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* Sign Up </login> * * Log In </login> 1 First Page Previous Page Next Page / 248 Sections SectionsSection 1 of 113

* 1.5 CHARTS AND DIAGRAMS USED IN METHOD STUDY (TOOLS AND TECHNIQUES)p. 27 <http://www.scribd.com/doc/49636090/1/CHARTS-AND-DIAGRAMS-USED-IN-METHOD-STU DY-TOOLS-AND-TECHNIQUES> * 1.5.4 Two-Handed Process Chart (or) Right Hand, Left Hand Chartp. 31 <http://www.scribd.com/doc/49636090/2/Two-Handed-Process-Chart-or-Right-Hand -Left-Hand-Chart> * 1.8 RATING FACTORp. 40 <http://www.scribd.com/doc/49636090/3/RATING-FACTOR> * 1.9 CALCULATION OF BASIC TIMEp. 41 <http://www.scribd.com/doc/49636090/4/CALCULATION-OF-BASIC-TIME> * 1.10 ALLOWANCESp. 41 <http://www.scribd.com/doc/49636090/5/ALLOWANCES> * 1.11 CALCULATION OF STANDARD TIMEp. 42 <http://www.scribd.com/doc/49636090/6/CALCULATION-OF-STANDARD-TIME> * 1.12 PRODUCTION STUDYp. 43 <http://www.scribd.com/doc/49636090/7/PRODUCTION-STUDY> * 1.13 RATIO DELAY STUDYp. 44 <http://www.scribd.com/doc/49636090/8/RATIO-DELAY-STUDY> * 1.14 SYNTHESIS FROM STANDARD DATAp. 45 <http://www.scribd.com/doc/49636090/9/SYNTHESIS-FROM-STANDARD-DATA> * 1.15 ANALYTICAL ESTIMATINGp. 47 <http://www.scribd.com/doc/49636090/10/ANALYTICAL-ESTIMATING> * 1.15.1 Procedurep. 47 <http://www.scribd.com/doc/49636090/11/Procedure> * 1.15.2 Advantagesp. 47 <http://www.scribd.com/doc/49636090/12/Advantages> * 1.15.3 Limitationsp. 47 <http://www.scribd.com/doc/49636090/13/Limitations> * 1.15.4 Applicationp. 47 <http://www.scribd.com/doc/49636090/14/Application> * 1.16.2 Method Time Measurement (M.T.M.)p. 48 <http://www.scribd.com/doc/49636090/15/Method-Time-Measurement-M-T-M> * 1.16.3 Table Preparationp. 48 <http://www.scribd.com/doc/49636090/16/Table-Preparation> * 1.16.4 Advantages of MTMp. 49 <http://www.scribd.com/doc/49636090/17/Advantages-of-MTM> * 1.16.5 Limitationsp. 49 <http://www.scribd.com/doc/49636090/18/Limitations> * 1.17 ERGONOMICSp. 49 <http://www.scribd.com/doc/49636090/19/ERGONOMICS> * 1.17.1 Objectivesp. 49 <http://www.scribd.com/doc/49636090/20/Objectives> * 1.17.2 Applicationsp. 50 <http://www.scribd.com/doc/49636090/21/Applications> * REVIEW QUESTIONSp. 52 <http://www.scribd.com/doc/49636090/22/REVIEW-QUESTIONS> * 2.0 INTRODUCTIONp. 54 <http://www.scribd.com/doc/49636090/23/INTRODUCTION> * 2.1 PROCESS PLANNING DEFINITIONp. 54 <http://www.scribd.com/doc/49636090/24/PROCESS-PLANNING-DEFINITION> * 2.1.1 Purpose of Process Planningp. 54 <http://www.scribd.com/doc/49636090/25/Purpose-of-Process-Planning> * 2.1.2 Concept of Process Planningp. 55 <http://www.scribd.com/doc/49636090/26/Concept-of-Process-Planning> * 2.2 OBJECTIVES OF PROCESS PLANNINGp. 56 <http://www.scribd.com/doc/49636090/27/OBJECTIVES-OF-PROCESS-PLANNING> * 2.3 SCOPE OF PROCESS PLANNINGp. 56 <http://www.scribd.com/doc/49636090/28/SCOPE-OF-PROCESS-PLANNING> * 2.4 INFORMATIONS REQUIRED TO DO PROCESS PLANNINGp. 57 <http://www.scribd.com/doc/49636090/29/INFORMATIONS-REQUIRED-TO-DO-PROCESS-P LANNING> * 2.5.2 Preparing Operation Planning Sheetp. 58

<http://www.scribd.com/doc/49636090/30/Preparing-Operation-Planning-Sheet> * 2.5.3 Process Planning Procedurep. 58 <http://www.scribd.com/doc/49636090/31/Process-Planning-Procedure> * 2.6 APPROACHES OF PROCESS PLANNINGp. 63 <http://www.scribd.com/doc/49636090/32/APPROACHES-OF-PROCESS-PLANNING> * 2.6.1 Manual Process Planningp. 63 <http://www.scribd.com/doc/49636090/33/Manual-Process-Planning> * 2.6.2 Computer Aided Process Planningp. 64 <http://www.scribd.com/doc/49636090/34/Computer-Aided-Process-Planning> * 2.6.2.1 Retrieval Type Approachp. 66 <http://www.scribd.com/doc/49636090/35/Retrieval-Type-Approach> * 2.6.2.2 Generative Approachp. 69 <http://www.scribd.com/doc/49636090/36/Generative-Approach> * 2.6.2.2.1 Process planning logicp. 69 <http://www.scribd.com/doc/49636090/37/Process-planning-logic> * I. Process planning logicp. 69 <http://www.scribd.com/doc/49636090/38/I-Process-planning-logic> * 2.6.2.3 Semi Generative Approachp. 73 <http://www.scribd.com/doc/49636090/39/Semi-Generative-Approach> * 2.7 SELECTION PROCESSESp. 73 <http://www.scribd.com/doc/49636090/40/SELECTION-PROCESSES> * 2.7.1 Factors Affecting Selection Processp. 74 <http://www.scribd.com/doc/49636090/41/Factors-Affecting-Selection-Process> * 2.7.2 Machine Capacityp. 75 <http://www.scribd.com/doc/49636090/42/Machine-Capacity> * 2.7.3 Analysis of Machine Capacityp. 76 <http://www.scribd.com/doc/49636090/43/Analysis-of-Machine-Capacity> * 2.7.4 Process and Equipment Selection Procedurep. 77 <http://www.scribd.com/doc/49636090/44/Process-and-Equipment-Selection-Proce dure> * 2.7.5 Process Sheet Descriptionp. 78 <http://www.scribd.com/doc/49636090/45/Process-Sheet-Description> * 2.7.6 Determination of Man, Machine and Material Requirementsp. 78 <http://www.scribd.com/doc/49636090/46/Determination-of-Man-Machine-and-Mate rial-Requirements> * 2.7.6.1 Manpower Requirementp. 78 <http://www.scribd.com/doc/49636090/47/Manpower-Requirement> * 2.7.6.2 Machine and Equipment Requirementp. 80 <http://www.scribd.com/doc/49636090/48/Machine-and-Equipment-Requirement> * 2.8 MATERIAL REQUIREMENTp. 80 <http://www.scribd.com/doc/49636090/49/MATERIAL-REQUIREMENT> * 2.8.1 Bill of Materialp. 81 <http://www.scribd.com/doc/49636090/50/Bill-of-Material> * 2.8.2 Machine Tool Replacementp. 82 <http://www.scribd.com/doc/49636090/51/Machine-Tool-Replacement> * 2.8.3 Factors Influencing Choice of Machineryp. 82 <http://www.scribd.com/doc/49636090/52/Factors-Influencing-Choice-of-Machine ry> * 2.8.4 Selection of Machineryp. 83 <http://www.scribd.com/doc/49636090/53/Selection-of-Machinery> * 2.8.4.1 Selection among Suitable Machinesp. 83 <http://www.scribd.com/doc/49636090/54/Selection-among-Suitable-Machines> * 2.8.4.2 Break Even Point Analysisp. 85 <http://www.scribd.com/doc/49636090/55/Break-Even-Point-Analysis> * 2.8.4.3 Production Cost Comparisonp. 90 <http://www.scribd.com/doc/49636090/56/Production-Cost-Comparison> * 2.8.4.4 Process Cost Comparisonp. 92 <http://www.scribd.com/doc/49636090/57/Process-Cost-Comparison> * 2.9 SET OF DOCUMENTS FOR PROCESS PLANNINGp. 94 <http://www.scribd.com/doc/49636090/58/SET-OF-DOCUMENTS-FOR-PROCESS-PLANNING

> * 2.10 DEVELOPING MANUFACTURING LOGIC AND KNOWLEDGEp. 94 <http://www.scribd.com/doc/49636090/59/DEVELOPING-MANUFACTURING-LOGIC-AND-KN OWLEDGE> * 2.11 PROCESS TIME CALCULATIONp. 94 <http://www.scribd.com/doc/49636090/60/PROCESS-TIME-CALCULATION> * 2.12 SELECTION OF COST OPTIMAL PROCESSp. 95 <http://www.scribd.com/doc/49636090/61/SELECTION-OF-COST-OPTIMAL-PROCESS> * 3.0 INTRODUCTIONp. 96 <http://www.scribd.com/doc/49636090/62/INTRODUCTION> * 3.1 REASONS FOR DOING ESTIMATESp. 96 <http://www.scribd.com/doc/49636090/63/REASONS-FOR-DOING-ESTIMATES> * 3.2 DEFINITIONp. 97 <http://www.scribd.com/doc/49636090/64/DEFINITION> * 3.2.1 Importance of Estimatingp. 97 <http://www.scribd.com/doc/49636090/65/Importance-of-Estimating> * 3.3 OBJECTIVES OR PURPOSE OF ESTIMATINGp. 98 <http://www.scribd.com/doc/49636090/66/OBJECTIVES-OR-PURPOSE-OF-ESTIMATING> * 3.4 FUNCTIONS OF ESTIMATINGp. 98 <http://www.scribd.com/doc/49636090/67/FUNCTIONS-OF-ESTIMATING> * 3.5 COST ACCOUNTING OF COSTINGp. 98 <http://www.scribd.com/doc/49636090/68/COST-ACCOUNTING-OF-COSTING> * 3.6 IMPORTANCE OF COSTINGp. 99 <http://www.scribd.com/doc/49636090/69/IMPORTANCE-OF-COSTING> * 3.7 AIMS OF COST ACCOUNTINGp. 99 <http://www.scribd.com/doc/49636090/70/AIMS-OF-COST-ACCOUNTING> * 4.4 MATERIALS AVAILABLE TO DEVELOP AN ESTIMATEp. 114 <http://www.scribd.com/doc/49636090/71/MATERIALS-AVAILABLE-TO-DEVELOP-AN-EST IMATE> * 4.5.2 Group Technologyp. 116 <http://www.scribd.com/doc/49636090/72/Group-Technology> * 4.5.3 Parametric Estimatingp. 117 <http://www.scribd.com/doc/49636090/73/Parametric-Estimating> * Use of parametric estimatingp. 117 <http://www.scribd.com/doc/49636090/74/Use-of-parametric-estimating> * 4.5.4 Statistical Estimatingp. 118 <http://www.scribd.com/doc/49636090/75/Statistical-Estimating> * 4.6 IMPORTANCE OF REALISTIC ESTIMATESp. 119 <http://www.scribd.com/doc/49636090/76/IMPORTANCE-OF-REALISTIC-ESTIMATES> * 4.7 ESTIMATING PROCEDUREp. 119 <http://www.scribd.com/doc/49636090/77/ESTIMATING-PROCEDURE> * 4.8 DIVISION OF ESTIMATING PROCEDUREp. 121 <http://www.scribd.com/doc/49636090/78/DIVISION-OF-ESTIMATING-PROCEDURE> * 4.9 CONSTITUENTS OF A JOB ESTIMATEp. 121 <http://www.scribd.com/doc/49636090/79/CONSTITUENTS-OF-A-JOB-ESTIMATE> * 4.10 COLLECTION OF COSTp. 123 <http://www.scribd.com/doc/49636090/80/COLLECTION-OF-COST> * 4.11 ALLOWANCES IN ESTIMATIONp. 123 <http://www.scribd.com/doc/49636090/81/ALLOWANCES-IN-ESTIMATION> * 5.0 INTRODUCTION PRODUCTION COST ESTIMATIONp. 125 <http://www.scribd.com/doc/49636090/82/INTRODUCTION-PRODUCTION-COST-ESTIMATI ON> * 5.1 ESTIMATION OF MATERIAL COSTp. 125 <http://www.scribd.com/doc/49636090/83/ESTIMATION-OF-MATERIAL-COST> * 5.1.1 Determination of Material Costp. 125 <http://www.scribd.com/doc/49636090/84/Determination-of-Material-Cost> * 5.1.3 Solved Problems in Material Costp. 130 <http://www.scribd.com/doc/49636090/85/Solved-Problems-in-Material-Cost> * 5.4 ALLOCATION OR DISTRIBUTION OF OVERHEADp. 153 <http://www.scribd.com/doc/49636090/86/ALLOCATION-OR-DISTRIBUTION-OF-OVERHEA D>

