Industrial Engineering and Quality Control Manual

Name
Roll No. 20_______

HEAD
Exam Seat No.____________________________
MECHANICAL GROUP| SEMISTER VI | DIPLOMA IN ENGINEERING AND TECHNOLOGY
Secretary,
Maharashtra State Board of TechnicalEducation A LABORATORY MANUAL
49, Kherwadi, Bandra (East), Mumbai - 400 051
Maharashtra(INDIA)
Tel: (022)26471255 (5 -lines)
Fax: 022 - 26473980
Industrial Engineering
Web -www.msbte.org.in
And
REGIONAL OFFICES:
MUMBAI PUNE
Deputy Secretary (T),
Quality Control
Deputy Secretary (T), Mumbai Sub-
region,
2n°Floor,Govt.PolytechnicBuilding,
M.S. Board of Technical Education,
Regional Office,
(22657)
49, Kherwadi, Bandra (East)
Mumbai - 400 051
412-E, BahiratPatilChowk, (ME)
Shivaji Nagar, Pune
Phone: 022-26473253/ 54
Phone: 020-25656994 / 25660319
Fax: 022-26478795
Fax: 020-25656994
Email: rbtemumbai @ msbte.com
Email: rbtepn @ msbte.com
NAGPUR
Deputy Secretary (T), Deputy Secretary (T),
M.S. Board of Technical Education M.S. Board of Technical Education,
Regional Office, Regional Office,
Mangalwari Bazar, Sadar, Nagpur - 440 001 Osmanpura, Aurangabad -431 001.
Phone: 0712-2564836 / 2562223 Phone: 0240-2334025 / 2331273
Fax: 0712-2560350 Fax: 0240-2349669
Email: rbteng @ msbte.com Email: rbteau @ msbte.com (Autonomous) (ISO 9001 : 2015) (ISO / IEC 27001 : 2013)
A Laboratory Manual for
Industrial Engineering and

Quality Control
(22657)
Semester – VI
(Diploma in Mechanical Engineering)
Maharashtra State
Board of Technical Education, Mumbai
(Autonomous) (ISO-9001-2008) (ISO/IEC 27001:2013)
Maharashtra State
Board of Technical Education, Mumbai
(Autonomous) (ISO-9001-2008) (ISO/IEC 27001:2013)
4th Floor, Government Polytechnic Building, 49, Kherwadi,
Bandra (East), Mumbai -400051.
(Printed on November 2019)
Maharashtra State
Board of Technical Education
Certificate
This is to certify that Mr. / Ms …………………………………….
Roll No……………………….of Fourth Semester of Diploma in
………………………………………………………….of Institute
……………………………………………... (Code……………..)
has completed the term work satisfactorily in course Industrial
Engineering and Quality Control (22657) for the academic year
20…….to 20…..... as prescribed in the curriculum.
Place ………………. Enrollment No……………………

Date:…..................... Exam Seat No. ………………......
Course Teacher Head of the Department Principal
Seal of the
Institute
Industrial Engineering and Quality Control (22657)
Preface
The primary focus of any engineering laboratory/ field work in the technical education
system is to develop the much needed industry relevant competencies and skills. With this in
view, MSBTE embarked on this innovative ‘I’ Scheme curricula for engineering diploma
programmes with outcome-base education as the focus and accordingly, relatively large
amount of time is allotted for the practical work. This displays the great importance of
laboratory work making each teacher; instructor and student to realize that every minute of the
laboratory time need to be effectively utilized to develop these outcomes, rather than doing
other mundane activities. Therefore, for the successful implementation of this outcome-based
curriculum, every practical has been designed to serve as a ‘vehicle’ to develop this industry
identified competency in every student. The practical skills are difficult to develop through
‘chalk and duster’ activity in the classroom situation. Accordingly, the ‘I’ scheme laboratory
manual development team designed the practical to focus on the outcomes, rather than the
traditional age old practice of conducting practical to ‘verify the theory’ (which may become a
byproduct along the way).
This laboratory manual is designed to help all stakeholders, especially the students,
teachers and instructors to develop in the student the pre-determined outcomes. It is expected
from each student that at least a day in advance, they have to thoroughly read through the
concerned practical procedure that they will do the next day and understand the minimum
theoretical background associated with the practical. Every practical in this manual begins by
identifying the competency, industry relevant skills, course outcomes and practical outcomes
which serve as a key focal point for doing the practical. The students will then become aware
about the skills they will achieve through procedure shown there and necessary precautions to
be taken, which will help them to apply in solving real-world problems in their professional
life.
This manual also provides guidelines to teachers and instructors to effectively
facilitate student-centered lab activities through each practical exercise by arranging and
managing necessary resources in order that the students follow the procedures and precautions
systematically ensuring the achievement of outcomes in the students.
In any mechanical industry, industrial engineering integrates men, machines,
materials, method of production, information, and energy to make a product and hence
enhance productivity by eliminating wastefulness in production processes. Mechanical
engineering technologists needs to determine the standardized process, time for its completion
known as work and time study, measuring the output in terms of productivity, evaluation of
jobs, workers and determining the wages and incentives, measurement of quality of product.
Total Quality Control is an effective system of integrating quality development, quality
maintenance and quality improvement efforts of the various groups in industry, so as to enable
production and services at most economical level which tends towards full customer
satisfaction. Understanding of fundamental principles of industrial engineering and quality
control helps technologists in maximizing efficiency within a company by finding the best use
of people, equipment, and facilities.
Although all care has been taken to check for mistakes in this laboratory manual, yet it
is impossible to claim perfection especially as this is the first edition. Any such errors and
suggestions for improvement can be brought to our notice and are highly welcome.
Maharashtra State Board of Technical Education i

Based mechanical engineering related problems.

PO 1. Experiments and practice: Plan to perform experiments and practices to use
the results to solve broad-based mechanical engineering problems.
PO 2. Engineering tools: Apply relevant mechanical technologies and tools with
an understanding of the limitations
PO 3. The engineer and society: Assess societal, health, safety, legal and cultural
issues and the consequent responsibilities relevant to practice in field of
mechanical engineering.
PO 4. Environment and sustainability: Apply mechanical engineering solutions
also for sustainable development practices in societal and environmental
contexts.
PO 5. Ethics: Apply ethical principles for commitment to professional ethics,
responsibilities and norms of the practice also in the field of mechanical
engineering
PO 6. Individual and team work: Function effectively as a leader and team
member in diverse/ multidisciplinary teams.
PO 7. Communication: Communicate effectively in oral and written form.
PO 8. Life-long learning: Engage in independent and life-long learning activities in
the context of technological changes also in the mechanical engineering and
allied industry.
Program Specific Outcomes (PSOs)
PSO 1: Modern Software Usage: Use latest mechanical related software for simple
design, drafting, manufacturing, maintenance and documentation of mechanical
components and processes.
PSO 2: Maintenance and selection of machines, equipment, instruments:
Maintain and select appropriate machine, equipment and instrument in field of
Mechanical Engineering.
PSO 3: Manage Mechanical Process: Manage the mechanical process by selection
and scheduling right type of machinery, equipment, substrates, quality control
techniques, operational parameters and software for a particular mechanical process
or job for economy of operations.
List of Industry Relevant Skills-
The theory, practical experiences and relevant soft skills associated with this course are to be
taught and implemented, so that the student demonstrates the following industry oriented
COs associated with the above mentioned competency:
a. Apply work study techniques to optimize manufacturing process.
b.Prepare the detailed sequence of operations carried out for manufacturing of
components.
c. Apply ergonomic concepts to redesign simple mechanical control member for
comfort conditions in various industrial environments.
d.Analyze the data obtained from the different quality control processes.
e.Interpret control charts for variable and attribute data.
Maharashtra State Board of Technical Education ii

Practical- Course Outcome matrix

Sr. Practical Outcome CO CO CO CO CO
No. a. b. c. d. e.
1. Apply method study approach to analyze the motions √ - - - -
involved in machining operation of the given job
2. Apply work measurement technique to analyze the √ - - - -
time components involved machining operation of
given job using stop watch.
3. Calculate standard time for all the operations involved √ - - - -
in step turning process.
4. Prepare motion chart of given activity using standard √ - - - -
symbols of therbligs (max 18).
5. Prepare supply chain chart in day-to-day situation - √ - - -
like supply of Cold drink/tooth paste/any grocery
item.
6. Prepare supply chain management chart for online - √ - - -
purchase of goods/products.
7. Prepare detailed process plan for manufacturing of - √ - - -
Hexagonal Nut/Hexagonal headed bolt/Stud/Wing
Nut/Plain Washer.
8. Prepare chart of Sequence of operation for - √ - - -
manufacturing of simple job
like manufacturing of hexagonal nut & bolt/
Manufacturing of V-Block on shaper machine.
9. Prepare Chart of sequence of operation for Single or - √ - - -
Double riveted lap joint/Single riveted butt joint
(single strap).
10. Redesign the given simple lever(s) like gear shifting - - √ - -
lever/brake/clutch lever/foot lever for best ergonomic
aspect.
11. Prepare and analyse steps to solve the given problem - - - √ -
in institute/industry using quality circle concept.
12. Draw the frequency histogram, frequency polygon for - - - √
the samples and calculate mean, mode and median for
same.
13. Draw the normal distribution curve, calculate - - - √
Deviation, Variance, Range and determine the process
capability for 3σ or 6σ.
14. Draw and interpret the control charts ( and R) for - - - √
given data.
15. Draw and interpret the control charts ( P-chart and C- - - - √
chart) for given data.
Maharashtra State Board of Technical Education iii

Guidelines to Teachers
1. Teacher need to ensure that a dated log book for the whole semester, apart from
the laboratory manual is maintained by every student which She/he has to submit
for assessment to the teacher in the next practical session.
2. There will be two sheets of blank pages after every practical for the student to
report other matters(if any), which is not mentioned in the printed practical.
3. For difficult practical if required, teacher could provide the demonstration of the
practical emphasizing of the skills which the student should achieve.
4. Teachers should give opportunity to students for hands-on after the demonstration.
5. Assess the skill achievement of the students and COs of each unit.
6. One or two questions ought to be added in each practical for different batches. For
this teachers can maintain various practical related question banks for each course.
7. If some repetitive information like data sheet, use of software tools etc. has to be
provided for effective attainment of practical outcomes, they can be incorporated
in Appendix.
8. For effective implementation and attainment of practical outcomes, teacher ought
to ensure that in the beginning itself of each practical, students must read through
the complete write-up of that practical sheet.
9. During practical, ensure that each student gets chance and takes active part in
taking observations/ readings and performing practical.
10. Teacher ought to assess the performance of students continuously according to the
MSBTE guidelines
Instructions for Students

