All questions of Industrial Engineering for Mechanical Engineering Exam

The standard time of an operation while conducting a time study is:   
  • a)
    Mean observed time + Allowances
  • b)
    Normal time + Allowances  
  • c)
    Mean observed time × Rating factor + Allowances  
  • d)
    Normal time × Rating factor + Allowances 
  • e)
     
Correct answer is option 'C'. Can you explain this answer?

Avinash Sharma answered
Correct Answer :- c
Explanation : Thus, Standard time = Average Time × Rating factor + Other allowances. 
Standard Time: It is the time, which is taken by a normal worker for a specific task or job, working under moderate conditions and includes other allowances such as fatigue, setting of tool and job, repairing of tool, checking of job etc.

In ABC analysis, A items require: 
  • a)
    No safety stock      
  • b)
    Low safety stock    
  • c)
    Moderate safety stock    
  • d)
    High safety stock 
Correct answer is option 'B'. Can you explain this answer?

Shruti Bose answered
ABC analysis is a technique used in inventory management to classify items into three categories based on their importance. A items are the most important items, B items are moderately important, and C items are the least important. In this context, safety stock refers to the extra inventory that is kept on hand to guard against unexpected demand or supply chain disruptions.

The correct answer is option 'B', which means that A items require low safety stock. Here's why:

Importance of A items
A items are the most important items in inventory management. They typically have the highest value, the highest demand, or the highest impact on production. As a result, they require close monitoring and careful management to ensure that they are always available when needed.

Risk of stockouts
Because A items are so important, the risk of stockouts is high. If an A item is out of stock, it can cause a ripple effect throughout the supply chain, resulting in lost sales, production delays, and unhappy customers. Therefore, it's important to keep enough inventory on hand to meet demand.

Safety stock for A items
While A items require enough inventory to meet demand, they typically require lower levels of safety stock than B or C items. This is because A items are usually high-volume items with predictable demand patterns. As a result, it's easier to forecast demand for A items than for B or C items, which may have more erratic demand patterns.

In addition, because A items are so important, there is often more pressure to keep inventory levels low to minimize carrying costs. Therefore, it's important to strike a balance between having enough inventory to meet demand and keeping inventory levels low.

Conclusion
In summary, A items require low safety stock because they are high-volume items with predictable demand patterns. However, it's important to monitor A items closely and keep enough inventory on hand to guard against stockouts.

Simplex method of solving linear programming problem uses   
  • a)
    All the points in the feasible region
  • b)
    Only the corner points of the feasible region  
  • c)
    Intermediate points within the infeasible region  
  • d)
    Only the interior points in the feasible region 
Correct answer is option 'B'. Can you explain this answer?

Bijoy Kapoor answered
Any linear programming problem involving two variables can be easily solved with the help of graphical method as it is easier to deal with two dimensional graph. All the feasible solutions in graphical method lies within the feasible area on the graph and we used to test the corner points of the feasible area for the optimal solution i.e. one of the corner points of the feasible area used to be the optimal solution. We used to test all the corner points by putting these value in objective function.

The manufacturing area of a plat is divided into four quadrants. Four machines have to be located, one in each quadrant. The total number of possible layouts is: 
  • a)
    4  
  • b)
    8  
  • c)
    16  
  • d)
    24 
Correct answer is option 'D'. Can you explain this answer?

Gargi Joshi answered
In quadrant I, we can locate any one of the four machines (i.e.) we can allocate quadrant I in 4 ways. Thereafter quadrant II in 3 ways, thereafter quadrant III in 2 ways. No further choice for quadrant IV.
∴ Total number of possible layouts
= 4 × 3 × 2 = 24

When using a simple moving average to forecast demand, one would   
  • a)
    Give equal weight to all demand data
  • b)
    Assign more weight to the recent demand data  
  • c)
    Include new demand data in the average without discarding the earlier data  
  • d)
    Include new demand data in the average after discarding some of the earlier demand data 
Correct answer is option 'D'. Can you explain this answer?

Bijoy Kapoor answered
A moving average is a technique to get an overall idea of the trends in a data set; it is an average of any subset of numbers. The moving average is extremely useful for forecasting long-term trends. You can calculate it for any period of time. ... Moving averages are usually plotted and are best visualized.