* 5.4.1 Percentage on Direct Material Costp. 153 <http://www.scribd.com/doc/49636090/87/Percentage-on-Direct-Material-Cost> * 5.4.2 Percentage on Direct Labour Costp. 154 <http://www.scribd.com/doc/49636090/88/Percentage-on-Direct-Labour-Cost> * 5.4.3 Percentage on Prime Costp. 155 <http://www.scribd.com/doc/49636090/89/Percentage-on-Prime-Cost> * 5.4.4 Man-Hour Ratep. 156 <http://www.scribd.com/doc/49636090/90/Man-Hour-Rate> * 5.4.5 Machine-Hour Ratep. 157 <http://www.scribd.com/doc/49636090/91/Machine-Hour-Rate> * 5.4.6 Combination of Man-Hour and Machine-Hour Methodp. 159 <http://www.scribd.com/doc/49636090/92/Combination-of-Man-Hour-and-Machine-H our-Method> * 5.4.7 Unit Rate Methodp. 159 <http://www.scribd.com/doc/49636090/93/Unit-Rate-Method> * 5.4.8 Space Rate Methodp. 159 <http://www.scribd.com/doc/49636090/94/Space-Rate-Method> * 5.5.1.1 Losses in Forgingp. 160 <http://www.scribd.com/doc/49636090/95/Losses-in-Forging> * 5.5.1.2 Forging Costp. 161 <http://www.scribd.com/doc/49636090/96/Forging-Cost> * 5.5.1.3 Solved Problemsp. 162 <http://www.scribd.com/doc/49636090/97/Solved-Problems> * 5.5.2 Estimation of Welding Shopp. 171 <http://www.scribd.com/doc/49636090/98/Estimation-of-Welding-Shop> * 5.5.2.1 Welding Costp. 171 <http://www.scribd.com/doc/49636090/99/Welding-Cost> * 5.5.3 Estimation of Foundry Shopp. 183 <http://www.scribd.com/doc/49636090/100/Estimation-of-Foundry-Shop> * 5.5.3.1 Estimation of Pattern Costp. 183 <http://www.scribd.com/doc/49636090/101/Estimation-of-Pattern-Cost> * 5.5.3.2 Foundry Lossesp. 183 <http://www.scribd.com/doc/49636090/102/Foundry-Losses> * 5.5.3.3 Steps for Finding Costing Costp. 184 <http://www.scribd.com/doc/49636090/103/Steps-for-Finding-Costing-Cost> * 5.5.4 Estimation of Machining Timep. 195 <http://www.scribd.com/doc/49636090/104/Estimation-of-Machining-Time> * 5.5.4.1 Introductionp. 195 <http://www.scribd.com/doc/49636090/105/Introduction> * 5.5.4.2 Importance of Machine Time Calculationp. 196 <http://www.scribd.com/doc/49636090/106/Importance-of-Machine-Time-Calculati on> * 5.5.4.3 Calculation of Machining Time for Different Lathe Operationsp. 197 <http://www.scribd.com/doc/49636090/107/Calculation-of-Machining-Time-for-Di fferent-Lathe-Operations> * 5.5.4.4 Machining Time Calculation for Drilling Lathe and Boringp. 198 <http://www.scribd.com/doc/49636090/108/Machining-Time-Calculation-for-Drill ing-Lathe-and-Boring> * 5.5.4.5 Machining Time Calculation for Milling Operationp. 199 <http://www.scribd.com/doc/49636090/109/Machining-Time-Calculation-for-Milli ng-Operation> * 5.5.4.6 Machining Time Calculation for Shaping and Planing (a) Shapingp. 202 <http://www.scribd.com/doc/49636090/110/Machining-Time-Calculation-for-Shapi ng-and-Planing-a-Shaping> * 5.5.4.7 Machining Time Calculation for Grindingp. 203 <http://www.scribd.com/doc/49636090/111/Machining-Time-Calculation-for-Grind ing>

* 5.5.4.8 Solved Problemsp. 203 <http://www.scribd.com/doc/49636090/112/Solved-Problems> Zoom Out Zoom In Fullscreen Exit Fullscreen Select View Mode View Mode SlideshowScroll Readcast Add a Comment Embed & Share <#> Reading should be social! Post a message on your social networks to let others know what you're reading. Select the sites below and start sharing. Readcast this DocumentTransparent <#> <#> Login </login> to Add a Comment <#> Share & Embed <http://www.facebook.com/sharer.php?u=http%3A%2F%2Fwww.scribd.com%2Fdoc%2F496360 90%2FProcess-Planning%23source%3Afacebook><http://twitter.com/home?source=scribd .com&status=Reading%20%22Process%20Planning%22%20on%20Scribd%20http%3A%2F%2Fwww. scribd.com%2Fdoc%2F49636090%20%23Readcast><http://www.google.com/buzz/post?url=h ttp%3A%2F%2Fwww.scribd.com%2Fdoc%2F49636090%2FProcess-Planning&message=> <#> Add to Collections Download this Document for Free Auto-hide: on <#>

This pageintentionally leftblank PROCESS PLANNING AND COSTESTIMATION SECOND EDITION R.KESAVAN AssistantProfessor ,_ Department of ProductionTechnologyM.I.T.Campus,AnnaUniversityChennai

C.ELANCHEZHIAN AssistantProfessor Department of MechanicalEngineeringSriSaiRamEngineeringCollegeChennai B.VIJAYARAMNATH SeniorFaculty Department of MechanicalEngineeringSriSaiRamEngineeringCollegeChennai PUBLISHINGFORONEWORLD NEWAGEINTERNATIONAL(P)LIMITED,PUBLISHERS NewDelhi>BangaloreChennaiCochinGuwahatiHyderabadJalandharKolkataLucknowMumbaiRanchi Visit us at www.newagepublishers.com Copyright 2009, 2005 New Age International (P) Ltd., PublishersPublished by New Age International (P) Ltd., PublishersAll rights reserved.No part of this ebook may be reproduced in any form, by photostat, microfilm, xerography,or any other means, or incorporated into any information retrieval system, electronic ormechanical, without the written permission of the publisher. All inquiries should beemailed to rights@newagepublishers.com ISBN (13) : 978-81-224-2941-1 P UBLISHING FOR ONE WORLD NEW AGE INTERNATIONAL (P) LIMITED, PUBLISHERS 4835/24, Ansari Road, Daryaganj, New Delhi - 110002Visit us at www.newagepublishers.com Dedicated to Our Dedicated to Our Dedicated to Our Dedicated to Our Dedicated to Our Beloved Parents and Future Engineers This pageintentionally leftblank The book on PROCESS PLANNING AND COST ESTIMATION by Dr. R. Kesavanet al. is a good attempt towards making a textbook for the students of Engineering and Technology.The book is written in five chapters in simple language, which will help the students immensely.The authors have taken pains in explaining in detail the concepts and the nuances of Cost Estimationand the steps involved in Process Planning. A number of illustrations make the book eminentlyreadable.I congratulate the authors for attempting to write a book on such an important subject. S. NATARAJAN Professor and HeadDepartment of Mechanical EngineeringCollege of Engineering, GuindyAnna University, Chennai - 600 025. FOREWORD This pageintentionally leftblank

This edition of Process Planning and Cost Estimation is based on the syllabus of B.E., B.Tech. Mechanical, Production, Metallurgy and Industrial Engineering courses. It is also a valuable assetfor entrepreneurs, training managers of various mechanical workshops and diploma students.Valuable suggestions and constructive criticism from number of colleagues at various institutionsand the feedback from the students as well as our friends motivate us to write this second edition.The second edition of this book has been presented in a simple and systematic way withnumerous diagrams and number of solved problems and review questions. This edition provides allnecessary information about process planning and cost estimation for various products, work study,ergonomics and production cost estimation.We are grateful to our management for their continuous support in bringing out this book successfully. Suggestions for improvement are most welcomed and would be incorporated in thenext edition to make this book more useful. Dr. R. KESAVANC. ELANCHEZHIANB. VIJAYA RAMNATH PREFACE TO THE SECOND EDITION This pageintentionally leftblank This edition of Process Planning and Cost Estimation is based on the latest syllabus of B.E.,B.Tech. Mechanical and Production Engineering. It is a valuable asset for entrepreneurs, trainingmanagers of various mechanical workshops, and diploma students.This book is an attempt to provide all necessary information about process planning and costestimation. The subject matter has been presented in a simple and systematic way with numerousdiagrams and illustrations so as to make thorough understanding of the topics.We have put our best efforts to provide solved problems and excellent exercise problems atthe end of each chapter. Various complex topics have been discussed pointwise and supported bypractical example problems wherever possible. To apprise the student about expected type of questions which can be asked in the examinations, important review questions have been providedat the end of each chapter.We thank the publishers who have come forward to publish this book.Suggestions for improvement of this book are welcomed and would be incorporated in the nextedition to make it more useful. Dr. R. KESAVANC. ELANCHEZHIANB. VIJAYA RAMNATH PREFACE TO THE FIRST EDITION This pageintentionally leftblank Foreword viiPreface to the Second Edition ixPreface to the First Edition xi UNIT1 WORK STUDY 134 1.0 Work Study 11.1 Improving Plant Layout 11.2 Importance of Working Conditions 21.3 Method Study 41.3.1 Objectives of Method Study 41.4 Basic Procedure for Method Study 41.5 Charts and Diagrams used in Method Study (Tools and Techniques) 81.5.1 Process Chart Symbols 91.5.2 Operation Process Chart 101.5.3 Flow Process Chart 111.5.4 Two-Handed Process Chart (or) Right Hand, Left Hand Chart 121.5.5 Man-Machine Chart 131.5.6 Flow Diagram 141.5.7 String Diagram 161.6 Work Measurement 171.7 Techniques of Work Measurement 181.7.1 Stop Watch Time Study 181.7.1.1 Breaking a Job into Elements 191.7.1.2 Measuring Time with a Stop Watch 21 CONTENTS Process Planning and Cost Estimation 1.8 Rating Factor 211.9 Calculation of Basic Time 221.10 Allowances 221.11 Calculation of Standard Time 231.12 Production Study 241.13 Ratio Delay Study 251.14 Synthesis from Standard Data 261.15 Analytical Estimating 281.15.1 Procedure 281.15.2 Advantages 281.15.3 Limitations

