Systems Engineering
Not publishedof exam
14–21 items; percentages not fixedMarkov, V&V, Value & CPMSystems & Queueing PickerVerification vs Validation
Facilities Engineering and Planning
Not publishedof exam
Layouts, Space & LocationMaterial Handling, OSHA & Present CostFacility Layout & Sizing PickerProcess vs Fixed-Position Layout
Operations Engineering
Not publishedof exam
Forecasting, EOQ & Reorder PointMRP, Scheduling, Break-Even & ABCInventory & Operations PickerEOQ vs Reorder Point
Work Design
Not publishedof exam
Quality Engineering
Not publishedof exam
SPC, Capability & Acceptance SamplingDOE, FMEA, Reliability & MaintenanceQuality & Reliability PickerControl Limits vs Spec Limits
Quick Facts
- Items
- 85, including unscored pretest items
- Answering Time
- 8.5 hours; appointment 9.5 hours
- Official Domain Counts
- 14–21 items in each of five
- Passing Standard
- Unpublished scaled-score standard; pass/fail results
- References
- Provided searchable handbook; no design standards
- Next Listed Administration
- 30 September 2027; guide page 17
- NCEES Exam Fee
- $400; board charges may apply
- Eligibility
- Board decides; exam passage ≠ licensure
- Percentage Weights
- Not fixed; use published item ranges
Little's Law Boundary Rule
Average WIP L equals throughput lambda times flow time W
L: average system inventoryλ: stable throughput rateW: total time in system
Verification vs Validation
Verification
- Meets specified design requirements
- Checks built system against blueprint
- Can pass while missing user-need
Validation
- Satisfies real stakeholder operational needs
- Tested in intended use environment
- Confirms right system was built
Spec compliance vs stakeholder need
Systems & Queueing Model Picker
- Independent Poisson arrivals; exponential service times→Steady-state single-server, infinite-buffer model(λ < μ; stable FCFS system)
- Throughput and flow time known→Little’s Law: L = λ × W(Stable averages; same boundary and units)
- Serial stations have unequal capacities→Smallest capacity gives ideal throughput ceiling(Variability, starvation, blocking reduce achieved output)
- Translating customer needs to specs→Build QFD House of Quality(Voice of customer)
- Checking ≤ constraint unused resource→Compute LP slack variable(Zero means binding)
QFD, LP, Queueing & Little's Law
- Pareto Chart
- Ranks largest contributors to problem
- QFD House of Quality
- Translates customer voice to specs
- LP Slack
- Nonnegative unused capacity for ≤ constraints
- M/M/1 Mean Queue Wait
- Wq = λ÷[μ(μ−λ)]λ < μ; infinite-buffer, single-server
- Little's Law
- Stable matching boundary: L = λW
- Serial Line Bottleneck
- Ideal upper bound: smallest station capacity
Markov, V&V, Value & CPM
- Markov Property
- Next state depends on present
- System Verification
- Checks conformance to specified requirements
- System Validation
- Checks stakeholder needs in use
- Value Engineering
- Lower cost while preserving functions
- Unconstrained CPM Duration
- Longest precedence path sets finish
- Domain Question Range
- 14-21 questions per NCEES domain
Layouts, Space & Location
- Process Layout
- Groups similar machines; low-volume high-variety
- Fixed-Position Layout
- Stationary product; resources move in
- Storage Footprint
- Pallet area plus aisle clearances
- Center of Gravity
- Weighted coordinate heuristic; not universal optimum
- Required Machine Count
- Ceil workload ÷ effective available machine-time
- Weighted Site Score
- Sum weight times criterion score
Material Handling, OSHA & Present Cost
- Forklift Load Center
- Forward center increases overturning moment
- OSHA 1910.176 Aisle Rule
- Safe clearance, clear, marked passageways
- Present Cost Discounting
- Discount future costs to base-date