Which of the following factors are to be considered for production scheduling?
1. Sales forecast
2. Component design
3. Route sheet  
4. Time stand ards
Select the correct answer using the codes given below: 
  • a)
    1, 2 and 3  
  • b)
    1, 2 and 4        
  • c)
    1, 3 and 4
  • d)
    2, 3 and 4 
Correct answer is option 'D'. Can you explain this answer?

Diya Ahuja answered
Factors to Consider for Production Scheduling

Production scheduling is an important aspect of manufacturing that helps in optimizing resources, reducing lead times, and improving productivity. The following factors are to be considered for production scheduling:

1. Sales Forecast
Sales forecast is an estimate of the future demand for a product or service. It is an important input for production scheduling as it helps in determining the quantity and timing of production. A company can use various methods to forecast sales, such as historical data analysis, market research, and trend analysis. By considering the sales forecast, a company can plan its production schedule to meet the demand and avoid overproduction or stockouts.

2. Component Design
Component design refers to the process of designing the parts or components that make up a product. The design of components can affect the production process, as some components may require specialized equipment or processes. By considering the component design, a company can plan its production schedule to ensure that the necessary resources and equipment are available to produce the components on time.

3. Route Sheet
A route sheet is a document that details the sequence of operations required to manufacture a product. It includes information such as the machines, tools, and materials required for each operation, as well as the time required to perform each operation. By considering the route sheet, a company can plan its production schedule to ensure that the necessary resources and equipment are available to perform each operation on time.

4. Time Standards
Time standards refer to the amount of time required to perform a specific operation or task. By considering time standards, a company can plan its production schedule to ensure that the necessary time is allocated for each operation. This can help in improving productivity, reducing lead times, and avoiding delays.

Conclusion
In conclusion, the factors to be considered for production scheduling include sales forecast, component design, route sheet, and time standards. By considering these factors, a company can plan its production schedule to meet the demand, optimize resources, and improve productivity.

In carrying out a work sampling study in a machine shop, it was found that a particular lathe was down for 20% of the time. What would be the 95% confidence interval of this estimate if 100 observations were made? 
  • a)
    0.16, 0.24
  • b)
    0.12, 0.28  
  • c)
    0.08, 0.32
  • d)
    None of these 
Correct answer is option 'B'. Can you explain this answer?

Divya Mehta answered
Confidence Interval Calculation for Lathe Downtime

Given:
- Lathe downtime = 20%
- Number of observations = 100
- Confidence level = 95%

We can calculate the 95% confidence interval for the estimate of lathe downtime using the following formula:

CI = p ± Zα/2 * sqrt(p(1-p)/n)

Where:
- CI = confidence interval
- p = sample proportion (downtime percentage)
- Zα/2 = Z-score for the desired confidence level (1.96 for 95%)
- n = sample size

Substituting the given values:

CI = 0.2 ± 1.96 * sqrt(0.2(1-0.2)/100)
CI = 0.2 ± 0.04
CI = (0.16, 0.24)

Therefore, the 95% confidence interval for the estimate of lathe downtime is 0.16 to 0.24.

Option B, 0.12 to 0.28, is the closest answer choice to the calculated confidence interval.

In a forecasting model, at the end of period 13, the forecasted value for period 14 is 75. Actual value in the periods 14 to 16 are constant at 100. If the assumed simple exponential smoothing parameter is 0.5, then the MSE at the end of period 16 is: 
  • a)
    820.31  
  • b)
    273.44  
  • c)
    43.75  
  • d)
    14.58 
Correct answer is option 'B'. Can you explain this answer?

Snehal Tiwari answered
Given Information:
- Forecasted value for period 14 = 75
- Actual value in periods 14 to 16 = 100
- Simple exponential smoothing parameter (alpha) = 0.5

Mean Squared Error (MSE) Formula:
The MSE is calculated by taking the average of the squared differences between the forecasted values and the actual values over a given period. The formula for MSE is:
MSE = (1/n) * Σ(F_t - A_t)^2

Where:
- MSE = Mean Squared Error
- n = Number of periods
- F_t = Forecasted value at time t
- A_t = Actual value at time t

Calculation:
To calculate the MSE at the end of period 16, we need to consider the forecasted and actual values for periods 14 to 16.

