-3)
13. Analyze the principles of JIT (BT-4)
14. Explain the Quality Function Deployment (QFD). (BT-4)
15. Compare Preventive maintenance & Breakdown maintenance. (BT-4)
16. Define Kaizen. (BT-1)
17. Explain systematic planning methodology. (BT-5)
18. Summarize the information in a red tag. (BT-5)
19. Prepare a machine loss pyramid. (BT-6)
20. Generalize the term man power reduction. (BT-6)

PART B
1. a) Describe in detail about the 5S system and write its advantages. (BT-1)
b) Classify and briefly explain the poka-yoke. (BT-4)
2. a) Give in detail, the various aspects of kaizen philosophy. (BT-2)
b) Explain Poka yoke systems with two examples in industrial application. (BT-4)
3. a) Discuss Hoshin planning system with a case study. (BT-2)
b) Demonstrate the 5S system in lean manufacturing. (BT-3)
4. Summarize the principles behind 5S? How are they implemented? Discuss the
implementation of 5S and the benefits with a case study. (BT-2)
5. a) List out the types of POKA YOKE systems. Discuss their practical applications with
examples. (BT-1)
b) Explain the concept of Kaizen techniques and list the advantages. (BT-4)
6. Give short notes on
i)

Hoshin planning methodology

ii)

Jidoka concept

iii)

Poka-yoke (BT-2)

7. a) Illustrate and explain the concept of quality circle. (BT-3)


b) Describe the common layouts of Kaizen. (BT-1)
8. a) Generalize the basic steps that would lead to start Total Productive Maintenance.
(BT-6)
b) Explain TPM and give its applications. (BT-5)
9. a) Analyze MUDA and KAIZEN with examples. (BT-4)
b) Assess the concept of lean culture with example. (BT-5)
10. a) Express the conditions that need to improve worker involvement in production. (BT-2)
b) Integrate mistake proofing with lean manufacturing. (BT-6)
11. Discuss briefly about the following. (BT-2)
i)

Principles of JIT

ii)

Systematic planning methodology

12. a) Give a short note on Muda with example. (BT-2)


b) Explain the lean production system with suitable examples. (BT-5)
13. a) Summarize the rules for implementation of lean production systems. (BT-2)

b) Give a case study for root cause analysis. (BT-2)


14. a) Describe PDCA cycle with the help of a block diagram. (BT-1)
b) Illustrate and explain the simplified lean production system using a tree diagram.
(BT-3)
PART C
1. Plan a case study on lean manufacturing systems. (BT-6)
2. Explain briefly about the origin of lean production systems and the customer focus on
lean manufacturing. (BT-5)
3. List out and explain Muda, standards and 5S systems. (BT-1)
4. Analyze the importance of total productive maintenance in manufacturing systems.
(BT-4)
UNIT V
JUST IN TIME
PART A
1. List out the benefits of flexible work force. (BT-1)
2. Define small lot sizes. (BT-1)
3. Name the various factors influence impanation of JIT. (BT-1)
4. Where the Kanban system can be used? (BT-1)
5. Describe the term flexible work force. (BT-1)
6. Define pull method. (BT-1)
7. Identify the characteristics of JIT. (BT-1)
8. Discuss the benefits of preventive maintenance. (BT-2)
9. Differentiate fixed time and fixed quantity conveyance. (BT-2)
10. Explain the strategic implications of JIT. (BT-5)
11. Illustrate various value stream mapping symbols. (BT-3)
12. Explain the term line flow strategy. (BT-4)
13. Compare Flow and Muda. (BT-4)
14. Analyze, how the flexible work force help to improve production. (BT-4)
15. Summarize the six rules of kanban. (BT-5)
16. Describe close supplier ties. (BT-2)
17. Discuss shortly about zero defects. (BT-2)

18. Generalize the term - reliable equipment. (BT-6)


19. Interpret the meaning of lean manufacturing. (BT-2)
20. Integrate small lot sizes with setup time. (BT-6)
PART B
1. a) Explain the strategic implications and implementations in JIT (BT-5)
b) Discuss about the preventive maintenance in JIT. (BT-2)
2. Formulate the method adopted to implement the JIT philosophy for a medium scale
industry. Summarize the problems to be faced while implementing JIT. (BT-6)
3. a) Describe the role of supplier ties in JIT. (BT-1)
b) Give the reasons for vendor development to improve. Also give examples. (BT-2)
4. a) List out the implementation issues of lean production system. (BT-1)
b) Explain the strategic implications. (BT-5)
5. Discuss various implementation issues on
i)

kanban and

ii)

JIT systems with a case study. (BT-2)

6. a) Explain with various applications on flexible work force in JIT. (BT-4)


b) Analyze the characteristics of just in time with an example. (BT-4)
7. a) Illustrate any two types of kanban with neat sketches. (BT-3)
b) Give a short note on pull systems. (BT-2)
8. a) Explain in detail about lean manufacturing. (BT-5)
b) Tabulate the advantages and disadvantages of lean manufacturing systems. (BT-1)
9. Discuss the effect of setup reduction on Economic Order Quantity (EOQ) and Inventory
Cost. Also state the various approaches for setup time reduction. (BT-2)
10. a) Compare lean production and mass production. (BT-4)
b) Explain how a simple kanban system works. (BT-4)
11. a) Discuss briefly about preventive maintenance. (BT-2)
b) Compare preventive maintenance with breakdown maintenance. (BT-4)
12. a) Assess the strategic implications on kanban systems. (BT-5)
b) Explain with various applications on flexible work force in JIT. (BT-5)
13. a) Give an engineering brief about continuous flow manufacturing. (BT-2)

b) Discuss briefly about line flow strategy. (BT-2)


14. Give short notes on the following (BT-2)
i)

Work station loads

ii)

Flexible work force

iii)

Close supplier ties

PART C
1. Develop a case study on Just In Time. (BT-6)
2. Describe the Characteristics of JIT and Pull method. Explain their importance in a
manufacturing industry. (BT-1)
3. Explain briefly about flexible work force and line flow strategy. (BT-4)
4. Explain the necessity of preventive maintenance and Kanban system. (BT-5)