ME 6005 PROCESS PLANNING & COST ESTIMATION

ANSWER KEY

INTERNAL TEST I

PART- A

1. Define Process Planning

It is defined as an Act of preparing a detailed work instructions for the manufacture and assembly
of components into a finished product in discrete part manufacturing environments
It is the systematic determination of the methods by which a product is to be manufactured
economically and competitively.
It is an intermediate between design and manufacturing.
Route sheet and operation are the two outputs of process planning activity.

2. List out the various approaches to process planning

1. Manual approach

(a) Traditional Approach (b) Workbook Approach

2. Computer Aided Process Planning

(a) Retrieval CAPP system (b) Generative CAPP system

3. What are the three main areas focused upon during the material evaluation?

The materials considered for selection are to be evalauated based on the following three considerations :

Shape or Geometry considerations

Material Property Considerations
Manufacturing considerations
4. What are the factors considered in machine selection?

1. Technical Factors
Physical size of the workpiece
Machine accuracy
Surface Finish
Cutting forces
Power of the machine

2. Operational Factors
Batch Size
Capacity
Availability
5. List out the stages of tool selection process

The five stages of tool selection process are

Stage I Evaluation of process and machine selection

Stage II Analysis of machining operations

Stage III - Analysis of workpiece characteristics

Stage IV tooling analysis

Stage V - Selection of tooling

6. What is meant by statistical quality control?

Statistical quality control (SQC) is about employing inspection methodologies derived from statistical
sampling theory to ensure conformance to requirements.

7. List the seven statistical tools of quality that are used in quality control

1. Flow Chart 2. Check Sheet 3. Histogram 4. Pareto diagram 5. Cause and effect diagram 6. Scatter
diagram 7. Control chart

8. What are the uses of control charts?

To check whether the process is controlled statistically or not
To determine process variability
To establish the process capability of the production process
To identify the type of variation that occurs
To determine the effects of process changes.

9. What do you understand by Break even analysis?

Break even analysis , also known as Cost-Volume Profit analysis , is the study of interrelationship among a
firms sales, costs and operating profit at various levels of output.
 PART B

10.Process Planning Activities :

Process Planning starts with a careful examination of the drawing or design of the part. The process planner must be able to
analyze the engineering drawing and visualize the three dimensional part configuration. The part configuration must then be
analyzed to determine its basic geometric components. Identifying these basic geometric elements assists the process planner
in selecting the most appropriate process to manufacture the product.

The concept of process planning is to determine

1. The operations involved in the manufacture of each product.
2. The machines on which operations are to be done.
3. The tools, jigs and fixtures required.
4. The material requirements including scrap.
5. The speeds and feeds that are to be used.
6. The type of labour required.
7. The time required for each operation.

Process Selection :

Consideration should be given to the following factors in selecting a particular process

1. Nature of part, including materials, tolerances, desired surface finish and operation required.
2. Method of fabrication including machining or assembling of similar parts or components.
3. Limitation of facilities including the plant and equipment available.
4. Possibility of likely product design changes to facilitate manufacturability or cost reduction.
5. In-plant and outside materials handling systems.
6. Inherent process to produce specified shape, surface, finish to give desired mechanical properties.
7. Available skill level of operators for the production.
Sometimes the following additional factors affect the selection of a particular process.
(a) Proposed or anticipated production requirements, including volume requirements, production rates and short- term or
long- term production runs.
(b) Total end-product costs.
(c) Time available for tooling-up.
(d) Materials receipt, storage, handling and transportation.

Machine Selection

Product manufacturing requires tools and machines that can produce economically as well as accurately. Economy depends to
a large extent on the proper selection of the machine or process for the job that will give a satisfactory finished product. The
selection of the machine is influenced, in turn by the quantity of items to be produced. Usually there is one machine best
suited for a certain output.

In small lot or jobbing type manufacture, general purpose machines such as the lathe, drill press, and milling machine may
prove to be the best type since they are adoptable, have lower initial cost, require less maintenance, and possess the flexibility
to meet changing conditions in the shop.
10. Methods of Process Planning :

(a) Manual Process Planning

This type of planning is known as non-variant process planning. It is the commonest type of
planning
used for production today. Planning the operations to be used to produce a part requires
knowledge
of two groups of variables.
(a) The part requirements, and
(b) The available machines and processes and the capabilities of each process.

