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There are 6 different questions Check the file below for all the questions and requirements null_1.pdf Unformatted Attachment Preview CW2 Online Assignment Programme: BEng CAME/POM/COE/EPE/EIE/TE Module Title: Industrial Studies Module Code: MHH624713 Student No. 140444 Question 1: A local company located in Nizwa assembles engines for customized trekking sport utility vehicle SUV. During the year end 2019 financial review, the company is concerned with its bloated inventory cost for the past five years. The profitability of the company has been declining year on year due to the effect of the increasing inventory costs. The newly hired manager who is a mechanical engineer is tasked to look into this matter and will provide a comprehensive proposal report to the company CEO to reduce the bloating inventory cost. The current consumption or usage of parts of the assembly department is shown in Table Q1. This data shows the typical annual usage or consumption of component parts for its engines. He found out that there is big mismanagement or neglect of the company inventories. Currently, the company is ordering parts from its suppliers locally and abroad once every three months. (i) Develop an ABC analysis for the companys inventories. Show completely the results in tabular form using excel. [6] (ii) Create a PARETO analysis for the ABC analysis using excel [4] (iii) Considering your class A inventories, determine the economic order quantity EOQ using the following assumptions; zero safety stock for each class A inventories, stocking cost is 10\% of the unit price, ordering cost for any class A inventories is 120 OMR per order. Determine the cost savings if EOQ is followed instead of the current ordering system of the company which is once every three months for class A inventories [6] Table Q1: Annual Usage of Component Parts Part Number 111D 128H 196G 205Y 216U 217J 228G 235D 249E 258L 261K 272J 324H 333C 334U 352S 391J 421A 432S 436S 452F 462R 463H 478L 521I 532Q 610B Annual quantity (unit) 31,821 49,199 7,172 2,854 2,950 3,150 824 62,381 13,268 2,131 19,503 4,195 21,997 2,136 7,507 12,126 2,120 4,087 4,526 72,560 3,253 3,937 2,532 26,766 2,764 1,061 28,741 Unit cost (OMR/unit) 1.00 0.50 22.40 270.00 12.80 122.40 98.40 1.80 6.30 62.40 1.20 9.00 1.50 15.40 24.00 19.20 51.60 9.60 7.60 0.25 13.50 16.80 132.00 1.20 13.80 144.00 5.10 [Total 16 marks] Question 2: (a) A Muscat Tools company manufactures toolkits and supplies to the local and overseas market within the GCC region. In the assembly line, the kits are packed in the tool boxes. The company produces the specified demand rate of toolkit in 8 hours per day with tasks, description of tasks, and time for each task shown in Table Q2a. (i) Draw the precedence diagram and determine the cycle time, and number of workstations; [5] iii) Balance the line using the longest task time rule, and determine the line efficiency. [5] Table Q2(a) Demand rate (units/day) 1225 Task Description Time (sec) Predecessors A Open tool box and place on assembly line 15 - B Place spanner in tool box 9 A C Place spark plug spanner in tool box 7 A D Place screw driver in tool box 7 A E Close internal lid 7 B, C, D F Place jack in tool box 18 E G Place jack handle in tool box 6 E H Place polishing cloth in tool box 7 E I Close tool box 10 F, G, H J Shrink wrap tool box 21 I (b) A company is unable to satisfy customer demand for one of their products. The ratios for mixing the outputs from processes C, D and E are 2, 1 and 1 respectively. The ratio for the departments F and G is 3 and 1, and the ratio for departments H and I is 4 and 1. Using Table Q2(b), Determine; (i) The system capacity and bottleneck; [4] (ii) How much system capacity can be gained by adding capacity to the bottleneck [2] Table Q2(b) Department Capacity (liters/hour) Predecessors A B C D E 450 450 350 250 250 A B - F G H I J K 750 300 950 350 1100 1400 C, D and E F, and G H and I J [Total 16 marks] Question 3: (a) KANJAR Company is a manufacturer of light aircraft components in Oman. For the past two years of operation, the company is experiencing production backlog. A number of its customers are complaining for long delays of deliveries. This backlog is hurting the competitive advantage and the profitability of the company. In order to address this issue, the operation manager decides to implement the following possible alternatives; production overtime, subcontracting, and possible hiring of additional workers if necessary. The company always prepares a nine-month aggregate plan to decide the optimum way to determine requirements for planning purposes, although this is modified when the demand requirements change. The estimated demand for a particular unit for the period January through September is given in Table Q3(a). The current workforce is based on the production level in the previous December. Operating data are given in Table Q3(b). Requirement: (i) Develop an aggregate plan AP based on level capacity strategy specified for the planning period.Subcontract to meet a 100\% service level every month and no overtime, no hiring, and no termination. Show graphically the demand forecast, actual production output, and ending inventory in single graph. Determine the total production cost for the specified period. [7] (ii) Table Q3(c) shows the demand orders of aircraft component of a local customer from January to September. Develop a master planning schedule MPS, assuming production lot size of 800 units, and beginning inventory intended for the particular customer is 150 units. In your MPS indicate the projected available balance PAB and the MPS per month. [3] Jan 1,935 TableQ3(a): Veatch Company Estimated demand for a product Feb Mar April May June July 2,000 2,250 2,125 2,450 2,700 2,250 August 1,900 Sep 1,650 Table Q3(b): Veatch Company Operating data Items Amount Initial inventory (units) 400 Stockout costs (OMR/unit) 125 Carrying