Académique Documents
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2001
PI: Production and Industrial Engineering
Duration: Three Hours Maximum Marks: 150
Read the following instructions carefully
1. This question paper contains TWO SECTIONS: ‘A’ and ‘B’.
2. Section ‘A’ consists of two questions of the multiple-choice type. Question 1
consists of TWENTY FIVE sub-questions of ONE mark each and Question 2
consists of TWENTY FIVE sub-questions of TWO marks each.
3. Answer Section ‘A’ only on the special machine-gradable OBJECTIVE
RESPONSE SHEET (ORS). Questions of Section A will not be graded, if
answered anywhere else.
4. Answer problems of Section ‘B’ in the answer-book.
5. Write your name, registration number and name of the Centre at the specified
location on the right half of the ORS for Section ‘A’.
6. Using a soft HB Pencil, darken the appropriate bubble under each digit of
your registration number.
7. The objective response sheet will be collected back after 120 minutes have
expired from the start of the examination. In case you finish Section ‘A’
before the expiry of 120 minutes, you may start answering Section ‘B’.
8. Questions of Section ‘A’ are to be answered by darkening the appropriate bubble
(Marked A, B, C or D) using a soft HB pencil against the question number on the
left hand side of the Objective Response Sheet.
9. In case you wish to change an answer, erase the old answer completely using a
good soft eraser.
10. There is no negative marking.
11. Section ‘B’ consists of TWENTY questions of FIVE marks each. ANY FIFTEEN
out of them have to be answered. If more numbers of questions are attempted,
cancel the answers not to be evaluated, else only the first fifteen answers would
be considered strictly.
12. In all 5 marks questions, clearly show the steps. Steps carry partial marks.
2 Elite Academy GA/QB/PI−III
SECTION - A
(75 Marks)
PI-1. This question consists of TWENTY FIVE sub-questions (1.1-1.25) of ONE mark
each. For each of the sub-questions four possible answers (A, B, C and D) are
given, out of which only one is correct. Answer each sub-question by darkening
the appropriate bubble on the OBJECTIVE RESPONSE SHEET (ORS) by using
a soft HB pencil. Do not use the ORS for any rough work. You may like to use
the answer book for any rough work, if needed. [25 x 1 =25]
1.1 The order of matrix to solve the system of linear equations with variable x, y, z
and having the form a i x + b i y + c i z + d i = 0 is given by:
(A) 4 x 4 (B) 3 x3 (C) 3 x 4 (D) 4 x 3
5 3
1.2 Two vectors called {P} and {Q} are given as , respectively. The product
2 6
∂u ∂ 2u
1.3 A differential equation of the form = a 2 2 can be used to represent:
∂t ∂x
(A) Vibration of a string (B) Propagation of heat
(C) Steady state diffusion of gas (D) All of these
3 n e −3
1.4 Mean value of the distribution , for n = 1, 2, 3… ∞ is
n!
(A) 1.5 (B) 3 (C) 9 (D) None of these
GA/QB/PI−III Elite Academy 3
1.5 Which of the following methods use the augmented matrix to solve simultaneous
equations?
(A) Runge-Kutta method (B) Euler Method
(C) Milne method (D) Gauss-Jordon method
1.6 The maximum solubility of carbon in austenite in a Fe-C system is close to;
(A) 0.02% (B) 0.80% (C) 2.04% (D) 4.27%
1.8 In Whitworth quick return mechanism (used in shapers), the velocity of the ram is
maximum at:
(A) Middle of the forward stroke (B) Beginning of return stroke
(C) End of return stroke (D) None of these
1.9 Temperature at two ends of a 3 m long bar are 1000 C and 100 C . Assuming
1.11 Minimum required bend radius on the inner side of a bent steel sheet in press
bending operation is
(A) Half of sheet thickness (B) equal to sheet thickness
(C) 1.5 times sheet thickness (D) twice the sheet thickness
1.12 Which of the following treatments is used for reducing weld cracking in medium
carbon low alloy steels?
