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HKIE Professional Assessment - Manufacturing, Industrial & Systems Discipline study materials
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HKIE Professional Assessment - Manufacturing, Industrial & Systems Discipline practice questions

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Question 1Manufacturing Processes and Production Engineering

In a manual assembly cell, a task requires a standard time of 4.0 minutes. The cell operates 450 minutes per shift with a 12% allowance for personal time, fatigue and delays. What is the effective available time per shift for productive work?

  1. 450 minutes
  2. 54 minutes
  3. 504 minutes
  4. 396 minutes Correct answer.

Explanation

Allowance time is deducted from the gross shift time: 450 × (1 − 0.12) = 396 minutes. The allowance fraction applies to the total paid time, not to the standard task time.

Question 2Manufacturing Processes and Production Engineering

Which production layout groups machines of the same function (all lathes together, all milling machines together) and routes each job between departments?

  1. Product layout
  2. Cellular layout
  3. Process layout Correct answer.
  4. Fixed-position layout

Explanation

A process (functional) layout clusters similar equipment, so each job travels between departments according to its routing. It suits low-volume, high-variety work where flexible routing matters more than short transport distances.

Question 3Manufacturing Processes and Production Engineering

A machined shaft has a specification of 25.00 ± 0.05 mm. The process mean is 25.03 mm with a standard deviation of 0.015 mm. What is the process capability index Cpk?

  1. 0.44 Correct answer.
  2. 1.33
  3. 2.22
  4. 0.89

Explanation

Cpk is the minimum of (USL − mean)/3σ and (mean − LSL)/3σ. Here USL = 25.05 and LSL = 24.95, giving (0.02)/(0.045) = 0.44 and (0.08)/(0.045) = 1.78, so Cpk = 0.44. The off-centre mean is what limits capability.

Question 4Manufacturing Processes and Production Engineering

In a lean value-stream map, which activity is classified as necessary non-value-adding rather than pure waste?

  1. Storing castings for three weeks awaiting a furnace slot
  2. Moving parts between two buildings because of poor layout
  3. Reworking a joint that failed inspection
  4. Inspecting a weld under a code-mandated procedure Correct answer.

Explanation

Mandatory inspection adds no customer value but cannot currently be removed because a code or standard requires it, so it is necessary non-value-adding. The aim is to reduce its cost or frequency, not to eliminate it outright.

Question 5Manufacturing Processes and Production Engineering

A single-station machine has a mean time between failures of 200 hours and a mean time to repair of 8 hours. What is its availability?

  1. 92.6%
  2. 4.0%
  3. 96.2% Correct answer.
  4. 25.0%

Explanation

Availability = MTBF / (MTBF + MTTR) = 200 / 208 = 0.962, or 96.2%. MTTR is downtime, so it must be added to uptime in the denominator.

Question 6Manufacturing Processes and Production Engineering

During a shielded metal arc welding pass, the operator notices porosity clustered at the start of the bead. Which cause is most consistent with this location-specific defect?

  1. Inadequate gas shielding caused by a long arc at arc initiation Correct answer.
  2. Excessive travel speed along the whole bead
  3. Base metal sulphur content above specification
  4. Welding current set too low for the electrode diameter

Explanation

Porosity concentrated at the start typically comes from poor shielding during arc initiation, when the welder holds a long arc before settling. The remedy is correct arc striking and sufficient shielding gas or flux coverage at the start.

Question 7Manufacturing Processes and Production Engineering

Which statement correctly describes the difference between forward and backward scheduling in a job shop?

  1. Forward scheduling is used only for continuous processes; backward scheduling only for batch processes.
  2. Forward scheduling starts from the release date and projects completion; backward scheduling starts from the due date and works back to the latest start. Correct answer.
  3. Forward scheduling ignores capacity; backward scheduling always respects capacity.
  4. Forward scheduling loads work from the due date; backward scheduling loads work from today.

Explanation

Forward scheduling begins at the earliest possible start and calculates when the job can finish. Backward scheduling begins at the due date and calculates the latest permissible start, which highlights feasibility against the deadline.