1. For incidental writing on the day of each practical session every student should
maintain a dated log book for the whole semester, apart from this laboratory
manual which s/he has to submit for assessment to the teacher in the next
practical session.
2. For effective implementation and attainment of practical outcomes, in the
beginning itself of each practical, students need to read through the complete
write-up including the practical related questions and assessment scheme of that
practical sheet.
3. Student ought to refer the data books, IS codes, Safety norms, Electricity act/rules,
technical manuals, etc.
4. Student should not hesitate to ask any difficulties they face during the conduct of
practical.
Maharashtra State Board of Technical Education iv

Content Page
List of Practical and Progressive Assessment Sheet
S. Practical Outcome Page Date of Date of Assessment Dated Rema

No No. perform submission t marks(25) sign. of rks (if
ance teacher any)
1. Apply method study approach to

analyze the motions involved in
1
machining operation of the given
job
2. Apply work measurement
technique to analyze the time
components involved machining 8
operation of given job using stop
watch.
3. Calculate standard time for all the
operations involved in step turning 14
process.
4. Prepare motion chart of given
activity using standard symbols of 22
therbligs (max 18).
5. Prepare supply chain chart in day-
to-day situation like supply of Cold 29
drink/tooth paste/any grocery item.
6. Prepare supply chain management
chart for online purchase of 36
goods/products.
7. Prepare detailed process plan for
manufacturing of Hexagonal
43
Nut/Hexagonal headed
bolt/Stud/Wing Nut/Plain Washer.
8. Prepare chart of Sequence of
operation for manufacturing of
simple job
51
like manufacturing of hexagonal
nut & bolt/ manufacturing of V-
Block on shaper machine.
9. Prepare Chart of sequence of
operation for Single or Double
58
riveted lap joint/Single riveted butt
joint (single strap).
Maharashtra State Board of Technical Education v

10. Redesign the given simple lever(s)

like gear shifting lever/brake/clutch
64
lever/foot lever for best ergonomic
aspect.
11. Prepare and analyse steps to solve
the given problem in
72
institute/industry using quality
circle concept.
12. Draw the frequency histogram,
frequency polygon for the samples
80
and calculate mean, mode and
median for same.
13. Draw the normal distribution curve,
calculate Deviation, Variance,
88
Range and determine the process
capability for 3σ or 6σ.
14. Draw and interpret the control
95
charts (Xbar and R) for given data.
15. Draw and interpret the control
10
charts ( P-chart and C-chart) for
3
given data.
Total
Note: To be transferred to Proforma of CIAAN-2017.
A suggestive list of PrOs is given in the above table. More such PrOs can be added to attain the COs and
competency. A judicial mix of minimum 12 or more practical need to be performed, out of which, the practical
marked as ‘*’ are compulsory, so that the student reaches the ‘Precision Level’ of Dave’s ‘Psychomotor Domain
Taxonomy’ as generally required by the industry.
Maharashtra State Board of Technical Education vi

Practical No.1 : Analyze the motions involved in machining

operation of the given job
I Practical Significance
Method study enables the industrial engineer to lead each operation to systematic
analysis. The main purpose of method study is to eliminate the unnecessary operations
and to achieve the best method of performing the operation. Method study is also
called as method engineering or work design. Method engineering is used to describe
collection of analysis techniques which focus on improving the effectiveness of men
and machines.
II Relevant Program Outcomes (POs)

PO1- Basic knowledge: Apply knowledge of basic mathematics, sciences and basic
Engineering to solve the broad-based Mechanical Engineering problems.
PO3- Experiments and practice: Plan to perform experiments and practices to use
the results to solve broad-based Mechanical Engineering problems.
III Competency and Skills

• The aim of this course is to help the student to attain the following industry
identified competency through various teaching learning experiences:
• Apply Industrial Engineering and Quality Control techniques for assuring
quality of products and services.
IV Relevant Course Outcome(s)

a. Apply work study techniques to optimize manufacturing process.
V Practical Outcome
Apply method study approach to analyze the motions involved in machining operation
of the given job.
VI Relative Affective Domain-

• Follow safety practices.
• Practice good housekeeping.
• Practice energy conservation.
• Demonstrate working as a leader/a team member.
• Maintain tools and equipment.
• Follow ethical practices.
VII Minimum Theoretical Background

Steps of Method Study:
Following steps are used in Method Study
1. Select a concern area (work to be studied).
2. Record all the relevant facts about the present method.
Maharashtra State Board of Technical Education 1

3. Examine the facts critically and in ordered sequences, using the techniques best
suited to the purpose.
4. Develop the most practical, economical and effective method having due regard to
all contingent circumstances.
5. Define the new method so that it can always be identified.
6. Install the method as standard practice.
7. Maintain the method by regular routine checks.

Event Symbol Description

Operation It represents an action. It indicates a main step in the
process. Ex .pressing, grinding, polishing.
Storage Representing stage when material awaits an action.

Ex. Holding, storing, stocking, or retaining.
Delay or Indicates delay or a temporary hurdle in the

temporary sequence of operations. Ex. waiting for transport or
storage operation etc.,
Transport Indicates movement of men, materials from one

place to another. Eg: movement, travelling etc.,
Inspection Represents an action of inspection or checking for

quality and quantity.
Verification or checking
Operation and It refers to operation during transportation.
transportation
Meaning of different symbols used in Process chart
VIII Experimental setup
Fig.1 Recording devices

IX Resources Required
S. Name of Resource Suggested Broad Specification Quantity

No.
1 Digital Video Camera Available in the market or even student 1
can use mobile camera.
X Precautions to be Followed
1. Avoid abrupt movements..
2. Keep safe distance from the machine.
XI Procedure
Steps involved in Motion Analysis are:
a) Select the operation to be studied.
b) List and chart various motions performed by the operator.
c) Identify the productive and idle motions.
d) Eliminate the unnecessary and non-productive motions.
e) Redesign the present operating procedure by employing minimum number of
motions in the most appropriate sequence and in accordance with the principles of
motion economy. Develop final set of operations & their sequence.
f) Impart necessary instructions to the worker so that he develops proper habit cycle.
g) Check once again the procedure in the light of step (e) above.
XII Resources used
S. Name of Resource Broad Specifications Quantity Remarks

No. Make Details (If any)
1.
2.
3.
XIII Actual Procedure Followed

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XIV Precautions Followed

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XV Observations and Calculations
Process flow chart
Figure 1
Summary -
Sr. Observed motions Essential motions Excess motions

No.
1
2
3
4
5
6
7
8
XVI Results
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XVII Interpretation of Results
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XVIII Conclusions
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XIX Practical Related Questions

Note: Below given are few sample questions for reference. Teachers must design more
such questions so as to ensure the achievement of identified CO.
1. Draw Process chart for
a. Toasting of Bread
b. Orange Juice Making
c. Book Binding
d. Kite Making
[Space for Answer]
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XX References / Suggestions for Further Reading
1. https://www.youtube.com/watch?v=XUs5xkJF0vs
2. https://slideplayer.com/slide/8053948/
3. https://www.youtube.com/watch?v=cxz_QKHmbMw
4. https://www.youtube.com/watch?v=K-t5bTLU6rc
XXI Assessment Scheme
Performance Indicators Weightage

Process Related (15 Marks) (40%)
1 Recording of motions 20%
2 Identifying motions 20%
Product Related (15 Marks) (60%)
3 Interpretation of result 20%
4 Conclusions 20%
5 Practical related questions 20%
Total (25 Marks) 100 %
Names of Student Team Members

1. ……………………..
2. ……………………….
3. …………………………
Marks Obtained Dated signature of

Teacher
Process Product Total
Related(10) Related(15) (25)

Practical No.2 : Apply work measurement technique to analyze the time

components involved in machining operation of given
job using stop watch.
Work measurement is the systematic determination of how long a task should take to
complete. One of the most common types of work measurement is time study.Time
studies determine how long a qualified worker under stated conditions can reasonably be
expected to complete a task.


• Apply Industrial Engineering and Quality Control techniquesfor assuring

b. Apply work study techniques to optimize manufacturing process.
V Practical Outcome
Apply work measurement technique to analyse the time components involved in
machining of given job using stop watch.

• Follow ethical Practices.

Work Measurement
Work measurement refers to the estimation of standard time for an activity, that is the
time allowed for completing one piece of job by using the prescribed method.
Time study is conducted for measuring work in process. Before making this time study
each operation is broken into definite number of elements, which are not large or too
short in time. Then select average cooperative operator(s). The stopwatch time study

is used to analyze a specific process by qualified workers in an effort to find the most
efficient ways in terms of time. Moreover, this method measures the time necessary
for a work process to be completed using the best ways. The time was measured using
snapback stopwatch equipment because it is easier and faster in data recording.
Moreover, this type of stopwatch is suitable for this research because it can develop
accurate data. This allows the element times to be entered directly on the time study
sheet without the need for subtractions.
Rating: Rating is the assessment of the worker’s rate of working relative to the
observer’s concept of the rate corresponding to standard pace. The society of
Advancement of Management National Committee defines rating as that process
during which the time study engineer compares the performance of the operator under
observations with the observer’s concept of proper (normal) or standard performance.
Fig 1 Recording devices

S. No. Name of Resource Suggested Broad Specification Quantity

1. Stop Watch Timing capacity:23hrs, 59mins and 1
59.99secs,Accuracy: ±3 seconds/day
2. Digital Video Camera for Available in the market or even 1
Micro Motion Analysis student can use mobile camera.
3. Steel Rule for Length Range 0-5 feet 1
Measurement
1. Avoid improper handling of stop watch
2. Keep safe distance from machine .
XI Procedure
i. Observe operators performing a task. i.e drilling operation.
ii. Record time taken for each element of operation, over several cycles.
iii. Record the time taken to perform an activity and to give the ratings of that
activity.
iv. Determine the total time for the activity
v. Find the unnecessary element and associated time /excess time in the activity
vi. Find percentage saving in time.
XII Resources Used
S. Name of Broad Specifications Quantity Remarks

No. Resource Make Details (If any)
1.
2.
3.