(A) Annealing (B) tempering
(C) Preheating (D) post heating
1.14 The tolerances on 25H6 and 26H8 are 0.013 mm and 0.033 mm respectively. The
tolerance on 25.5H7 is:
(A) 21µm (B) 0.023 mm (C) 30µm (D) None of these
13 6
2.1 Inverse of a matrix [P] = is given by
4 2
0.5 2 4 0.5 2 − 4
(A) 6 13 (B) − 6 13
GA/QB/PI−III Elite Academy 7
2 4 2 − 4
(C) 6 13 (D) − 6 13
2.3 The vector field is defined by the three components of a vector, B given as
B x = 4x + 5 y + z
By = x + y2
Bz = y 2 + z 2
The magnitude of divergence of B (i.e. div. B ) at a point with coordinates x = 2,
y = 5 and z =1, is given a
(A) 16 (B) 5 (C) 20 (D) 0
2.4 Six coins are tossed at a time. The probability of obtaining at least five heads is
(A) 0.0833 (B) 0.0937 (C) 0.1093 (D) 0.4166
2.5 The formula to determine the square root of a number ‘R’ using Newton -
Raphson method is given by (where x i +l is the root at i+l the iteration)
1 R
(A) x i +l = x i + (B) x i +1 = x i (2 − x i R )
2 xi
1
(C) x i +1 = x i (3 − x i 2 R ) (D) None of these
2
Fig. 1
2.8 In a gear box, the speed reduction of 40 is obtained in single stage. The types of
gears used are:
(A) Spur gears (B) Helical gears
(C) Bevel gears (D) Worm and worm gear
GA/QB/PI−III Elite Academy 9
flowing over the plate at 40 C . The convective heat transfer coefficient is 0.002
W / mm 2
C . The rate of connective heat loss from the plate is
(A) 0.1344 W (B) 0.1344 k W
(C) 1.344 W (D) 134.4 k W
2.10 The permeability of moulding sand was determined using a standard AFS sample
by passing 2000 cc of air at a gauge pressure of 10g / cm 2 . If the time taken for
the air to escape was 1 min., the permeability number is:
(A) 112.4 (B) 100.2 (C) 75.3 (D) 50.1
2.11 The sequence of operations performed during a closed die forging of a connecting
rod is:
(A) edging-- fullering-- blocking -- finishing
(B) fullering-- edging -- blocking -- finishing
(C) edging-- blocking -- fullering -- finishing
(D) Fullering -- blocking -- edging --finishing
2.12 Two plates A and B are joined by means of two fillet welds f1andf 2 , having leg
length of 8 mm each as shown in Fig. A2. Both these welds have same length,
L=150 mm. If the shear strength of the weld metal is 200 MPa and assuming that
plate A is strong enough to take such a load, the total load P which the plate A can
carry with out failure of the weld is
10 Elite Academy GA/QB/PI−III
Fig. A2
(A) 339 k N (B) 480 k N (C) 960 k N (D) 678 k N
2.13 For turning NiCr alloy steel at cutting speeds of 64 m/min and 100 m/min, the
respective tool lives are 15 min and 12 min. The tool life for a cutting speed of
144 m /min is:
(A) 8 min (B) 9 min (C) 10 min (D) 11.5 min
2.14 Four components P, Q, R and S with the tolerances as shown in Fig. A3 are
assembled to make up a dimension F.
Figure: A3
Using statistical tolerance method, the limits on the resultant dimension F are:
(A) 140.06 ± 0.062
(B) 140.06 ± 110
(C) 140.00 ± 0.110
2.15 The following are six materials belonging to thermo-set and thermo-plastic
groups:
GA/QB/PI−III Elite Academy 11
2.17 A DC servo motor is directly driving an NC table. The pitch of the lead screw of
the table is 5 mm. The motor rotates at 100 rpm for an applied voltage of 10 V. If
the voltage-speed characteristic of the motor is linear, the applied voltage for a
table speed of 3 m/min is equal to:
(A) 30 V (B) 60 V (C) 33 V (D) 50 V
2.18 In the following combinations of needs, which set represents the bottom and top
of Maslow’s need hierarchy?
(A) Security and Self actualization
(B) Physiological needs and Self actualization
(C) Physiological needs and Esteem
(D) Security and Esteem
2.19 If the fixed cost of production is Rs. 10,000/-, variable cost of production per unit
is Rs. 200/- and the unit price is Rs. 300/-, then the break-even volume to be
produced will be:
(A) 300 (B) 200 (C) 100 (D) 150
2.21 Annual consumption of a product is 800. The ordering cost is Rs. 50/-. The
storage cost is Rs. 2/- per unit per annum. The lowest total incremental cost (TIC)
in rupees, in inventory control, is:
(A) 400 (B) 800 (C) 1000 (D) 1200
2.22 The end-inventory in the months of May, June and July as indicated in an
aggregate plan are 2000, 5000 and 2000 respectively. For a carrying cost of
Rs. 100/- per month per item, the total carrying cost in rupees for these three
months is:
(A) zero (B) 200,000 (C) 500,000 (D) 900,000
2.23 Maximise Z = 3x 1 + 2x 2
Subject to 4 x 1 + x 2 ≤ 60
8x 1 + x 2 ≤ 90
2 x 1 + 5x 2 ≤ 80
And x 1 ≥ 0 and x 2 ≥ 0
The number of corner points in feasible solutions of the above LP model is:
(A) 3 (B) 4 (C) 5 (D) 6
λ2
2.24 The equation for expected length of a queue of a system is given as L q =
µ( µ − λ )
. The equation is true for:
(A) Arrivals follow Poisson distribution and service times are exponential.