281.15.4 Application 281.16 Predetermined Motion Time System (PMTS) 291.16.1 Definition 291.16.2 Method Time Measurement (M.T.M.) 291.16.3 Table Preparation 291.16.4 Advantages of MTM 301.16.5 Limitations 301.17 Ergonomics 301.17.1 Objectives 301.17.2 Applications 31 Review Questions 33 UNIT2 PROCESS PLANNING 3576 2.0 Introduction 35 2.1 Process Planning Definition 352.1.1 Purpose of Process Planning 352.1.2 Concept of Process Planning 362.2 Objectives of Process Planning 372.3 Scope of Process Planning 372.4 Informations Required to do Process Planning 382.5 Process Planning Activities 382.5.1 Concept of Process Planning 382.5.2 Preparing Operation Planning Sheet 392.5.3 Process Planning Procedure 392.6 Approaches of Process Planning 442.6.1 Manual Process Planning 442.6.2 Computer Aided Process Planning 45 Contents 2.6.2.1 Retrieval Type Approach 472.6.2.2 Generative Approach 502.6.2.2.1 Process planning logic 502.6.2.3 Semi Generative Approach 542.7 Selection Processes 542.7.1 Factors Affecting Selection Process 552.7.2 Machine Capacity 562.7.3 Analysis of Machine Capacity 572.7.4 Process and Equipment Selection Procedure 582.7.5 Process Sheet Description 592.7.6 Determination of Man, Machine and Material Requirements 592.7.6.1 Manpower Requirement 592.7.6.2 Machine and Equipment Requirement 612.8 Material Requirement 612.8.1 Bill of Material 622.8.2 Machine Tool Replacement 632.8.3 Factors Influencing Choice of Machinery 632.8.4 Selection of Machinery 642.8.4.1 Selection among Suitable Machines 642.8.4.2 Break Even Point Analysis 662.8.4.3 Production Cost Comparison 712.8.4.4 Process Cost Comparison 732.9 Set of Documents for Process Planning 752.10 Developing Manufacturing Logic and Knowledge 752.11 Process Time Calculation 752.12 Selection of Cost Optimal Process 76 Review Questions 76 UNIT3 INTRODUCTION TO COST ESTIMATION 7791 3.0 Introduction 773.1 Reasons for Doing Estimates 773.2 Definition 783.2.1 Importance of Estimating 783.3 Objectives or Purpose of Estimating 793.4 Functions of Estimating 793.5 Cost Accounting of Costing 793.6 Importance of Costing 803.7 Aims of Cost Accounting 80 Process Planning and Cost Estimation 3.8 Difference between Cost Estimating and Cost Accounting 803.9 Difference between Financial Accounting and Cost Accounting 813.10 Methods of Costing 823.11 Elements of Cost Introduction 843.12 Material Cost 853.12.1 Direct Material Cost 853.12.2 Indirect Material Cost 853.13 Labour Cost 863.13.1 Direct Labour Cost 863.13.2 Determination of Direct Labour Cost 863.13.3 Indirect Labour Cost 883.14 Expenses 893.14.1 Direct Expenses 893.14.2 Indirect Expenses (Overheads) 893.15 Cost of Product (Ladder of cost) 90 Review Questions 91 UNIT4 COST ESTIMATION 92105 4.0 Introduction 924.1 Types of Estimate 924.1.1 Guesstimates 924.1.2 Budgetary 924.1.3 Using Past History 934.1.4 Estimating in Some Detail 934.1.5 Estimating in Complete Detail 934.1.6 Parametric Estimating 934.1.7 Project Estimating 934.2 How Estimates are Developed? 934.2.1 Single Person 944.2.2 Committee Estimating 944.2.3 Department to Department 944.2.4 Reporting Relationships 944.3 Standard Data 944.3.1 How Standard Data are Developed? 944.3.2 Past History 954.3.3 Time Study 954.3.4 Predetermined Time Standards 954.3.5 Standard Data Specific to a

Shop and Lot Size 95 Contents 4.4 Materials Available to Develop an Estimate 954.5 Methods of Estimates 964.5.1 Computer Estimating 964.5.2 Group Technology 974.5.3 Parametric Estimating 984.5.4 Statistical Estimating 994.6 Importance of Realistic Estimates 1004.7 Estimating Procedure 1004.8 Division of Estimating Procedure 1024.9 Constituents of a Job Estimate 1024.10 Collection of Cost 1044.11 Allowances in Estimation 104 Review Questions 105 UNIT5 PRODUCTION COST ESTIMATION 106226 5.0 Introduction Production Cost Estimation 1065.1 Estimation of Material Cost 1065.1.1 Determination of Material Cost 1065.1.2 Mensuration in Estimating 1065.1.3 Solved Problems in Material Cost 1115.2 Estimation of Labour Cost 1245.3 Estimation of Overhead Cost 1335.3.1 Introduction 1335.4 Allocation or Distribution of Overhead 1345.4.1 Percentage on Direct Material Cost 1345.4.2 Percentage on Direct Labour Cost 1355.4.3 Percentage on Prime Cost 1365.4.4 Man-Hour Rate 1375.4.5 Machine-Hour Rate 1385.4.6 Combination of Man-Hour and Machine-Hour Method 1405.4.7 Unit Rate Method 1405.4.8 Space Rate Method 1405.5 Estimation of Different Types of Jobs 1415.5.1 Estimation of Forging Shop 1415.5.1.1 Losses in Forging 1415.5.1.2 Forging Cost 1425.5.1.3 Solved Problems 1435.5.2 Estimation of Welding Shop 152 Process Planning and Cost Estimation 5.5.2.1 Welding Cost 1525.5.2.2 Solved Problems 1535.5.3 Estimation of Foundry Shop 1645.5.3.1 Estimation of Pattern Cost 1645.5.3.2 Foundry Losses 1645.5.3.3 Steps for Finding Costing Cost 1655.5.3.4 Solved Problems 1655.5.4 Estimation of Machining Time 1765.5.4.1 Introduction 1765.5.4.2 Importance of Machine Time Calculation 1775.5.4.3 Calculation of Machining Time for Different Lathe Operations 1785.5.4.4 Machining Time Calculation for Drilling Lathe and Boring 1795.5.4.5 Machining Time Calculation for Milling Operation 1805.5.4.6 Machining Time Calculation for Shaping and Planing 1835.5.4.7 Machining Time Calculation for Grinding 1845.5.4.8 Solved Problems 184 Review Questions 220 Index 227229 1.0 WORK STUDY The main problem in our country is poor standard of living of most of our population. More than70% of our people live in very poor living conditions. They are not in a position to satisfy theirbasic needs like food, cloth and shelter.If we want to raise the standard of living of our people we must produce goods at a lessercost. This can be done only by increasing the efficiency of production. Efficiency in production isknown as productivity. There are many techniques used for increasing productivity. Work study isone of the technique for improving productivity and hence raise the standard of living. Definition: Work study is a generic term for the techniques of method study and work measurement.These techniques are used in the examination of human work in all its contexts. They leadsystematically to the investigation of all the factors which affect the efficiency and economy at thework place in order to affect improvement.Work study was previously known as time and motion study. This was developed by F.W.Taylorand Frank B.Gilberth. 1.1 IMPROVING PLANT LAYOUT Work study consists of method study and work measurement. Work study is

considered as animportant tool in increasing productivity because of the following reasons.1. By method study,Working condition is improved.Work content is reduced.Workers efficiency is increased.Plant layout is improved.2. By work measurement,Ineffective time is reduced.Production time is standardized.It helps in planning and controlling. Unit1 WORK STUDY 2 Process Planning and Cost Estimation Work study can be applied to any field of activity. The increase in productivity can be achievedimmediately. It needs very less investment. Work study finds out the defects in the organization.Work study is always the first technique applied for increasing productivity.Hence, work study is considered as a valuable tool in increasing productivity. 1.2 IMPORTANCE OF WORKING CONDITIONS Working conditions mean the physical conditions and facilities available in the working place. Theyare1. Lighting and ventilation.2. Temperature and humidity.3. Safety and healthy.4. Layout and house keeping.5. Noise and vibration.6. Ergonomics.Bad working conditions will affect the performance of the workers. The worker will not beable to work efficiently. So, production is affected. Workers will not be regular in their duty. Becauseof the bad working conditions, the workers may even resign their job. If work study is done in badworking condition, it will give inaccurate results. Only in good working conditions, the workers willgive their normal performance. The different working conditions are explained here. 1. Lighting and Ventilation Lighting: For doing any work, proper lighting is essential. Proper lighting will lead to the increasedproduction and hence increased productivity. Improper lighting will cause headache, visual fatigueand avoidable accidents.Level of lighting required will depend upon the type of works viz., casual work, rough work,fine work, inspection work etc. As a general rule, lighting should be uniformly spread. Natural lightshould be used wherever possible. Artificial light should add to natural light to give uniform light.Glare should be avoided. Fluorescent light with anti-glare fitting is ideal for industrial applications. Ventilation: Ventilation means free and fresh supply of air. Insufficient air circulation will affectthe health of workers. It leads to fatigue of workers. It reduces productivity. Therefore, goodventilation must be provided. Recommended minimum air flow is 50 cubic metres per hour. Fumes,smokes and dusts should be driven out using exhaust fans. Main function of ventilation areDispersal of atmospheric contaminations.Dispersal of heat generated by men and machines.Maintaining correct level or oxygen, carbon dioxide and carbon monoxide. 2. Temperature and Humidity High temperature and humidity in the shop floor will cause fatigue to workers. In deep mines, textilemills and sugar mills, ventilation will be poor and relative humidity will be high. So working conditionwill be very poor. Humidity must be controlled by proper means. More rest during work must beprovided.Similarly, workers working at low temperature must be provided with suitable clothing andfootwear. They must be given periodic exposure to normal temperature. They must be provided Work Study 3 with not drinks at regular intervals. The air temperature normally recommended is 20 to 22C forlight physical work and 14 to 16C heavy work in standing position.