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Performance Rating -
Basic time –
Department Operator Analyst Tot No. Av Most Mi Ra Nor

al of g. freq nim tin mal
Ti Obs Ti uentl um g Ti
Operation Foreman Date me . me y rea me
readi din
No. Element Unit 1 2 3 4 5 6 7 8 9 10 11 12 ng g
Produ
ced
XVI Results
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XVIII Conclusions
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1. Differentiate between work measurement and Time Study
2. Define ‘Basic Time ‘
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i. https://slideplayer.com/slide/7439691/
ii. https://www.youtube.com/watch?v=0ufrez3JMIQ
iii. https://www.youtube.com/watch?v=jDaa1HZQQZg
iv. https://www.youtube.com/watch?v=Ewy7ps51FZI
XX Assessment Scheme

1 Identification of elements for one cycle 20%
2 Recording of time elements for multiple cycles 20%
4 Conclusions 20%

1. ……………………..
2. ……………………….
3. …………………………

Teacher

Practical No.3 : Calculate standard time for all the operations involved
in step turning process.
Work measurement involves finding out the time taken for doing each element. The
time taken for each element is totaled. Time study with the help of a stopwatch is the
most commonly used work measurement method. Time study is best suited for short-
cycle repetitive jobs Most of the production jobs can be easily timed by a time-study.
The technique helps to determine performance rating of workers and their wage rates.


• Apply Industrial Engineering and Quality Control techniquesfor assuring

c. Apply work study techniques to optimize manufacturing process.
V Practical Outcome
Calculate standard time for all the operations involved in step turning process.

Stop Watch Time Study:

Stop Watch is one of the equipment used for Time Study. It is employed for measuring
the time taken by an operator to complete the work. Stop watch used for time study
purpose should be very accurate and preferably be graduated in decimals so that it can
recover even up to 0.01 minute.

A large hand in the stop watch is revolved at a speed of one revolution per minute. The
dial of the stop watch is divided into 100 equal divisions. The small hand inside the
stop watch revolves at a speed of one revolution in 30 minutes.
Figure 1 This shows how standard time is made up
Rating: Rating is the assessment of the worker’s rate of working relative to the
observer’s concept of the rate corresponding to standard pace. The society of
Advancement of Management National Committee defines rating as that process
during which the time study engineer compares the performance of the operator under
observations with the observer’s concept of proper (normal) or standard performance.
Standard time= Basic time + Allowances

Figure 2 stop watch

1. Stop Watch Timing capacity:23hrs, 59mins 1
and 59.99secs,Accuracy: ±3
seconds/day
2. Digital Video Camera for Micro Available in the market or even 1
Motion Analysis student can use mobile cmera.
3. Steel Rule for Length Range 0‐5 feet 1
Measurement
1. Avoid improper handling of stop watch
2. Maintain safe distance from the machine
XI Procedure
a. Understand the job to establish the quality to be achieved in the job.
b. Identify key operations to be timed in the job.
c. Get improved procedure from the method study department. (Refer to Expt. 1)
d. Organize resources and explain the objectives of time study to the worker and
supervisor.
e. Explain details to worker about improved working procedure.
f. Break operation into elements to separate the constant elements from variable
elements.
g. Observe and record the time taken by an operator.
h. Determine for number cycles to be timed and then the average time or
representative time can be found out.
i. Rate the performance of the worker during observation.
j. Calculate normal time from observed time by using performance rating factor.

k. Add process allowance rest and personal allowance and special allowances to the
normal time in order to obtain standard time or allowed time.
l. Standard time determination by adding normal time and allowances.
XII Resources Used

1.
2.
3.

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Performance rating -
Basic time –
Allowances –
Standard Time -

XVI Results
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XVIII Conclusions
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Problem 1:
Naresh, a marketing surveyor, takes an average of 10 minutes to complete a particular
questionnaire. His performance rating (pace) is 110% and there is an allowance of
10%.
1. Calculate the Normal time for completing questionnaire.
2. Calculate the Standard time for completing questionnaire.
Problem 2:
Krishna, Rama, Govinda, and Shreekumar, takes 3 hours and 25 minutes to write an
end of month report. Krishna is rated at 95% (work pace is 95%) and the office has a
personal time allowance of 8%. There is no delay time or fatigue time.
1. Calculate the Normal time for writing an end of month report.
2. Calculate the Standard time for writing an end of month report.
Problem 3:
The two steps in preparing chocolate candy bars are molding and packaging. Personal
fatigue and delay allowances are set at 15%. The molding machine operator is rated at
110% and the packer is rated at 80%. Observed times per batch are given below.
Observed Time in Minutes

Task 1 2 3 4
Molding 26 30 29 31
Packing 45 50 35 30
Determine the Normal and standard times for both tasks.

Problem 4:
A work-study sample of a manufacturing activity conducted over a 40-hour period
shows that a worker with an 85% rating produced 12 parts. The worker’s idle time was
10% and the allowance factor was 12%
Find the Normal and Standard time for this activity.
[Space for Answer]
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i. https://slideplayer.com/slide/7439691/
ii. https://www.youtube.com/watch?v=0ufrez3JMIQ
iii. https://www.youtube.com/watch?v=jDaa1HZQQZg
iv. https://www.youtube.com/watch?v=Ewy7ps51FZI

1 Observing and Identifying elements in cycle 20%
2 Recording of time for multiple cycles 20%
4 Conclusions 20%

1. ……………………..
2. ……………………….
3. …………………………

Teacher

Practical No.4 : Prepare motion chart of given activity using standard

symbols of therbligs
Micro motion study technique is best suited for those operations or activities which are
of short duration and which are repeated hundreds of time. These are the operations or
motions which require very small time and it is quite difficult to measure time for
these motions accurately and the time required by these motions cannot be neglected
due to repetitive operations.
In such activities it is interesting to go into greater details in order to find out which
movement and effort can be avoided. All this is done to develop the best possible
pattern of movement so that the operator can perform the operations repeatedly with a
minimum effort and fatigue.
II. Relevant Program Outcomes (POs)


The aim of this course is to help the student to attain the following industry identified
competency through various teaching learning experiences:

d. Apply work study techniques to optimize manufacturing process.
V Practical Outcome
Prepare motion chart of given activity using standard symbols of therbligs



Micromotion study is a set of techniques intended to divide human activity into group
of movements or micromotions and the study of such movements helps to find for an
operator one best pattern of movements that consumes less time and requires less
effort to accomplish the task.
Short cycle operations require to be studied for microscopic motions e.g., operation of
picking up a nut from bin and its fixing consists of three hand motions namely reach
for the nut, grasp nut and move hand back to assembly position. Such detailed analysis
help to develop the best possible pattern of movements and hence enabling the
operator to perform various operations repeatedly with minimum effort and fatigue.
Micro motion study is one of the most accurate techniques of work analysis used for
work improvement. It makes use of motion pictures of the different activities or
movement, so with the help of camera. Very small time upto 0.0005 minute can be
measured and recorded by this system. When picture camera is utilized, the procedure
is known as “MICR-MOTION STUDY”. The motion time data from the film is
transferred to simo chart. The simo chart data can be further analyzed for the purpose
of work place layout or method improvement.
This technique was developed by Fran Gilbreth who considered that an operation
consists of minute elements which may be repetitive or non repetitive. He termed these
elements THERBLIG (after his name Gilbreth if spelt back word is Therblig).
Therbligs primarily refer to motion of human body at the workplace and to the mental
activities associated with it. They permit much more precise and detailed description
of the work than any other recording techniques.Therbligs were suggested by Frank B.
Gilberth the founder of motion study who differentiated 17 fundamental hand or hand
and eye motions to which an eighteenth has been added.Each therblig has a specific
color, symbol and letter for recording purposes.
Therbligs are used for the following:

1. In studying the activities of two or more persons on a group work.
2. In studying the relationship of the activities of the operator and the machine as a
means of timing operations.
3. In obtaining motion time data for time standards.
4. Acts as a permanent record of the method and time of activities of the operator and
the machine.

Industriall Engineering and Quality Control
C (22657)
VIII E
Experimen
ntal setup
Sr.
S Theerblig Symboll Collour Definiition
N
No.
1
1. Assembble A Violet Puttinng objects toogether.
2
2. Disasseemble D
DA Lighht Sepaarating differeent parts of an
a
viollet assem
mbled unit.
3
3. Avoidaable A
AD Lem
mon A delay within opperator’s
delay yellow contrrol.
4
4. Unavoiidable U
UD Yelllow A delay on whichh operator haas
delay no coontrol.
5
5. Transport T
TL Green Moving an articlee from one
loaded placee to another.
6
6. Transport T
TE Oliv
ve Moving (a body m
member, say
y
empty greeen handd) empty.
7
7. Search S
SH Blacck Huntting for an obbject.
8
8. Plan P
PN Brow
wn Menttal reaction bbefore action
n.
9
9. Rest R Oran
nge An allowance,
a iddleness or pau
use
to ovvercome fatiggue incurred
durinng previous wwork.
10. Positionn P Bluee Turnning to line upp, orient or
change position.
11. Find F Gray
y Menttal reaction aat end of
searcch.
12. Inspectt I Burnnt mining an obj
Exam bject for its
ochrre qualiity.
13. Preposiition P
PP Palee Locaating an article in
bluee predeetermined poosition so thaat
it is ready
r for usee.
14. Grasp G Red
d Takinng hold of soomething.
15. Use U Purp
ple Maniipulating or ccausing a too
ol
to doo its functionn.
16. Hold H Gold Retenntion (after ggrasp).
ochrre
17. Select S
ST Ligh
ht Chooosing one objject from
gray
y amonngst many.
18. Releasee load R
RL Carmmine Releaasing an objeect.
red
Figurre no 1 Theerbligs
Maharashhtra State Boaard of Techniccal Education 24


1. Stop Watch Timing capacity:23hrs, 59mins and 1
59.99secs,Accuracy: ±3 seconds/day
2. Digital Video Camera for Micro Available in the market or even 1
Motion Analysis student can use mobile camera.
3. Steel Rule for Length Range 0-5 feet 1
Measurement
1. Avoid improper handling of camera / recording devices
2. Keep safe distance from the machine.
XI Procedure
i. Select a job for step turning operation for method study.
ii. Observe and record movements /motions in the operation.
iii. Chart the recorded motions with the help of symbols.
iv. Analyze the motions with respect to man, machine and materials.
XII Resources Used

1.
2.
3.