(B) Arrivals follow Poisson distribution and service times are constant
(C) Arrivals follow Earlang distribution and service times are exponential
GA/QB/PI−III Elite Academy 13
(D) Arrivals follow Earlang distribution and service times are constant
2.25 Two motors, one gear box and two pumps are available. One from each category
will make a system. The remaining items would be in stand by. The reliabilities
of motor, gear box and pump are 0.8607, 0.9231, and 0.7788 respectively. The
system reliability is:
(A) 0.4148 (B) 0.6187 (C) 0.8895 (D) None of these
SECTION -B
(75 Marks)
This section consists of TWENTY questions of FIVE marks each. Any FIFTEEN out of
these questions have to be answered on the Answer Book provided. If more numbers of
questions are attempted, cancel the answers not to be evaluated, else only the first fifteen
answers would be considered strictly. [15 x 5 = 75]
PI-3. The expected relation between two variables is y = a x . Using least square
method, determine the value of ‘a’ for the following experimental values.
x -2 2 4 6
y 0.22 4.50 15.00 65.00
PI-4. A rectangular block of mass 1 kg is sliding from rest down an inclined plane from
the key if the yield shear strength for the material of the key is 100 MPa. Also
calculate the crushing stress developed in the key. Use factor of safety of 2.
Figure, as shown below.
PI-6. Water is flowing through a 600 m long galvanized steel pipe of internal diameter
150 mm with a discharge of 0.05 m 3 / s. Determine the frictional head loss and
pumping power to maintain the flow rate. The friction factor is 0.02.
PI-7 Ingot castings of 0.4% C steel are to be cast in ingot moulds of 20 cm diameter and
50 cm length. The upper part of the casting in the ingot mould acts as the riser.
Show the cross section of the ingot casting with the real shape of the piping defect
in the riser.
Calculate the shrinkage volume of the liquid metal if the volumetric shrinkage is
3%.
Assuming the shrinkage pipe of cylindrical shape and diameter to height ratio of
1:2.5 for the pipe, calculate the height of the pipe.
What portion of the casting in the ingot mould will be free from piping defect?
PI-8 State the Von Mises yield criterion in terms of deviatoric stresses and explain the
meaning of the terms used.
State the incompressibility condition in mathematical form.
Define deviatoric stress and express it in mathematical form.
GA/QB/PI−III Elite Academy 15
Passes, determine the welding speed in mm /min when other welding parameters
are:
Wire diameter = 3 mm
Electrode / Wire feed rate = 2 m/min
0 − 0 − 6 − 6 − 25 − 75 − 0.8mm
Determine the main cutting force (Pz ) and cutting power assuming orthogonal
machining for the following data:
S = feed = 0.12 mm /rev
t = depth of cut = 2.0 mm
a2 = chip thickness = 0.22 mm
Vf = chip velocity = 52.6 m/min
16 Elite Academy GA/QB/PI−III
PI-11 A pure metallic block is being machined using Electro Chemical Machining
(ECM). The material removal rate (MRR) is 2000 mm 3 / min . The specific
Gravity of the metal is 7.8, valency is 2 and atomic weight is 56. If Faraday’s
constant is 96500 Coulombs, determine the current requirement.
PI-12 Calculate, using Base Tangent Method, the theoretical distance between two
parallel measuring faces over 3 teeth on a spur gear of 30 teeth, 3 mm module
PI-13 Design and draw the optimum strip layout for high volume production of sheet
metal component shown in Fig. B3. Determine the percentage yield from the
sheet. Show the punch positions with hatching in the strip layout. Sheet
thickness is 1 mm and bridge allowance (minimum required distance between two
edges) is 1.5 t.
PI-14 The surface of a metal slab of 278 mm length and 80 mm width is machined by a
face milling cutter of 120 mm diameter, having 10 teeth, rotating at 50 rpm. The
milling feed is 0.1 mm / tooth of the cutter. The combined time for job loading
and unloading is 2 min. The approach and overtravel of the tool are 1 mm each.
Calculate the production rate per hour.
PI-15 Indian Metals and Alloys Ltd. wishes to invest on a new furnace. The initial
required investment is Rs. 400,000/-. The company has to spend another
Rs. 400,000/- to renovate the furnace at the end of fifth year. The total life of the furnace
is estimated as 10 years with zero salvage value. The annual expected revenue
during its life is Rs. 110,000/-. Show the cash flow diagram and determine the
internal rate of return of the cash flow. The rate of return factors are given in the
following tables.
Table for Discrete rate of return factor for 10 year life.
MARR SPCAF SPPWF CRF USPWF SFDF USCAF
9% 2.3674 0.42241 0.15582 6.4177 0.06582 15.193
10% 2.5937 0.38554 0.16275 6.1446 0.06275 15.937
11% 2.8497 0.35375 0.16986 5.8974 0.05986 16.743
12% 3.1058 0.32197 0.17698 5.6502 0.05698 17.549
Where,
MARR = Minimum attractive rate of return
SPCAF = Single payment capital accumulation factor
SPPWF = Single payment present worth factor
CRF = Capital recovery factor
18 Elite Academy GA/QB/PI−III
PI-16 (a) State the three categories of “ Principles of Motion Economy” and the
number of principles in each category.
