Unit 1: Foundations of Manufacturing and Production Systems
1. Explain manufacturing industries and products with suitable examples from discrete
manufacturing and process manufacturing industries.
2. State and explain different manufacturing operations used to convert raw materials into
finished products. Explain any two operations in detail with suitable examples.
3. What are manufacturing facilities? Explain the role of production facilities, machine
tools, material handling systems, and inspection systems in manufacturing industries.
4. Explain the concept of a production system and describe its major elements such as
manpower, machines, materials, methods, and management.
5. Explain the relationship between product variety and production quantity in
manufacturing systems with suitable examples.
6. Differentiate between low-volume, medium-volume, and high-volume production
systems based on layout, flexibility, and product variety.
7. State and Explain different types of factory layouts such as process layout, product
layout, fixed-position layout, and cellular layout with applications.
8. What are production performance metrics? Explain productivity, cycle time, lead time,
utilization, availability, and overall equipment effectiveness (OEE).
9. Explain manufacturing costs and discuss different cost elements such as material cost,
labor cost, overhead cost, tooling cost, and maintenance cost.
Unit 2: Automation in Manufacturing
1. Define automation in manufacturing and explain the need and objectives of
automation in modern industries.
2. Explain different types of automation such as fixed automation, programmable
automation, and flexible automation with suitable industrial examples.
3. State and explain automation principles and strategies
4. Explain the basic elements of an automated system such as power source, program
of instructions, and control system with neat sketches.
5. What are advanced automation functions? Explain safety monitoring, maintenance
diagnostics, process optimization, and automated quality inspection.
6. Explain different levels of automation in manufacturing systems with neat block
diagrams.
7. Explain the advantages and limitations of automation in manufacturing industries.
8. State and explain automation principles and strategies used for improving
productivity and reducing manufacturing costs.
9. Explain the role of automation in smart manufacturing and Industry 4.0
environments.
Unit 3: Sensors, Actuators, and Control
1. Define sensors and actuators. Explain different types of sensors used in manufacturing
industries with suitable applications.
2. Differentiate between Servomotor and Stepper motor
3. Explain Analog-to-Digital Conversion (ADC) and Digital-to-Analog Conversion
(DAC) with neat block diagrams.
4. Explain input devices and output devices used for discrete data collection in automated
manufacturing systems.
5. Differentiate between continuous control systems and discrete control systems with
suitable industrial examples.
6. Compare process industries and discrete manufacturing industries based on production
methods, control systems, and product characteristics.
7. Explain the role of sensors in process monitoring, inspection, and quality control in
automated manufacturing.
8. Explain the working principle and applications of temperature sensors, displacement
sensors, and optical sensors.
9. Explain the importance of control systems in manufacturing automation and discuss
open-loop and closed-loop control systems.
Unit 4: Material Handling and Storage
1. Define material handling and explain its importance in manufacturing industries.
2. Explain the objectives and principles of material handling systems used in production
environments.
3. Explain different types of material transport systems used in manufacturing industries
and explain any four in detail.
4. Classify material handling equipment and explain industrial trucks, conveyors, cranes,
and hoists with applications.
5. Explain different types of conveyors used in manufacturing industries with neat
sketches and applications.
6. Differentiate between AGV and Autonomous Mobile Robot (AMR) with suitable
examples.
7. State different types of cranes used in material handling explain any three with neat
sketch.
8. Explain conventional storage methods used in manufacturing industries and discuss
their advantages and limitations.
9. Explain Automated Storage and Retrieval Systems (ASRS) and discuss their
components, working principle, and applications.
Unit 5: Manufacturing Systems and Cells
1. Explain the concept of manufacturing systems and discuss their major components.
2. Classify manufacturing systems and explain job shop, batch production, mass
production, and continuous production systems.
3. Classify manufacturing systems and explain Single station automated cell
4. Compare manual vs automated assembly lines.
5. Explain automated production lines and assembly systems with suitable industrial
examples.
6. What is Flexible Manufacturing System (FMS)? Explain its components, working
principle, advantages, and applications.
7. Explain the role of robotics in manufacturing industries and discuss different industrial
robot configurations.
8. Explain the applications of industrial robots in welding, painting, material handling,
assembly, and inspection operations.
9. Explain the advantages, challenges, and future scope of flexible and automated
manufacturing systems.
Unit 6: Digital Manufacturing and Industry 4.0
1. Define Manufacturing Execution System (MES) and explain its functions in production
planning, monitoring, and control.
2. Define Enterprise Resource Planning (ERP and discuss its functions and modules of
Enterprise Resource Planning (ERP) systems.
3. Differentiate between MES and ERP systems based on functions, scope, data handling,
and industrial applications.
4. Explain different checkpoints of MES and ERP systems in manufacturing industries.
5. Explain the mapping of MES and ERP systems with manufacturing KPIs such as
productivity, quality, downtime, and inventory control.
6. Explain the concept of Industry 4.0 and discuss its major technologies such as IoT, AI,
cloud computing, big data, and cyber-physical systems.
7. Analyze the role of Industry 4.0 technologies in transforming manufacturing.
8. Explain future factories and discuss emerging trends and technologies in smart
manufacturing environments.
9. Compare traditional manufacturing systems with smart factories
.