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Operation : Film No. :

Operator : Operator No. :
Part Name : Date :
Method : Present / Proposed Charted by :
Left hand Symbol Time (Wink) Total Time Symbol Right hand
(Wink)
XVI Results
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XVIII Conclusions
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1. Differentiate Cycle graph v/s Chrono cycle graph.
2. Discuss the comparison of various techniques of work measurements.

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1. https://www.youtube.com/watch?v=XUs5xkJF0vs
3. https://www.youtube.com/watch?v=cxz_QKHmbMw
4. https://www.youtube.com/watch?v=K-t5bTLU6rc

1 Observing and Identifying the motions 20%
4 Conclusions 20%

1. ……………………..
2. ……………………….
3. …………………………

Teacher

Practical No.5 : Prepare supply chain chart in day-to-day situation like

supply of cold drink/tooth paste/any grocery item.
Supply chain plays important role in ensuring right time delivery of goods & services
to the customer economically. For various functions like planning, purchasing,
production, transportation, distribution & customer service , supply chain people play
important role. Supply chain management increases competitiveness in market and
achieves customer satisfaction.

PO 8.Individual and team work: Function effectively as a leader and team member
in diverse/ multidisciplinary teams.


Prepare the detailed sequence of operations carried out for manufacturing of
components.
V Practical Outcome
Use technique of Supply Chain Management in production of goods & services.


Supply Chain consists of all the parties, vendors, manufacturers, suppliers involved
directly or indirectly in fulfilling all the customer needs and changing demands. The
flow of materials, products, money, information not only between the manufacturer

and suppliers but also with transport, logistics, warehouses and retailers in the entire
value chain.
Cold drink production – Raw material needed is sugar, fresh juices, flavors, &
concentrate. Water treatment is necessary to for bacteria, salts etc. Simple syrup
prepared with sugar & water. Then concentrate is mixed to get final syrup. A flash
pasteurization ensures more shelf life. Treated & cooled water is them mixed with
syrup with carbon dioxide. Drinks are then hermetically sealed, labeled, coded and
tested in automatic plants. Non returnable glass bottles, PET bottles, cans are used for
packaging. Then packaged bottles are supplied to wholesalers. Further they are
transferred to retailers before they reach final customers.
Figure 1. Types of channel Relationships
Figure 2. SCM chart for a typical consumer store

C (22657)
SCM
M chart
Figurre 3. SCM chart for a Amul prooducts
IX R
Resources R
Required
S. No. Name off Resource Suggessted Broad Specificatiion Quan

ntity
1. Websites, relevant books, NA NA
manufactturing comppany
websites
X Precaution
P ns to be Folllowed
1. Use stanndard terminology
2 Consideer all processses involveed from supplier to disttributor endds.
2.
XI Procedure
P
i
i. Know demands & necessitiess of customeers
i
ii. Identify
fy suppliers for raw maaterial.
i
iii. Determmine methodds of shipping, delivery y and payment.
i
iv. Construuct deliveryy & paymennt processess.
v Set faccility for recceiving & exxamining materials.
v. m
v Transfe
vi. fer raw mateerials to mannufacturing
g.
v Determ
vii. mine & schhedule actiivities for manufactuuring, testinng, packag
ging and
synchronize for deelivery.
v Deliverr product too customer destination.
viii. d
i
ix. Establiish networkk for warehoouses.
x Establiish networkk for return of
x. o damaged d / defective products.
x Preparee performannce assessm
xi. ment / contro
ol metrics.

XII Resources Used

1.
2.
3.

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(Students are expected to draw SCM chart of any suitable day-to-day product.)
XVI Results
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XVIII Conclusions
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Q1. Define SKU in supply chain management
Q2. List key elements of supply chain management?
Q3. Define inbound & outbound transportation in SCM.
Q4. State purpose of control metrics in SCM? Draw a typical one
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1. https://www.scribd.com/document/347303313/Supply-Chain-Management-of-
Coca-Cola-pdf (COCA COLA SCM)
2. https://www.slideshare.net/chandan9211/presentation-on-supply-chain-
management-of-amul (AMUL SCM)
3. https://www.mhlnews.com/global-supply-chain/how-measure-supply-chain-
performance (performance measurement for SCM)

1 Identify elements of supply chain 20%
2 Preparation of SCM chart 20%
4 Conclusions 20%

1. ……………………..
2. ……………………….
3. …………………………

Teacher

Practical No.6 : Prepare Supply Chain Management Chart For Online

Purchase Of Goods/Products.
It is expected that in 2020 India will have US$120 billion dollar revenue from e-
commerce and by 2026 it will touch US$200 billion dollars. (Source – India Brand
Equity Foundation) The product portfolio has also increased to multifold times within
a very short span of time. Supply chain management is important in online trading.
Not only manufacturers but customers are largely benefitted due to online shopping. It
has brought customers & online seller under one roof along multiple brands of
multiple products. Online trading has resulted in reduced costs to customers as well as
overheads of manufacturers & sellers drastically. SCM for online trading has it’s own
challenges.

engineering to solve the broad-based Mechanical Engineering problems.
PO 8.Individual and team work: Function effectively as a leader and team member
in diverse/ multidisciplinary teams.


components.
V Practical Outcome
Use technique of Supply Chain Management in online trading.



Supply chain management is also defined as central organization of company’s all
resources and materials required to rationalize production process with reduction in
costs.
Major components of online trading of goods are
1. Web server
2. Stock database
3. Bank systems for payments
4. Warehouse & dispatch
5. Transportation arrangements for goods.
Online traders have their delivery centers at various locations. Once order is received
from customer it is checked in delivery center stock. If it is available then it is
delivered. If no, order is placed with company. Depending on locations different
logistic bodies are identified. Like DHL etc.
In inventory management online trader, wholesaler / distributor, supplier /
manufacturer can have their own system. Online trader carries inventory of high
demand items where as purchases low demand items from distributor in response to
customer order.
Some concepts -
• Product sourcing is locating a source of products to sell that you do not manufacture
yourself.
• Drop shipping involves transferring customer orders to another company, who fulfills
the orders by shipping the items directly to the customer on your behalf.
• Wholesale suppliers are simply providing you items at wholesale prices from the
manufacturers.
Important points to be thought of while designing SCM chart for e-commerce

Before preparing SCM charts ascertain following points
• Will you manufacture or resell items?
• Will you keep an inventory or not?
• How much control do you want over the packaging and shipping?
• How critical is price control to your business model at this stage?
• What volumes will you be dealing in?
• Contact Trade Magazines and Associations to Develop Suppliers
• Evaluate Local Retailers as a Source
• Sourcing Directly From Manufacturers.

Figure 1 Typical SCM chart for online goods

manufacturing company
websites
2.
1. Use standard terminology
2. Consider all processes involved from supplier to distributor ends.
XI Procedure
i. Identify demands & necessities of customers
ii. Identify products suitable for online selling
iii. Identify suppliers for raw material / final products.
iv. Design mobile / personal computer interface for online booking, online
payments & online tracking as well as online cancellation.
v. Decide delivery period for different products based on inventory availability.
vi. Tie-ups with distributors & courier companies.

vii. Determine methods of shipping, delivery and cash on delivery payment.

viii. Set facility for receiving & examining materials.
ix. Issue supplier payments
x. Deliver product to customer destination.
xi. Establish network for warehouses.
xii. Establish network for return of damaged / defective / cancelled products.
xiii. Prepare performance assessment / control metrics.
XII Resources Used

No Resource Make Details (If any)
.
1.
2.
3.

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XVI Results
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XVIII Conclusions
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Q1. Define ‘Reverse logistics’
Q2.State pros& cons of online shopping.
Q3.Elaborate multiple tier inventory model used by amazon.
Q4. Explain term ‘ logistic outsourcing’
Q5. State benefits & risks of drop shipping.
Q6. State elements / activities involved in Demand Planning, supply planning &
demand fulfillment.
Q7. Give examples of B2B, B2C & C2C trading via ecommerce.
[Space for Answer]

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1. https://www.thebalancesmb.com/supply-chain-strategy-1141735 (drop shipping
etc.)
2. https://www.webretailer.com/lean-commerce/ecommerce-supply-chain/
3. https://slideplayer.com/slide/5378700/ (Ecommerce supply chain)

1 Identifying supply chain elements 20%
2 Preparation of SCM chart 20%
4 Conclusions 20%

1. ……………………..
2. ……………………….
3. …………………………

Teacher

Practical No. 7 : Prepare detailed process plan for manufacturing of

simple job.
Once the product is designed, one of the primary aims of mechanical group branch
student is to plan manufacturing processes in best possible ways. Develop & use tools,
processes, machines & equipment used for carrying out specific job. Integrate all
necessary facilities to produce quality & economic product. In short process planning
can be defined as systematic determination of methods by which a product can be
manufactured economically & competitively. It consists of devising & specifying
process, machine tools and other equipment to convert raw materials in to finished /
assembled product. The aim of process planning is to develop best process for each
job.

PO2 - Discipline knowledge: Apply Mechanical engineering knowledge to solve
broad-based mechanical engineering related problems.
PO6 - Environment and sustainability: Apply Mechanical engineering solutions also
for sustainable development practices in societal and environmental contexts.

• Apply Industrial Engineering and Quality Control techniques for assuring quality
of products and services.

components.
V Practical Outcome
Prepare detailed process plan for manufacturing of Hexagonal Nut/Hexagonal headed
bolt/Stud/Wing Nut/Plain Washer.



Contents of process plan - A process plan should contain
1. Identification of purpose of process including name and number of components to
be produced, lot size, material, assembly in which this part will fit, number of
components per assembly.
2. List of operations making up the processes and place where they will happen.
3. Specifications for interchangeability. Locating surfaces, clamping surfaces,
dimensions, tolerances, surface quality etc.
4. Specifications of methods, machines, tools &equipments to produce required
quality & quantity in lowest cost. Include information on what is to be done in
each operation, kind of machine, m/c location, accessories and attachments, special
tools, jigs & fixtures, set up, feed speed and so on.
5. Specifications of performance expected from each operation, standard time of each
operation, setup time, output expected per unit time etc.
After this one need to understand various process operation required. Depending on
nature of operations one has to decide which operation shall be done before other
operations. Operation include basic operations, principal operations, major operations
(critical operations, secondary operations, qualifying operations, re-qualifying
operations)
Figure 1. Steps in preparation of process plan


websites
2. Consider all possible alternative options available.
XI Procedure – (to prepare process plan)
i. Requirements and conditions of process – specifications of finished product, raw

material conditions, quantity to be produced. Various requirements of product
should be studied.
ii. Improvement of specifications – Investigate part design to economize
production. Suggest changes.
iii. List basic operations – Without any particular sequence list down all necessary
operations.
iv. Determine most practical & economical manufacturing method – Consider
economic materials, tooling, labor costs, overheads. Calculate & compare these
costs. Principal operations are decided by method by which work piece is
originated like forging, sheet metal etc.
v. Selection of equipment – They are long term investments. Consider size and
shape of material, work material, accuracy & surface finish required, quantity,
lot sizes, personal preferences are some considerations in selection of
equipments. This step will consider use of general or special purpose machines.
vi. Combine operations and put them in proper sequence – Put operations in best
sequence. Operations are combined in two ways: simulation & Integration.
vii. Specify gauging required for the process – Gauging requirements must be
specified to maintain quality & functionality of the parts.