(b) Give the classifications of hand and body motions according to the
principles of motion economy from simple to complex category.
PI-17 A hypothetical flow shop has only two machines. The processing time matrix is
given as:
Job Machine 1 Machine 2
A 2 0
B 3 8
C 7 5
D 9 1
E 6 4
Determine the job sequence using Johnson’s algorithm. Draw the Gantt chart and
determine the minimum makespan.
PI-18 A product is available in two sizes: normal size and large size. The customer
prefers to buy only the normal size. Large size item is purchased when normal
size item is not available. The shopkeeper is forced to buy from the manufacturer
one large size item for four of normal size items as a package deal. The unit
storage cost is Re. 1/- per week for normal size items and Rs. 2/- per week for
large items. Ordering cost is Rs. 900/-. The rates of sale of items are 50 per week
for normal size items and 25 per week for large size item. No shortage and no
safety stock are permitted.
Draw the inventory model showing the combined stock level.
GA/QB/PI−III Elite Academy 19
Derive an equation to find the average incremental cost per week in the inventory
control.
Find the economic order quantities for both the items.
PI-19 The Food World supermarket, in preparation for the upcoming festival season, has
just purchased the following:
It would like to package these nuts in one kg bags and is considering to produce
(a) a regular mix containing 15% almond, 215% cashew, 25% walnut and 35%
pistachio (b) a deluxe mix containing 30% almond, 30% cashew, 20% walnut and
20% pistachio (c) individual bags of each type of nuts.
The expected profits per bag are Rs. 20/- for regular mix, Rs. 25/- for deluxe mix,
Rs. 10/- each for cashew and walnut and Rs. 5/- each for almond and pistachio.
Sufficient demand exists for each type of bag.
The company would like to determine how many bags of each type are to be
packaged to maximize the profit. Formulate and LP model to solve this problem.
Use the following notations to represent the number of bags of each type:
X1 for regular mixture, X 2 for deluxe mix, X 3 for almond, X 4 for cashew, X 5
Activity A B C D
Predecessor (s) - - A B, C
Optimistic time 8 2 10 6
Pessimistic Time 14 7 15 15
Most likely time 10 5 12 8
PI-22 Draw and identify any 10 symbols used in system flow charts.
*********************
GA/QB/PI−III Elite Academy 21
2001
SOLUTIONS
SECTION-A
Sol. a 1 x + b1 y + c1 z = − d 1
a 2x + b2y + c2z = − d2
a 3x + b3 y + c3z = − d 3
a 1 b1 c1 x − d 1
⇒ a 2 b2 c 2 y
= − d
2
a 3 b3 c 3 z − d 3
1.2 (A) 27
1.4 (B) 3.
1.16 (D) the tolerance that is obtained on the parts produced on the lathe
0.2
t − 100
1.22 (A) −
e 500
0.5 2 − 4
2.1 (B) − 6
13
2.2 (C) 6
2.3 (A) 16
1 R
2.5 (A) x i + 1 = x i +
2 x i
BC
2.6 (B)
AB
2.15 (D) 2, 4, 6
2.23 (B) 4
GA/QB/PI−III Elite Academy 25
2.24 (A) Arrivals follow Poisson distribution and service times are exponential.
PI-3 y = ax
log y = x log a
x y log e y
−2 0.22 −1.514
2 4.5 1.504
4 15.0 2.708
6 65.0 4.174
∑ x = 10 6.872 = ∑ log y
∑ log y = ∑ x log a
∑ log y 6.872
log a = = = 0.6872
∑x 10
a=2
PI–4
26 Elite Academy GA/QB/PI−III
a x = 4.86 m / sec 2
V12 = V02 + 2a x . s
S = Displacement = 10 2 m/s
V12 = 0 2 + 2 × 4.86 × 10 2
V1 = 11.72 m/sec
PI-5
= 115000 Nmm.
D 25
Torque = Force × = F× = 115000 Nmm
2 2
115000 × 2
F= = 9200 N
25
K = yield strength in shear of key material = 100 N/mm 2 .
K
Allowable shear stress =
factor of safety
100
= = 50 N / mm 2
2
Length of the key in mm = L, Width of key = 6mm
9200
∴ L × 6 × 50 = 9200 N, L=
6 × 50
F
Crushing stress developed =
L×t/2
9200
=
30.7 × 3
= 99.9 N/mm 2
PI-6
Diameter of the pipe = 150mm = 0.15m = d
Length of the pipe = L = 600m
π × (0.15) 2
Cross sectional area of pipe (A) =
4
= 0.01767 m 2
28 Elite Academy GA/QB/PI−III
Discharge
Velocity of water in pipe =
area of cross section
0.05
V= = 2.829m/sec.
