OM & SM by CA PRAVEEN BAFNA

CHAPTER – 3
DESIGNING OF OPERATIONAL SYSTEM & CONTROL
2015 – June

Q.1. “The design of product is crucial to success in to day’s global competition”. Justify the statement by
providing the features of an excellent product design. [5]
Q.2. How do you distinguish among Product Design. Process Design and Production Design? [3]

2017 – June

Q.3. Discuss the term “Process Strategy”. What does it involve? [3+3=6]

2017 – Dec

Q.4. Discuss about the following process types to be implemented by a Production Manager as a
strategy:
a. Batch process
b. Repetitive process [3+4=7]

2018 – June
Q.5. “Virtually all goods or services are made by using some variation of one three process Strategies”.
Discuss about each of the three process strategies. Also state the situation during the decline stage
of a product life cycle. [2x3 + 2 = 8]
2018 – Dec
Q.6. What are the various activities and responsibilities of product design? [6]

2019 - June

Q.7. Examine the following types of Process decisions:

a. Job shop process
b. Project process [6]

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CHAPTER - 4
PRODUCTION PLANNING & CONTROL
2010 – June
Q.1. What is Degeneracy in a simplex LPP? How is it resolved? [2+2=4]
Q.2. Briefly explain “Flow control” as a basic type of Production Control. [2]

2010 – Dec
Q.3. Please describe the situation where ‘Assembly Line Balancing’ is required. What are the factors that
cause problems in Line Balancing? Suggest the steps in solving the issue. [2+2+3=7]

2011 – Dec
Q.4. Explain what is a Slack Variable under Simplex Method of Linear Programming. [2]

2012 – Dec
Q.5. What are the three methods mainly used for finding the optimal solution for a given linear
programming problem? [3]

2014 – June
Q.6. List down various phases of the simulation process. [2]

2014 – Dec
Q.7. Answer the question:
a. List the advantages of method study. [6]
b. Write a sentence or two on each of the various methods applied for finding the optimal
solution for a given linear programming problem. What is ‘non-negativity condition’?
[4+1=5]
c. Classify the functions of Production Planning & Control. [9]
d. What are the managerial considerations in Scheduling? [3]

2015 – June
Q.8. With reference to Time Study. Define the terms
(a) Relaxation Allowance (b) Contingency Allowance (c) Process – Allowance by providing
appropriate examples. [2x3=6]

2015 – Dec
Q.9. Define simulation and identify its four phases. [2+2=5]
Q.10. Define Work Measurement. [3]

2016 – June
Q.11. Name the activity denoted by the following standard symbols used in Process Charting: (i) O (ii) ⟹. [2]
Q.12. ‘The principles of motion economy are divided into three groups.’ List the three groups. [2+3=5]

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2016 – Dec.
Q.13. Describe the areas of Production Planning and Control. [8]
Q.14. List the objectives of scheduling in an organization. [5]

2018 – June
Q.15. Discuss the principles of scheduling. Explain briefly the relationship between routing and scheduling.
[6+2=8]
2018 – Dec.
Q.16. Describe the objectives of Production Planning and Control. [10]

2019– June
Q.17. Describe the different types of Production Control. [10]

PRACTICAL QUESTION
2011 – Dec.
Q.18. Draw the schematic diagram for the following table showing tasks to be performed on an assembly
line the sequence and time specified: [3]
Task Time (Seconds) Tasks that must precede
A 50 .
B 40 .
C 20 A
D 45 C
E 20 C
F 25 D
G 10 E
H 35 B, F, G

Ans.: 45 25
D F
50 20 35
A C H
20 10
E G
40
B

2013 – June
Q.19. A company manufactures two items X1 and X2. They are sold at a profit of Rs.30 per unit of X1 and Rs.20
per unit of X2. X1 requires 2 kg. of materials, 3 man hours and 1 machine hour per unit. X 2 requires 1 kg
of material, 2 man hours and 3 machine hours per unit.
During each production run there are 280 kg of material available, 500 labour hours and 420 hours of
machines used. Please introduce the slack variables and write down the equations, including the

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objective function, that will and write down the equations, including the objective function, that will
determine the quantity of production of the two items to maximize profits. [4]
Ans.
The equation can be developed as under for introducing slack variable S1, S2 and S3. Objective
function is
Maximise Z = 30X1 + 20X2 + OS1 + OS3
Subject to the constraints
X1, X2, S1, S2, S3 = 0