Figure 2. Typical Process Plan
XII Resources Used
S. Name of Broad Specifications Quan Remarks

No Resource Make Details tity (If any)
.
1.
2.
3.

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(Students are expected to prepare process plan of a simple job.)
1. Analyze print – Largest diameter -

Assume tolerance –
Bar size needed
2. List basic operations –
Stop drill
Drill ………. mm
Turn ……… mm dia
Turn ……… mm dia
Form …….. mmdia
Face ………………
Radius ………
Cutoff
3. Machine tool selected –
4. Combine operations and put in sequence –

5. Specify gauging
6. Prepare operations sheet
Operation Sheet
Part Name - Material -
Part Number -
Operation Operation Machine Tools, gauge
No.
1
2
3
4
5
6
7
XVI Results
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XVIII Conclusions
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Q1. List processes involved in manufacturing of hexagonal nut / V-block. Prepare

process plan for the same.
Q2. Define 1. Principal operations 2.Qualifying operations 3.Re-qualifying operations.
Q3. Describe product & process critical areas.
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1. https://books.google.co.in/books?id=GRSbGhQ-
ywwC&printsec=frontcover&dq=production+engineering&hl=en&sa=X&ved=0a
hUKEwji3N2fwtfjAhVK4nMBHaDvDekQ6AEIKDAA#v=onepage&q=productio
n%20engineering&f=true (book on production Engineering)
2. https://www.slideshare.net/MurugananthanK/unit-1-introduction-to-process-
planning (process planning)

1 Identifying elements of process plan 20%
2 Preparation of process plan 20%
4 Conclusions 20%

1. ……………………..
2. ……………………….
3. …………………………

Teacher

Practical No. 8: Prepare chart of sequence of operations of a simple job.
Operation process chart is one of the tools useful in method study. It shows all the
operations that occur from reception of raw material to packaging of finished product.
Hexag onal nut & bolt are very common components required in almost all machines
used for production purpose. As well as in very common appliances that we use in our
day to day life these components are frequently used. Preparation of operation sheets
for such small components enables students to prepare complex operation sheets. A
typical gear can have as many as 30 operations. And similarly more complex parts can
have more number of operations.



components.
V Practical Outcome
Prepare chart of Sequence of operations for manufacturing of simple job like
manufacturing of hexagonal nut & bolt/ manufacturing of V-Block on shaper machine.


C (22657)
VII Minimum Theoretica

M T al Backgrou und
I method study inform
In mation recoording is im
mportant tassk. One of ttechniques used for
t same is process chaarts. Process charts can
the n be operation process chart / floww process
c
chart / operrator chart. Operation process
p charrt provides sequence oof all operattions and
a inspectiions that occur duringg manufactturing / business proccess. It also
all o shows
m
materials ussed and andd time takenn by operatoor for differeent elements of work.
I preparattion of thesse charts syymbols of operation ( ) and innspection ( ) are
In
n
necessary.
O
Operation i
indicates m
main steps, usually
u a material
m / product
p is m
modified, ad
dding or
s
subtracting during asseembly / disaassembly. In
nspection iss done to chheck quality
y and / or
q
quantity. e. g. measurinng dimensioons, countin ng number of o componeents.
A
Advantage es of OPC
( To improove shop/pllant layout
(i)
( Helps inn specifyingg the basic manufacturi
(ii) m ing system.
( Helps in
(iii) i determiniing sequencce of assemb bly and the scheduling activities reegarding
d
dates of purrchased matterial and coompletion dates
d for fabbricated partts.
( To introoduce the new
(iv) n technicaal personal withw the maanufacturingg system.
VIII E
Experimen
ntal setup
Figure 1 Typical hexagonal

h nut
n manufa
facturing

Figure 2 Typical operation process chart

1. Simple job drawing NA NA
2.
2. Best possible method of doing job must be used.
XI Procedure – (to prepare process plan)

i. Prepare list of operations to be carried out for a given part.
ii. Arrange all these operations in a sequence in which they must be manufactured.
iii. Identify operations which must follow inspection.
iv. Identify parameters for inspection.
v. Prepare a chart in standard format indicating all operations and inspections.
vi. Represent all operations & inspections along with symbols.

XII Resources Used

1.
2.
3.

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(Students are expected to prepare operation sheet of a simple job using suitable
method.)
S. No. Operation S. No. Inspection

XVI Results
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XVIII Conclusions
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Q1. List alternative methods for hexagonal nut manufacturing.
Q2. State advantages of cold forming.
Q3. List heat treatment methods required in manufacturing of hexagonal nut / v block.
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1. https://books.google.co.in/books?id=ecJWJZjuC-
cC&pg=PR5&source=gbs_selected_pages&cad=2#v=onepage&q&f=true
2. https://www.wuerth-
industrie.com/web/media/en/pictures/wuerthindustrie/technikportal/dinokapitel/Ka
pitel_04_DINO_techn_Teil.pdf

1 Identifying operations and inspections 20%
2 Preparation of Operation sheet 20%
4 Conclusions 20%

1. ……………………..
2. ……………………….
3. …………………………

Teacher

Practical No. 9 : Prepare chart of sequence of operations of a riveted joint.
Permanent joints cannot be dissembled without damaging the components. These
joints can be of two kinds depending upon the nature of force that holds the two parts.
The force can be of mechanical origin, for example, riveted joints, joints formed by
press or interference fit etc, where two components are joined by applying mechanical
force. The components can also be joined by molecular force, for example, welded
joints, brazed joints, joints with adhesives etc. Not until long ago riveted joints were
very often used to join structural members permanently. However, significant
improvement in welding and bolted joints has reduced the use of these joints. Even
then, rivets are used in structures, ship body, bridge, tanks and shells, where high joint
strength is required.



components.
V Practical Outcome
Prepare Chart of sequence of operation for Single or Double riveted lap joint / Single
riveted butt joint (single strap).



A Rivet is a short cylindrical rod having a head and a tapered tail. The main body of
the rivet is called shank.
The plates that are to be joined are brought face to face such that an overlap
exists. Rivets are inserted on the overlapping portion. Single or multiple rows of rivets
can be used to give necessary strength to the joint. Based on the number of rows the
riveted joints can be classified as single riveted lap joint, double or triple riveted lap
joint etc. While multiple joints are used, the arrangement of rivets between two
adjacent rows can be of two kinds. In chain type of riveting the adjacent rows have
rivets in the same transverse line. In zig-zag riveting, on the other hand, the adjacent
rows of rivets are staggered.
Riveting includes preparation of sheet metals plates, drilling / punching, using rivet
tool & die, heating rivet area, deform tail section manually or using machine.
Single riveted lap joint Double riveted lap joint

1. Internet, actual operation. NA NA
2.
1. List operations by observing the process.
2. Best possible method of doing job must be used.

XI Procedure –
i. Prepare list of operations to be carried out for an application need riveting.
ii. Arrange all these operations in a sequence in which they must be manufactured.
iii. Identify operations which must follow inspections.
iv. Identify parameters for inspection.
v. Prepare a chart in standard format indication all operations and inspections.
vi. Represent all operations & inspections along with symbols.
XII Resources Used

1.
2.
3.

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(Students are expected to prepare operation sheet of a riveting job using suitable
method.)
Chart of sequence of operations
Name of part – Drg. Number -
S. No. Operation S. No. Inspection

XVI Results
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XVIII Conclusions
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Q1. Define Pitch, diagonal pitch, transverse pitch, marginal pitch.
Q2. State essential qualities of rivet and it’s materials.
Q3. Compare hot riveting & cold riveting

Q4. State applications of riveted joints.

Q5. Comment on chain type & zigzag type riveted joints.
Q6. State relation between diameter of rivet & thickness of plate.
[Space for Answer]

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1. https://www.youtube.com/watch?v=tIgZi1duP3E
2. https://www.youtube.com/watch?v=H137Yb8TGvI
3. https://www.youtube.com/watch?v=IDbTUt3OG9s

1 Identifying operations and inspections 20%
2 Preparation of Operation sheet 20%
4 Conclusions 20%

1. ……………………..
2. ……………………….
3. …………………………

Teacher

Practical No.10 : Redesign the given simple lever(s) for best ergonomic
aspect.
A system is a set of elements, the relations between these elements and the boundary
around them. Most systems consist of people and machines and perform a function to
produce some form of output. Inputs are received in the form of material, energy and
information. In ergonomics, the human is part of the system and must be fully
integrated into it at the design stage. Human requirements are therefore system
requirements, rather than secondary considerations and can be stated in general terms
as requirements for:
• Equipment that is usable and safe
• Tasks those are compatible with people’s expectations, limitations and training
• An environment that is comfortable and appropriate for the task
• A system of work organization that recognize people’s social and economic needs.