The manual approach to process planning begins when a detailed engineering drawing and
data
onbatch size are issued to a production engineer. This information is used to determine the
following:
The manufacturing processes involved.
The machine tools required to execute these processes.
The tools required at each stage of processing.
The fixtures required at each stage of processing.
The number and depth of passes in a machining operation.
The feeds and speeds appropriate to each operation.
The type of finishing process necessary to achieve the specified tolerances and surface
quality.

As a first step, the production engineer examines the part drawing to identify similarities
with previously produced parts. If similarities are recognized, a process plan is manually
retrieved for the similar item. The process plan is either used without modifications for identical
parts or modified to meet the manufacturing requirements of the new part.

The experience of the process planner plays a significant role in modifying or creating
process plans, since the planner selects processes and process variable settings which have
been successfully implemented in similar situations in the past. Since manual process planning
is largely subjective, the quality of the process plan is directly related to the skill and
experience of the planner.

(b) Computer Aided Process Planning

Computer Aided Process Planning (CAPP) has been investigated for more than 20 years; it can
be categorized in two major areas; variant planning, where library retrieval procedures are
applied to find standard plans for similar components, and generative process planning, where
plans are generated automatically for new components without reference to existing plans. The
latter system is most desirable but also the most difficult way of performing CAPP.

The process planning function bridges the gap between engineering design and manufacturing
and is thus a critical element in integrating activities within manufacturing organizations.
Current CAPP systems range from simple editors for manual planning to fully-automated
systems for planning a range of products. Some of the specific benefits of CAPP are:
1. Improved productivity
2. Lower production cost
3. Consistency
4. Time savings
5. Rapid integration of new production capabilities
 12.

13. Factors to be considered for selection of measuring instruments:

1. Accuracy : The accuracy of the measuring instrument should be 10 times that of the tolerance of the quality

Characrteristic being measured

2. Linearity : It is the accuracy of the measurements of an instrument throughout its operating range
3. Magnification : It is the amplification of the output reading on an instrument over the actual input dimension
4. Repeatability : It is the ability of the instrument to achieve the same degrees of accuracy on repeated applications
.
5. Resolution : It is the simplest increment of difference in dimension that can be read on an instrument.
6. Sensitivity : It is the increment of difference in dimension that can be detected by an instrument.
7. Stability : It is the ability of the instrument to maintain the calibration over a period of time.
 ME 6005 PROCESS PLANNING & COST ESTIMATION

ANSWER KEY

INTERNAL TEST II

PART- A

UNIT III
INTRODUCTION TO COST ESTIMATION
PART A
1. What do you understand by costing and estimatng?
Cost estimating is the process of determining the probable cost of the product before the start of
its manufacture .

Costing also known as Cost accounting is the determination of an actual cost of a component after adding
different expenses incurred in various departments.

2. State the functions of estimation

Cost estimates are required to submit accurate tenders for getting the contracts

Cost estimates are required for the manufacture to choose from various methods of production
the one which is likely to be most economical

Cost estimation are required for fixing the selling price of a product.

Cost estimates give detailed information of all the operations and their costs thus setting a
a standard to be achieved in actual practice.

3. Brief about direct and indirect material cost

Direct material cost is the cost incurred in purchase of raw materials for making the product.

Indirect material cost is the cost incurred for maintaining and operating the plant and equipment not be a part
of the product cost.

Ex : Grease , lubricating oil used to lubricate the equipment , coolants used to control the job and the tool ,
cotton waste.

4. Find the weight of steel sphere of diameter 140mm taking steel density as 7150 Kg/m3
 Weight = Density x Volume

4 4
= 7150 x 3 r3 = 7150 x 3 (70 x 10-3)3 = 10.22 Kg

5. Distinguish between direct labour cost and indirect labour cost

Direct labour cost can be charged directly to the job under preparation
Indirect labour cost cannot be charged directly to a particular job, but are charged on the number of
products produced in the plant during a particular period.

