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Regulation – 2013

Academic Year 2019– 2020

Prepared by
Mr.R.Srinivasan, Assistant Professor

Mr.K.P.Manikandan, Assistant Professor

Mr.G.Lokesh, Assistant Professor


SRM Nagar, Kattankulathur - 603 203.




Brief introduction to CAD and CAM – Manufacturing Planning, Manufacturing control- Introduction to
CAD/CAM – Concurrent Engineering-CIM concepts – Computerised elements of CIM system –Types of
production - Manufacturing models and Metrics – Mathematical models of Production Performance – Simple
problems – Manufacturing Control – Simple Problems – Basic Elements of an Automated system – Levels of
Automation – Lean Production and Just-In-Time Production.
PART-A (2 Marks)

Q.No Questions BT Level Competence

1 Define CAD & CAM. BTL-1 Remembering
2 Mention the practical applications of open loop and closed loop BTL-1 Remembering
3 Identify what is CIM and automation. BTL-1 Remembering
4 Examine Manufacturing Planning BTL-1 Remembering
5 Where is Manufacturing Control applied? BTL-1 Remembering
6 Distinguish between CAD/CAM and CIM? BTL-1 Remembering
7 Summarize Concurrent Engineering. BTL-2 Understanding
8 What are the major communication used in manufacturing industry. BTL-2 Understanding
9 Contrast the elements of CIM system. BTL-1 Remembering
10 Express the types of production. BTL-2 Understanding
11 Define Manufacturing lead time. BTL-3 Applying
12 Distinguish between MTBF and MTTR. BTL-3 Applying
13 Differentiate between JIT and Traditional method. BTL-3 Applying
14 Quote the expression for production capacity. BTL-1 Remembering
15 Define automation and classify the basic elements of automated BTL-1 Understanding
16 Differentiate between pull and push production system. BTL-3 Applying
17 Mention the factors used to increase or decrease plant capacity over BTL-2 Understanding
short term.
18 Define Lean Production. BTL-5 Evaluating

19 Prepare the salient features of JIT . BTL-1 Applying

20 Formulate the key principles of Lean manufacturing. BTL-6 Creating
PART-B (13 Marks)
Q.No BT Level Competence
Questions Marks
1 Describe the evolution of CIM and list CIM hardwares and 13 BTL-1 Remembering
(a) Examine what is meant by product data management? 7 BTL-1 Remembering
2 Explain why it is important in CAD/CAM integration.
(b) Identify about computerized elements of a CIM system. 6
3 (a) Write short notes on (i) Poka yoke (ii) Jidoka (iii) 5S 7 BTL-2 Understanding
(b) Define MUDA and KAIZEN with example.

4 The average part produced in a certain batch manufacturing 13 BTL-3 Applying

plant must be processed sequentially through six machines on
average. Twenty (20) new batches of parts are launched each
week. Average operation time = 6 minutes, average setup
time = 5 hours, average batch size = 25 parts, and average
non-operation time per batch = 10hr/machine. There are 18
machines in the plant working in parallel. Each of the
machines can be setup for any type of job processed in the
plant. The plant operates an average of 70 production hours
per week. Scrap rate is negligible. Determine (a)
manufacturing lead time for an average part, (b) plant
capacity, (c) plant utilization. (d) How would you expect the
non-operation time to be affected by the plant utilization?
5 (a) Describe the need for CIM and the issues addressed by 7 BTL-5 Evaluating
(b) Explain the five levels of automation in a production 6
(a) Discuss the concurrent engineering and its characteristics. 7 BTL-2 Understanding
(b) A certain part is produced in a batch size of 100 units. The
batch must be routed through five operations to complete 6
the processing of the parts. Average set up time is 3
6 hr/operation and average operation time is 6 min (0.1 hr).
Average non-operation time due to handling, delays,
inspections is 7 hours for each operation. Determine how
many days it will take to complete the batch, assuming the
plant runs one 8-hr shift/day
7 (a) Distinguish the different types of manufacturing. 7 BTL-5 Evaluating
(b) A certain part is routed through six machines in a batch
production plant. The setup and operation times for each 6
machine are given in the table below. The batch size is
100 and the average non-operation time per machine is 12
hours. Determine (a) manufacturing lead time (b)
production rate for machine 1, 3, 5 & 6.