.
• Apply ergonomic concepts to redesign simple mechanical control member for
comfort conditions in various industrial environments.
IV Practical Outcome
Redesign the given simple lever(s) like gear shifting lever /brake / clutch lever / foot
lever for best ergonomic aspect.
V Relative Affective Domain-


VI Minimum Theoretical Background

The focus is on the interaction between the person and the machine and the design of
the interface between the two. Every time we use a tool or a machine we interact with
it via an interface (a handle, a steering wheel, a computer keyboard and mouse, etc.).
We get feedback via an interface (the dashboard instrumentation in a car, the computer
screen, etc.) The way this interface is designed, determines how easily and safely we
can use the machine.
VII Experimental setup
Figure 1. Ergonomic chart for a typical setup
Figure 2. Ergonomics at BMW

General ergonomic variables
VIII Resources Required

websites
2. Charts
IX Precautions to be Followed
1. Redesign shall be economic
2. Aesthetic & ease of use shall be priority.
X Procedure
To increase efficiency many industries are using the concept of “Ergonomics”.
Example of Office is studied in following example
i. Chair – Should offer pneumatic seat-pan height adjustment, a backrest that tilts
backward and forward, backrest tension control and lumbar support.
ii. Adjustable workstation – Should offer height adjustability of work surface and
have a large surface with ample room to perform tasks.
iii. Keyboard/keyboard tray – Should lie flat and offer slope adjustability to
achieve up to ± 15° slope and have a low profile (approximately 1" or 30 mm).
iv. Input device – Features should include a long cord for proper placement or
wireless, should move easily and be usable by left- and right-handed users.

v. Monitor – Adjustable brightness and contrast, free from flicker and adjustable
tilt.
vi. Monitor arm/stand – Should be height-adjustable 27" (69 cm) to 34" (86 cm)
above the seat pan and the weight of monitor should match the weight of the
stand or arm.
vii. Wrist rest – Should be constructed of compressible or soft material to reduce
external pressure on the wrist and offer a non-friction surface.
viii. Headset – Should be digital, rather than analog, and offer a quick-disconnect
capability.
ix. Footrest – Needs to be height adjustable from 11" (28 cm) to 18" (46 cm).
x. Task lighting – Should offer 75 to 140-foot candles of adjustable lighting and be
asymmetrical to reduce shadows and glare spots.
xi. Laptops – Use an external mouse and keyboard for extended periods of
computer use and take regular breaks and change your posture when working for
long periods of time.
XI Resources Used

1.
2.
3.
XII Actual Procedure Followed

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XIII Precautions Followed

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XIV Observations and Calculations

Name of component selected – (Say Gear shifting level /students may use their
own chart if needed for other applications he / she has selected)

Parameter Existing situations Redesign suggested Justification

Location
Near to dashboard
/ Away from dash
board / steering
mounted
Level with respect
to driver seat
Below / Upwards
Readability
During day/ during
night
Posture while
shifting
Awkward / relaxed
Mechanical stress
Present / absent
Grip
Pinch / power
Activation pressure
Push / pull force
Seat up / down
adjustments
Lay out
(gear positions on
knob)
Reach from body
(inches / cm)
Knob / push button
type / touch button
Knob Material
XV Results
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XVI Interpretation of Results

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XVII Conclusions
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XVIII Practical Related Questions

Q1. Define Ergonomics.
Q2. State brief history of Ergonomics.
Q3. Write short note on Modern Ergonomics.
Q4. In brief explain design procedure for standing.
Q5. Explain design procedure for Sitting. Draw a typical one
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XIX References / Suggestions for Further Reading

1. https://en.wikipedia.org/wiki/Gear_stick
2. https://delphi.portal.covisint.com/.../Design-InErgonomicGuidelines.pdf/d9af2c23-
38...
3. http://www.allsteeloffice.com/SynergyDocuments/ErgonomicsAndDesignReferenc
eGuideWhitePaper.pdf
XX. Assessment Scheme

1 Listing parameters for design of existing 20%
component
2 Listing parameters of redesign suggested. 20%
4 Conclusions 20%

1. ……………………..
2. ……………………….
3. …………………………

Teacher

Practical No.11: Prepare and Analyze Steps To Solve The Given

Problem In Institute/Industry Using Quality Circle
Concept
Quality Circle is a small group of employees in the same work-area or doing a similar
type of work who voluntarily meet regularly for about an hour every week to
identify, analyses and resolve work-related problems, leading to improvement in
their total performance, and enrichment of their work life



e. Analyze the data obtained from the different quality control processes.
V Practical Outcome
Prepare and analyse steps to solve the given problem in institute/industry using quality
circle concept.


Quality circle is a management tool which is implemented in many organizations to
improve effectiveness of equipment in an organization. Quality circle is a tool which
gives a number of benefits like organizational performance improvement, product
quality improvement and improvement in the relationship within the organization
which motivate workers and improve team work among them. Implementation of

quality circle contains brief study of all factors which affect it. The main objective of
this practical is to study the factors which help in implementation of quality circle for
the success of organization.

Steps in quality circle problem solving

1. 1
2. 1
3. 1
4. 1
5. 1
6. 1
7. 1
8. 1
1. Avoid improper handling of Transducer
2. Don’t apply excessive pressure on tips of Transducer .
XI Procedure
The steps involved in the implementation process of Quality Circle are following:
1) Identification of problem: First of all the problem is identified by the Quality
Circle members which is to be solved.

2) Analysis of the problem: The selected problem is then analyzed by basic problem
solving techniques.
3) Generate alternative solution: On the basis of various causes the alternative
solutions are generated.
4) Selection of best solution: The best and the most suitable solutions is selected
from the alternative solutions.
5) Prepare action plan: The members prepare plan for the area of implementation,
date, time etc.
6) Presentation of solution to management: The solution is then presented before
the management for the approval.
7) Implementation of solution: The management evaluates the solution and
implements it for a small run to check its reliability.
Quality Circle Process

Student quality circle Traditional teaching methods are lacking in effective knowledge
transfer due to one way communication from teachers. But enhancement of course quality and
quality of teaching depends to the greater extent on a system to assess its effectiveness at the
receivers end and seeking important suggestions to overcome lacuna. Student involvement is
the most important condition for promotion of excellence in education. The more students are
involved in education, more intensely they engage in their education to make learning happen.

The use of quality circles in classroom is one way of increasing student involvement.
Classroom quality circle is small voluntary group of students enrolled from the same class
who meet regularly to provide continuous student generated feedback to the teaching team in
order to improve course content, structure and environment in the class. Student quality
circles are formed one for each class, with 5-10 student members in each circle. The quality
circle is structured as one of the members is selected as leader and the concerned staff
member as facilitator. The selection of the members is based on voluntary participation part of
it. Apart from this, selection can be done with a view to form diver;:; e committee in terms of
gender, class rank etc. In the beginning of every semester, concept and purposes of quality
circle along with its background and operation, needs to be explained to the member to ensure
appropriate results in the end. The QC members conduct the meeting at regular intervals
during the semester to collect and process data using appropriate quality citcle tools and
techniques. The QC members are required to take a proactive approach in soliciting feedback
from class members and should see that whole process is carried out in anonymous fashion
The feedback obtained is to be shared by QC members with teaching team and discussion is
expected regarding incorporating suggestions accrued and their implementation. Here, what is
important is teaching needs to be more flexible, open and responsive to student observations,
their opinion and suggestions to strengthen the objective with which quality circles are setup.
The classroom quality circles are beneficial for the reason that there is positive interaction
between staff and students. Some of the inputs, which the classroom quality circle team
receives for ensuring better teaching learning process, are;
• Frequency of written assignments,
• Content of lectures, • Assessment methods to be used,
• Frequency, duration and period of class tests during semester,
• Need to conduct extra evening sessions on 'How to Study',
• Extra lecture series for slow learners and those for those with backlog subjects,
• Providing lecture outlines and lecture material in the beginning of semester,
• Utilization of lecture hours more for discussion.
Finally, the gains expected to be achieved due to effective implementation of student quality
circles as above are;
• Improvement in students learning of course material,
• Enhancement in student's involvement,
• Increased students morale and satisfaction
• Enhancement in course quality and structure,
• Better way of utilizing student's input for restructuring course content and pedagogical
methodology,
• Improvement in climate of learning by open communication between students and faculty
members,
• Opportunity for students to share their inputs in a confidential manner.

XII Resources Used

No Resource Make Details (If any)
.
1.
2.
3.

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XVI Results
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XVIII Conclusions
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1. Enlist the advantages of Non-Contact type measuring Instruments

2. Compare between contact and Non-contact type Measuring Instruments
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1. http://www.academia.edu/12409229/A_study_of_the_quality_circles_concept_in_
Indian_industry_a_case_study_on_Bharat_Electronics_Limited_Ghaziabad_
2. https://www.jstor.org/stable/20712775
3. https://www.youtube.com/watch?v=sOU5FN7aD0Y
4. https://study.com/academy/lesson/quality-circle-definition-process.html

1 Preparing the steps in quality circle 20%
2 Analyzing the steps in Quality circle 20%
4 Conclusions 20%

1. ……………………..
2. ……………………….
3. …………………………

Teacher

Practical No. 12: Draw the frequency histogram, frequency polygon for
the samples and calculate mean, mode and median for
same.
Histograms or bar charts are quality improvement tools that are instantly recognizable
but are often neglected. They can offer a powerful analysis of problems. Continuous
process improvement requires that we collect data through simple quality tools such as
tally charts, but then people need to be able to analyze this data. One of the simplest
tools to do this with is a histogram or bar chart, a quality tool that many of us will be
familiar with from school. Histograms and other quality tools are key to achieving
continual process improvement of your business

PO4 - Engineering tools: Apply relevant Mechanical technologies and tools with an
understanding of the limitations.


Interpret control charts for variable and attribute data.
V Practical Outcome
Draw the frequency histogram, frequency polygon for the samples and calculate mean,
mode and median for same.



A histogram is a graphical representation of data. The data is represented by columns
on a graph which vary in height depending on the frequency (how many times) the
specific range of data occur.
Why use a histogram as a quality tool?
1. Displays data in an easy-to-interpret graphical manner
2. Shows frequency of occurrence of data values
3. Reveals the centering, variation and shape of the data
4. Illustrates the underlying distribution of the data
5. Enables future prediction of process performance
6. Enables identification in changes in processes parameters
7. Allows one to answer the question: “Is the process capable of meeting the
customer requirements?”
The frequency polygon is a polygon - a closed two-dimensional figure of straight line
segments - joining the mid points of the top of the bars of a histogram.
Histogram tells us -
• Centering of the process data: The centering of the data provides information on
the process about some mean.
• Spread of the data: Histogram width defines the variability of the process about
the mean
• Shape of the histogram: Bell or normal shaped histogram is expected. Other than
normal or bell shape means something wrong with the process responsible for poor
quality.