6. Define prime cost

Prime cost , also known as direct cost , consists of direct material costs, direct labour cost and direct expenses.

7. What are the methods of allocation of expenses?

(a) Allocation by cost proportion

Percentage on prime cost
Percentage on direct labor cost
Percentage on direct material cost
(b) Allocation by Hourly rate
Man hour rate
Machine hour rate
Combination of man-hour and machine hour rate
(c) Allocation by unit rate
Unit rate method

8. Define depreciation

Depreciation is the process of allocating the acquisition cost of the tangible asset less salvage value , if any in
a systematic and a rational number over the estimated life of the asset.

9. What are the causes of depreciation

1. Depreciation due to physical changes

Wear and tear
Physical delay
Accident
Poor maintenance and neglect
2. Depreciation due to physical changes

Inadequacy
Obsolescence
 PART-B

10.Procedure of Cost Estimating

For estimating the cost of a product, the various items of expenditure discussed earlier are grouped as follows :

1. Direct material costs : It is the cost of those materials which become a part of final product.
2. Direct labour costs : It is the expenditure made on the wages and salaries of workers who are directly engaged in the
manufacturing processes e.g. turner, milling machine operator, painter, etc.
3. Direct other expenses : These are the expenses, except direct materials cost and direct labour cost, which can be identified and
allocated to a particular product, e.g. cost of machine hours and cost of tools, jigs and fixtures etc.
4. Overhead costs : Overhead expenses include all other expenditure made on the product except direct materials cost, direct labour
charges and direct other expenses. Administrative expenses, sales and advertisement costs etc., form a part of overhead expenses.

BASIC STEPS IN COST ESTIMATION

The basic steps in the cost estimation of any product are given below :
1. Make thorough study of cost estimation request to understand it fully.
2. Make an analysis of the product and prepare a bill of materials.
3. Make separate lists of parts to be purchased from the market and parts to be manufactured in plant.
4. Determine the cost of parts to be purchased from outside.
5. Estimate the material cost for the parts/components to be manufactured in plant.
6. Make manufacturing process plan for the parts to be manufactured in plant.
7. Estimate the machining time for each operation listed in the manufacturing process plan.
8. Multiply each operation time by the labour wage rate and add them up to find direct labour cost.
9. Add the estimate of step 4, 5, and 8 to get prime cost of component.
10. Apply overhead costs to get the total cost of the component.

11. Various Methods of Costing

1. Job Costing

It is essentially a method of costing applicable to industrial manufacture in which the cost figures are determined for each job or
a batch of jobs. This method proves valuable in jobbing work (job shop production i.e., or production of low quantities, often
one of a kind of specialized products) or batch production.

2. Output Costing

In many cases cost figures for a job or a batch may not be easy to isolate (e.g. in the case of foundry operations, chemical
plants, collieries, etc.) and in such cases the cost figures are usually expressed in terms of overall output, viz. Rs. per ton, or
Rs. per kg, or Rs. per litre etc.

3. Operating Cost
 This method usually applies to utilities or service undertakings viz. transport, gas, electricity etc. and is same as
servicing cost (Rs. per km, Rs. per kWHr/unit).

4. Process Costing

Process costing refers to accumulation of cost by process (Dept./section) rather than by jobs. Cost of a process such as
filtering or of a Dept. is distributed to units of products processed through by simple division of total cost by number of
units or products processed.

There are other methods of classification of costs also :

(a) Fixed Costs and Variable Costs

The Fixed Costs are the items of expenditure which remain more or less constant irrespective of the quantity or volume of production.
Examples of fixed costs are : Supervisory charges, cost of lighting, cost of cleaning the works, operator charges, rent of building,
interest on capital, depreciation of plant and building.

The Variable Costs are those items of expenditure which vary with quantity or volume of production. Examples are : direct material
cost, cost of energy or fuel consumed, cost of tools used, cost of consumables, repair and maintenance charges and storage charges.