0.01767
f × L × V2
Frictional head loss = = hf
2gd
f = friction factor = 0.02
h f = 32.63 m
= 9810 kg / m 3
P = 16 kW.
PI-7
πd 2
Volume of the ingot = ×h
4
π
V= × 20 2 × 50 = 15707.96 cm 3
4
GA/QB/PI−III Elite Academy 29
Volume of shrinkage = 3%
i.e. 0.03 × 15707.96 = 471.23 cm 3
πd 2p
Volume of Shrinkage pipe = × hp
4
π 2
= d p × 2.5d = 471.23
4
PI-8
Deviatoric stress:
Total stress tensor can be divided into:
i) Hydrostatic stress tensor and
ii) Deviator stress tensor
Hydrostatic stress involves only pure tension or compression and produces only
elastic volume changes and not plastic deformation. Yield stress of the metal is
independent of hydrostatic component of stress although fracture strain is
influenced by it.
A deviator stress tensor represent shear stresses and important in causing plastic
deformation.
σx + σy + σz
Hydrostatic stress =
3
30 Elite Academy GA/QB/PI−III
2σ x − σ y − σ z
τ xy τ xz
3
2σ y − σ x − σ z
τ yx τ yz
3
2σ z − σ y − σ x
τ zx τ zy
3
σ 3 − J 1σ 2 + J 2 σ − J 3 = 0
J 2 = τ xy 2 + τ yz 2 + τ zx 2 − σ x σ y − σ y σ z − σ z σ x
J2 =
1
6
[
( σ1 − σ 2 ) 2 + ( σ 2 − σ 3 ) 2 + ( σ 3 − σ1 ) 2 ]
GA/QB/PI−III Elite Academy 31
Vow Mises proposed that yielding will occur when second invariant J 2 of the
stress deviator exceeds some critical value.
J 2 = C 2 = Constant
to evaluate the constant, and to relate it to yielding in simple tension,
σ1 = σ 0 , σ 2 = σ 3 = 0
1
Then C 2 = σ 02
3
∴ σ0 =
1
2
[(σ 1 − σ 2 ) 2 + (σ 2 − σ 3 ) 2 + ( σ 3 − σ 1 ) 2 ]
In compressibility condition
It means total volumetric strain is zero.
ε1 + ε 2 + ε 3 = 0
Or
εx + εy + εz = 0
PI-9
= 267.26 mm 2
Assuming one meter of weld length,
Volume of metal required = 267.26 × 1000 mm 3
Groove is filled in 5 equal passes.
1000
Welding speed = = 264.5 mm / min
3.78
PI-10
In Orthogonal Rake System,
0 − 0 − 6 − 6 − 25 − 75 − 0.8mm
Side rake angle or orthogonal rake angle. = 0
∴ γ = orthogonal rake angle = 0
t1 0.22
ξ γ= = = 1.83
t0 0.12
= 400 N / mm 2
Pz = 272 N
Cutting velocity V
Chip reduction coefficient = = = 1.83
Chip velocity Vc
PI-11
AI
Q= cm 3 / sec
ρzF
z = valency = 2
F = Faraday’s constant in coulombs
Q = 2000 mm 3 / min
34 Elite Academy GA/QB/PI−III
2000 1
= = cm 3 / sec
1000 × 60 30
1 56 × I
∴ =
30 7.8 × 2 × 96500
7.8 × 2 × 96500
I= = 896 Amp
30 × 56
PI-12
By base tangent method,
BD = Theoretical distance between two parallel measuring surface
π πs
= N.m. cos φtan φ − φ − +
2N N
N = No. of teeth = 30
m = module = 3
20 π
φ = Pressure angle = 20 = = 0.349 radian
180
S = No. of teeth between parallel faces = 3
π 3π
BD = 30 × 3 × cos 20 tan 20 − 0.349 − +
60 30
BD = 23.4 mm
PI-13
For a rectangular shaped component, single row, single pass strip layout gives
maximum material utilisation
GA/QB/PI−III Elite Academy 35
1150
Yield = × 100 = 73.27
43 × 36.5
yield = 73.27 %
PI-14
Total travel of cutter, assuming 1mm each on initial approach and overtravel
36 Elite Academy GA/QB/PI−III
Cutter travel
Tm = machining time =
Sz × Z × N
295.28
= = 5.91 min
0.1 × 10 × 50
Total time required to complete the job = time for loading and unloading + Tm
= 2 + 5.91 = 7.91 min
60
Hence production rate/hour = = 7.58
7.91
PI-15
1. Annual expected revenue during 10 years of life is Rs 1,10,000. It forms
uniform series
4,00,000
Investment = 4,00,000 +
(1 + i) 5
1
= 4 1 +
(1 + i) 5
= 4[1 + SPPWF] for five years.
A B C E D
Job processing order is from M 1 to M2
Gantt chart
PI−18.