2014 – Dec.
Q.20. An industrial Engineer, appointed to conduct a time-study for a job has after observation, divided the
job into 5 elements. He had noted the timing for four cycles of the job as below:
Element Time in minutes Performance
Cycle 1 Cycle 2 Cycle 3 Cycle 4 rating (%)
1 1.327 1.254 1.351 1.269 85%
2 0.983 1.854 0.882 0.956 95%
3 1.894 1.821 1.928 1.963 100%
4 2.569 2.173 2.132 2.285 120%
5 1.358 1.139 2.561 1.438 100%
a. Are there any outliners in the data i.e. probable errors in reading or recording data which
should not be included in the analysis?
b. Compute the basic time for the job. Also compute the standard time if a relaxation
allowance of 13%, a contingency allowance of 4% and an incentive of 25% are applicable
for the job. (1+6=7)
[Ans. a. The times for element no.2 in cycle 2 and for element no.5 in cycle 3 are suspect and should
be disregarded as they very much as compared with time values for these elements in other cycles.
b. Calculate of standard time = 9.313 minutes; Incentive scheme = 11.641 minutes]

Q.21. In a simulation operation, a firm’s maintenance person received requests for service and provided
service during an 8 hour period as shown below:
Request Arrival Time (Clock Time) Service Time (Hours)
0 1.00
0.3 1.00
2.00 1.50
3.00 1.50
6.30 0.50
The maintenance labour cost is Rs.150 per hour, and the delay time cost is Rs.500 per hour Find:
a. The idle time cost for the maintenance person and
b. The delay time cost for the machinery. [5]
[Ans. a. Idle time cost for maintenance crew = 2.5x150=Rs.375
c. Delay time or waiting time = 1.0 hour; Delay time cost for the machinery = 1.0x500=Rs.500]

2015 – June
Q.22. The time study of a machinery operation recorded average cycle time of 9.0 minutes. The analyst
rated the observed worker as 90%. The firm uses a 0.15 allowance fraction. Compute the standard
time. [2]

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[Ans. Standard Time = 9.53 minutes]
2015 – Dec.
Q.23. Calculate the standard time per article produced from the following data obtained by a work
sampling study; [7]

Total No. of observations 2597

No. of working observations 2000
No. of unit produced in 100 hours duration 5000 numbers
Proportion of manual labour 3/4
Proportion of machine time 1/4
Observed rating factor 120%
Total allowances 15% of normal time.
[[Link] labour time per unit = 0.9563 minute; Standard time per unit of article produced = 1.187
minute]
Q.24. The work-study engineer carries out the work sampling study for 120 hours. The following observation
were made for a machine shop.
Total number of observations 7000
No. of idle activities 1200
Ratio between manual to machine elements 3:1
Average rating factor 120%
Total number of job produced during study 800 units
Rest and personal allowances 17%
Compute the standard time for the job. [6]
[Ans. Standard time per piece = 10.04 minutes]

2016 – June
Q.25. Calculate the standard production per shift of 8 hours duration, with the following data : [6]
Observed time per unit = 5 minutes, Rating Factor – 120%, total Allowances = 30% of normal time.
[Ans. Standard time per unit = 7.8 minutes/units; Standard production in shift of 8 hours = 61.538 units]

2017 – June
Q.26. A Bakery shop sells bakery items. Past data of demand per week in hundered kilograms with frequency
is given below:
Demand/week 0 6 12 18 24 30
Frequency 1 12 19 8 6 4
Using the following sequence of random numbers, generate the demand for the next 10 weeks. Also
find out the average demand per week: [10]
Random 12 27 18 58 43 75 31
numbers
62 47 35 53 42 68 71
[Ans. Average weekly demand = 11.4]
Q.27. An incentive scheme allows proportionate production bonus beyond 100% performance level.
Calculate the amount of
a. Incentive bonus of
b. Total payment received by an operator on a particular day during which the following
particular apply:
Operation : Assembling a table clock set
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Work content : 40 Standard minutes per assembled set
Attended Time : 8 hours
Time spent on unmeasured work : 3 Hours
Number of sets assembled during the day : 10
Wage rate : Rs.5 per hour
c. What is the net labour productivity achieved by the operator during the day? [2x3=6]

2017 – Dec.
Q.28. The below Table shows the time remaining (number of days until due date) and the work remaining
(number of days’ work) for5 jobs which were assigned the letters A to E as they arrived to the shop.
Sequence there jobs by priority rules viz.
(i) FCFS (ii) EDD (iii) LS (iv) SPT (v) LPT [2x5=10]
Job Number of days until due date Number of days’ work remaining
A 9 5
B 4 7
C 5 3
D 6 6
E 8 2
[Ans. (i) FCFS = ABCDE (ii) EDD = BCDEA (iii) LS = BDCAE (iv) SPT = ECADB (v) LPT = BDACE]