S. Machine Setup Operation time

No Time (hr) (min)
1 1 4 5
2 2 2 3.5
3 3 8 10
4 4 3 1.9
5 5 3 4.1
6 6 4 2.5
(a) List the various forms of waste denoted in Lean concept. 7 BTL-4 Analysing
8 (b) Illustrate how CIM can act as an enabling technology for
concurrent engineering. 6
9 (a) Examine lean production and mass production. 7 BTL-4 Analysing
(b) Show the characteristic of Just-In-Time.
10 (a) Analyze the benefits of JIT system. 7 BTL-4 Analysing
(b) Explain the objectives of JIT system.
11 (a) Point out the effect on Pull systems with various 7 BTL-3 Applying
(b) Compare Lean and Agile manufacturing systems.
12 Analyze a case study on manufacturing in competitive 13 BTL-6 Creating
A production machine operates 80 hr/week (2 shifts, 5days) at BTL-5 Evaluating
full capacity. Its production rate is 20 units/hr. During a
13 certain week, the machine produced 1000 parts and was idle 13
the remaining time. (a) Determine the production capacity of
the machine. (b) What was the utilization of the machine
during the week under consideration?
14 Generalize the structure of Lean production system and also 13 BTL-2 Understanding
mention its objectives.
PART-C (15 Marks)
Q.No Questions Competence
1 Explain the design processed by shigley and the applications of BTL-3 Applying
computer to the design process.
2 Enumerate on the manufacturing metrics and describe the commonly used BTL-5 Evaluating
production performance measures.
3 With respect to principles, tool and examples explain lean manufacturing BTL-6 Creating
and just in time production systems.
4 Identify and explain five level of automation in production plant with BTL-4 Analysing
suitable illustrations.
Process planning – Computer Aided Process Planning (CAPP) – Logical steps in Computer Aided Process
Planning – Aggregate Production Planning and the Master Production Schedule – Material Requirement
planning – Capacity Planning- Control Systems-Shop Floor Control-Inventory Control – Brief on
Manufacturing Resource Planning-II (MRP-II) & Enterprise Resource Planning (ERP) - Simple Problems.
PART-A (2 Marks)
Q.No Questions Competence
1 Define process planning. BTL-1 Remembering
2 List the activities associated with process planning. BTL-1 Remembering
3 What is meant by CAPP? BTL-1 Remembering
4 Name few of CAPP system and their advantages. BTL-2 Understanding
5 List out some logical steps involved in computer aided process planning. BTL-1 Remembering
6 Define reorder point system in inventory control. BTL-1 Remembering
7 Summarize the various components of a generative CAPP system. BTL-1 Remembering
8 Distinguish some commercial variant and generative CAPP software BTL-2 Understanding
9 Express master production schedule (MPS). BTL-2 Understanding
10 Give an important function of PPC. BTL-2 Understanding
11 Mention the two inputs and outputs to process planning. BTL-3 Applying
12 Illustrate MRP and capacity planning. BTL-3 Applying
13 State the 3 strategies of agrregate planning. BTL-1 Remembering
14 Analyze the of inputs data to MRP and outputs of MRP. BTL-4 Analyzing
15 Define Economic order quantity. BTL-4 Analyzing
16 Point out the functions of shop floor control. BTL-2 Understanding
17 Assess the phases of SFC. BTL-3 Applying
18 State the objective of inventory control. BTL-1 Remembering
19 Mention the reasons for keeping the inventories. BTL-6 Creating
20 Define enterprise resource planning (ERP). BTL-1 Remembering
PART-B (13 Marks)
Questions Marks Competence
1 List the two approaches commonly used in CAPP systems 13 BTL-1 Remembering
bringing out their advantages and limitations.
2 Define process planning. What are the activities associated with 13 BTL-1 Remembering
(a) Examine the details of logical steps in computer aided 6 BTL-4 Analyzing
3 process planning.
(b) Identify the features of retrieval type and generative CAPP
(a) Name the criteria for selection of CAPP systems. 6 BTL-4 Analyzing
4 (b) Define what is meant by CAPP. List various advantages and
disadvantages of the retrieval and generative types of CAPP 7