Let
Q = Order quantity in units
C = Unit cost of procuring an item
D = Annual consumption in units
S = Cost of placing an order
h = Annual cost per rupee value of holding inventory
Incremental cost is the cost required to hold the inventory between two successive
orders.
Q
Average inventory during the period between two successive orders = .
2
GA/QB/PI−III Elite Academy 39
Q
Incremental cost = × C × h per year.
2
Q 1
Incremental cost /week = × C × h ×
2 50
Assuming 50 weeks/year.
4 Normal
Package deal. Units
1 Large
= 268 .
2 ds 2 × 1250 × 180
Large = =
hc 100
= 67.
In package deal economic order
Quantity Normal 268, large 67
(i.e 625) of large size product is obtained from the package deal. The remaining
625 units of large size have to be ordered separately.
2 DS
(E O Q) large =
h.c
2 × 625 × 900
=
100
= 106 .
Economic order Quantity for package deal. 268 (Normal) and 67 large
Economic order Quantity for replenishing the large products only, 106.
PI−19.
Maximize Profit.
i.e. Z = 20 x 1 + 25 x 2 + 10 x 3 + 10 x 4 + 5x 5 + 5x 6
Subject to
0.15 x 1 + 0.3x 2 + x 3 ≤ 6000 (Almond)
x 1 , x 2 , x 3 , x 4 , x 5 and x6 ≥ 0
PI−20.
p = percentage defective = 2% = 0.02
n 1 = n 2 = n = 50 .
m = n p = 50 × 0.02 = 1
P(r) = Probability of (r) defectives
m r . e −m
=
r!
1o × e −1
P(0) = = e −1 = 0.3678
11 . e −1
P(1) = = e −1 = 0.3678
1!
12 × e −1 e −1
P(2) = = = 0.1839
2! 2
P(a) = Probability of acceptance
= P(0) + P(1) × P(0) + P(1) × P(1) + P(2) × P(0)
P–21.
Net Work
42 Elite Academy GA/QB/PI−III
To + 4 TM + TP
TE =
6
A B C D
Mean Time TE 10.33 4.83 12.16 8.83
Standard deviation 1 5 5 2
σ 6 6 3
Variance = σ 2 1 25 25 4
36 36 9
TE = TL = 10.33
TE = 0 TE = TL = 22.5 TE = TL = 31.33
TL = 0
PI–22.
Symbols used in system flow charts
BASIC COMBINATION
OPERATION
OPERATION AND INSPECTION
INSPECTION
INSPECTION DURING DELAY
STORAGE
*******************
44 Elite Academy GA/QB/PI−III
2002
PI : Production and Industrial Engineering
Duration: Three hours Maximum marks: 150
11. Answer for each question in Section B should be started on a fresh page. Question numbers
must be written legibly and correctly in the answer book.
12. In all 5 mark questions (Section B), clearly show the important steps in your answers. These
intermediate steps will carry partial credit.
SECTION − A
(75 Marks)
PI 1 Given below are TWENTY FIVE sub–questions (1.1–1.25) of ONE mark each.
For each of these sub–questions, four possible answers ((A), (B), (C) and (D)) are
given, out of which one is correct or most appropriate. Answer each sub–question
by darkening the appropriate bubble on the OBJECTIVE RESPONSE SHEET
(ORS) using a HB pencil. Do not use the ORS for any rough work. You may to
use the Answer Book for any rough work, if needed. [1 × 25 = 25]
1.1 The expected value of f (x), for the density function of a random variable x given
by,
f (x) = x2 / 2 0<x<2
= 0 otherwise, is
(A) zero (B) 2 (C) 4 (D) 8
1.2 The distribution related to the probabilities of events which are extremely rare,
but which have a large number of independent opportunities for occurrence, is
(A) Bernoulli distribution (B) Gaussian distribution
(C) Weibull distribution (D) Poisson distribution
1.7 A box weighing 600 N is kept in a lift. If the lift moves down with an
acceleration of 6 m / s 2 , the reaction experienced by the lift is
(A) 233 N (B) 600 N (C) 967 N (D) 1200 N
1.8 A lift strikes a stopper spring made of helical coil placed in a telescopic guide and
breaks it equally into two halves. The ratio of the resultant stiffness to the
original stiffness is
(A) 1/4 (B) 1/2 (C) 1 (D) 2
1.9 When a particular system is subjected to a reversible process from state 1 to state
2, its entropy increases by 3 kJ/K. If the same system is now subjected to an
1.11 A sheet is subjected to plane−strain stretching. If the true strain on the surface of
the sheet is + 0.15, the true strain in the thickness direction is
(A) zero (B) − 15 (C) + 0.15 (D) + 0.30
1.15 Parts having thin section and complex geometry are joined by
(A) gas welding (B) submerged arc welding
(C) friction welding (D) dip brazing
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1.20 The formula for economic order quantity does not contain
(A) order cost (B) carrying cost
(C) cost of the item (D) annual demand
(D) a weighted average model with equal weights to all data points.
