BTM 3713 Set 1 - Final Exam Question Paper (v2)

FINAL EXAM QUESTIONS
COURSE : LEAN MANUFACTURING SYSTEM
COURSE CODE : BTM3713
COURSE COORDINATOR : MOHD GHAZALI BIN MAAROF
DATE : 16 FEBRUARY 2022
DURATION : 2.5 HOURS
SESSION/SEMESTER : SESSION 2021/2022 SEMESTER I
PROGRAMME CODE : BTM
INSTRUCTIONS TO CANDIDATES:
1. This examination paper consists of FIVE (5) questions. Answer ALL questions.
2. All answers to a new question should starts on a new page.
3. All the calculations and assumptions must be clearly stated.
4. Candidates are not allowed to bring any materials other than those allowed by the
invigilator into the examination room.
EXAMINATION REQUIREMENTS:
1. NIL
APPENDIX:
1. NIL
DO NOT TURN THIS PAGE UNTIL YOU ARE TOLD TO DO SO
This examination paper consists of SIX (6) printed pages including the front page.
CONFIDENTIAL 2122I/BTM3713
ANSWER ALL QUESTIONS [100 MARKS]
QUESTION 1 [20 MARKS]
a) Jidoka is consider as the second pillar used in the Toyota Production System. Apply
FIVE (5) lean tools that can help manufacturing firm to improve quality. Support your
argument by giving an example to each tool that you have proposed.
[10 Marks]
[CO3, PO11, A3]
b) The Toyota Production System (TPS) integrates and attains different production goals
while pursuing its goal to improve the company’s “efficiency”. By applying the TPS
principles, propose strategies that can help companies to attain cost reductions in the
design and production phase.
[10 Marks]
[CO3, PO11, A5]
a) Total Productive Maintenance (TPM) is a lean tool used to prevent machine downtime
within the production process. Identify strategies that can support the automotive
manufacturing companies to implement TPM effectively.
[10 Marks]
[CO3, PO11, A4]
b) In a preliminary study, Kamari has observed his workers perform the assemble of the
ceiling fan for five times as shown in Table 1. Each reading shown in the table are in
seconds. The observations were made under an air-conditioned, well-lighted training
facility, with all tools and equipment clean and readily available.
2
Table 1: Cycle time to assemble the ceiling fan
Tasks Observation 1 2 3 4 5
Task A 40 40 80 45 42
Task B 30 29 50 32 29
Task C 45 44 82 41 44
Task D 30 32 75 30 31
Task E 40 43 90 42 41
i) Find the actual average time for one complete cycle time of the ceiling fan?
[2 Marks]
[CO3, PO11, A3]
ii) Calculate the normal time for this task if the employee worked at a 20% faster pace
than a typically adequately trained worker.
[2 Marks]
[CO3, PO11, A3]
iii) Calculate the standard time for this task if allowances are 8% constant and 6%
variable.
[2 Marks]
[CO3, PO11, A3]
iv) Propose FOUR (4) methods that can improve the accuracy of your time-study.
[4 Marks]
[CO3, PO11, A5]
3
a) Company X assemble the high quality LED bicycle lights in their factory that is located
in Pekan, Pahang. Based on the information given int Table 2:
Table 2: Production data of the LED bicycle lights
Item Data
Shift length 8 hrs = 480 min.
Short Breaks 2@ 15 min. = 30 min
Meal Break 1 @ 30 min = 30 min
Down Time 47 min
Ideal Run Time 60 pieces per min
Total Input 19,271 pieces
Pieces
Reject Pieces 423 pieces
Calculate:
i) Equipment Availability (EA)
[2 Marks]
[CO3, PO11, A3]
ii) Equipment Efficiency Performance (EEP)

[2 Marks]
[CO3, PO11, A3]
iii) Equipment Quality Performance (EQP)

[2 Marks]
[CO3, PO11, A3]
iv) Overall Equipment Effectiveness (OEE)

[2 Marks]
[CO3, PO11, A3]
v) Propose actions that can improve the OEE result you get in part (iv)
[2 Marks]
[CO3, PO11, A5]
4
b) Explain FIVE (5) effects of having a high inventory in an assembly line.

[10 Marks]
[CO3, PO11, A4]

a) In a pull system, synchronization is achieved by setting the Cycle times (CTs) at every
upstream operation according to the cycle time at final assembly. Cycle Time (CT) is
the voice of the process while Takt Time (TT) is driven by the customer. There are two
conditions.
CT is greater than TT and
CT is too low than TT
i) Compare the effect of those two conditions.

[4 Marks]
[CO3, PO11, A4]
ii) Propose the solution to overcome these two conditions.

[6 Marks]
[CO3, PO11, A5]
b) Instead of using a push system, lean manufacturing applies the pull system with kanban
as the main tool to ensure the discipline of its implementation.
i) Explain TWO (2) main objectives of pull system.

[4 Marks]
[CO3, PO11, A5]
ii) Differentiate between pull and push systems based on at least THREE (3)
characteristics between the two systems.
[6 Marks]
[CO3, PO11, A5]
5
QUESTION 5 [20 MARKS]:

a) A lean system is characterized by mixed model production in small lot size, which can
only be realized when setup is done quickly. For this purpose, Shigeo Shingo developed
a technique, which is called single-minute exchange of die (SMED). Differentiate
between internal and external setups.
[6 Marks]
[CO3, PO11, A5]
b) As originally presented by Taiichi Ohno (1988), there are SEVEN (7) types of cardinal
waste, which lean management aims to reduce. Discuss the waste in lean.
[14 Marks]
[CO3, PO11, A5]
END OF QUESTION PAPER

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FINAL EXAM QUESTIONS

COURSE : LEAN MANUFACTURING SYSTEM

COURSE CODE : BTM3713

COURSE COORDINATOR : MOHD GHAZALI BIN MAAROF

DATE : 16 FEBRUARY 2022

DURATION : 2.5 HOURS

SESSION/SEMESTER : SESSION 2021/2022 SEMESTER I

PROGRAMME CODE : BTM

DO NOT TURN THIS PAGE UNTIL YOU ARE TOLD TO DO SO

ANSWER ALL QUESTIONS [100 MARKS]

QUESTION 1 [20 MARKS]

QUESTION 2 [20 MARKS]

Table 1: Cycle time to assemble the ceiling fan

QUESTION 3 [20 MARKS]

ii) Equipment Efficiency Performance (EEP)

iii) Equipment Quality Performance (EQP)

iv) Overall Equipment Effectiveness (OEE)

b) Explain FIVE (5) effects of having a high inventory in an assembly line.

QUESTION 4 [20 MARKS]

i) Compare the effect of those two conditions.

ii) Propose the solution to overcome these two conditions.

i) Explain TWO (2) main objectives of pull system.

QUESTION 5 [20 MARKS]:

END OF QUESTION PAPER

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