Question 8Manufacturing Processes and Production Engineering

A lathe operation turns a 60 mm diameter bar at a cutting speed of 120 m/min. What spindle speed should be set, to the nearest rev/min?

  1. 2000 rev/min
  2. 1274 rev/min
  3. 637 rev/min Correct answer.
  4. 318 rev/min

Explanation

Spindle speed N = 1000V/(πD) = 1000 × 120 / (π × 60) ≈ 637 rev/min. Using diameter in millimetres requires the factor of 1000 to convert cutting speed from m/min.

Question 9Manufacturing Processes and Production Engineering

In a two-bin kanban system on a production line, what determines the size of each bin?

  1. The batch size fixed by the machine's setup time alone
  2. The maximum storage space available at the workstation
  3. The demand during the replenishment lead time plus a safety allowance Correct answer.
  4. The annual purchase order quantity for the part

Explanation

Each bin must cover consumption while the empty bin is being replenished, so its quantity reflects demand rate times lead time plus a buffer. Two bins then give a simple visual trigger for reordering.

Question 10Manufacturing Processes and Production Engineering

A manufacturer wants to reduce the risk of shipping nonconforming product while keeping inspection effort low. Which sampling approach best matches this objective?

  1. 100% inspection of every batch
  2. Zero acceptance number sampling with a defined AQL Correct answer.
  3. Random spot checks with no defined acceptance rule
  4. Skip-lot sampling based only on supplier reputation

Explanation

A defined sampling plan with an acceptance number and an agreed quality level gives a statistical, auditable decision rule at lower cost than full inspection. Zero acceptance plans are common where the consequence of a defect is severe.

Question 11Manufacturing Processes and Production Engineering

Which additive manufacturing characteristic most limits its use for high-volume production of a simple plastic bracket?

  1. Restriction to a single material family
  2. Low build rate per machine and high cost per part Correct answer.
  3. Inability to create internal channels
  4. Poor surface finish on all geometries

Explanation

Additive processes build parts layer by layer, so throughput per machine is low and unit cost stays high compared with moulding or stamping at volume. The technology's strength is complexity and low tooling cost, not mass output.

Question 12Manufacturing Processes and Production Engineering

A factory measures Overall Equipment Effectiveness. If availability is 0.90, performance is 0.85 and quality is 0.98, what is OEE?

  1. 0.91
  2. 0.83
  3. 0.68
  4. 0.75 Correct answer.

Explanation

OEE is the product of the three factors: 0.90 × 0.85 × 0.98 ≈ 0.75. Multiplying rather than averaging reflects that losses compound across availability, speed and quality.

Question 13Manufacturing Processes and Production Engineering

In a manufacturing cell, a worker operates three machines with cycle times of 2, 3 and 4 minutes per piece. What is the maximum output rate the worker can sustain when machine attention times are negligible?

  1. 12 pieces per hour
  2. 30 pieces per hour
  3. 15 pieces per hour
  4. 20 pieces per hour Correct answer.

Explanation

The bottleneck machine sets the cell rate: 4 minutes per piece gives 60/4 = 15 pieces per hour only if machines run in parallel. With one worker serving them sequentially, the combined attention cycle is 2+3+4 = 9 minutes, but the question states attention is negligible, so the slowest machine governs at 15 per hour.

Question 14Manufacturing Processes and Production Engineering

Which heat treatment is applied to a low-carbon steel to increase surface hardness while retaining a tough core?

  1. Full annealing
  2. Case carburising followed by quenching and tempering Correct answer.
  3. Stress relieving
  4. Normalising

Explanation

Carburising adds carbon to the surface layer, and subsequent quenching and tempering hardens that case while the low-carbon core stays tough. This combination suits gears and shafts needing wear resistance with shock tolerance.

Question 15Manufacturing Processes and Production Engineering

A production line runs at a takt time of 90 seconds. One station has a cycle time of 105 seconds. What is the most direct consequence?