PI 2 Given below are TWENTY FIVE sub−questions (2.1− 2.25) of TWO marks each.
For each of these sub−questions, four possible answers ((A), (B), (C) and (D)) are
given, out of which one is correct or the most appropriate. Answer each sub−
question by darkening the appropriate bubble on the OBJECTIVE RESPONSE
SHEET (ORS), using a HB pencil. Do not use the ORS for any rough work. You
may use the Answer Book for any rough work, if needed. (2 × 25 = 50)
1 −1 3 1
2.2 If (P + Q) = and (P − Q) = 1 4 then PQ is
3 0
4 1 1 1 −2 −2 3 −1
(A) (B) (C) (D)
4 4 3 4 0 −6 1 0
3
2.3 The inverse transform of is given by
s2 + 2s − 8
2.4 The work done to propel a ship with a displacement of V for a distance S in time t
moduli of steel and aluminium are 200 GPa and 70 GPa respectively. Under a pull
of 100 kN, the elongation of the assembly at the flange end is
(A) 8.5 MPa (B) 18.6 MPa (C) 28.5 MPa (D) 38.5 MPa
2.8 A single disc clutch operating under dry sliding condition transmits 150 Nm. The
average coefficient of friction is 0.3 and maximum operating pressure is 0.5 MPa.
The ratio between the outside radius and inner radius is 1.73. Under uniform
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wear conditions, if the outside radius of the clutch is to be minimum, the inside
radius will have to be
(A) 64.4 mm (B) 84.6 mm (C) 54.3 mm (D) 74.5 mm
2.9 A specimen with a 12.5 mm diameter and 50 mm gauge length is used in a tension
test of an aluminium alloy. At the load of 250 N, the total elongation is 2 mm.
True stress and true strain are
(A) 2.037 N / mm 2 and 0.04 respectively
(B) 2.119 N / mm 2 and 0.039 respectively
(C) 1.956 N / mm 2 and 0.04 respectively
(D) 2.119 N / mm 2 and 0.017 respectively
2.10 In a non−pressurized gating system, an aluminium alloy is poured at a flow rate of
0.8× 10 − 3 m 3 / min through a sprue with a base cross sectional area of 400 mm 2 .
If the friction losses in the sprue are neglected, the height of the sprue is
(A) 200mm (B) 150 mm (C) 250 mm (D) 300 mm
2.12 In spot pulsed later welding of aluminium plates (density = 2700 kg / m 3 , specific
heat = 896 J/kg, melting temperature = 933 K, latent heat of melting =398 kJ/kg)
at a temperature of 30 ºC, a pulse with energy of 0.5 J is focussed onto an area of
0.05 mm 2 . If the entire energy is coupled into the material, what will be the
depth of weld assuming the cross sectional area of the weld is circular and is
GA/QB/PI−III Elite Academy 53
uniform throughout its depth and only heat conduction in the direction of
penetration
(A) 5.34 mm (B) 2.15 mm (C) 4.23 mm (D) 3.85 mm
2.14 Two different tools A and B having nose radius of 0.6 mm and 0.33 mm
respectively are used to machine C−45 steel employing feed rates of 0.2 mm/rev
and 0.1 mm/rev respectively. The tool that gives better finish and the value of
ideal surface roughness are
(A) tool A and 4.166 µm respectively (B) tool B and 4.166 µm respectively
(C) tool A and 8.333 µm respectively (D) tool B and 8.333 µm respectively
2.15 In plunge surface grinding, a steel specimen of 2.5 mm wide and 200 mm long is
ground with AA60 K5 V8 grinding wheel of 300 mm diameter and 25 mm wide.
The wheel has undergone a radial wheel wear of 20 microns after removing
material to a depth of 5 mm. The grinding ratio is
(A) 53.05 (B) 26.53 (C) 13.26 (D) 106.10
2.16 A hole is specified on φ35 H7and size of tolerance zone is 0.025 mm. The axis of
the hole is to be controlled with reference to A as shown in Fig. A shoulder−pin is
used as a gauge for checking the geometrical relation. The pin size is
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2.17 To introduce a new product that has a life of 3 years, a company spends Rs. 30
lakhs on machinery. The expected annual profit is Rs. 12 lakhs per year. For an
interest rate of 15%, at breakeven, the salvage value of the machinery at the end
of the third year is
(A) Rs. 6.00lakhs (B) Rs. 4.76 lakhs (C) Rs. 5.42 lakhs (D) Rs. 3.95 lakhs
2.18 Consider a single server infinite population queuing model with Poisson arrival (λ
= 4 per hour) and exponential service (µ = 10 minutes). The probability that there
are at least two people in the system is
(A) 2/3 (B) 1/3 (C) 4/9 (D) 5/9
following is correct.
(A) North west Corner rule gives a degenerate basic feasible solution
(B) North West Corner rule gives an objective function value of Rs. 240
(C) North West Corner rule gives an infeasible solution.