cost, (OMR/unit/month) Hiring cost per unit (OMR/unit) Termination cost per unit (OMR/unit) 30 70 85 Subcontract cost (OMR/unit) 85 Production units the previous December In-house production cost, (OMR/unit) 1,500 75 Labor hours/ unit 3.2 Workweek (hours) 40 Weeks/month 4 Table Q3(c): Veatch Company Operating data Jan Feb Mar April May June July August Sep 400 450 450 550 600 650 700 750 800 (b) Salalah Electro-Mechanical Company manufactures a product PQR345. The product PQR345 consists of two PQ890 assemblies, three QR432 assemblies and one PR678 assembly. The PQ890 assembly consists of one P456, two Q921 and one Q239. The QR432 assembly consists of three P456, one R478 and two S590. (i) Prepare a Bill of Material (BOM) product tree for the product PQR345. [2] (ii) Using Table Q3(b)-1 and Table Q3(b)-2 complete the Material Requirements Planning (MRP) calculations to determine when the Purchase Orders should be placed for item S590. Note: The product PQR345 are being sold complete as well as the spare parts (e.g. items QR432, PQ890, R478 etc) are being sold separately also. [4] Week PQR345 QR432 10 70 100 11 50 - Table Q3(b)-1 12 120 - 13 60 250 14 90 - 15 100 150 16 40 100 Table Q3(b)-2 Item Lead Time (Weeks) On Hand PQR345 QR432 S590 1 2 2 200 200 700 Batch Size Safety Stock 200 300 600 0 150 350 [Total 16 marks] Question 4: (a) The Marino Company in Ventura County, southern California sells swimming pool equipment. The sales for swimming pool motors in southern California over the last 12 months is given in Table Q4(a). Forecast the demand from March to December of the current year using the following forecasting models. Use excel for the tabulation. (i) Three-month simple moving average; [2] (ii)Three-month weighted moving average. Use 0.7, 0.2, and 0.1 for the weights, with 0.7 for the most recent period, and 0.1 for the oldest period. [3] (iii) Simple linear regression; [3] (iv) Determine the MAD, and SE for all the models, and choose which model is most appropriate. [2] Table Q4(a) Marino Company Sales of Swimming pool motors Month Quantity (units) 11,560 January 14,477 February 16,912 March 10,143 April 15,476 May 17,128 June 11,895 July 14,945 August 17,659 September 12,170 October 14,314 November 16,824 December (b) Oman Steel Company is currently having five jobs to be completed in details of which is given in Table Q4(b) . Using the following priority rules determine the order in which the jobs given in Table Q4(b) should be processed using the following rules; (i) Critical ratio [2] (ii) Least amount of Slack per operation [2] (ii) Johnson’s rule [2] Table Q4(b) Jobs (in the order they arrived) Days until due date R S T U V 4 9 5 7 6 Remaining processing time (days) Cutting 1 3 3 5 3 Drilling 2 2 4 3 1 [Total 16 marks] Question 5: (a) For a compressor the probability of failure occurring during a given week is given in Table Q5(a). (i) Calculate the Annual Breakdown Maintenance Costs (where no Preventive Maintenance is carried out). The costs are 300 OMR to repair the compressor, every time it fails. [3] (ii) Preventive maintenance costs 60 OMR for each service. Calculate if Preventive Maintenance is cheaper than Breakdown Maintenance, and if so how often Preventive Maintenance should be carried out. There are 48 Table Q5(a) Week of Operation Probability of failure during the given week 1 2 3 4 5 0.00 0.12 0.13 0.30 0.45 (b) In a conventional production, operations of turning, splines cutting and grinding are followed in sequence to produce splined shaft for gear boxes and lathe, milling and grinding machines are used for the operations. The reliability of the lathe, milling machine and grinder are 0.89, 0.87 and 0.93 respectively. It has been suggested that to improve reliability two identical machines could be used at each stage. If one fails the other can be used while the first one is being repaired. Another suggestion has been put forward to buy a CNC machining center with a reliability of 0.90 which will do the functions of the lathe and the milling machine. Calculate the system reliability for each of the 3 layouts and decide which is the most reliable. [4] Figure Q5(b): Splined shaft (c) Sur Power & Utility company is considering to replace the existing high power ammonia compressor with a new one. Maintenance records show the relative frequency of the compressor for 300 week period is given in Table Q5(c)-1. (i) Use Monte Carlo Simulation, the probability distributions and the random numbers given in Table Q5(c)-2, to simulate the breakdowns which occur in the next 25 week lifespan. Calculate the average number of breakdowns. Decide which blower will have the better reliability if the new blower is expected to have an average one(1) breakdown per week. [7] Table Q5(c)-1 Number of Breakdowns Number of Weeks 0 1 2 3 4 96 75 63 42 24 18 48 44 22 42 67 3 63 20 36 Table Q5(c)-2 81 4 59 39 4 67 66 33 2 95 25 91 46 43 2 [Total 16 marks] Question 6: (a) Applying the various motivation theories in human resource management, make a necessary recommendations to motivate the personnel in the following scenarios. Write at least 100 words for each scenario. (i) An experienced and senior technician of an Oil and Gas company who has been in the workforce for almost 25 years is already performing very poorly in the maintenance department. [4] (ii) A newly hired Mechanical engineer as companys Deputy Manager Production of Lube Oil department. [4] (b) Discuss briefly the importance of Training and Development in reducing staff turnover in the organization. Provide at least two examples to support your answer. [4] (c) Develop a simple FMECA for a high capacity centrifugal pump used in waste water treatment plant. Provide at least three failure modes, cause of failures, failure effects, detection techniques, and the corresponding occurence, detection, and severity, and RPN, and preventive actions. [8] [Total 20 marks] End of the question paper ... Purchase answer to see full attachment