- Life-Cycle Costing
- Include capex, opex, maintenance, disposal
- Handling Device Selection
- Match load, route, layout, conditions
- Unit Load Stability
- Check weight, size, center position
Core MRP Inputs
Master Schedule, Bill of Materials, Inventory Records drive MRP
MPS: end-item timingBOM: component structureInventory: on-hand and scheduled
Facility & Inventory Model Picker
- Low-volume high-variety routing flexibility needed→Select functional process layout(Group similar machines)
- Product too large to move→Select fixed-position layout(Bring tools to job)
- Steady demand; instantaneous replenishment; no shortages→EOQ with fixed order/holding costs(No discounts; matching demand/holding periods)
- Setting continuous-review order trigger level→Add lead-time demand and safety-stock(Use inventory position)
- Stationary demand without trend/seasonality→Use simple exponential smoothing(Weight actual and forecast)
Forecasting, EOQ & Reorder Point
- Simple Exponential Smoothing
- F_next = αA_current + (1−α)F_current
- Mean Absolute Deviation
- Average absolute forecast error magnitude
- Basic EOQ Formula
- √(2DS/H); matching periods
- Reorder Point
- Lead-time demand plus safety stock
- Inventory Position
- On-hand plus on-order minus backorders
- Cross-Docking
- Consolidate inbound-to-outbound with minimal storage
MRP, Scheduling, Break-Even & ABC
- Core MRP Inputs
- MPS, BOM, and inventory records
- SPT Sequencing Rule
- All released; nonpreemptive single-machine completion-time minimum
- Break-Even Volume
- Fixed cost over unit contribution-margin
- Ordinary Annuity PV
- Discount year-end cashflows to present
- Activity-Based Costing
- Pool cost over total driver-units
- Contribution Margin
- Unit price minus variable cost
Time Study Sequence
Observed × rating = normal; standard = normal/(1−A)
NT = OT × RatingST = NT / (1-A)A: fraction of total time
Anthropometric Reach vs Clearance
Reach Design
- Accommodates smaller-reach users
- Uses lower-percentile limb dimensions
- Keeps controls within easy grasp
Clearance Design
- Accommodates larger-body users
- Uses upper-percentile body dimensions
- Includes clothing and gear allowance
Small reaches; large fits through
Work Design & Ergonomics Picker
- Allowance given as total-time fraction→Divide normal time by 1-minus-A(Not multiplied by 1+A)
- Sizing minimum stations or machines→Round fractional count upward(Check precedence separately)
- 8-hour TWA noise hits 85 dBA→Start OSHA hearing conservation program(50% noise dose)
- Computing OSHA DART incidence rate→Multiply cases by 200,000 hours(Divide by employee-hours)
Methods, Line Balance & Time Study
- Man-Machine Chart
- Shows concurrent work and idle-time
- Theoretical Min Stations
- Ceiling of work-content over cycle-time
- Normal Time
- Observed time times performance rating
- Standard Time
- NT÷(1−A)A: allowance fraction of total time
- Cumulative-Average Learning
- Doubling output multiplies average by r
- Work-Sampling Plan n
- n = ceil[z²p(1−p)/e²]; independent samples
OSHA DART 200,000 Constant
100 workers times 40 hours times 50 weeks equals 200,000
100 FTE workers2,000 hours per worker-yearCount cases, not lost days
Ergonomics, OSHA Noise & Safety
- NIOSH Lifting Index
- Load/RWL; applicable two-handed lifting tasks
- Anthropometric Reach Rule
- Design reach for small-stature users
- Anthropometric Clearance Rule
- Design clearance for large-stature users
- OSHA 1910.95 Action Level
- 85 dBA 8-hour TWA, 50% dose
- DART Incidence Rate
- DART cases × 200,000 ÷ employee-hours
- Keyed Connector Poka-Yoke
- Physical design prevents wrong orientation
Control Limits vs Specification Limits
Control Limits
- Calculated from process data
- Detect statistical special-cause signals
- Represent voice of the process