3. Safety and Health Safety of workers in the work place is very important. Management must provide safe environmentto the workers and prevent occurrence of accidents. Only when the workers feel that they are inan accident free environment, they can give maximum output.Safe workplace layout should be provided with safe material handling methods. Personalprotective devices for protecting head, face, eyes, lungs and other body parts like hand, foot andlegs should be provided.Clean workplace with healthy environment must be provided to protect workers against infectionand occupational diseases. 4. Layout and Housekeeping Good workplace layout and housekeeping play important roles in providing better working condition.Workplace should have1. Sufficient window area at least 20% of floor area.2. Ceiling height should be at least 3 metres.3. Every workers should be provided with at least 10 cubic metres of air and a free floorarea of 2 square metres.4. Traffic aisles should be wide enough to allow free movement of material handling equipmentand workers.5. Floor should be non-slip, non-dust forming and easy to clean.A good house keeping should be ensured in the plant. There should be a place reserved forevery material and every material should be stored in its place. Tools and other production aidsmust be stored systematically in their own locations. In process materials should be kept in such away that they do not obstruct the free movement of men and material. 5. Noise and Vibration Noise: Noise is defined as unwanted sound to which an individual is exposed. In industries, almostall machines generate noise and this must be reduced to the lowest level. The effects of noise are1. Disturbs concentration and causes annoyance.2. Interferes with speech communication.3. Causes hearing losses to workers.4. Increases fatigue and blood pressure.Exposure to continuous noise above 90 dB is dangerous for hearing. Noise level can be controlledin the following ways:1. Replacing noisy machine and equipment.2. Dynamically balancing rotating parts.3. Using rubber and plastic components wherever possible.4. Separating the noise sources with brick walls.5. Using ear plugs and protecting the ears. Vibration: Vibration is created by1. Rotating components. 4 Process Planning and Cost Estimation 2. Machines during hand grinding.3. When using pneumatic chipping and riveting hammers.When ones body is in contact with vibration source continuously, it may lead to1. Loss of sense of touch and temperature in fingers.2. Muscular weakness.3. Loss of mental alertness.4. Pain and stiffness in joints.Vibrations can be controlled by the following means.1. Control at source by balancing all revolving parts.2. Reducing speed of rotating parts.3. Maintaining machineries and tools regularly.4. Protecting the workers by minimizing the exposure and providing rest breaks. 6. Ergonomics Ergonomics can be defined as human engineering which studies the relationship between man andhis working environment. Ergonomic process attempts to fit the job to the worker. It aims at1. Designing the workplace to fit the requirement of the worker.2. Designing the equipment, machines and controls to minimize physical and mental strain tothe workers.3. Providing a favourable environment for working.The workplace should be designed for the use of the specific worker whose dimensions areknown. It may be designed to suit a group of persons. It can be adjusted to suit the individuals.Workplace layout, design of seat and arrangement of different equipment should not causediscomfort to

workers. Proper foot rest, arm rest and leg room must be provided. Design and locationof various manual controls, knobs, wheels and levers should not cause excessive strain to workers. 1.3 METHOD STUDY Method study is the technique of systematic recording and critical examination of existing andproposed ways of doing work and developing an easier and economical method. 1.3.1 Objectives of Method Study 1. Improvement of manufacturing processes and procedures.2. Improvement of working conditions.3. Improvement of plant layout and work place layout.4. Reducing the human effort and fatigue.5. Reducing material handling6. Improvement of plant and equipment design.7. Improvement in the utility of material, machines and manpower.8. Standardisation of method.9. Improvement in safety standard. 1.4 BASIC PROCEDURE FOR METHOD STUDY The basic procedure for conducting method study is as follows:1. Select the work to be studied. 112 Process Planning and Cost Estimation b = 31.7h = 101.6Hence, A B = 2679.7Volume. V B = A B ThicknessVolume of part B, V B = 2679.7 31.7= 84,946.49V B = 84,946.49 mm 3 Fig. 5.3 Total volume of wedgeV = V A + V B = 110,470.696 mm 3 V = 110470.696 mm 3 Now, volume of the cylindrical bar stock (from which the wedge is to be forged) is given asV 1 = 2 d4 l d = Dia of stock= ( ) 2 38.14 l l = Length of stockV 1 = 1140.091 l As volume does not change V

1 = V1140.091 l = 114070.696= 96.89 96.9 97 mm l ; Thus, the length of the bar stock is 97 mm or 9.7 cms. Exam le 5.2 An iron wedge has been made by forging a 3 cm diameter bar stock. The length and breadthof the base being 4.5 cm and 2.5 cm. Length 4 cm and height 12 cm. If the density remainsunchanged after forging. What length of bar is required to make the wedge?All diamensions are in cms. Production Cost Estimation 113 Fig. 5.4 Solution The wedge re resents a solid, vertical TRAPEZIUM.We know, Surface area; A = ( ) 1a b h2 + Volume V = A tHere a = 4b = 4.5h = 12t = 2.5 Volume, V = ( ) 14 4.5 12 2.52 + = 127.5 cm 3 = 127.5 cu.cmHence, volume of the wedge is 127.5 cm 3 .Now, the volume of the cylindrical bar stock (from which the wedge is forged) is 21 V d4 l = Now, as density remains unchanged in forging (given, volume also remains unchanged)Hence, V = V 1 Hence, ( ) 23 3 127.5 cm 3 cm4 l = l = 18.037 cm = 180.3 mmThe length of the cylindrical bar stock is 180.3 mm. 114 Process Planning and Cost Estimation Exam le 5.3 Three orthogra hic view of a C.I. V-block are shown. What would be the weight of the materialrequired for the block if CI weighs = 7.2 gm/cm 3 ? 182415107510BAC C37.5157556 Fig. 5.5 Solution The total volume of the V-block is calculated as follows,V = V A

+ V C V B V D Volume of the section A, V A = l g h = 95 56 75V A = 3,99,000 mm 3 Volume of the section B V B = ( ) ( ) 1 1b h 75 37.5 562 2 l = V B = 78,750 mm 3 Volume of section C V C = 2 ( l b h) = 2 (38 15 56) = 63,840 mm 3 Volume of section D V D = ( ) 2 12 bh d2 4 l + = ( ) 2 12 15 18 15 18 152 4 + = 11917.035 mm 3 Hence, total volume V = V A + V C V B V D Production Cost Estimation 115 = 372,171.43 mm 3 Weight of the block = 372171.43 mm 3

 7.2= 2679.6 gm = 2.67 kgThe weight of the block is 2.67 kgs. Exam le 5.4 The following roduct is manufactured by forging rocess from a block of cast iron. Find theweight of the material required for the block if cast iron weighs 7 gms/cm 3 . Fig. 5.6 Solution As erformed earlier, s lit the roduct into four sections A, B, C and D.The total volume of the given roduct is calculated as followsV = V A + V B + V C V D Volume of section A is ( ) A 1V a b h t2 = + Here a = 12 mmb = 30 mmh = 15 mmt = 30 mmV A = ( ) 112 30 15 302 + V A = 9450 mm 3 116 Process Planning and Cost Estimation Volume of section B, V B = l b hHere l = 15 mmb = 10 mmh = 12 mmV B = 15 10 12= 1800 mm 3 V B = 1800 mm 3 Volume of section C = Volume of section B V C = V B = 1800 mm 3 Volume of section D = Volume of section BV D = V

B = V C V D = 1800 mm 3 Now V A + V B V C V D = VV = 9450 + 1800 + 1800 1800V = 11250 mm 3 = 11.25 cm 3 Volume of the machined roduct is 11,250 mm 3 The weight of the material required = (11250 10 3 ) 7.0 g/cm 3 = 11.25 7 = 78.75 g/cm 3 Hence, the weight of the material required is 78.75 g/cm 3 . Exam le 5.5 The following com onent is manufactured by forging from a rod 25 cm long. If the volumedoes not undergo any change, find the radius and surface area of the rod. Solution The com onent can be s lit into three sections A, B and C.Volume of the total com onent V = V A + V B + V C Consider section A,Volume, V A = ( ) 1a h h t2 + a = 15 mmb = 30 mmh = 15 mmt = 15 mmV A = ( ) 115 30 15 152 + Production Cost Estimation 117 Fig. 5.7 V A

= 5062.5 mm 3 Consider section B V B = l b h= 15 15 15 ( l = b = h = 15)= 3375 mm 3 N B = 3375 mm 3 1515A15 Fig. 5.8 Consider section C V C = l b h= 30 15 15= 6750V C = 6750 mm 3 Total volumeV = V A + V B + V C = 15187.5V = 15187.5 mm 3 Now total volume = Volume of bar stock 15187.5 = 2 d4 l Fig. 5.9 151515B 118 Process Planning and Cost Estimation 2 15187.5d250 4 = d 2 = 77.3459d = 8.79 9 mm r = 4.5 mm A = r 2 = 63.6 mm 2 1515C30

Fig. 5.10 Hence, radius of bar stock is 4.5 mm and the surface area is 63.6 mm 2 . Exam le 5.6 The following figure shows a lathe stock. Estimate the weight and cost of material if C.I.weighs 7.787 gm/cm 3 and material cost is 11.45 kg. h60 E37.5BCA756.256.2525D5050 Fig. 5.11 Solution The dimensional figure is divided into five sections A, B, C, D and E.Section A is a FRUSTUM of A cone.Now, Volume of frustum of cone ( ) A 1 2 1 2 hV a a a a3 = + + Production Cost Estimation 119 Here a 1 = ( ) 21 d4 h = 75 mmd 1 = 31.25 mma 1 = ( ) 2 31.254 a 2 = ( ) 2 504 V A = ( ) ( ) 2 21 2 7531.25 50 a a4 4 3 + + = 33410.10 mm 3 = 33.410 cm 3 Section BVolume of section B, V B = ( )( ) 2 d 50 6.254 4

l = = 12271.84 mm 3 V B = 12.271 cm 3 Section CVolume of section C, V C = 2 d4 l = ( ) 23 37.5 25 27611.65 mm4 = V C = 27.611 cm 3 Section DVolume of section D, V D = Volume of BV D = V B = 12.276 cm 3 Section ESection E is a cone with base 50 mm. We have to determine the slant height l of the cone.We know that, tan = Half baseSlant ht.tan =2560 l = l = 251/ 3 l =25 3 mm Production Cost Estimation 147 Solution Volume of snap head (A) = ( ) 3 h 3R h3 = ( ) ( ) 23 2.1 3 2.8 2.1 29.09 cm3 =