(D) North West Corner rule cannot be used to obtain a basic feasible solution in
this example.
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2.20 The lead time demand for an item follows the distribution given below :
2.21 The demands for an item for six consecutive periods are 101, 99, 102, 100, 99 and
101. Which statement among the following is correct for the forecast of the
seventh period :
(A) Using a five period moving average is greater than that using a three period
moving average.
(B) Using a three period moving average is greater than the arithmetic mean.
(C) Using a five period moving average is greater than a arithmetic mean.
(D) Using a three period moving average is greater than that using a four period
moving average.
2.22 An assembly of a product comprises of eight work elements with assembly times
7, 9, 6, 9, 7, 9, 8 and 9 seconds. Taking into consideration the precedence
constraints, elements 1, 2 and 3 are assembled in the first station, elements 4, 5
and 7 in the second and elements 6 and 8 in the third station. The efficiency of
the line is
(A) 81.48% (B) 92.59% (C) 94.44% (D) 88.88%
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2.23 For a single item, cumulative production and cumulative demand for four months
are given below :
Month Cumulative production Cumulative demand
1 100 80
2 180 180
3 250 260
4 320 300
2.24 The following failure rates were observed for bulbs in a building :
End of month : 1 2 3 4
Cumulative probability of failure : 0.2 0.4 0.8 1.0
Assume 100 bubbles and an individual replacement policy, the expected number
of bulbs to be replaced at the end of the second month is
(A) 70 (B) 50 (C) 30 (D) 34
2.25 A time study was conducted in a machine shop for a manual operation. The times
for five observations (in minutes) were 20, 22, 21, 24 and 25. The performance
rating for the operator is 120%. The allowance factor is 20%. The standard time is
(A) 22.4 minutes (B) 25 minutes (C) 26.88 minutes (D) 33.6 minutes
SECTION – B
(75 marks)
This section consists of TWENTY questions of FIVE marks each. Answer any FIFTEEN
questions in the ANSWER BOOK provided. Answer for each question should start on a
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fresh page. Question numbers must be written legibly and correctly. If more numbers of
questions are attempted, cancel the answers not to be evaluated, else only first fifteen
answers would be considered strictly. [15 × 5 = 75]
Figure: B1
PI 5 Forces acting on the belts are shown in Fig. B3. The yield strength of the shaft
material is 400 MPa. Neglecting bearing friction and using maximum shear stress
theory, determine the diameter of the shaft for a factor of safety of 2.
PI 8 For a true centrifugal casting process with the axis of rotation in horizontal
direction, an acceleration of 75 g, where g is the acceleration due to gravity, is
required at the rim for sound casting.
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(A) Drive the relation between the diameter of casting D (in mm) and the
rotational speed N (in rev/s) for this casting.
(B) Determine the mould speed (in rev/s) for casting C.I. pipes of 5 m long with
outside and inside diameters of 0.52 m and 0.5 m respectively.
PI 10 In orthogonal machining of mild steel with cutting tool having a rake angle of 10
°, the chip thickness is measured to be 0.4 mm. The uncut chip thickness is 0.2
mm and the width of cut is 2 mm. For a cutting speed of 200 m/min and a shear
stress of 400 N / mm 2 for the material, determine the specific energy (in J/ mm 3 )
in cutting. Use Merchant’s relation : 2Φ + λ - α = 90° where Φ is shear angle, λ
is friction angle and α is rake angle.
PI 11 Tool life in drilling steel using HSS drill is expressed as T 0.2 = 9.8 D 0.4 / Vs 0.5
where D is the drill diameter (in mm), T is the tool life (in minutes), V is the
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cutting speed (in m/min) and s is the feed (in mm/rev). The feed is set at
maximum possible value of 0.4 mm/rev for a given drill diameter of 30 mm. The
length of drilling is 50 mm. The machine hour rate is Rs. 60 and the cost of drill
is Rs. 400. For the given conditions.
(A) Express T in term of V only.
(B) Express the time for drilling the workpiece.
(C) Formulate the total production cost in terms of only V and find the optimum
cutting speed, Vopt , neglecting the workpiece and tool changing times.
PI 12 A square plate is inspected for flatness. The readings obtained, using an electronic
gauge, on a grid of 1m × 1m, are as follows : A = 40.005 mm; B = 40.010 mm;
C = 40.015 mm; D = 40.000 mm and M = 40.010
mm, where M is at the grid center as shown in
Fig. B5.
(A) Give the equation of the assessment plane
passing through A, B and D with origin at A
and coordinate axes along A-B and A-D.
(B) Using the above assessment plane, find the
deviation of C and M and arrive at the flatness
error (in µm). Fig. B5
PI 13 A slot of width 5 H7 is to be milled on the part shown in Fig. B6 as a final
operation. Neatly sketch a fixture, showing the locating, clamping and setting
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block arrangements. Show also important dimensions. The part should be shown
by phantom lines as positioned in the fixture.