5 Enumerate the role of process planning in CAD/CAM 13 BTL-3 Applying
6 Discuss in details in phase of shop floor control system. 13 BTL-1 Remembering
7 Express about production planning process in discrete part 13 BTL-6 Creating
8 Demonstrate production planning and control. Describe the 13 BTL-2 Understanding
various activities of PPC systems.
a) Aggregate Production planning 3 BTL-3 Applying
b) Master production planning 3
c) Material requirements planning 4
d) Capacity planning 3
a) Analyze shop floor control and bring out its functions. 6 BTL-4 Analyzing
10 b) Explain the various priority sequencing rules used for job
sequencing. 7
11 a) Name four of the capacity adjustment for the short term. 6 BTL-2 Understanding
b) Interpret any five guidelines of DFMA with advantages.
Explain material requirement planning (MRP) with a neat sketch. 13 BTL-2 Understanding
12 What are the inputs and outputs of MRP? Also list the benefits of
13 Assess an engineering brief about 13 BTL-3 Applying
i) MRP-II and (ii) ERP
14 Develop an engineering brief about the various types of 13 BTL-3 Applying
automatic identification technologies.
PART-C (15Marks)
Q.No Questions Competence
1 Explain about factory data collection system. BTL-5 Evaluating
2 Derive the expression for EOQ when the demand of the of the item is BTL-4 Analyzing
uniform, the production rate is infinite and no stock-outs are allowed.
3 Beta industry estimates that it will sell 10,000 units of its product for the BTL-5 Evaluating
forthcoming year. The ordering cost is Rs.36 per order and carrying cost
per unit per year is 9% of the purchase price per unit which is Rs 2
.Determine (i) EOQ (ii) optimal number of order to be placed per
annum.(iii) Minimum total cost of inventory per annum.
4 Derive and relate the expression that evaluated the WIP and MLT. BTL-6 Creating
Group Technology(GT), Part Families – Parts Classification and coding – Simple Problems in Opitz Part
Coding system – Production flow Analysis – Cellular Manufacturing – Composite part concept – Machine cell
design and layout – Quantitative analysis in Cellular Manufacturing – Rank Order Clustering Method -
Arranging Machines in a GT cell – Hollier Method – Simple Problems.
PART-A (2 Marks)
Q.NO Questions Competence
1 Define group technology. BTL-1 Remembering
2 List the roles of group technology in CAD/CAM integration. BTL-1 Remembering
3 Compare mono code with poly code. BTL-2 Understanding
4 Define part family. BTL-1 Remembering
5 List components of GT and applications of GT. BTL-1 Remembering
6 Examine the general methods used for grouping parts into part families. BTL-2 Understanding
7 Summarize the ways to arrange machines in a factory. BTL-3 Applying
8 Distinguish the steps involved in production flow analysis. BTL-4 Analyzing
9 Mention the three basic code structure used in GT application. BTL-3 Applying
10 Express the factors to be considered in selection of coding systems. BTL-2 Understanding
11 Mention the production system where GT & cellular manufacturing BTL-3 Applying
12 Illustrate what do you understand concept of DCLASS? BTL-3 Applying
13 Express the concept of Opitz classification system. BTL-3 Applying
14 Mention the differences between hierarchical codes and attribute code BTL-4 Analyzing
15 What are production conditions under which group technology and BTL-1 Remembering
cellular manufacturing are most applicable?
16 Define cellular manufacturing. BTL-4 Analyzing
17 Assess any four benefits implementation of cellular manufacturing. BTL-1 Remembering
18 Summarize any four design considerations guiding the cell formation. BTL-1 Remembering
19 List the limitations for implementation cellular manufacturing. BTL-6 Creating
20 State the applications of rank order clustering algorithm. BTL-6 Creating
PART-B (13 Marks)
Q.No Questions Marks Competence
1 (a) List the various benefits of implementing a GT in a firm. 7 BTL-2 Understanding
Also bring out the advantages and limitation of using GT.
(b) Discuss the ways to identify the part families. 6