  1. The takt time automatically adjusts to 105 seconds
  2. Inventory between stations falls to zero
  3. The line output is limited by the 105-second station Correct answer.
  4. The line output increases because the station is busy

Explanation

Takt time is set by customer demand, so a station exceeding it becomes the constraint and output falls below the required rate. The fix is to rebalance work from that station rather than to change takt.

Question 16Manufacturing Processes and Production Engineering

Which inspection method is best suited to detecting internal voids in a production aluminium casting without destroying it?

  1. Hardness testing
  2. Radiographic testing Correct answer.
  3. Visual inspection under magnification
  4. Dye penetrant testing

Explanation

Radiography passes penetrating radiation through the casting, and internal voids show as density differences on the image. It reveals volumetric internal defects that surface methods cannot reach.

Question 17Manufacturing Processes and Production Engineering

A company moves from a push system to a pull system. Which change in performance is most expected during stable demand?

  1. Lower work-in-progress with shorter lead times Correct answer.
  2. Lower work-in-progress with longer lead times
  3. Higher work-in-progress with shorter lead times
  4. Unchanged work-in-progress with higher throughput

Explanation

Pull systems authorise production only when downstream consumption occurs, which caps WIP and exposes bottlenecks. Lower WIP shortens queueing time, so lead time falls as well.

Question 18Manufacturing Processes and Production Engineering

Which factor most strongly justifies using a dedicated transfer line rather than a flexible machining cell?

  1. High variety with low volume per variant
  2. Frequent engineering change orders
  3. High volume of a stable product design Correct answer.
  4. Short product life cycles

Explanation

Transfer lines carry high fixed cost but very low unit cost when volume is high and the design is stable. Variety and change frequency erode that advantage by forcing rework of hard tooling.

Question 19Manufacturing Processes and Production Engineering

In a manufacturing context, which item is a leading indicator rather than a lagging indicator of quality performance?

  1. Percentage of operators current on required training Correct answer.
  2. Customer complaint rate last quarter
  3. Warranty claims cost for the year
  4. Scrap rate last month

Explanation

Training currency predicts future capability and can be acted on before defects occur, so it is a leading indicator. Complaint, scrap and warranty figures record outcomes after the fact.

Question 20Manufacturing Processes and Production Engineering

A stamped part shows splitting at the die radius during drawing of a low-carbon steel sheet. Which change is most likely to reduce the defect?

  1. Increasing the draw depth in a single stroke
  2. Increasing the punch speed sharply
  3. Increasing the blank-holder force Correct answer.
  4. Reducing the die corner radius

Explanation

Splitting at the die radius often follows excessive stretching from insufficient material restraint or poor lubrication. Increasing blank-holder force can improve control, but if splitting persists the usual remedies are a larger die radius and better lubrication.

Question 21Manufacturing Processes and Production Engineering

Which statement correctly distinguishes design for assembly from design for manufacture?

  1. DFA is performed after production launch; DFM is performed during concept design.
  2. DFA focuses on reducing part count and easing handling; DFM focuses on making each part easy to produce. Correct answer.
  3. DFA applies only to manual assembly; DFM applies only to automated assembly.
  4. DFA and DFM are different names for the same activity.

Explanation

DFA targets the assembly system, mainly through part-count reduction and handling simplicity. DFM targets the individual manufacturing processes, such as casting, moulding or machining feasibility.

Question 22Manufacturing Processes and Production Engineering

A work-sampling study makes 400 random observations of a machine and finds it idle in 80. What is the 95% confidence interval half-width for the proportion idle?

  1. About 0.01
  2. About 0.10
  3. About 0.04 Correct answer.
  4. About 0.20

Explanation

The estimated idle proportion is 0.20, and the half-width is 1.96 × sqrt(0.20 × 0.80 / 400) ≈ 0.039, or about 0.04. The interval widens with higher variability and narrows with more observations.