(b) Direct Costs and Indirect Costs

Direct costs are costs of those factors which directly contribute to the final product and hence can be directly charged or allocated to
the manufacture of a specific product. Examples : cost of raw materials, cost of labour processing the materials, cost of equipment and
special toolings, jigs and fixtures used in the manufacturing of the product.

Indirect costs are costs which cannot be directly allocated to the manufacture of a particular product. Examples : Wages of inspection
and supervisory staff, selling and distribution expenses, administrative expenses, overhead charges, and cost of indirect materials like
lubricants, coolants, grease, repair and maintenance cost.

12. (a)Solution

Volume of part A = 32 cm3

Volume of part B = 9 cm3
Volume of part C = 16 cm3
Volume of hole D = 22.5 cm3
Volume of bush = 2A + 2B + C-D

237.3 cm3

Weight of bush = 1.97 kg

Weight of material required for 20 bushes = 1.97 x 20 x 1.1 = 43.34 Kg

Material cost = 43.34 x 350 = Rs 15169

(b) Normal time = Observed time X rating factor = 0.75 x 1.1 = 0.825 min
Total allowances = Personal allowance % + Relaxation allowance % + Delay allowance %
(3% + 10% + 2%) of normal time
15% of normal time
= 0.15 x 0.825
= 0.12375 min
 Standard time = Normal time + Allowances
0.825 + 0.12375
= 0.948 min

13. a
Prime cost = Direct material cost + Direct labour cost + Direct expenses

14 + 18 + 0 = Rs 32
Factory Overheads = 100% of prime cost

Rs 32
Factory cost = Prime cost + factory overheads
32 + 32
= Rs 64
General overheads = 25% of factory cost

0.25 x 64 = Rs 16
Selling cost or Total cost = Factory Cost + General Overheads

64 + 16 = Rs 80
Profit = 10% of total cost

0.1 x 80 = Rs 8
Selling price = Total cost + profit
80 + 8 = Rs 88

b.

Depreciation annuity :

1(1+ r)

1(1+ r)
D=
[ C ( 1+r )S ]

D = Rs 3534.14

Value of machine after 2 Years

C2 = Value of the machine after 2 years

C2 = Rs 9292.51
The reduced value of asset after two years will be Rs 92.92.51
 ME 6005 PROCESS PLANNING & COST ESTIMATION

ANSWER KEY

INTERNAL TEST III

PART- A

1. Define forging.
Forging is the process of forming a metal into desired shape and size by the application of localised
compressive forces. The component may be forged in cold or hot condition.

2. What are the various material losses considered for forging?

1. Shear Loss 2 .Scale loss 3. Sprue loss 4. Tonghold loss 5. Flash Loss

3. Simplify welding operation. List the types of welding.

Welding is a fabrication or sculptural process that joins materials, usually metals or thermoplastics, by
causing fusion, which is distinct from lower temperature metal-joining techniques such as brazing and
soldering, which do not melt the base metal.

Types of welding:

1. Gas Welding 2. Arc Welding

4.Name the various allowances provided to the pattern

Shrinkage allowance
Draft allowance
Distortion or camber allowance
Rapping or Shaking allowance
Finishing allowance

5. Elaborate the terms foundry, mould and casting.

Foundry : Foundry is a metal casting process in which the metal is melted and poured into the moulds to
get the components in desired shape and size.

Mould : A hollow container used to give shape to molten or hot liquid material when it cools and hardens.

Casting : Casting is a manufacturing process in which a liquid material is usually poured into a mold, which
contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is
also known as a casting.

6. Distinguish between feed and depth of cut.

Feed : Feed is the rate at which the tool is moved into the part or the part into the tool

Depth of Cut : The measurement (normally in inches or millimeters) of how wide and deep the tool cuts
into the workpiece.
 7. Estimate the time for reaming a 18mm dia hole having 26mm depth to make it 18.3mm dia hole. Take the
cutting speed as 15 m/min and feed 0.3/rev

d1 = 18mm , d2 = 18.3mm , S = 15 m/min , F = 0.3 mm/rev

Time required for machining =

8. Differentiate drilling, boring and reaming operations.

Drilling : Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section in solid
materials. The drill bit is usually a rotary cutting tool, often multipoint.