Volume of stem (B) = ( ) 22 3 d h 3 4 28.27 cm4 4 = = Volume of an head (C) = ( ) 2 2 h D d Dd12 + + = ( ) 2 2 2.1 4.8 3 4.8 312 + + = 25.55 cm 3 Total volume of one rivet = a + b + c= 29.09 + 28.27 + 25.55 = 82.91 cm 3 Considering 10% scale loss on total volume of one rivet,Volume required = 3 11082.91 91.2 cm106 = Weight of material required for one rivet = 91.2 7.92= 722.3 gms = 0.722 kg Number of rivets than can be roduced from 19 kg of H.S.=1926.3 27 27 Numbers.0.7223 = = ; Exam le 5.32 A hexagonal bolt with a finished diameter of 25 mm, shank length 110 mm and bolt head heightof 25 mm is to be forged. What would be the size of the stock and its length, if forging loss is 3%?Find the total length of stock for 300 bolts, if scra loss is 4%. 25110 M25 Fig. 5.20 148 Process Planning and Cost Estimation Solution Volume of hexagonal head = 2 3 3S h2 = ( ) 23 3 325 25 40.593 mm2 = Head volume = 40.593 cm 3 Volume of shank = 2 d4 l

= ( ) 23 25 110 53,968 mm4 = Shank volume = 53.968 cm 3 Total volume = Head volume + Shank volume= 40.593 + 53.968Total volume of one bolt = 94.561 cm 3 Diameter of stock taken = 25 mmConsidering 3% forging loss, loss, volume of material required for one bolt.= 94.561 1.03 = 97.398 cm 3 Taking diameter of bar stock equal to the diameter of bolt shank, length of bar shock for eachbolt is= ( ) 2 97.3982 54 Length of bar stock/bolt = 20.72 cmNow, considering 4% scrap loss, total length of stock re uired for 300 bolts.= 300 20.72 1.04= 6464.64 cm= 64.64 meters Ans. (i) Diameter of stock (Assumed) = 25 mm (ii) Length of stock for one bolt = 20.75 cm (iii) Length of stock for 30 bolts = 64.64 meters. Example 5.33 The figure shows a centre punch to be drop forged. Calculate net weight, gross weight andlength of M.S. bar. Mild steel density 7.83 g/cm 3 . Production Cost Estimation 149 Fig. 5.21 A45 22 B C D Fig. 5.22 Solution Section ZVolume of portion Z, can be calculated as follows. It is being a frustum of cone.V Z = 2 2 h R r Rr 3 + + Where R = Outer radius of unch 2512.5 mm2 = r = Convergent radius of unch= 12.56.25 mm, h 25 mm2 = = V Z = Volume of ortion Z= ( ) ( ) ( ) ( ) 2 2

25 12.5 6.25 12.5 6.253 + + = 7154.88 mm 3 Section YThe holding ortion Y consists of 8 triangles as in figure. 150 Process Planning and Cost Estimation AC =2512.5 mm2 = V Y = Volume of ortion Y= Number of triangle Area of triangle lengthArea of each triangle =1AD BC2 = ( ) 1 1AC cos 22 2 CD2 2

= 2 1 1AC sin 22 2A sin 22 2 2 = 55.246 mm 2 Volume of Y ortionSection XThe cutting ortion volume V X , which is a cone can be found as follows.V X = 2 1r h3 Where r = 12.5 mmh = 40 mmV X = ( ) ( ) 23 12.5 40 6541.6 mm3 = Total volume Total volume of unch V = V Z + V Y + V X = 7154.88 + 44,196.8 + 6541.6= 57,893.28 mm 3 = 57.8 cm 3 Net weight of unch = Volume Density= 57.8 7.83 = 452.57 gmsDro forging losses (a) Shear loss = 5% of net weight=5452.57 22.6 gms100 =

=1 1 1AC cos 22

2 AC sin 22

2 2 2

(b) Tong hold loss = 25 mm long and equal to diameter of stock Production Cost Estimation 151 Tong hold volume = 2 d4 l d = Stock diameter = 25 mm l = Tong hold length = 25 mm= ( ) 2 25 254 = 12,265.6 mm 3 Tong hold loss = Density Tong hold volume= 7.83 12.265 = 96 gms (c) Scale loss 6% of the net weight=6452.57 27.15 gms100 = (d) Flash lossIt de ends u on the eri hery of forging (P L )P L = 12.5 + 2 (25 + 100 + 40) = 342.5 mmP L = 34.25 cmFor flash loss 20 mm wide and 4 mm thick all around the eri heryWide = w = 20 mm = 2 cmThickness = t = 4 mm = 0.04 cmFlash loss = w t P L e= 2 .3 34.25 7.83 = 214.54 gm (e) S rue loss: 7% of net weight=7452.57 31.68 gms100 = Total material loss during forging= (i) + (ii) + (iii) + (iv) + (v)= 22.6 + 96 + 27.15 + 214.54 + 31.68= 391.97 gmsGross weight = Net weight + losses= 452.57 + 391.97 = 844.54 gms.Length of bar required for forging the centre unch,L =Gross weightArea of cross section of stock 152 Process Planning and Cost Estimation Area of cross section of stuck = ( ) 22 2 d 2.5 4.9 cm4 4 = = L =844.544.9 7.83 Length of bar required = 21.99 cm 22 cm. ; 5.5.2 Estimation of Welding Sho 5.5.2.1 Welding Cost

Cost rocedure In estimation welding cost of a job, the different items which are to the taken into account arematerial, labour and tooling cost. Material cost In this, costs of all materials are included used in fabrication rogress like metallic sheet or latestock costing stam ings, forging etc. Another major item is the consumable electrode or weld wireused to rovide for the additional metal in the weld groove. This quantity is determined by the cross-sectional area, length and the articular welding rocess. In case of gas welding cost of gases likeoxygen and acetylene consumed are taken into consideration. Table 5.1 Plate Welding Filler O 2 Consum - Acetylene Welding Length of thickness technique rod dia tion in cu consum - time er filler rod in mm in mm m/hr tion in cu metre in required/mm/hr min of weldingin metre 1 Leftward 1.00 0.04 0.02 9 to 11 1.02 Leftward 2.0 0.10 0.04 10 to 12 1.53 Leftward 2.5 0.2 0.07 12 to 13 1.64 Leftward 3.0 0.15 0.10 13 to 15 2.65 Leftward 3 to 4 0.21 0.14 15 to 17 4.0 to 1.85 Rightward 2.5 0.3 0.20 16 to 18 3.36 Rightward 3.0 0.4 0.25 18 to 20 3.48 Rightward 4.0 0.5 0.30 20 to 28 3.610 Rightward 5.0 0.7 0.50 30 to 35 4.515 Rightward 6.0 1.0 0.60 45 to 50 6.820 Rightward 6.0 1.2 0.80 60 to 67 10.025 Rightward 6.0 1.6 0.90 85 to 100 16.0 Labour cost Under this category, costs of all ersons are directly related to the making of weldment. First of all welding times are calculated and from that the labour cost is calculated. The labour cost is sub-divided into following grou s:

Production Cost Estimation 153 (i) Pre aration The cost of re aring raw materials for welding would include re aring of edges according torequirements machining of welded joints to sha e, and the cleaning of the foreign material from thesurface to be welded. (ii) Set-u This includes assembling the arts in the welding fixture, heating rior to welding etc. Table 5.2 Plate Nozzle O 2 ressure, kg/cm 2 Consum tion, m 2 /hr Cutting s eed thick- dia in O 2 C 2 H 2 m/hr ness in mmmmHand Machine Hand Machine Hand Machine Hand Machine 3 0.8 to 11.0-1.65 1.0-2.0 1.3-1.4 1.2-1.4 0.20-0.25 0.18-0.25 30-45 30-505 1 0.75-1.50 0.75-2.0 1.8-2.0 0.8-2.0 0.15-0.20 0.12-0.20 20-30 18-3210 1 or 15 1.5-2.0 1.5-3.5 1.2-2.4 1.0-2.4 0.20-0.25 0.15-0.25 15-30 15-3015 1.5 1.7-2.5 1.5-3.5 3.4-4.5 3.4-4.5 0.30-0.45 0.33-0.42 18-27 18-305 1.5 3.1-2.8 2.0-2.8 3.6-5.0 3.6-5.0 0.36-0.47 0.35-0.47 18-28 18-30 (iii) Material de osition This is determined by the rate of weld de osit, weld joint re aration,

number of asses requiredfor the weld. (iv) Post welding o eration This includes the cost for the removal of excess of weld metal, slag, rough or finish machining toweldment dimensions.Cost of heat treatment o erations after welding such as annealing, normalising, hardening etc.,are also including under this. (v) Finishing Cost of cleaning welded ortion for surface finish is considered under finishing cost. Tooling cost Under this item would be the costs of welding fixtures, machining fixtures and machining tem late. 5.5.2.2 Solved ProblemsExam le 5.34 Estimate the time required for making an o en tank size 50 50 50 cm by gas welding size of sheets used is 50 40 0.3 cm. Welding to be done on inner surface only. Assume fatigue allowancesto be 5%. Solution Length of ortion where welding is required to be done, which is clear in figure 5.23. 162 Process Planning and Cost Estimation (b) Welding cost For 8 mm thick late,Filler rod dia = 4 mmOxygen consum tion = 0.5 cu. m/hrAcetylene consum tion = 0.3 cu. m/hrWelding time/m. length = 25 minLength of filler rod used/m of welding = 3.6 mThe length of ortion to be welded is 1 mTime required for welding = 25 1 = 25 min (i) Oxygen consumed =250.5 0.209 cu. m60 Cost of oxygen at Rs. 10.00/m 3 = 0.209 10 Rs. 2.09 (ii) Acetylene consumed =250.3 0.125 cu.m60 = Cost of acetylene consumed Rs. 50/cu. m= 0.125 50 = Rs. 6.25 (iii) Length of filler rod used for 1 m welding = 3.6 mWeight of filler rod = ( ) 2 0.4 360 7gm4 = 316.8 gm = 0.3168 kgCost of filler rod at Rs. 14/kg = 14 0.3168 = Rs. 4.4352 (iv) Labour charges of welding at 1.80/hr for 25 min=251.8 Rs. 0.7560 = Total cost of welding2.09 + 6.25 + 4.4352 + 0.75 = Rs. 13.5252Hence, Cost of cutting = Rs. 3.18Cost of welding = Rs. 12.19 Exam le 5.43 Calculate the cost of welding two lates 200 100 8 mm thick to obtain a iece 200 200 8 mm a roximately using right ward welding technique. (i) Cost of filler material = Rs. 7/kg