Question 23Manufacturing Processes and Production Engineering

Which maintenance strategy is most appropriate for a bearing whose failure pattern shows a clear wear-out region and whose replacement is inexpensive?

  1. Deferred corrective maintenance
  2. Condition monitoring with vibration analysis only
  3. Run to failure
  4. Preventive replacement before the wear-out region Correct answer.

Explanation

When a wear-out pattern is known and replacement cost is low, scheduled replacement before the wear-out region avoids unplanned downtime cheaply. Condition monitoring is more justified where failure is unpredictable or replacement is costly.

Question 24Manufacturing Processes and Production Engineering

Which of the following best explains why a Manufacturing Execution System differs from an Enterprise Resource Planning system?

  1. MES and ERP perform identical functions on different servers
  2. MES replaces the need for any quality management system
  3. MES manages real-time shop-floor execution and traceability; ERP manages enterprise-wide planning and finance Correct answer.
  4. MES plans long-range demand; ERP controls shop-floor equipment in real time

Explanation

An MES sits close to the equipment and tracks work orders, machine status and genealogy in real time. ERP operates at enterprise level for planning, purchasing, inventory and finance, and the two exchange data.

Question 25Manufacturing Processes and Production Engineering

A process has a stable mean but Cp = 1.0 and Cpk = 0.6. Which action addresses the dominant problem?

  1. Centre the process mean on the target Correct answer.
  2. Reduce common-cause variation
  3. Increase the specification limits
  4. Tighten the sampling frequency

Explanation

The gap between Cp and Cpk shows that the process is off-centre rather than excessively variable. Re-centring the mean raises Cpk toward Cp without needing to reduce spread first.

Question 26Manufacturing Processes and Production Engineering

A press tool is to blank 2.0 mm thick mild steel strip. Which die clearance practice is normally specified to obtain a clean sheared edge with minimal burr?

  1. Clearance of roughly 30 to 40 percent of sheet thickness per side
  2. Clearance equal to the punch diameter divided by the strip width
  3. Zero clearance so that the punch rubs the die wall
  4. Clearance of roughly 5 to 10 percent of sheet thickness per side Correct answer.

Explanation

In blanking and piercing of mild steel, the die opening is made larger than the punch by a clearance of about 5 to 10 percent of sheet thickness per side, which allows the crack from the punch edge and the crack from the die edge to meet and produce a clean fracture zone. Too little clearance causes secondary shearing, high punch load and heavy burring, while excessive clearance produces rollover, tearing and a ragged edge.

Question 27Manufacturing Processes and Production Engineering

A machining centre drills a 10 mm diameter hole 25 mm deep in a free-cutting steel at a feed of 0.15 mm/rev and a spindle speed of 1200 rev/min. What is the approximate material removal rate?

  1. About 2.4 cm3/min
  2. About 0.24 cm3/min
  3. About 14 cm3/min Correct answer.
  4. About 0.94 cm3/min

Explanation

For drilling, removal rate equals cross-sectional area of the hole multiplied by the axial feed speed. Area is pi times 5 mm squared, about 78.5 mm2, and feed speed is 0.15 mm/rev times 1200 rev/min, that is 180 mm/min, giving roughly 14 140 mm3/min or about 14 cm3/min.

Question 28Manufacturing Processes and Production Engineering

An engineer is selecting a welding process to join 6 mm thick aluminium plate in a production shop, and the priority is a stable, high-integrity arc with good cleaning action on the oxide layer. Which process choice is most appropriate?

  1. Alternating current gas tungsten arc welding with argon shielding Correct answer.
  2. Manual metal arc welding with a rutile electrode designed for steel
  3. Direct current electrode negative gas tungsten arc welding in air
  4. Oxy-acetylene gas welding with a carburising flame

Explanation

Aluminium carries a tenacious oxide film with a high melting point, so AC gas tungsten arc welding with argon is used because the electrode-positive half cycle gives cathodic cleaning of the oxide while the electrode-negative half cycle limits tungsten erosion and heat input to the work. This makes it a standard choice for 6 mm plate where arc stability and cleanliness matter.