2 Describe what is Group Technology? Also explain why GT is 13 BTL-3 Applying

important in achieving CAD and CAM integration.
3 (a) State the criteria used for cell design 6 BTL-1 Remembering
(b) Enumerate on the parts classification and coding system and
its features. 7
4 Explain the Quantitative analysis in cellular manufacturing and 13 BTL-1 Remembering
its advantages.
5 Summarize how group technology is used in designing 13 BTL-2 Understanding
manufacturing cells.
6 Describe the applications of Group technology in 13 BTL-3 Applying
(i) manufacturing (ii) Product design
7 Discuss about (i) Composite part concept (ii) Key machine 13 BTL-1 Remembering
8 Write short notes on BTL-1 Remembering
a) DCLASS systems with suitable examples. 7
b) PFA systems with suitable examples.
c) MICLASS system with suitable examples. 6
d) OPTIZ system with suitable examples.

9 Illustrate the form code (first five digits) in the Opitz system for a 13 BTL-5 Evaluating
given part.
10 Two components are shown in Fig. do they belong to the same 13 BTL-5 Evaluating
part family? Compare.

11 Analyze the rank order clustering technique to the part-machine 13 BTL-5 Evaluating
incidence matrix in the following table to identify logical part
families and machine groups. Parts are identified by letters, and
machines are identified numerically.


Machine A B C D E
1 1
2 1 1
3 1 1
4 1 1
5 1
12 Explain that four machines 1, 2, 3, and 4 have been identified 13 BT 4 Analyze
as belonging in a GT machine cell. An analysis of 50 parts
processed on these machine has been summarized in the From-
To chart of table below. Additional information is that 50 parts
enter the machine grouping at machine 3, 20 parts leaved after
processing at machine 1, and 30 parts leave after machine 4.
Determine the a logical machine arrangement using Hollier

1 2 3 4

1 0 5 0 25

2 30 0 0 15

3 10 40 0 0

4 10 0 0 0

13 Assess Four machines used to produce a family of parts are to 13 BT 4 Analyze

be arranged into a GT cell. The From-To data for the parts
processed by the machines are shown in the table below.
Determine the most logical sequence of machines for this data
using. Hollier methods (b) construct the flow diagram for the
data, showing where and how many parts enter and exit the