(ii) Cost of oxygen = Rs. 80 er 100 cu. meter (iii) Cost of acetylene = Rs. 800 er 100 cu. meters Production Cost Estimation 163 (iv) Consum tion of oxygen = 0.8 cu. m (v) Consum tion of acetylene = 0.8/cu. m (vi) Diameter of filler rod = 4 mm (vii) Density of filler material = 7.3 gms/cc (viii) Filler rod used/m of weld = 350 cms (ix) S eed of welding = 2.5 m/hr Solution Labour is aid Rs. 2/hr and overheads may be taken as 100% of labour cost. 100 100 200 Fig. 5.25 Total length of weld = 200 mmFiller rod used =200350 70 cms1000 = Volume of filler rod used = Cross-sectional area of rod Length of rod= 2 3 0.4 70 8.79 cm4 = Weight of filler rod = 8.79 7.3 = 64.17 gmsCost of filler material =764.17 Rs.0.44921000 = Time to weld 200 mm length =2000.08 hrs1000 2.5 = Oxygen consumed = 0.08 0.8 = 0.064 cu. mAcetylene consumed = 0.08 0.8 = 0.064 cu. mCost of oxygen consumed =800.064 Rs. 0.0512100 = 164 Process Planning and Cost Estimation Cost of acetylene consumed =7000.064100 = Rs. 0.448Time to weld =1hrs 5 min12 = Add 4 min (80% of time to weld) for edge re aration and finishing and handling time.5 + 4 = 9 minLabour cost =92 Rs. 0.360 = Overhead = 100% of labour cost = Rs. 0.3Cost of making joint = 0.4492 + 0.0512 + 0.448 + 0.3 + 0.3= Rs. 1.55. 5.5.3 Estimation of Foundry Sho 5.5.3.1 Estimation of Pattern Cost After finding the volume of rough wood by the rocess described in the revious article, it ismulti lied by the existing rice er unit volume to obtain the cost of wood required for the attern of furniture. The labour cost for the work is more difficult to determine, since the rocess in values alot of manual work. Similar works undertaken reviously are taken as guides in this res ect. Ex eriencetells us that a good attern-maker, working entirely manually, can finish the work on 0.025 m 3 of wood in 8 hours. Other charges are usually taken in ro ortion to

either the material cost or thelabour cost. 5.5.3.2 Foundry Losses Losses influence strongly the economies of roduction of castings. Losses occur mainly during melting because of oxidation or volatilization of alloying elementsand the entra ment of molten metal in the dross or slag removed from the furnace orcrucible. Melting losses are most serious when they occur in costly alloys. Melting losses vary with the ty e of foundary and its conditions such as raw material, melting ractice, com osition of alloy etc. Highest melting losses occur when the surface area to volume ratio of the charge is morei.e., in a scra charge containing large ro ortion of turnings, swarf and fines (and that tooheavily contaminated). Furnace ty e and design also affect melting losses. Rotary and reverberatory furnaces, owing to more ronounced contact of melt with furnaceatmos here and constant renewal of metal surface are susce tible to higher losses than acrucible furnace with a small bath area. Losses in the melting of cast iron in cu ola are lesser than obtained in air furnace. In the melting of steel, cu ola converter ractice roduces highest losses of the order of 12.5% whereas they are only 3 to 5% in electric are furnace and about 1% in high frequencyinduction heating furnace. Production Cost Estimation 165 Melting losses de end u on the time of ex osure of molten metal to the furnaceatmos hered. Melting losses and gas contamination can be minimized by carrying out melting at a fastrate and with minimum of disturbance. Melting losses can also be reduced by avoiding, excessive liquid metal tem eratures andtoo many liquid metal transfers. In brief, a ro er care and close control of melting conditions will definitely hel in loweringmelting losses. 5.5.3.3 Ste s for Finding Costing Cost 1. Calculate the volume of the casting from the ast drawing, as ex lained earlier.2. Multi ly the volume by the density of the art material in order to arrive at net weight of the casting.3. Calculate the weight of metal lost in oxidation in the furnace and as s rues, gates, risersetc. This metal loss is roughly 10% of the net weight of the casting.4. Calculate the weight of foundry rocess scra .5. Add (2), (3) and (4) above to get total weight.6. Calculate cost of metal by multi lying the total weight with the cost er unit weight of themetal.7. Calculate rocess scra return value and deduct it from the cost of metal in order to arriveat Net direct material cost.8. Calculate indirect material cost by estimating the amount of coke, flux, etc., required tomelt and cleanse the molten metal for casting.9. Calculate direct and indirect labour costs. (a) Cost of making moulds. (b) Cost of making and baking cores. (c) Cost of firing the furnace (d) Cost of melting metal. (e) Cost of ouring molten metal into the moulds. (f) Cost of removing solidified castings from the moulds. (g) Cost of fettling and finishing of castings. (h) Cost of heat-treatment, if any.10. Cost of ins ection. 5.5.3.4 Solved ProblemsExam le 5.44

What will be the cost of manufacturing one set of fast and loose ulleys as given in figure. The ulleys are to be machined on the to (belt surface) sides and bore and a machining allowance of 3 mm is rovided on a casting for machining, other articulars:CI castings cost Rs. 85 er quintal and brass casting Rs. 5 er kg.Boring, turning and side cutting will roughly take 9 h for each ulley at 60 aises er/hr cuttingkey-way 30 aise er cm of keyway. Overhead charges are 10% on labour rofits are 5% on totalcost. 166 Process Planning and Cost Estimation ABCB 120 140400 CI weights 0.0073 kg/cm 3 . Brass weighs kg/cm 3 missing dimensions in the drawing and other data, if required, may be assumed. Reference sketch Formulae and Calculation Volume cm 3 Remarks Fast ulley Volume of art A Belt surface (to ),= ( )( ) 22 40 2 0.3440 2 1.5 + (15 + 2 (0.3))= 3422.78 cm 3 3422.78Volume of part B= ( ) 22 40 2 1.5 14 1.54 2 4 8 1.54 Fig. 5.26 = 1145.04 cm 3 1145.04Volume of part C= ( ) ( ) 22 14 8 2 0.34 12 + 2(0.3) = 1397.8 cm 3 1397.8Volume of part A 3422.8Volume of part B 1145.04Volume of part C ( ) ( ) 22 14 10 2 0.34 (12 + 2 0.3)= 1065.3 cm 3 1065.3Total volume of casting of the loose pulley = 5633.14 cm 3 Total volume of casting of the fast pulley = 5965.62 cm

3 Grand total of CI casting volume for both pulley = 11598.76 cm 3 Grand total of CI casting wt for both pulley = 84.67 kg Fig. 5.27 sides and bore of CI pulley are to bemachined [3 mmm/c allowance] BACCA 100 33 Production Cost Estimation 167 Brass casting Volume of rough casting for Volumebrass bush the brass bush m/c allowance of 3 mm ( ) 2 10 2 0.34 + 570 cm 3 all over for [(8 2 0.3) 2 ] (12.6) the brass bushWeight of brass casting at 0.0078 kg/cm 3 = 570 0.0078 = 4.44 kg1. Cost of castings (a) CI at Rs. 85 er quintal 8584.67100 71.96 (b) Brass at Rs. 5 er kg 5 4.44 22.22. Boring, Turning, side cutting 9 hr 0.6 9 2 10.8on each ulley at 60 aise/hr 3. Key way cutting at 30 aise 0.3 10 3 er cm4. Overhead charges at 10010100 10.00 Exam le 5.45 Figure re resents a face chuck and the dimensions shown are finished dimensions. You arerequired to find out the esteemed cost of manufacturing and the selling rice of the face chuck onthe basis of the data su lied below. Solution CI casting = Rs. 70 er 120 kgFettling = 90 aise/ ieceTurning and facing at 7 aise er cm 3 of material removed.Reaming and boring at 7 aise/mm de th of hole.Overhead charges at 100% on labour cost.Profit at 15% on total cost.Double arrows in the figure indicate machined surface.SketchFormulae and calculationVolume of art A ( ) ( ) ( ) 2 23 350 2 3 70 2 3 20 3 2215.4 cm4 + + = 100% on labour Description Calculation Cost 168 Process Planning and Cost Estimation Volume of part B

( ) 22 3 3 100 70 2 3 70 mm 324.6 cm4 = Fig. 5.28 By turning ( ) 22 3 Vol. 356 350 23 76.52 cm4 = = By facing ( ) ( ) 22 3 3 Vol. 350 70 6 3 mm 278.9 cm4 = = Total volume of material removed by turning and facing only= 355.5 cm 3 Total volume of CI casting = 2539.9 cm 3 Costing Costing, wt of CI casting = 2539.9 7.3 g= 18541.3 = 18.54 kg(Sp. wt of CI = 7.3 g)1. Cost of costing at Rs. 70 per 120 kg 7018.54100 = 12.982. Fettling charge at 90 paise per piece 0.9 1 = 0.93. Turning and facing at 7 paise per cm 3 0.07 355.5 = 24.89of material removed4. Reaming and boring at 7 paise per mm depth 0.07 (50 + 15) = 4.555. Overhead charge at 100% on labour 0.09 + 4.55 + 24.89 = 30.34Cost of manufacturing one face chuck = 73.66 = (Total cost here)Now profit at 15 paise on total cost = Rs. 11.05Selling price of face chuck = Rs. 84.71. Production Cost Estimation 169 Example 5.46 What will be the cost of manufacturing one solid bearing as shown in figure? Select the surfacesto be machined and provide for proper machining allowances on such surface. CI weighs 0.0073kg/cc.Other casting at 95 paise/kgCI casting at 95 paise/kgBoring at 25 paise/cm length of boreFacing at 1.25 paise/s . cm of surface facedDrilling at 25 paise per drilled holeOverhead charges at 100% on labour charges. Solution Formula and calculation volume of half cylinder considered solid. (A) ( ) 23 3 17.2 2 8.6 cm 200.3 cm2 4 = = Volume of rectangular section considered section B2 7.2 (7.2 3.5) 8.6 = 458.21 cm 3 Volume of shaft hole with 3 mm machine allowance (C) ( ) 2 2 4.7 2 0.3 8.64 = 523.1 cm 3 Volume of part D with 3 mm m/c at bottom35 (35 + 0.3) 8.6 = 10625.3= 700.3 + 458.1 523.1 + 10625.3= 11260.6 cm

