Process Planning and Cost Estimation

220 Pages·2009·4.34 MB·English

by  M. Adithan

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Copyright © 2007, New Age International (P) Ltd., Publishers
Published by New Age International (P) Ltd., Publishers
All rights reserved.
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ISBN (13) : 978-81-224-2655-7
PUBLISHING FOR ONE WORLD
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CONTENTS
Page No.
Preface................................................................................................................... (v)
1. Work study and Ergonomics ........................................................................... 1 — 47
●● ●●● Method study...................................................................................................... 1
●● ●●● Definition............................................................................................................. 1
●● ●●● Objectives of Work study.................................................................................. 2
●● ●●● Objectives of Method study.............................................................................. 2
●● ●●● Basic Procedure for Method Study................................................................. 2
(Select, Record, Examine, Develop, Define, Install and Maintain)
●● ●●● Recording Techniques used in Method Study ............................................... 7
●● ●●● Work Measurements.......................................................................................... 17
●● ●●● Objectives of work Measurements.................................................................. 17
●● ●●● Work Sampling ................................................................................................... 21
●● ●●● Analytical Estimating........................................................................................ 24
●● ●●● Synthesis ............................................................................................................. 25
●● ●●● Pre-Determined Motion Time System (PMTS).............................................. 26
●● ●●● Ergonomics......................................................................................................... 28
●● ●●● Ergonomics Principles Applied to Instrument Design and Control........... 29
●● ●●● Ergonomics Principles Applied to Machines and Controls......................... 32
●● ●●● Ergonomics Principles Applied to Layout of a Work place......................... 35
●● ●●● Evaluative Questions (Method Study).................................................... 39
●● ●●● Evaluative Questions (Work Measurements)....................................... 43
●● ●●● Evaluative Questions (Ergonomics)........................................................ 47
2. Process Planning................................................................................................. 48 — 94
●● ●●● Product Design................................................................................................... 48
●● ●●● Manufacturing Planning.................................................................................... 49
●● ●●● Process Design................................................................................................... 49
●● ●●● Basic Factors Affecting Process Design........................................................ 50
●● ●●● Types of Production........................................................................................... 50
●● ●●● Job Production................................................................................................... 51
●● ●●● Batch Production............................................................................................... 52
●● ●●● Mass Production ................................................................................................ 52
(vii)
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(viii)
●● ●●● Specialization ..................................................................................................... 54
●● ●●● Simplification...................................................................................................... 54
●● ●●● Standardization .................................................................................................. 54
●● ●●● Process Planning................................................................................................ 55
●● ●●● Steps involved (Procedure) in Process Planning.......................................... 56
●● ●●● Bill of Materials.................................................................................................. 56
●● ●●● Process Planning Sheet..................................................................................... 57
●● ●●● Uses of Process Sheet....................................................................................... 59
●● ●●● Routing ................................................................................................................ 59
●● ●●● Route Sheet......................................................................................................... 59
●● ●●● Calculation of Man-hours and Machine-hours .............................................. 60
●● ●●● Uses of Computers in Process Planning and Cost Estimation................... 61
●● ●●● Computer Aided Process Planning (CAPP)................................................... 61
●● ●●● Approaches to Process Planning..................................................................... 62
●● ●●● Variant or Retrieval Method of Process Planning......................................... 62
●● ●●● Generative Method of Process Planning........................................................ 63
●● ●●● Benefits of CAPP................................................................................................ 63
●● ●●● Practices of Process Planning ......................................................................... 64
●● ●●● Process Selection............................................................................................... 64
●● ●●● Process Planing Activities................................................................................ 65
●● ●●● Machine Selection.............................................................................................. 66
●● ●●● Factors Influencing Process Selection........................................................... 67
●● ●●● Process Selection Parameters......................................................................... 67
●● ●●● Material Selection.............................................................................................. 68
●● ●●● Material Selection Parameters......................................................................... 68
●● ●●● Documents Required for Process Planning................................................... 69
●● ●●● Developing Manufacturing Logic and Knowledge........................................ 70
●● ●●● Steps in Process Planning................................................................................. 70
●● ●●● Selection of Cost-Optimal Process.................................................................. 76
●● ●●● Breakeven Charts............................................................................................... 77
●● ●●● Breakeven Point and Breakeven Analysis..................................................... 82
●● ●●● Evaluative Questions in Process Planning ............................................ 92
●● ●●● Evaluative Questions in Breakeven Point and Breakeven Chart... 93
3. Introduction to Cost Estimation................................................................... 95 — 117
●● ●●● Cost Estimating.................................................................................................. 95
●● ●●● Cost Accounting................................................................................................. 95
●● ●●● Objectives of Cost Estimation......................................................................... 96
●● ●●● Components of a Cost Estimate...................................................................... 96
●● ●●● Cost Estimation Procedure.............................................................................. 98
●● ●●● Classification of Costing................................................................................... 100
●● ●●● Elements of Cost................................................................................................ 102
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(ix)
●● ●●● Cost of Product (Ladder of Costs).................................................................. 105
●● ●●● Evaluative Questions in Cost Estimation.............................................. 115
4. Cost Estimation ..................................................................................................118 — 128
●● ●●● Types of Cost Estimates.................................................................................... 118
●● ●●● Methods of Cost Estimates............................................................................... 120
●● ●●● Data Requirements and Sources of information........................................... 124
●● ●●● Allowances in Estimation (of Standard Time).............................................. 125
●● ●●● Evaluative Questions in Cost Estimation.............................................. 128
5. Production Cost Estimation ...........................................................................129 — 193
●● ●●● Estimation of material cost, labour cost and overhead............................... 129
●● ●●● Cost Estimation in Foundry Shop (Casting).................................................. 129
●● ●●● Cost Estimation in Welding Shop (Weldments & Welded joints)............... 134
●● ●●● Cost Estimation in Forging Shop (Forging)................................................... 146
●● ●●● Cost Estimation in Machine Shop (Machined components)....................... 153
●● ●●● Overhead Expenses........................................................................................... 181
●● ●●● Allocation of Overhead Expenses or Distribution of overhead costs....... 182
●● ●●● Types of Overhead Costs.................................................................................. 185
●● ●●● Evaluative Questions in Production Cost Estimation....................... 187
●● ●●● Model Questions.................................................................................................194 — 195
●● ●●● Objective Type Questions ................................................................................196 — 201
●● ●●● Model Question Papers.....................................................................................202 — 209
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