1. From the given data in the table find out mean and standard deviation.
Class 0-4 5-9 10-14 15-19 20-24 25-29 30-34
Frequency 5 10 15 20 14 11 6

1. Relevant inspection data for a NA NA
typical process
2.
2. Adequate sampling data shall be collected.

XI Procedure – (Histogram)
1. Define Categories for Data
2. Collect Data, sort them into the categories
3. Count the Data for each category
4. Draw the Diagram. Each category finds its place on the x-Axis.
5. The bars will be as high as the value for the category
1. MeanorAverage:Meanoraverageisameasureofcentraltendencyorlocation.Thenotation
x (x bar) is used to denote mean or average. Thus if there are “n” number of
observations valued
x1, x2, x3………xn, then
……..
The mean for grouped data i.e. data having frequency can be find using
∑
Where
…..
…..
2. Mode: Mode is the value that occurs most frequently. But the most important one
used in statistical quality control is half the mean oraverage.
For grouped data where frequency is given: Mode will be the value with the largest
frequency. If class or cell is given: The mode can be found out by using the formula
mode = L + *i
Where, L= Lower Boundary of the class having
maximumfrequency
=Frequency of the class before the class having
maximumfrequency
=Frequency of the class after the class having
maximumfrequency
3. Median:Medianisthemagnitudeofmiddleclass,i.e,thevaluethathastheobservationab
ove its half and half below it. Therefore, median can be said as middle
observation, dimension or figure.
For simple data: First arrange the data in ascending order and then find the middle
value. If the observation is even, then adding the two middle values and divide it by 2.
For grouped data having frequency: The median can be find using the following
formula:

First divide the frequency by 2, we will get the class by answer of the division then
using the formula
median = + *i
Where, L= Lower Boundary of the median class

N= number of observations
=Frequency of the median class
C = Sum of Frequencies of all classes below median class
i = class interval
Spread or dispersion: The manner in which the observation is spreader between
minimum and maximum is called spread or dispersion. They are of twotypes:
1. Range:Itisameasureofdispersionanditisthedifferencebetweenthelargestobserve
dvalue and the smallest observed value of a set of observations. It is
represented by the symbol‘R’.
2. Standard Deviation: It is defined as the root mean square deviation of the
observed value from their arithmetic mean. It is denoted as σ (sigma)
So,
..
Variance: The square of standard deviation is called variance.
Normalized deviation of Z-value: For measuring the areas under normal

distributioncurve, the normal deviation is used. It is also calledZ-value
Z=
= The value up to which area is tobe
found
= Mean Value
σ = Standard Deviation
XII. Resources Used

1.
2.
3.

XIII. Actual Procedure Followed

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XIV. Precautions Followed

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XV. Observations and Calculations

(Students are expected to find mean, median standard deviation and draw
normal distribution curve for a suitable data / data given by teacher .)

XVI. Results
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XVII. Interpretation of Results

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XVIII. Conclusions
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XIX. Practical Related Questions

Q1. Draw Histogram, Frequency Bar Chart, Frequency Polygon and Frequency
Distribution Curve from the followingdata:
75, 80, 63, 65, 70, 12, 18, 22, 31, 33, 34, 35, 38, 40, 52, 55, 57, 60, 41, 45, 47, 49
Q2. Calculate mean, median, mode and range for the
following data: 2, 4, 5, 4, 9, 6, 4, 6
[Space for Answer]

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1. https://toughnickel.com/business/Histograms-Bar-Charts-Quality-Tools
2. https://www.researchoptimus.com/article/x-bar-and-r-chart-difference.php
3. https://ncss-wpengine.netdna-ssl.com/wp-
content/themes/ncss/pdf/Procedures/NCSS/X-bar_and_R_Charts.pdf

1 Drawing of frequency Histogram, frequency 20%
polygon
2 Calculation of mean, mode and median 20%
4 Conclusions 20%

1. ……………………..
2. ……………………….
3. …………………………

Teacher

Practical No. 13 : Draw the normal distribution curve, calculate deviation,

variance, range and determine the process capability for 3σ Or 6σ.
In day to day routine, the event in which the normal distribution curve can applied
are figures for age of students studying in a class, eligible voters’ data, and rainfall
figures at a place during tenyears. Standard deviation is widely used to obtain
important findings in the subjects like sociology, psychology andstatistics.
Standard deviation is useful in controlling quality inindustries. It is also useful to
estimate the quality of whole lot, only by drawing & checking a small sample from
that lot. It helps to indicate the process that is stable, but not able to produce items
withintolerances. Also it helps to indicate that the process is stable, producing item
within tolerances. If this is pulled to one side, then it shows that either there are
more number of larger or smaller products than the normalsize..



V Practical Outcome
Draw the normal distribution curve, calculate Deviation, Variance, Range and
determine the process capability for 3σ or 6σ.




Normal Distribution Curve: Normal distribution curve shows the simplest pattern of
distribution upon the type of thing being measured. There is generally a pattern of
distribution that indicates the way in which a dimension can vary. If the dimensional
variability in products of a system is by chance, then it will follow approximately
‘Normal Distribution Curve’
In a normal distribution curve, there are two statistical controls, average and standard
deviation. It has been calculated that two times the standard deviation covers about
68% of the total area. Four times the standard deviation covers 95.5% and six times
the standard deviation covers 99.73% of the total area.
1. From the given data in the table find out mean and standarddeviation.
Class 0-4 5-9 10-14 15-19 20-24 25-29 30-34
Frequency 5 10 15 20 14 11 6
2. Draw Normal Distribution curve from the followingdata:

Upper & lower specification limits of shaft diameter are 30.20 and 30.00mm
respectively. Mean diameter of shaft is 30.05mm and standard deviation is
0.05mm. Find out how many parts out of 400 will be accepted.
Z-value Area
3 0.4987
-1 0.3413

1. Relevant inspection data for a NA NA
typical process

XI Procedure –
1. MeanorAverage:Meanoraverageisameasureofcentraltendencyorlocation.Thenota
tion
x (x bar) is used to denote mean or average. Thus if there are “n” number of
observations valued
x1, x2, x3………xn, then
……..
The mean for grouped data i.e. data having frequency can be find using
∑
Where
…..
…..
2. Mode: Mode is the value that occurs most frequently. But the most important one
used in statistical quality control is half the mean oraverage.
For grouped data where frequency is given: Mode will be the value with the largest
frequency. If class or cell is given: The mode can be found out by using the formula
mode = L + *i
Where, L= Lower Boundary of the class having
maximumfrequency
=Frequency of the class before the class having
maximumfrequency
=Frequency of the class after the class having
maximumfrequency
3. Median:Medianisthemagnitudeofmiddleclass,i.e,thevaluethathastheobservationab
ove its half and half below it. Therefore, median can be said as middle
observation, dimension or figure.
For simple data: First arrange the data in ascending order and then find the middle
value. If the observation is even, then adding the two middle values and divide it by 2.
For grouped data having frequency: The median can be find using the following
formula:
First divide the frequency by 2, we will get the class by answer of the division then
using the formula
median = + *i

Where, L= Lower Boundary of the median class

N= number of observations
=Frequency of the median class
C = Sum of Frequencies of all classes below median class
i = class interval
Spread or dispersion: The manner in which the observation is spreader between
minimum and maximum is called spread or dispersion. They are of twotypes:
3. Range:Itisameasureofdispersionanditisthedifferencebetweenthelargestobserve
dvalue and the smallest observed value of a set of observations. It is
represented by the symbol‘R’.
4. Standard Deviation: It is defined as the root mean square deviation of the
observed value from their arithmetic mean. It is denoted as σ (sigma)
So,
..
Variance: The square of standard deviation is called variance.
Normalized deviation of Z-value: For measuring the areas under normal

distributioncurve, the normal deviation is used. It is also calledZ-value
Z=
=
Thevalueuptowhichareaistobefound
= Mean Value
σ = Standard Deviation
XXI. Resources Used

1.
2.
3.
XXII. Actual Procedure Followed

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XXIII. Precautions Followed

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XXIV. Observations and Calculations

(Students are expected to find mean, median standard deviation and draw
normal distribution curve for a suitable data / data given by teacher.)
XXV. Results
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XXVI. Interpretation of Results

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XXVII. Conclusions
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XXVIII. Practical Related Questions

Q1. Draw Histogram, Frequency Bar Chart, Frequency Polygon and Frequency
Distribution Curve from the followingdata:
75, 80, 63, 65, 70, 12, 18, 22, 31, 33, 34, 35, 38, 40, 52, 55, 57, 60, 41, 45, 47, 49
Q2. Calculate mean, median, mode and range for the
following data: 2, 4, 5, 4, 9, 6, 4, 6
[Space for Answer]

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1. https://www.pqsystems.com/qualityadvisor/DataAnalysisTools/x_bar_range.php
XXIX. Assessment Scheme

1 Drawing normal distribution curve 20%
2 Calculation of various parameters 20%
4 Conclusions 20%

1. ……………………..
2. ……………………….
3. …………………………

Teacher

Practical No. 14 : Draw and interpret the control charts ( − R chart).
Control charts like the X-Bar and R-Chart are often used in business applications like
manufacturing, to measure equipment part sizes; in service, industries to evaluate
customer support call handle times, or in healthcare for uses like measuring blood
pressure over time. These are variable control charts. Variable data include things we
can measure. Example includes length, weight, time, temperature, diameter, etc.
Variable Quality is one that can be measured like . Diameter of shaft, length of bolt,
radius of pulley, hardness of materials, strength, density, weight and temperatures are
the examples of variablequality. X-bar and R charts are used to monitor the mean and
variation of a process based on samples taken from the process at given times (hours,
shifts, days, weeks, months, etc.). The measurements of the samples at a given time
constitute a subgroup. Typically, an initial series of subgroups is used to estimate the
mean and standard deviation of a process. The mean and standard deviation are then
used to produce control limits for the mean and range of each subgroup.

PO3 - Experiments and practice: Plan to perform experiments and practices to use
the results to solve broad-based Mechanical engineering problems.


V Practical Outcome
Draw and interpret the control charts ( − Rchart) for given data.




− R charts - This type of control charts is used for manufactured parts which the
inspector checks by measurement and not by gauging. This method of control is more
expensive. It reveals much more about the behavior of the process. The − R charts
supply a basis on which to judge the stability of the pattern of variation. To found out
whether the process is in the state of control or not, control limits are setup. The
control chartisusually maintained for averages and not for individual components. The
distribution for individual may or may not be normal but the distribution for averages
follow normal distribution. In any manufacturing process there is some variation from
piece to piece. Two kinds of variation exist in manufacturing. The variation due to
chance causes & assignable causes. The chance causes are inevitable in any process.
This inherent process variation is a characteristic of the process and is the result of
random causes. These random fluctuations cause the process to deviate either side of
the average.