3 Weight of casting = 12.98 kgArea of surface to be faced = 35 + 8.6 s cm. = 301 s . cm Costing (i) Cost of CI casting at 95 paise/kg 0.95 12.98 = Rs. 12.331 (ii) Cost of boring at 25 paise/cm length of bore 0.25 8.6 = Rs. 2.15 (iii) Cost of facing at 1.25/s .cm of surface faced 0.0125 301 = Rs. 3.76 (iv) Drilling at 25 paise/drilled hole 0.15 2 = 0.3 (v) Overhead charges at 100% on labour Rs. 6.21Cost of manufacturing one solid bearing = Rs. 24.75 Example 5.47 Calculate the weight of rough casting of a fly wheel with a machining allowances of 5 mm onthe surfaces to be machined. How much material has to be removed during machining? 86 72 35 4.7 Fig. 5.29 170 Process Planning and Cost Estimation Solution CI weight 0.0073 kg/cm 3 . Formulae and calculation Vol. (i) Before machiningvol. of rim (A) ( ) ( ) 2 2 250 2 0.5 250 2 104 + 7933.306 cm 3 (25 + 2 0.5) (ii) Volume of 6 arms ( ) ( ) 2 17 250 2 10 35 64 2 22513.44 cm 3 (iii) Volume of box (part C) ( ) ( ) ( ) 22 35 25 2 0.5 15 2 0.54 + = 8155.6 cm 3 Total volume of rough casting = 38602.34 cm 3

wt of rough casting = 1729.6 kgAfter machiningvol. of rim ( ) ( ) 22 250 250 2 15 254 = 27682.8 cm 3 Volume of 6 arms same as before, = 22513.4 cm 3 vol. of box, = 7061.1 cm 3 ( ) 2 2 35 25 15 15 2 14 Total volume of finish casting = 306427 cm 3 Weight of finish casting = 2236.9 kgSo, weight of material removed during machining = 507 kg Example 5.48 Find the volume, weight and cost of the material re uired for making a mild steel shaft. Assumethat mild steel cost is Rs. 13 per kg. 5 10 19 10 5 8 510 5 10 10 Fig. 5.31 AAcc 100250Key way 20 x 103502500 50 Fig. 5.30 Production Cost Estimation 171 Solution Volume of portion A = 2 3 5 5 98.12 mm4 = Volume of ortion B which is frustum of coneV B = 2 2 3 105 10 50 1831.66 mm3 + + = Volume of ortion C = 2 3 17 5 1134.9 mm4 = Volume of ortion D = 2 3 10 10 785.4 mm4 = Volume of ortion E = ( ) 2 2 3 6 5 10 86.39 mm4 = Total volume = V A

+ V B + V C + V D + V E = 3.94 cm 3 Weight of the product = 30.90 gHence, cost of the material =1230.9 Rs. 0.3711000 = Example 5.49 Estimate the cost of production of the job.Material CI casting 70 mm 150 mm longWeight o material (CI) = 0.0075 kg/cm 3 Cost o CI Rs. 500/kg.Turning at Rs. 0.85/cm 3 o metal removedFacing at Rs. 0.85/cm 3 o metal removed.Drilling and boring Rs. 2.00/cm 3 o metal removed. Solution Formulae,Volume o 40 hole ( ) 23 3 4 5 cm 62.83 cm4 = Volume o ta er hole ( ) 22 3 0.854 5.5 4 5.5 15.19 cm12 + + = Volume o 55 hole (E) Fig. 5.32 40555080 172 Process Planning and Cost Estimation = ( ) 2 3 5.5 8 2 0.85 149.67 cm4 = Total volume o the hole = Volume o material removed in drilling and boring1. Volume o rough casting V 1 = 2 3 7 15 577.3 cm4 = 2. Volume o the solid job a ter turning and acing i.e., be ore drilling and boringV 2

= ( ) ( ) 23 6 4 6 4 395.84 cm4 + + = = 395.84 cm 3 3. Volume o material removed in turning and acing= V 1 V 2 = 181.43 cm 3 4. Weight o rough casting = 4.33 kg Costing Cost o CI at Rs. 5 er kg labour charges= 5 4.329 = Rs. 21.65(a) Turning and acing Rs. 0.85/cm 3 o metal removed= 0.75 181.43 = Rs. 136.07(b) For drilling and boring Rs. 1/cm 3 o metal removed= 1 227.69 = Rs. 227.69Cost o roduction o the job = Rs. 385.41. Exam le 5.50 Figure shows a bevel gear blank made u o ms. Find the weight and cost o material required or it. Assume the density o ms = 7.85 gm/cm 3 and its cost as Rs. 12/kg. 17550 100100DABC10250 300 350 Fig. 5.33 Production Cost Estimation 173 Volume o ortion A = 2 250 1754 = 8585937.5 mm 3 Volume o ortion B = ( ) 2 2 150 175 125 175 1253 + + = 3565208.3 mm 3 Volume o ortion C = ( ) 2 2 100 175 150 175 1503 + + = 8303916.6 mm 3 Volume o ortion D = 2 2 100 315 250 104 4 + = 2963375 mm 3 Total volume o bevel gear = V A

+ V B V C V D = 17495.67 cm 3 The weight o the bevel gear =7.8517495.67 137.34 kg1000 = Hence, the cost o material o the bevel gear137.34 12 = Rs. 1648. Exam le 5.51 Find the weight o the material and material cost o the brass com onent as shown in igure.Assume density o brass as 85 gm/cm 3 . Cost o brass o Rs. 90/kg. 11015 404015 R30 1525 70 Fig. 5.34 Solution Volume o ortion A = ( ) 2 k 3D 2h6 Where h = 15 mm and D = 2 30 = 60 mm 174 Process Planning and Cost Estimation V A = ( ) 2 3 15 3 60 215 17662.5 mm6 = Volume o ortion B = 2 3 35 40 38465 mm4 = Volume o ortion C = 2 3 70 15 57697.5 mm4 = Volume o ortion D = ( ) 2 2 40 35 12.5 35 12.53 + + = 76145 mm 3 Volume o ortion E = 2 3 15 40 7065 mm4 = Volume o illet F = 0.215 R 2 Mean eri heral

 = V A + V B + V C + V D V E + V F = 185444.68 mm 3 = 185.4 cm 3 Total weight o the com onent = 185.44 8.51.576 kg1000 = Hence, the cost o material = 1.576 90 = Rs. 141.84 Exam le 5.52 Estimate the weight and cost o material required or manu acturing 10 CT wheels as shown in igure. Assume density o CI = 7.2 gm/cm 3 and its cost Rs. 10/kg. S o k e Rim60 Fig. 5.35 Solution Volume o rim = 2 30 D mean4 = 2 30 1004 Production Cost Estimation 175 = 222066.1 mm 3 Volume o hub = ( ) 2 2 3 40 10 60 70685.8 mm4 = Volume o 4 s okes 4V s = ( ) ( ) 2 14 5 125 30 30 404 2 = 981.74 mm 3 Total volume = 293.73 mm 3 Weight =7.2293.731000

Weight o wheels = 21.1 kgHence, the cost o material = Rs. 211 Exam le 5.53 Estimate the weight and cost o the ms casting as shown in igure. Assume density o steel as7.85 gm/cm 3 and steel cost as Rs. 11/kg. 20 30540 20 203010 Fig. 5.36 Solution Volume o ortion A = 20 20 20 = 8000 mm 3 Volume o ortion B = 2 3 20 30 9420 mm4 = Volume o ortion C = 2 3 30 5 3532.5 mm4 = Volume o ortion D = ( ) 2 2 4015 10 1503 + + = 19886.35 mm 3 Volume o ortion E = 2 3 15 20 3532.3 mm4 = Total volume o the art = 44.37 cm 3 176 Process Planning and Cost Estimation The weight o the art = 7.8544.37 0.348 kg1000 = Hence, the cost o the art = 0.348 11 = Rs. 3.82. 5.5.4 Estimation o Machining Time 5.5.4.1 Introduction In general all com onents or roducts manu actured in the worksho , required one or moremachining o erations to be done on them. Hence, the roducts have to travel through the machinesho to attain their inal sha e and size. The machining o erations necessary or a job may be o di erent ty es, such as turning, sha ing, laning, drilling, milling, boring and grinding.In estimating the time requires to er orm an o eration on a work iece by any machine, the ollowing actors must be considered.1. Set u time.2. O eration time.3. Tear down time.4. Personal allowance.5. Fatigue allowance.6. Checking allowance.7. Miscellaneous allowance. 1. Set u time This takes into account the time required to re are the machine or doing the job, together, withthe time taken to study the blue rint. The time to re are the machine, in turn, includes the time toinstall and adjust the tools in the machine, as well as to make the machine ready to start the work. 2. O eration time The sum o handling time and machining time or a job is called o eration time. It is the durationo time that ela ses between out ut o

two consecutive units o roduction. It is also called cycletime. 3. Tear down time Tear down time takes into account the time necessary to remove rom the machine all toolsand accessories, such as jigs and ixtures, gauges and instruments etc. The time required or clearingo erational chi s rom the machine table and clearing o the machine itsel are included on this.Tear down time is generally 10 15 minute er shi t o 8 hrs. 4. Personal allowance The time allowed or workers to meet their ersonal needs, such as going to the urinal, drinkingwater, smoking, washing their hands, etc., is known as ersonal allowance. It is generally 5 to 7%o the total working hours in a day. 5. Fatigue allowance The long working hours and oor working conditions such as oor lighting, oor ventilation etc.,cause itigue and e ect the e iciency o worker is atigue decreases the worker ca acity to work.The allowance or atigue is taken de ending u on the ty e o work. Production Cost Estimation 177 5.5.4.2 Im ortance o Machine Time Calculation To ind the manu acturing cost o a articular job which requires one or more machining o erations,the calculation o machining time is im ortant. A ter determining the total time or machining, andknowing the machining cost er unit time, the total cost o machining can be worked out. Machiningtime is calculated by a lying certain basic ormulae, tables o variables and constants.The basic ormula used isMachining time = Travel o the tool necessaryFeed r m 1. Travel o the tool This is determined rom the dimensions in the actual drawing o the art to be manu actured.The necessary allowances or the tool a roach and over run or clearing the tool o the job aretaken into account with the actual length o the work, to ind the travel o the tool.I actual length o the work = l Amount o tool a roach = AAmount o tool over run = OThen, travel o the tool L = l + A + O Tool at inishingTool atstarting L l AOJob Fig. 5.37 2. Feed Feed is the distance that the tool travels into the job in one revolution i the work or the distancethat the table holding the work travels is one stroke o the tool. In metric units, eed is usuallyex ressed in mm/revolution or mm/stoke. Feed de ends on the de th o cut, itness o the work desired, r m o the job, etc. 3. De th o cut It is the enetration o the cutting tool into the job in a single cut. In metric units, the de th o cut is ex ressed in mm. The de th o cut de ends u on the itness o the job required, such ashigher de th o cut or rough cut and smaller de th o cut or inish cut. 4. RPM It re resents the number o revolutions o the m/c s indle in one minute. Thus it is the number o revolutions er minute o the job or o tool. 178 Process Planning and Cost Estimation