Reaming : A type of drilling operation to enlarge a drilled hole by using a Reamer.

Boring : In machining, boring is the process of enlarging a hole that has already been drilled (or cast),
by means of a single-point cutting tool.

9. Write the formula to calculate the machining time for a shaping / planning / slotting operation

Shaping , Planning and Slotting operations

PART- B

10.

(a) Cost of filler material :

Filler rod required per metre of weld = 4.5m

Filler rod required per 0.16m of weld = 4.5 x 0.16 = 0.72m

Volume of filler rod used = X-sectional area of rod length of rod = 14.14cm3

Weight of filler rod = Volume x desnity = 14.14 x 7 = 98.98 gms

Cost of filler material = Rs 12/Kg

Actual cost of filler material = 98.98 x 10-3 x 12 = Rs 1.187

(b) Cost of O2 and C2H2 consumed:

Welding time = 30 min/m of welding

 Welding time for 0.16m of weld = 30 x 0.16 = 4.8 min

Consumption of O2 = 0.7 m3 /hr

Cost of O2 = Rs 10/m3

Actual consumption of O2 = 0.7 x 0.08 = 0.056 m3

Actual cost of O2 = 10 x 0.056 = 0.56

Consumption of C2H2 = 0.5 m3 /hr

Cost of C2H2 = Rs 60/ m3

Actual Consumption of C2H2 = 0.5 x 0.08 = 0.04 m3

Actual cost of C2H2 = 60 x 0.04 = Rs 2.40

(c ) To find material cost

Total material cost = Cost of filler material + Cost of O2 Consumed + Cost of C2H2 consumed

Rs 1.187 + Rs 0.56 + Rs 2.40 = Rs 4.15

11.
12.

S = 50m/min , f = 0.3 mm/rev

Solution

First operation : Turning from 40mm dia to 38mm and 120mm long

1000 X 50
N= 3.14 X 40 = 397.89 rpm

L 120
Time taken for turning = T1 = f XN = 0.3 X 397.89 = 1.005 min

Second Operation : External relief from 38mm dia to 35mmdia and 50mm long

1000 X 50
N= 3.14 X 38 = 418.83 rpm
 L 50
Time taken for external relief = T2 = f XN = 0.3 X 418.83 = 0.4 min

Third Operation : facing of both ends

L = Length of cut = 38/2 = 19mm

D = 38mm ; S = 50 m /min

1000 X 50
N= 3.14 X 38 = 418.83 rpm

L 19
Time for facing one end = f XN = 0.3 X 418.83 = 0.1512 min

Fourth operation : Chamfering 45 x 4mm on both sides

L = 4mm , D = 38mm S = 50 m/min

1000 X 50
N= 3.14 X 38 = 418.83 rpm

L 4
Time for chamfering one end = f XN = 0.3 X 418.83 = 0.032 min

Time for chamfering both sides = T 4 = 0.032 x 2 = 0.064 min

Total Machining time = T1 + T2 + T3 + T4 = 1.005 + 0.4 + 0.302 + 0.064 = 1.771 min

13. (a)

Feed = w/2 = 20/2 = 10mm/rev

1000 X 15
N= 3.14 X 40 = 119.37 rpm

Depth of stock
Number of passes required = be removed
Depth /cut
 (4038)/2
0.25 =4

Length of cut = Lo w+5 = 150-20+5 = 135mm

Length of cut
135 X 4
Feed x Number of passes = =
Total grinding time =
( rev )X (r . p . m) 10 X 119.37

0.452 min

(b)

L = 200mm , w = 50mm , S = 50m/min , f = 50mm/min , D = 100mm , Number of cutter teeth = 16

To find cutter R.P.M

Cutter r.p.m =

1000 X 50
N= 3.14 X 100 = 159.15 rpm

To find feed per tooth

Feed /min
Feed per tooth = Number of teeth X ( r . p . m)

50
159.15 X 16 = 0.0196mm/tooth

To find milling time

 1
Added Table travel = 2 [D D2W 2 ] = 6.698mm

Milling time = 4.134 mi n