Question 29Manufacturing Processes and Production Engineering

A CNC lathe is to finish-turn a slender shaft where deflection under cutting force is causing taper. Which measure most directly reduces the radial deflection during the finishing pass?

  1. Increasing the feed rate to shorten the time under load
  2. Increasing depth of cut so fewer passes are needed
  3. Reducing coolant pressure at the cutting zone
  4. Fitting a travelling steady to support the workpiece near the cutting zone Correct answer.

Explanation

Radial deflection of a slender shaft varies with the cube of the unsupported span, so a travelling steady placed close to the tool reduces the effective span and stiffens the workpiece where the force acts. This directly limits taper and vibration during finishing.

Question 30Manufacturing Processes and Production Engineering

A plant is choosing between a conventional press line and a hydraulic press for a deep drawing operation on stainless steel where the material tends to wrinkle and crack. Which combination of machine characteristics best supports robust deep drawing of this part?

  1. Maximum tonnage rating alone, with a mechanical crank drive and no cushion
  2. Short stroke length to maximise strokes per minute
  3. Programmable ram speed profile with independent, closed-loop control of blank-holder force through the stroke Correct answer.
  4. High ram speed with a fixed blank-holder force set once at setup

Explanation

Deep drawing success depends on controlling the balance between blank-holder force and punch force throughout the stroke, since the required holding force changes as the flange area shrinks and the material work-hardens. A hydraulic press with a programmable ram speed profile and a servo-controlled cushion allows the blank-holder force to be varied by position or force, suppressing wrinkling early in the stroke and preventing tearing near the end.

Question 31Industrial Engineering and Operations Research

In a work-measurement study, a worker completes a task in an average observed time of 4.0 minutes. The analyst rates the worker's performance at 110% and applies a 15% allowance factor. What is the standard time for the task?

  1. 5.60 minutes
  2. 4.60 minutes
  3. 5.06 minutes Correct answer.
  4. 4.40 minutes

Explanation

Standard time = observed time × performance rating × (1 + allowance). Here 4.0 × 1.10 = 4.40 minutes normal time, then 4.40 × 1.15 = 5.06 minutes. The allowance is applied to the normal time, not to the raw observed time.

Question 32Industrial Engineering and Operations Research

Which statement best describes the purpose of a control chart in statistical process control?

  1. It replaces the need for any product inspection before shipment
  2. It distinguishes between common-cause and special-cause variation in a process Correct answer.
  3. It sets the performance rating used in time studies
  4. It calculates the economic order quantity for purchased components

Explanation

A control chart plots a process statistic against statistically derived control limits so that stable common-cause variation can be separated from unusual special-cause signals. Its role is diagnosis of process stability, not the elimination of inspection or the calculation of inventory or work-measurement parameters.

Question 33Industrial Engineering and Operations Research

A production line has six sequential stations with reliabilities of 0.95 each, arranged in series with no redundancy. What is the approximate reliability of the whole line?

  1. 0.90
  2. 0.57
  3. 0.74 Correct answer.
  4. 0.95

Explanation

For components in series, overall reliability is the product of individual reliabilities: 0.95^6 ≈ 0.735, or about 0.74. Series reliability always falls below the reliability of the weakest single station.

Question 34Industrial Engineering and Operations Research

In the economic order quantity model, which cost components are balanced to determine the optimal order quantity?

  1. Set-up cost and scrap cost
  2. Transport cost and inspection cost
  3. Purchase price and labour cost
  4. Ordering cost and inventory holding cost Correct answer.

Explanation

The EOQ minimises total relevant cost by trading annual ordering cost, which falls with larger orders, against annual holding cost, which rises with larger orders. The optimum occurs where these two marginal costs are equal.

Question 35Industrial Engineering and Operations Research

A single-server queue has a mean arrival rate of 8 customers per hour and a mean service rate of 10 customers per hour, with Poisson arrivals and exponential service. What is the average number of customers in the system?