Specification Limits
- Set by engineering or customer
- Define acceptable unit conformance
- Not estimated from process subgroup sigma
Stability signal vs product tolerance
Quality & Reliability Picker
- Stable approximately normal, two-sided process capability→Cpk includes mean location and spread(Signed distance; negative outside specification limits)
- Monitoring fraction nonconforming across subgroups→Use binomial 3-sigma p-chart(Independent Bernoulli items; n-specific limits)
- Constant failure rate lambda given→R(t) = exp(−λt)(Memoryless hazard rate)
- Degradation sensor indicator is available→Use condition-based predictive maintenance(Instead of fixed calendar)
SPC, Capability & Acceptance Sampling
- Control vs Spec Limits
- Process voice vs customer requirements
- p-Chart 3-Sigma UCL
- p̄ + 3√[p̄(1−p̄)/n]Upper bound: 1
- Process Capability Cp
- (USL−LSL)÷(6σ)Stable, approximately normal process
- Two-Sided Capability Cpk
- min[USL−mean, mean−LSL]/(3σ); signed distances
- Producer Risk Alpha
- Rejecting good lot at AQL
- Consumer Risk Beta
- Accepting poor lot at LTPD
Cp vs Cpk Capability
Cp Index
- Equals USL-minus-LSL over 6-sigma
- Measures centered potential capability
- Ignores process mean location
Cpk Index
- Uses smaller signed specification distance
- Penalizes off-center process mean
- Equals Cp only when centered
Stable-process spread vs centering effect
DOE, FMEA, Reliability & Maintenance
- Factorial Interaction
- Factor effect depends on another
- ISO 9001 Scope
- Quality management system process requirements
- Proactive FMEA Goal
- Anticipate failure modes, causes, effects
- Exponential Reliability
- Surviving interval under constant hazard
- Predictive Maintenance
- Triggered by measured condition degradation
- Evidence-Based Root Cause
- Verify causal links with data
Producer's Risk α vs Consumer's Risk β
Producer's Risk (α)
- Type I sampling error
- Rejecting good lot at AQL
- Hurts compliant supplier
Consumer's Risk (β)
- Type II sampling error
- Accepting bad lot at LTPD
- Passes poor quality to buyer
Reject AQL vs accept LTPD
Predictive vs Preventive Maintenance
Predictive Maintenance
- Driven by measured equipment condition
- Tracks vibration, heat, or wear
- Intervenes before detected degradation fails
Preventive Maintenance
- Driven by calendar or run-hours
- Fixed schedule regardless of condition
- Suited for predictable wear-out
Condition sensor vs fixed clock
Common Traps
MAD vs Signed Mean Forecast Error
MAD: average absolute error magnitude ≠ Signed mean error: cancellation exposes bias
Reorder Point vs Order Quantity
ROP: when inventory position triggers replenishment ≠ EOQ: how much each order contains
Two Different Allowance Denominators
Fraction of standard time: NT/(1−A) ≠ Normal-time allowance: NT×(1+A)
DART Cases vs Lost Workdays
DART numerator: qualifying injury/illness cases ≠ Lost-day total: duration, not case count
OSHA Noise Action vs Permissible Exposure
85 dBA eight-hour TWA: conservation action ≠ 90 dBA eight-hour exposure: permissible limit
Active Specification vs Research Survey
Linked specification: effective October 2020 ≠ 2026 PAKS survey: future-update research
Last Minute
- 1.85 items; 8.5 h answering time
- 2.Five domains: 14–21 items each
- 3.Wrong answers: no deduction
- 4.Alternative items: no partial credit
- 5.Provided handbook; no design standards
- 6.M/M/1 Wq: λ÷(μ²−μλ)
- 7.M/M/1 stable: λ<μ
- 8.Stable Little’s Law: L = λW
- 9.EOQ: √[2DS/H]; matching periods
- 10.ROP: lead-time demand plus safety stock
- 11.Total-time allowance: ST = NT/(1−A)
- 12.Two-handed lifting: LI = load÷RWL
- 13.Noise conservation: 85 dBA, eight-hour TWA
- 14.Cpk: minimum signed distance ÷ 3σ
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