1 2 3 4
1 0 10 0 40
2 0 0 0 0
3 50 0 0 20
4 0 50 0 0

14 List out the various coding systems widely used in industries. 13 BTL-1 Remembering
PART-C (15 Marks)
Q.No Questions Competence
1 Develop the form code (five digits) in the opitz system for the Flange BTL-6 Creating
coupling components.(take All dimensions are in mm).
2 What are exceptional elements and bottleneck machines? In what ways BTL-4 Analyzing
one can eliminate exceptional elements?
3 Explain the various machine cell design and layout with the neat BTL-4 Analyzing
Five machines constitute a GT cell. The From/To data for the BTL-5 Evaluating
machines are shown in the table below.
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 2 0 0
4 5 0 75 0 20 0
(a) Determine the most logical sequence of machines 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 percentage of in-sequence moves, bypassing moves
and back tracking moves in the solution. Develop a feasible
layout for the cell based on the solution.
Types of Flexibility - FMS – FMS Components – FMS Application & Benefits – FMS Planning and Control–
Quantitative analysis in FMS – Simple Problems. Automated Guided Vehicle System (AGVS) – AGVS
Application – Vehicle Guidance technology – Vehicle Management & Safety.
PART-A ( 2 Marks)
Questions Level
1 Define flexible manufacturing system. BTL-1 Remembering
2 List the components of FMS. BTL-1 Remembering
3 Identify any four functions of the material handling systems in a FMS. BTL-2 Understanding
4 Name the different types of layout configuration prevalent in FMSs BTL-1 Remembering
5 Differentiate between primary and secondary material handling systems. BTL-2 Understanding
6 List the capabilities for a manufacturing system must possess in order to be BTL-1 Remembering
7 Summarize some of the functions of a FMS computer system. BTL-4 Analyzing
8 Classify FMS based on number of machines. BTL-1 Remembering
9 List any two advantages and disadvantages of FMS implementation. BTL-1 Remembering
10 Mention the different types of data files required for a FMS. BTL-4 Analyzing
11 Differentiate between FMS and FMC. BTL-3 Applying
12 Illustrate the problems faced by FMS. BTL-3 Applying
13 Show how FMS classified does based on level of flexibility? BTL-4 Analyzing
14 Differentiate between dedicated FMS and random-order FMS. BTL-3 Applying
15 Analyze some important advantages of implementing FMS. BTL-4 Analyzing
16 Distinguish between rail guided vehicle and automated guided vehicle. BTL-2 Understanding
17 Assess how an AGV differs from Robot? BTL-4 Analyzing
18 Define vision enhancement. BTL-1 Remembering
19 Identify the various applications of AGVs. BTL-2 Understanding
20 State the factors that should be considered in selection of AGV. BTL-2 Understanding
PART-B (13 Marks)
Q.No Questions Marks Competence
1 (a) List the major components of an FMS. Explain them in 6 BTL-1 Remembering
(b) Describe the various workstations of FMS. 7
2 (a) Discuss the various aspects of FMS layout configurations. 6 BTL-1 Remembering
(b) Interpret the various functions that are performed by the 7
FMS computer control system.
3 Examine flexible manufacturing system. In what ways, FMS 13 BTL-2 Understanding
differs from other manufacturing systems?
4 (a) List the functions of the material handling system in a FMS 6 BTL-2 Understanding
(b)Explain the applications, advantages and disadvantages of a 7
5 Summarize with suitable sketches, explain the various FMS 13 BTL-2 Understanding
layout configurations prevalent today.
6 (a) Discuss the important of In-process monitoring of work 6 BTL-1 Remembering
piece quality in FMS.
(b) Express how is tool life monitored in FMS? 7
7 (a) Give principle of an automated storage and retrieval system. 6 BTL-4 Analyzing
(b) Discuss FMS optimization. 7
8 (a) Show distinguishing facts between FMS and FMC. 6 BTL-4 Analyzing
(b) Distinguishing facts between Dedicated FMS and Random- 7
order FMS.
9 Write short notes on the following. BTL-3 Applying
(i) Anti lock braking system. 4
(ii) Airbag 3
(iii) Seat belt 3
(iv) Child lock 3
10 (a) Illustrate short notes various material handling equipment 6 BTL-4 Analyzing
that are commonly found in a FMS.
(b) Analyze a case study on an AGVS. 7
11 (a) Explain AGV and its principle of operation. 6 BTL-3 Applying
(b) Explain various types of software in FMS. 7
12 Contrast extrinsic and intrinsic functions. Denote the factor to be 13 BTL-3 Applying
considered for implementing FMS.
13 Assess following types of AGVs along with their application Remembering
a. AGVs towing vehicles 13 BTL-1
b. AGVs pallet trucks
c. AGVs fork lift trucks
d. AGVs unit load transporters
14 Explain in detail about collision warning system. 13 BTL-4 Analyzing
PART-C (15 Marks)
1 Enumerate on the vehicle management system & vehicle safety deployed in BTL-4 Analyzing
the material handling system of the FMS.
2 Explain the main FMS operational issues to be considered and What types BTL-6 Creating
of quantitative analysis may be used with regard to FMS.
3 Discuss in detail about Vehicle and Equipment Guidance . BTL-5 Evaluating
4 Elaborate the purpose of traffic control in AGVS. Explain the various BTL-5 Evaluating
methods of traffic control employed.
Robot Anatomy and Related Attributes – Classification of Robots- Robot Control systems – End Effectors –
Sensors in Robotics – Robot Accuracy and Repeatability - Industrial Robot Applications – Robot Part
Programming – Robot Accuracy and Repeatability – Simple Problems.
PART-A (2 Marks)