  1. 4.0 Correct answer.
  2. 0.8
  3. 5.0
  4. 2.0

Explanation

For an M/M/1 queue, utilisation ρ = λ/μ = 8/10 = 0.8, and the average number in the system L = ρ/(1 − ρ) = 0.8/0.2 = 4.0. The result must exceed the utilisation because customers also queue.

Question 36Industrial Engineering and Operations Research

Which of the following best defines takt time in a lean production system?

  1. The interval between successive preventive maintenance activities
  2. The time a machine takes to complete one cycle at full speed
  3. The total labour content of a product divided by the number of operators
  4. The available production time divided by customer demand rate Correct answer.

Explanation

Takt time sets the pace at which a product must be completed to match customer demand, calculated as available time divided by demand quantity. It is a demand-driven target, distinct from machine cycle time or labour content.

Question 37Industrial Engineering and Operations Research

A firm uses a fixed-order-quantity system with a reorder point of 250 units. Lead time demand averages 200 units with a standard deviation of 25 units. What safety stock is being held?

  1. 250 units
  2. 200 units
  3. 50 units Correct answer.
  4. 25 units

Explanation

Safety stock is the reorder point minus expected lead-time demand: 250 − 200 = 50 units. The standard deviation describes demand variability but is not itself the safety stock unless a service-level factor is applied.

Question 38Industrial Engineering and Operations Research

In a manufacturing context, which activity is the primary focus of method study?

  1. Auditing financial statements of a supplier
  2. Analysing and improving the way a job is performed Correct answer.
  3. Setting the wage rate for a production team
  4. Forecasting quarterly product demand

Explanation

Method study systematically examines how work is done in order to simplify, improve and standardise the method before times are set. Work measurement then quantifies the improved method.

Question 39Industrial Engineering and Operations Research

A process has a Cp of 1.33 and its mean is shifted 1.0 standard deviation above the target. Which conclusion is most defensible?

  1. The process standard deviation must be reduced before any shift correction
  2. The process spread is capable but the off-centre mean will raise defect rates Correct answer.
  3. The process is centred and fully capable
  4. Cp cannot be interpreted when a mean shift exists

Explanation

Cp measures potential capability based on spread alone, so 1.33 indicates adequate spread relative to tolerance. Because the mean is displaced, the actual capability index Cpk will be lower and defects will increase, so centring the process is the priority.

Question 40Industrial Engineering and Operations Research

Using the simple exponential smoothing formula F(t+1) = α·A(t) + (1 − α)·F(t), with α = 0.3, actual demand this period 120 and forecast this period 100, what is the forecast for next period?

  1. 106 Correct answer.
  2. 120
  3. 112
  4. 90

Explanation

Substituting gives 0.3 × 120 + 0.7 × 100 = 36 + 70 = 106. The forecast moves only part of the way toward the actual value because α is relatively low.

Question 41Industrial Engineering and Operations Research

A company faces annual demand of 9,000 units, an ordering cost of $50 per order and a holding cost of $4 per unit per year. What is the economic order quantity?

  1. 474 units Correct answer.
  2. 1,500 units
  3. 300 units
  4. 225 units

Explanation

EOQ = sqrt(2DS/H) = sqrt(2 × 9,000 × 50 / 4) = sqrt(225,000) ≈ 474 units. The square-root form shows that order quantity rises with the square root of demand.

Question 42Industrial Engineering and Operations Research

In a linear programming formulation for a production mix problem, a slack variable with a positive value in the optimal solution indicates what?

  1. The corresponding product is unprofitable to make
  2. The objective function is unbounded
  3. The corresponding resource constraint is not fully used Correct answer.
  4. The solution is infeasible

Explanation

A slack variable measures unused capacity in a less-than-or-equal constraint. A positive slack at optimum therefore means that resource has surplus capacity and is not binding.

Question 43Industrial Engineering and Operations Research

A factory operates 480 minutes per shift, produces 240 units per shift, and customer demand is 300 units per shift. What is the takt time?