Step 1: Calculate the forecasted values for periods 15 and 16 using the simple exponential smoothing formula:
F_15 = F_14 + α * (A_14 - F_14)
F_15 = 75 + 0.5 * (100 - 75) = 87.5

F_16 = F_15 + α * (A_15 - F_15)
F_16 = 87.5 + 0.5 * (100 - 87.5) = 93.75

Step 2: Calculate the MSE using the forecasted values and the actual values for periods 14 to 16:
MSE = (1/3) * [(F_14 - A_14)^2 + (F_15 - A_15)^2 + (F_16 - A_16)^2]
MSE = (1/3) * [(75 - 100)^2 + (87.5 - 100)^2 + (93.75 - 100)^2]
MSE = (1/3) * [(-25)^2 + (-12.5)^2 + (-6.25)^2]
MSE = (1/3) * [625 + 156.25 + 39.06]
MSE = (1/3) * 820.31
MSE ≈ 273.44

Therefore, the correct answer is option B) 273.44.

MTM is a work measurement technique by: 
  • a)
    Stopwatch study    
  • b)
    Work sampling study  
  • c)
    Pre-determined motion time systems  
  • d)
    Past data comparison 
Correct answer is option 'C'. Can you explain this answer?

Arya Menon answered
MTM is a work measurement technique by Pre-determined motion time systems

Pre-determined motion time systems (PMTS) is a work measurement technique that is used to determine the time required to perform a specific task or operation. It is based on the principle that the time required to perform a task can be broken down into a series of basic motion elements, each with a predetermined time value.

What is MTM?

MTM stands for Methods-Time Measurement, which is a predetermined motion time system that is widely used in industries to establish standard times for performing various tasks. It is a systematic and scientific approach to measure the time required to perform a specific task, taking into account various factors such as the method, motion, and human capabilities.

How does MTM work?

MTM uses a set of predetermined time values called motion units to measure the time required for various basic motions involved in a task. These motion units are based on extensive studies and observations of human motions and have been standardized for different types of motions such as reach, grasp, move, and release.

Advantages of MTM:
- MTM provides a standardized and objective method for measuring the time required to perform a task, which helps in establishing fair and accurate time standards.
- It allows for the comparison of different methods and techniques used for performing a task, helping in identifying the most efficient and productive method.
- MTM helps in identifying and eliminating unnecessary or inefficient motions, leading to improved productivity and reduced fatigue.
- It provides a basis for determining labor costs and estimating production rates accurately.
- MTM can be used for job design and work simplification, enabling the development of more efficient and ergonomic workstations.

Conclusion

MTM is a valuable work measurement technique that allows for the accurate determination of time required to perform a task. It is based on the use of predetermined motion time systems, such as the MTM system, which provides standardized time values for different basic motions. By using MTM, organizations can establish fair and accurate time standards, identify and eliminate inefficiencies, and improve overall productivity and worker well-being.

Setup costs do not include 
  • a)
    Labour cost of setting up machines  
  • b)
    Ordering cost of raw material  
  • c)
    Maintenance cost of the machines  
  • d)
    Cost of processing the work piece 
Correct answer is option 'C'. Can you explain this answer?

Neha Choudhury answered
Setup cost is the costs incurred to configure a machine for a production run. This cost is considered a fixed cost of the associated batch, so its cost is spread over the number of units produced. Setup costs include the following:

1. Labor to position tools and materials next to the machine
2. Labor to configure the machine
3. Scrap cost of test units run on the machine

An item can be purchased for Rs 100. The ordering cost is Rs. 200 and the inventory carrying cost is 10% of the item cost annum. If the annual demand is 4000 units, then economic order quantity (in units) is: 
  • a)
    50    
  • b)
    100  
  • c)
    200    
  • d)
    400 
Correct answer is option 'D'. Can you explain this answer?

Poulomi Patel answered
Calculation of Economic Order Quantity (EOQ)

To calculate the Economic Order Quantity (EOQ), we need to consider the ordering cost and the carrying cost. The formula for EOQ is as follows:

EOQ = √((2DS) / H)

Where:
D = Annual demand
S = Ordering cost per order
H = Carrying cost per unit per annum

Given data:
Annual demand (D) = 4000 units
Ordering cost (S) = Rs. 200
Carrying cost (H) = 10% of item cost = 10% of Rs. 100 = Rs. 10

Substituting the values in the formula:

EOQ = √((2 * 4000 * 200) / 10)

Simplifying the equation:

EOQ = √(8000000 / 10)

EOQ = √800000

EOQ ≈ 894.43

Interpretation of the result:
Since the economic order quantity (EOQ) represents the optimal order quantity that minimizes the total cost of ordering and carrying inventory, we need to round up the result to the nearest whole number to determine the actual quantity to be ordered.