Q.No Questions BT Competence

1 Define an industrial robot. BTL-1 Remembering
2 List the main functions of robot. BTL-2 Understanding
3 List out the importance of industrial robots. BTL-3 Applying
4 Define robot anatomy. BTL-1 Remembering
5 Identify the types of joints in an industrial robot . BTL-1 Remembering
6 Examine the term degrees of freedom. BTL-2 Understanding
7 Summarize the commonly used robot configuration system. BTL-2 Understanding
8 Mention the general application areas of robotics. BTL-3 Applying
9 Express various parameters while considering robot design. BTL-2 Understanding
10 Define the terms "SCARA" & "BRU". BTL-2 Understanding
11 Classify the different types of control techniques. BTL-3 Applying
12 Show the types of path control. BTL-4 Analyzing
13 Define work volume of a robot manipulator. BTL-1 Remembering
14 Define end effectors. Give some examples. BTL-1 Remembering
15 Classify the types of Grippers. BTL-4 Analyzing
16 Point out the basic classifications of sensors. BTL-5 Evaluating
17 Define the term Palletizing operation. BTL-2 Understanding
18 Express the methods of robot programming. What are the 2 types of Lead
BTL-3 Applying
through programming?
19 Define repeatability of robot. BTL-1 Remembering
20 What are the advantages and disadvantages of joint arm robot? BTL-1 Remembering
PART-B (13 Marks)
Q.No Questions Marks Competence
1 (a) List the different types of robotic movements. 6 BTL-1 Remembering
(b) Specify the types of joints used in robots and explain its 7
2 (a) List our four common robot configuration and explain its 6 BTL-5 Evaluating
(b) Name the relative merits and demerits of different types of 7
robot configuration.
3 (a) Describe the various types of industrial robot. 6 BTL-2 Understanding
(b) Describe the basic structure of a robotic system with neat 7
4 Identify and Draw the neat sketch of components of teach 13 BTL-2 Understanding
pendant and explain briefly.
5 (a)Describe the various types of robot control. 6 BTL-5 Evaluating
(b)Discuss briefly about the need for robots in industries. 7
6 (a)Express in detail robot anatomy and its related attributes. 6 BTL-2 Understanding
(b)Recognize the advantages, disadvantages and applications of 7
7 (a) Explain about the robot end effectors & classify them. 6 BTL-3 Applying
(b) Discuss various drive systems used for robot gripper. 7
8 Write short notes on types of robot part programming language. 13 BTL-1 Remembering
9 Classify the various types of gripper mechanism with neat 13 BTL-1 Remembering
10 (a)Explain briefly the lead through programming method in 6 BTL-5 Evaluating
(b)Indicate the capabilities and limitations of lead-through 7
programming methods.
11 Explain in detail robot language structure and motion commands 13 BTL-1 Remembering
12 Analyze a Program for pick and place robot. 13 BTL-4 Analyzing
13 Explain at least four languages meant for robot programming 13 BTL-3 Applying
and briefly discuss the features of any two of them.
14 (a)Specify principle of operation of teach pendent. 6 BTL-3 Applying
(b)Point out the limitations of teach pendent control. 7
PART-C (15 Marks)
Q.No Questions Competence
1 If your college or company operates a robotics laboratory, prepare a catalog BTL-6 Creating
of all of the robots in the lab in terms of their anatomy notations. (i.e) write
the notation scheme codes for all the robots in the lab.
2 Prepare a checklist of factors in the selection and design of grippers. BTL-4 Analyzing
3 Draw the diagram of the following robots using the notation scheme for BTL-5 Evaluating
defining manipulation configuration: (a) TRT (b) VROT (c) LVL
(d) TRT:R .
4 Describe various industrial robot and their applications in detail. BTL-4 Analyzing