Q.29. A department works on 8 hours shift, 285 days a year and has the usage data of a machine as given
below;
Product Annual demand (units) Processing time (standard time
in hours)
A 360 7.0
B 435 5.0
C 570 6.0
Calculate:
1. Processing time needed in hours to produce products A, B and C.
2. Annual production capacity of one machine in standard hours and
3. Number of machines required [2x3=6]
[Ans. (i) The Processing time needed = 8,115 hrs.; (ii) Annual Production = 2,280 hours/year (iii) Number
of machine = 4 Machines ]

2018 – June
Q.30. A blacksmith supervisor in his workshop is considering how he should assign the four jobs that are to be
performed, to four of the workers under him. He wants to assign the jobs to the workers such that the
aggregate time to perform the jobs is the least. Based on previous experience, he has the information
on the time taken by the four workers in performing these jobs and the same is given in the table
below:
Time Taken (in minutes) by 4 workers
Worker Job
A B C D
1 46 40 51 68
2 57 42 63 55
3 49 53 48 64
4 41 45 61 55
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Solve the assignment problem for optimal solution using Hungarian method: [8]
[[Link] final patter of assignments is 1-B, 2-D, 3-C and 4-A involving a total time of 40+55+48+41=184
minutes. This is the optimal solution to the problem]

2018 – June
Q.31. At a toll service centre, the arrival rate is 3 per hour and the service potentials 4 per hour. Simple queue
conditions exist. The hourly wage paid to the attendant at the service centre is Rs.2 per hour and the
hourly cost of a machinist away from his work is Rs.5.
Calculate;
a. The average number of machinists being served or waiting to the serviced at any given time.
b. The average time a machinist spends waiting for service.
c. The total cost of operating the system for an eight-hour day.
d. The cost of the system if there were two attendants working together as a team, each paid
Rs.2 per hour and each able to service on average 3 per hour. [2x4=8]
Q.32. The following jobs have to be shipped a week from no (week has 5 working days)
Job A B C D E F
No. of day’s work remaining 4 5 8 7 6 3
Sequence the jobs according to priority established by;
a. Least slack rule
b. Critical ratio rule [4x2=8]
[Ans. (I) Least Slack Rule Sequence = C D E B A F; (ii) Calculation of Critical Ratio = C D E B A F]

2018 – Dec.
Q.33. Find initial Feasible Solution by ‘North-West Corner Method.
W1 W2 W3 W4 Supplies
F1 47 59 55 57 150
F2 44 54 52 59 270
F3 49 65 59 61 370
F4 51 63 54 60 230
Demand 210 330 260 220
Wj -> Warehouse
Fj -> Factory and
Cell entries are unit costs. [6]

Q.34. A departmental store is running a snack items selling outlet. Past data of snack items’ demand per
week in hundered kgs with frequency is given below;
Demand/week 0 6 12 18 24 30
Frequency 3 10 9 20 6 2
Using the following sequence of random numbers generate the demand for next 10 weeks. Also find
out the average per week. [10]

Random 21 34 48 97 72 31 45 56
numbers
47 37 82 44 67 75 63

2019 - June
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Q.35. A period consists of four major jobs, for which four contractors have submitted tenders. The amounts, in
thousands of Rupees are given below;
Contractor Jobs
A B C D
1 110 98 75 95
2 85 95 115 65
3 105 135 125 98
4 95 95 75 95
Find the assignment, which minimizes the total cost of the Project. Each contractor has to be assigned
one job. [8]
Ans. The Optimal assignment is:
Contractors Job Cost(in thousands of rupees)
1 C 75
2 D 65
3 A 105
4 B 95
Hence, total minimum cost of project will be Rs.3,40,000.

Q.36. Table shows the time remaining (number of days until due date) and the work remaining (number of
days still required to finish the work) for 5 jobs which were assigned the letters A to E as they arrived to
the shop. Sequence these jobs by priority rules viz. (u) FCFS (ii) EDD (iii) LS (iv) SPT (v) LPT. [10]
Job Number of days until due date Number of days of work
remaining
A 10 8
B 4 5
C 8 7
D 11 4
E 5 9
[Ans.(i) FCFS = A B C D E (ii) EDD = B E C A D (iii) LS = E B C A D (iv) D B C A E (v) E A C B D]

2019 – Dec.

Q.37. Find initial Feasible Solution by ‘North-West Corner Method.

W1 W2 W3 W4 Supplies
F1 10 12 14 18 210
F2 25 19 21 30 330
F3 18 16 11 23 430
F4 28 34 17 15 290
Demand 270 300 320 280
Wj -> Warehouse
Fj -> Factory and
Cell entries are unit costs in Rs.. [8 ]

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