In this case, the EOQ is approximately 894.43 units. However, since we cannot order fractional units, we need to round up to the next whole number, which is 895 units. Therefore, the economic order quantity for this item is 895 units.

Conclusion:
The economic order quantity (EOQ) for the given scenario is 895 units. However, in the options provided, the closest whole number to the EOQ is 400 units, so the correct answer is option D) 400.

In PERT analysis a critical activity has 
  • a)
    Maximum Float  
  • b)
    Zero Float  
  • c)
    Maximum Cost  
  • d)
    Minimum Cost
Correct answer is option 'B'. Can you explain this answer?

PERT Analysis and Critical Activity

PERT (Program Evaluation and Review Technique) analysis is a project management tool used to evaluate and analyze the tasks involved in completing a project. It helps to identify the critical path and critical activities that are essential for the successful completion of the project. The critical path includes all the activities that have zero float or slack, which means any delay in these activities will delay the entire project.

Critical Activity and Zero Float

A critical activity is an activity that has zero float or slack in the PERT analysis. It means that the activity has no room for delay or flexibility, and any delay in the critical activity will delay the whole project. The critical path includes all the critical activities, and the duration of the project is determined by the critical path.

Importance of Identifying Critical Activities

Identifying critical activities is essential for project managers as they need to focus their attention on these activities to ensure they are completed on time. Any delay in the critical activities will delay the entire project, and project managers need to take appropriate actions to avoid delays.

Example of a Critical Activity

Suppose a construction project has a critical activity of laying the foundation of a building. If this activity is delayed due to any reason, the entire project will be delayed, and the project completion date will be pushed back. Therefore, project managers need to focus on completing this activity on time to ensure the project is completed within the given timeframe.

Conclusion

In PERT analysis, a critical activity is an activity that has zero float or slack. Identifying critical activities is essential for project managers as they need to focus their attention on completing these activities on time to ensure the project is completed within the given timeframe.

Assertion (A): A product layout is preferred when the flexibility in sequence of operations is required.
Reason (R): Product layout reduces inventories as well as labour cost.  
  • a)
    Both A and R are individually true and R is the correct explanation of A  
  • b)
    Both A and R are individually true but R is not the correct explanation of A  
  • c)
    A is true but R is false  
  • d)
    A is false but R is true 
Correct answer is option 'D'. Can you explain this answer?

Rajat Khanna answered
Explanation:

Product Layout and Flexibility:
- A product layout is designed to optimize the production process for a specific product or product line.
- It is characterized by a fixed sequence of operations, with each operation dedicated to a specific task related to the product being manufactured.
- This layout is not flexible and does not easily accommodate changes in the sequence of operations.

Reduced Inventories and Labor Cost:
- Product layout is known for its efficiency in reducing inventories and labor costs.
- By streamlining the production process and eliminating unnecessary movements or handling of materials, product layout can help in minimizing the need for excess inventory.
- Additionally, the specialized nature of tasks in a product layout reduces the labor requirements and can lead to cost savings in terms of labor expenses.

Relation to the Given Assertion:
- The assertion that a product layout is preferred when flexibility in the sequence of operations is required is not accurate.
- Product layout is actually chosen for its efficiency in handling a specific product or product line with a fixed sequence of operations.
- Therefore, the reason provided in the assertion does not correctly explain why a product layout is preferred.

Correct Answer:
- Option D is the correct answer, as the assertion is false (A is false) since product layout is not preferred for flexibility in sequence of operations, while the reason (R is true) stating that product layout reduces inventories and labor costs is accurate.

If the total investment is Rs. 5,00,000 for a target production, the income for the current year is Rs. 3,00,000 and total operating cost is Rs. 1,00,000; what is the economic yield? 
  • a)
    10%  
  • b)
    30%  
  • c)
    20%  
  • d)
    40% 
Correct answer is option 'D'. Can you explain this answer?

Calculation of Economic Yield:
1. Total Investment: Rs. 5,00,000
2. Income for the Current Year: Rs. 3,00,000
3. Total Operating Cost: Rs. 1,00,000

Formula for Economic Yield:
Economic Yield = (Income - Operating Cost) / Total Investment

Calculation:
Economic Yield = (3,00,000 - 1,00,000) / 5,00,000
Economic Yield = 2,00,000 / 5,00,000
Economic Yield = 0.4
Therefore, the Economic Yield is 40%, which is option 'D'.