  1. 1.25 minutes per unit
  2. 1.6 minutes per unit Correct answer.
  3. 0.625 minutes per unit
  4. 2.0 minutes per unit

Explanation

Takt time = available time / customer demand = 480 / 300 = 1.6 minutes per unit. Current output of 240 units is below demand, so the line is not keeping pace with takt.

Question 44Industrial Engineering and Operations Research

In a single sampling plan, which change would increase the probability of accepting a lot with a given fraction defective?

  1. Decreasing the acceptance number while holding sample size constant
  2. Increasing the acceptance number while holding sample size constant Correct answer.
  3. Reducing the lot size while holding sample size and acceptance number constant
  4. Increasing the sample size while holding the acceptance number constant

Explanation

Raising the acceptance number allows more defectives in the sample before rejection, so the operating characteristic curve shifts and the probability of acceptance rises for the same incoming quality. Increasing sample size with a fixed acceptance number has the opposite effect.

Question 45Industrial Engineering and Operations Research

A planned maintenance policy replaces a component at fixed intervals regardless of its condition. Which statement about this policy is correct?

  1. It is the same as condition-based maintenance
  2. It may replace healthy components, incurring avoidable cost Correct answer.
  3. It requires continuous vibration monitoring
  4. It eliminates all unplanned failures

Explanation

Fixed-interval replacement is time-based and ignores actual condition, so serviceable items are discarded and their remaining life is wasted. It reduces but does not eliminate random failures between replacements.

Question 46Industrial Engineering and Operations Research

In the context of facility layout, which layout type is most appropriate for high-volume, low-variety production?

  1. Process layout
  2. Product layout Correct answer.
  3. Fixed-position layout
  4. Cellular layout

Explanation

A product layout arranges equipment in the sequence of operations for a standardised product, which suits high volume and low variety. Process layouts group similar machines and suit low volume with high variety.

Question 47Industrial Engineering and Operations Research

Which of the following is a defining characteristic of a Just-in-Time production system?

  1. Producing items only as they are needed by the next process Correct answer.
  2. Scheduling production in large batches to gain economies of scale
  3. Maintaining large buffer stocks between all work centres
  4. Inspecting quality only at the final assembly stage

Explanation

JIT pulls material through the process in response to downstream need, so production is triggered by consumption rather than by forecast. This exposes problems and reduces inventory, but it depends on stable quality and reliable supply.

Question 48Industrial Engineering and Operations Research

A workstation produces 60 units in a 7.5-hour shift including a 30-minute planned break. What is the available time per unit, expressed as cycle time?

  1. 6.5 minutes per unit
  2. 8.0 minutes per unit
  3. 7.0 minutes per unit Correct answer.
  4. 7.5 minutes per unit

Explanation

Available time is 7.5 hours minus 0.5 hour of break, or 7.0 hours = 420 minutes. Dividing 420 minutes by 60 units gives 7.0 minutes per unit.

Question 49Industrial Engineering and Operations Research

In a Six Sigma DMAIC project, at which stage would a cause-and-effect diagram most typically be constructed?

  1. Define
  2. Measure
  3. Analyse Correct answer.
  4. Control

Explanation

The Analyse phase investigates root causes of variation identified in the Measure phase, and tools such as cause-and-effect diagrams and hypothesis tests are used there. Define sets the charter and Control sustains the gains.

Question 50Industrial Engineering and Operations Research

A project has the following activity durations on its critical path: A = 4 days, B = 6 days, C = 5 days. Activity B has a most likely duration of 6 days, an optimistic duration of 4 days and a pessimistic duration of 14 days. Using PERT expected duration for B, what is the revised critical path length?

  1. 18 days
  2. 16 days Correct answer.
  3. 15 days
  4. 17 days

Explanation

PERT expected duration = (O + 4M + P)/6 = (4 + 24 + 14)/6 = 7 days for B. Replacing 6 with 7 gives 4 + 7 + 5 = 16 days. The weighted average pulls the estimate above the most likely value because the pessimistic estimate is far out.