Construct -R Chart and show calculations for the following:
1. From the given data find out control limits for X-bar & R chart. Calculate
standard deviation and process capability.
Observation
No. 1 2 3 4 5 6 7 8
26.00 34.00 28.50 32.75 29.25 26.00 27.25 30.25
R 30 17 18 23 30 15 19 18
A2=0.73, D4=2.28, d2=2.059

1. Product samples with defects NA NA

XI Procedure –
I. Take random sample from production process, and measure its important
quality such as length, diameter. Indicate this dimension as -variable for
all such sub-groups it is necessary to take 4 or 5 observations. For inspection
take such 25sub-groups.
II. Calculate andRforallsubgroups.Risthedifferencebetweenthemaximumandmi
nimum value of individual subgroup.
III. The values of-and R follows the principle of standard deviation. Calculate the
mean of and R asunder:
x R
x=n R n
'Where = mean of or mean of average of subgroup
= mean of Spread-R
= Average or mean of thesubgroup
R=spread
N=No. of random sample
is the central or middle line of chart.
is the central or middle line of R chart.
IV. Calculate the upper control limit- UCL. This line is at a distance of 3σ from the
central line of chart, above the line.
= +3
= + 2
The is constant which depends upon size of subgroup and can be found from the
table of constants.
V. Calculate lower control limit-LCL. This line is at a distance of 3σ from the

central line of chart, below the line.
= −3 = − 2
VI. To draw control lines for R-chart. Calculate as mean of R observations & then
find upper control limit (UCL ) lower control limit(LCL),
= 4 & = 3
Where 3& 4 are constants which are obtained from the table of
constants
VII. To draw each chart mark, the value of and R & obtain corresponding
points. Joint these points by straight lines.
VIII. Calculate standard deviation using formula as given below:
=
2

IX. Calculate Process capability, ́ = 6 ·
Where , is the constant for standard deviation which is given in table of constants.
Following is table of constants

Sample Constant Constant for
Size for -chart Constants for R-chart Standard
Deviation
n 2 3 4 2
2 1.880 0 3.268 1.128
3 1.023 0 2.574 1.693
4 0.729 0 2.282 2.059
5 0.577 0 2.114 2.326
6 0.483 0 2.004 2.534
7 0.419 0.076 1.924 2.704
8 0.373 0.136 1.864 2.847
9 0.337 0.184 1.816 2.970
10 0.308 0.223 1.777 3.078
X. Resources Used
1.
2.
3.
XII. Actual Procedure Followed

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XIII. Precautions Followed

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XIV. Observations and Calculations

(Students are expected to prepare − R chart on a sheet separately.)
XV. Results
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XVI. Interpretation of Results

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XVII. Conclusions
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XVIII. Practical Related Questions

Q1. Amachineisworkingtoaspecificationof12.58±0.05mm.Astudyof50

consecutive pieces shows the following measurements for 10 groups of sample:

Construct − R chart and show the calculations. Find process capability
1 2 3 4 5 6 7 8 9 10
12.54 12.58 12.61 12.57 12.57 12.58 12.6 12.65 12.6 12.65
12.58 12.57 12.6 12.61 12.60 12.59 12.62 12.57 12.59 12.61
12.62 12.6 12.64 12.56 12.62 12.59 12.61 12.57 12.6 12.6
12.56 12.6 12.58 12.59 12.61 12.56 12.67 12.56 12.63 12.62
12.59 12.61 12.64 12.59 12.58 12.57 12.6 12.61 12.56 12.62
Q2. Define process capability.
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XIX. References / Suggestions for Further Reading

1. https://www.pqsystems.com/qualityadvisor/DataAnalysisTools/x_bar_range.php

1 Handling of the measuring Instruments 20%
4 Conclusions 20%

1. ……………………..
2. ……………………….
3. …………………………

Teacher

Practical No. 15 : Draw and interpret the control charts

(p-chart and c-chart).
These are attribute control charts. It can not have fractions or decimals. These control
charts deals with attributes like presence or absence of something, success or failure,
accept or reject, correct or not correct. P chart informs number of defective items as a
percentage of whole. For e.g number of broken eggs in a cartoon, number of leaking
tubes in a box of 48. C chart are used for discrete defects where there can be more than
one defects per unit. For e.g. number of flaws in a carpet, number of complaints per
customer of a hotel.

PO3 - Experiments and practice: Plan to perform experiments and practices to use
the results to solve broad-based Mechanical engineering problems.


V Practical Outcome
Draw and interpret the control charts (P-chart and C-chart) for given data.



Statistical control charts are graphs used to monitor a production process.
Samples are taken from the process periodically and observations are plotted on the
graph. Upper and lower control limits are determined. If any observation is outside
the limit it indicates that some thing is wrong with the process. Attribute of a product
can be color, surface texture, cleanliness, smell, taste etc. If quality specifications are
complex attribute test can be useful for determining product acceptance.
1. Construct P-chart using data given
There are 10 samples of shaft taken for inspection. Draw P-chart and state
whether the process is under control or not, from the data given asunder:
Number
of 200 200 200 200 200 200 200 200 200 200
Products
Defective 12 4 8 3 7 6 0 8 5 9
Products
2. Construct C-chart using data given below
During the production of Nano Car, 10 cars were inspected and defects in each car
were as under. Draw C-chart, control limits and comment about theprocess:
Nano Car No. 1 2 3 4 5 6 7 8 9 10
Defects in
Nano Car 1 3 13 4 2 5 3 3 4 5

1. Product samples with defects NA NA
2.

XI Procedure – (for p-chart)

i. Samples are taken from manufactured product and number of faults or defects in it
are counted.
ii. The size of the defect is not measured. For example, say 100 pins are inspected out
of which 12 are found defective then it is rejected.
iii. Note that the size, location or shapeof the defects is not important and
notmeasured.
iv. Fraction defective, P is defined as the ratio of number of defective units in each lot
v. inspected to the number of units in thelot.
Suppose we have taken a lot of ‘n’ number of products from the process, out of which
‘d’ number of products found defective, then fraction defective of that lot can be found
out as under:
fraction defective = p = d / n
i. Find out standard deviation = ρp = SQRT (
Where p-bar is Average fraction defective = Σp / N
Where Σp = number of defective products in all samples
N = Number of samples taken
Control Limits for p-chart can be calculated as
1. Upper control limit (UCL) = + 3 * SQRT (
2. Lower control limit (LCL) = - 3 * SQRT (

For R chart –
The control limit of C-Chart is based on Poisson’s distribution. So the center line of C-
chart can be found out using the following
Average defect = Total number of defects / numbers of assembly inspected.
Control limits of C-chart can be calculated as
1. Upper control limit (UCL) = + 3 * SQRT (
2. Lower control limit (LCL) = - 3 * SQRT (
XII Resources Used

1.
2.
3.

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(Students are expected to draw p-chart & c-chart for suitable data / data given by
teacher)
Calculate UCL & LCL for both charts
Use separate sheets to prepare charts and attach them.

XVI Results
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XVIII Conclusions
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such questionsso as to ensure the achievement of identified CO.
Q1. State importance of capability analysis?

Q2. A hospital manager receives complaints as per following table in 15 days. What
are control limits one will construct a control chart using three sigma limits.
Days No. of Days No. of Days No. of Days No. of
complaints complaints complaints complaints
1 4 5 4 9 5 13 4
2 6 6 8 10 3 14 6
3 4 7 6 11 5 15 4
4 5 8 7 12 4
Q3. In a car manufacturing company, 10 assembly of a car was inspected and the
defects were found as under. Draw C-chart, control limits and comment about the
process:
Car Assembly 1 2 3 4 5 6 7 8 9 10
No.
Number of 5 4 4 10 5 9 7 3 2 1
defects

Q4. No. of defectives Spark plugs for ten samples are 4,3,4,5,3,4,5,3,5,4 in a sample
size of 100. Selecting suitable control chart, find upper control limit and lower control
limit. Also give your comment either the process is under control ornot.
[Space for Answer]

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1. https://www.pqsystems.com/qualityadvisor/DataAnalysisTools/c_chart.php
content/themes/ncss/pdf/Procedures/NCSS/C_Charts.pdf
3. https://www.spcforexcel.com/knowledge/attribute-control-charts/c-control-charts

1 Handling of the measuring Instruments 20%
4 Conclusions 20%

1. ……………………..
2. ……………………….
3. …………………………

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Roll No. 20_______

MECHANICAL GROUP| SEMISTER VI | DIPLOMA IN ENGINEERING AND TECHNOLOGY

Industrial Engineering and

Place ………………. Enrollment No……………………

Course Teacher Head of the Department Principal

Maharashtra State Board of Technical Education i

Based mechanical engineering related problems.

Maharashtra State Board of Technical Education ii

Practical- Course Outcome matrix

Maharashtra State Board of Technical Education iii

Instructions for Students

Maharashtra State Board of Technical Education iv

S. Practical Outcome Page Date of Date of Assessment Dated Rema

1. Apply method study approach to

Maharashtra State Board of Technical Education v

10. Redesign the given simple lever(s)

Note: To be transferred to Proforma of CIAAN-2017.

Maharashtra State Board of Technical Education vi

Practical No.1 : Analyze the motions involved in machining

II Relevant Program Outcomes (POs)

III Competency and Skills

IV Relevant Course Outcome(s)

VI Relative Affective Domain-

VII Minimum Theoretical Background

Maharashtra State Board of Technical Education 1

Maharashtra State Board of Technical Education 2

Event Symbol Description

Storage Representing stage when material awaits an action.

Delay or Indicates delay or a temporary hurdle in the

Transport Indicates movement of men, materials from one

Inspection Represents an action of inspection or checking for

Meaning of different symbols used in Process chart

VIII Experimental setup

Fig.1 Recording devices

Maharashtra State Board of Technical Education 3

S. Name of Resource Suggested Broad Specification Quantity

XII Resources used

S. Name of Resource Broad Specifications Quantity Remarks

XIII Actual Procedure Followed

XIV Precautions Followed

Maharashtra State Board of Technical Education 4

XV Observations and Calculations

Process flow chart

Sr. Observed motions Essential motions Excess motions

Maharashtra State Board of Technical Education 5

XIX Practical Related Questions

[Space for Answer]

Maharashtra State Board of Technical Education 6

XXI Assessment Scheme

Performance Indicators Weightage

Names of Student Team Members

Marks Obtained Dated signature of

Maharashtra State Board of Technical Education 7

Practical No.2 : Apply work measurement technique to analyze the time

II Relevant Program Outcomes (POs)

III Competency and Skills

IV Relevant Course Outcome(s)