Explanation:
An economic yield of 40% indicates that for every rupee invested, there is a return of 40 paise. This is a measure of the profitability and efficiency of the investment. In this case, the company has generated a significant return on investment, making it a financially viable decision. It is crucial for businesses to monitor and improve their economic yield to ensure sustainable growth and profitability.

Production flow analysis (PFA) is a method of identifying part families that uses data from 
  • a)
    Engineering drawings
  • b)
    Production sc hedule  
  • c)
    Bill of materials
  • d)
    Route sheets 
Correct answer is option 'B,C'. Can you explain this answer?

Rajeev Menon answered
Production flow analysis (PFA) is a method for identifying part families and associated machine groupings that uses the information contained on production route sheets rather than on part drawings. Workparts with identical or similar routings are classified into part families.
The procedure, for production flow analysis must begin by defining the scope of the study, which means deciding on the population of parts to be analyzed. Choice should be made if all the parts in the shop be included in the study, or a representative sample be selected for analysis. 

A control chart is established with limits of ± 2 standard errors for use in monitoring samples of size n = 20. Assume the process to be in control. What is the likelihood of a sample mean falling outside the control limits? 
  • a)
    97.7%  
  • b)
    95.5%  
  • c)
    4.5%  
  • d)
    2.3% 
Correct answer is option 'C'. Can you explain this answer?

To find the likelihood of a sample mean falling outside the control limits, we need to consider the properties of a control chart and the characteristics of the normal distribution.

**Control Chart and Control Limits:**
A control chart is a statistical tool used to monitor and control processes. It consists of a central line (often the process mean) and upper and lower control limits. These control limits are typically set at a certain number of standard errors away from the central line.

In this case, the control chart is established with limits of 2 standard errors. This means that the upper control limit (UCL) is set at 2 standard errors above the process mean, and the lower control limit (LCL) is set at 2 standard errors below the process mean.

**Sampling Distribution of the Sample Mean:**
When we take multiple samples from a population, the sample means will have a distribution known as the sampling distribution of the sample mean. This distribution follows the properties of the normal distribution.

One important characteristic of the normal distribution is that approximately 95% of the data falls within 2 standard deviations (standard errors) of the mean. This means that if the process is in control, we would expect about 95% of the sample means to fall within the control limits.

**Likelihood of a Sample Mean Falling Outside the Control Limits:**
Since the control limits are set at 2 standard errors away from the process mean, and approximately 95% of the sample means are expected to fall within these limits, the remaining 5% would fall outside the control limits.

Therefore, the likelihood of a sample mean falling outside the control limits is 5%. This corresponds to option C, which states that the likelihood is 4.5%.

While solving a linear programming problem by simplex method, if all ratios of the right-hand side (bi) to the coefficient, in the key row (aij) become negative, then the problem has which of the following types of solution? 
  • a)
    An unbound solution
  • b)
    Multiple solutions  
  • c)
    A unique solution
  • d)
    No solution 
Correct answer is option 'A'. Can you explain this answer?

Suyash Patel answered
Explanation:

Simplex Method:
The simplex method is an iterative procedure used to solve linear programming problems. It starts with an initial feasible solution and then iterates to improve the objective function value until an optimal solution is reached.

Ratios of the Right-Hand Side to Coefficients:
In the simplex method, the ratios of the right-hand side (bi) to the coefficients (aij) in the key row are calculated. These ratios are used to determine the pivot column and pivot row in each iteration of the simplex method.

Types of Solutions:
There are four types of solutions that can be obtained while solving a linear programming problem by the simplex method:

a) Unbounded solution: If all the ratios of the right-hand side to the coefficients in the key row become negative, it indicates that the objective function can be improved indefinitely. This implies that the feasible region is unbounded, and there is no optimal solution to the problem.

b) Multiple solutions: If there are multiple optimal solutions to the linear programming problem, it means that there are different combinations of decision variables that can yield the same optimal objective function value.

c) Unique solution: If there is only one combination of decision variables that yields the optimal objective function value, then the problem has a unique solution.

d) No solution: If the feasible region is empty or there are no feasible solutions that satisfy all the constraints, then the problem has no solution.

Answer Explanation:
In the given problem, if all the ratios of the right-hand side to the coefficients in the key row become negative, it indicates that the objective function can be improved indefinitely. This implies that the feasible region is unbounded, and there is no optimal solution to the problem. Therefore, the correct answer is option 'A' - An unbounded solution.

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