5. Cutting s eed The cutting s eed can be de ined as the relative sur ace s eed between the tool and the job.It is ex ressed in metres er minute (m m).For exam le, i a job o diameter D mm is revolving at a s eed o N r m, thenCutting s eed VDNm/min1000 = 5.5.4.3 Calculation o Machining Time or Di erent Lathe O erations Turning DDe th o cutTool Fig. 5.38 Time o turning, T m =L A ON + + Where, L = Tool distanceN = Number o revolution/minuteA = Tool a roach mmO = Tool over travel, mm = Feed/revolution, mm/rev.Number o cuts =D d2 De th o cut Where D = Diameter o given blank,d = Diameter o blank a ter turningIt turning o eration, the de th o cut should not exceed 3 mm or rough cuts and 0.75 mm or inishing cuts. Production Cost Estimation 179 Facing WorkFacing toolLength o cutFeed Fig. 5.39 T m = 1min N Where N = av 1000 VD Here, o cut = D2 Other turning o eration For turning o eration like cham ering, knurling, orming etc., the machining time ormula is thesame.T m = Length o cut N Feed r m l = Where N = 1000 VD 5.5.4.4 Machining Time Calculation or Drilling Lathe and Boring Drilling d0.3d Fig. 5.40 180 Process Planning and Cost Estimation Drilling is the o eration o roduction a hole in an object by orcing a drill against it. The timetaken to drill a hole de ends u on the cutting s eed and eed given to the tool. Due allowancesmust be made or the distance. The drill must travel be ore the cut commences. Some holes aredrilled to a s eci ied de th. Such holes are called blind holes.Time or drilling blind holes T

m = 0.3d N l ++ Time or drilling through holes T m = 0.5d N l ++ Where l = De th o hole = Feedd = Diameter Boring The inishing or enlarging o internal diameter o a hole, which has been reviously drilled bya boring tool, is called the boring o eration.Time taken or boring o eration = Length o cutFeed r m 5.5.4.5 Machining Time Calculation or Milling O eration De ending u on the di erent requirements o the di erent jobs, various milling o erations areado ted. But all o erate on same rinci le.N = 1000 VD Time or one cut T m = Total table travelTable eedmin Where, Total tabel travel = Length o job + Added table travel Table eed minmin = Feed/tooth Number o teeth r mThe a roach is the distance the cutter must be engaged be ore the ull de th o cut is reached. (a) When cutter diameter is less than the width o the work. A O Total table travelLength o workA A roachO Over run Fig. 5.41 Production Cost Estimation 181 A roach = 0.5 d (b) When cutter diameter is greater than the width o the work. eA BAD2A roachW/2Over runTotal table travel Fig. 5.42 A roach A = AC ABIn ABC,AB = 2 2 AC BC DA2 = 2 2 D W2 2 A = 2 2

182 Process Planning and Cost Estimation Where d = De th o cutD = Diameter o the cutter I the de th o cut equals or exceeds the cutter radius the added table travel will be equal toradius o the cutter.Added table travel = D2 For inishing ass, the cutter is ermitted to travel beyond the end o the work iece, so thetrailing edges give the same wi ing action to the entire sur ace.when d D2 A OLength o workTotal table travel Fig. 5.44 Added table travel = A + O= 2 2 D d d when d < D2 = D Dwhen d2 (c) When cutting a lat across the round bar stock Length o cut will be the length o chordL = 21 2 D d d Added table travel = 2 22 1 1 D d D d d D d d + D 1 dD 2 LdLWAddedtable travel Fig. 5.45 or Sha ing and Planing (a) Sha ing

Production Cost Estimation 183 5.5.4.6 Machining Time Calculation FeedDe th o cut D i r e c t i o n o e e d Length o cutTool Fig. 5.46

D D W2 2 2 A = 2 2 1D D W2 Slab milling o eration De th o cut (D)Addedtable travelLength o travelCutter dia (D) Fig. 5.43 Added table travel = 2 Dd d when d < D2

mill cutTotal table

Usually Return strokeForward stroke = 23 Time o orward stroke = 3Total time5 L = Length o the work S = Stroke lengthIt is generally taken as (L + 50) mm.Similarly, i B is the width o the work, the width or calculation ur ose is taken as (B + 25) mmN = Number o stroke/min = Feed/stroke in mmV = Cutting s eed m/minK = Return time/Cutting timeCutting stroke time = L 501000 V + Return stroke time = K Cutting stroke time= L 50K 1000 V + Total time/cycle = ( ) ( ) L 50 K L 501000V 1000 V + ++ = ( ) ( ) L 50 1 k 1000 V + + Process Planning

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* 1.5 CHARTS AND DIAGRAMS USED IN METHOD STUDY (TOOLS AND TECHNIQUES) <http://www.scribd.com/doc/49636090/1/CHARTS-AND-DIAGRAMS-USED-IN-METHOD-STU DY-TOOLS-AND-TECHNIQUES> * 1.5.4 Two-Handed Process Chart (or) Right Hand, Left Hand Chart <http://www.scribd.com/doc/49636090/2/Two-Handed-Process-Chart-or-Right-Hand -Left-Hand-Chart> * 1.8 RATING FACTOR <http://www.scribd.com/doc/49636090/3/RATING-FACTOR> * 1.9 CALCULATION OF BASIC TIME <http://www.scribd.com/doc/49636090/4/CALCULATION-OF-BASIC-TIME> * 1.10 ALLOWANCES <http://www.scribd.com/doc/49636090/5/ALLOWANCES> * 1.11 CALCULATION OF STANDARD TIME <http://www.scribd.com/doc/49636090/6/CALCULATION-OF-STANDARD-TIME> * 1.12 PRODUCTION STUDY <http://www.scribd.com/doc/49636090/7/PRODUCTION-STUDY> * 1.13 RATIO DELAY STUDY <http://www.scribd.com/doc/49636090/8/RATIO-DELAY-STUDY> * 1.14 SYNTHESIS FROM STANDARD DATA <http://www.scribd.com/doc/49636090/9/SYNTHESIS-FROM-STANDARD-DATA> * 1.15 ANALYTICAL ESTIMATING <http://www.scribd.com/doc/49636090/10/ANALYTICAL-ESTIMATING> * 1.15.1 Procedure <http://www.scribd.com/doc/49636090/11/Procedure> * 1.15.2 Advantages <http://www.scribd.com/doc/49636090/12/Advantages> * 1.15.3 Limitations <http://www.scribd.com/doc/49636090/13/Limitations> * 1.15.4 Application <http://www.scribd.com/doc/49636090/14/Application> * 1.16.2 Method Time Measurement (M.T.M.) <http://www.scribd.com/doc/49636090/15/Method-Time-Measurement-M-T-M> * 1.16.3 Table Preparation <http://www.scribd.com/doc/49636090/16/Table-Preparation> * 1.16.4 Advantages of MTM <http://www.scribd.com/doc/49636090/17/Advantages-of-MTM> * 1.16.5 Limitations <http://www.scribd.com/doc/49636090/18/Limitations> * 1.17 ERGONOMICS <http://www.scribd.com/doc/49636090/19/ERGONOMICS> * 1.17.1 Objectives <http://www.scribd.com/doc/49636090/20/Objectives> * 1.17.2 Applications <http://www.scribd.com/doc/49636090/21/Applications> * REVIEW QUESTIONS <http://www.scribd.com/doc/49636090/22/REVIEW-QUESTIONS> * 2.0 INTRODUCTION <http://www.scribd.com/doc/49636090/23/INTRODUCTION> * 2.1 PROCESS PLANNING DEFINITION <http://www.scribd.com/doc/49636090/24/PROCESS-PLANNING-DEFINITION> * 2.1.1 Purpose of Process Planning

<http://www.scribd.com/doc/49636090/25/Purpose-of-Process-Planning> * 2.1.2 Concept of Process Planning <http://www.scribd.com/doc/49636090/26/Concept-of-Process-Planning> * 2.2 OBJECTIVES OF PROCESS PLANNING <http://www.scribd.com/doc/49636090/27/OBJECTIVES-OF-PROCESS-PLANNING> * 2.3 SCOPE OF PROCESS PLANNING <http://www.scribd.com/doc/49636090/28/SCOPE-OF-PROCESS-PLANNING> * 2.4 INFORMATIONS REQUIRED TO DO PROCESS PLANNING <http://www.scribd.com/doc/49636090/29/INFORMATIONS-REQUIRED-TO-DO-PROCESS-P LANNING> * 2.5.2 Preparing Operation Planning Sheet <http://www.scribd.com/doc/49636090/30/Preparing-Operation-Planning-Sheet> * 2.5.3 Process Planning Procedure <http://www.scribd.com/doc/49636090/31/Process-Planning-Procedure> * 2.6 APPROACHES OF PROCESS PLANNING <http://www.scribd.com/doc/49636090/32/APPROACHES-OF-PROCESS-PLANNING> * 2.6.1 Manual Process Planning <http://www.scribd.com/doc/49636090/33/Manual-Process-Planning> * 2.6.2 Computer Aided Process Planning <http://www.scribd.com/doc/49636090/34/Computer-Aided-Process-Planning> * 2.6.2.1 Retrieval Type Approach <http://www.scribd.com/doc/49636090/35/Retrieval-Type-Approach> * 2.6.2.2 Generative Approach <http://www.scribd.com/doc/49636090/36/Generative-Approach> * 2.6.2.2.1 Process planning logic <http://www.scribd.com/doc/49636090/37/Process-planning-logic> * I. Process planning logic <http://www.scribd.com/doc/49636090/38/I-Process-planning-logic> * 2.6.2.3 Semi Generative Approach <http://www.scribd.com/doc/49636090/39/Semi-Generative-Approach> * 2.7 SELECTION PROCESSES <http://www.scribd.com/doc/49636090/40/SELECTION-PROCESSES> * 2.7.1 Factors Affecting Selection Process <http://www.scribd.com/doc/49636090/41/Factors-Affecting-Selection-Process> * 2.7.2 Machine Capacity <http://www.scribd.com/doc/49636090/42/Machine-Capacity> * 2.7.3 Analysis of Machine Capacity <http://www.scribd.com/doc/49636090/43/Analysis-of-Machine-Capacity> * 2.7.4 Process and Equipment Selection Procedure <http://www.scribd.com/doc/49636090/44/Process-and-Equipment-Selection-Proce dure> * 2.7.5 Process Sheet Description <http://www.scribd.com/doc/49636090/45/Process-Sheet-Description> * 2.7.6 Determination of Man, Machine and Material Requirements <http://www.scribd.com/doc/49636090/46/Determination-of-Man-Machine-and-Mate rial-Requirements> * 2.7.6.1 Manpower Requirement <http://www.scribd.com/doc/49636090/47/Manpower-Requirement> * 2.7.6.2 Machine and Equipment Requirement <http://www.scribd.com/doc/49636090/48/Machine-and-Equipment-Requirement> * 2.8 MATERIAL REQUIREMENT <http://www.scribd.com/doc/49636090/49/MATERIAL-REQUIREMENT> * 2.8.1 Bill of Material <http://www.scribd.com/doc/49636090/50/Bill-of-Material> * 2.8.2 Machine Tool Replacement <http://www.scribd.com/doc/49636090/51/Machine-Tool-Replacement> * 2.8.3 Factors Influencing Choice of Machinery <http://www.scribd.com/doc/49636090/52/Factors-Influencing-Choice-of-Machine ry> * 2.8.4 Selection of Machinery

<http://www.scribd.com/doc/49636090/53/Selection-of-Machinery> * 2.8.4.1 Selection among Suitable Machines <http://www.scribd.com/doc/49636090/54/Selection-among-Suitable-Machines> * 2.8.4.2 Break Even Point Analysis <http://www.scribd.com/doc/49636090/55/Break-Even-Point-Analysis> * 2.8.4.3 Production Cost Comparison <http://www.scribd.com/doc/49636090/56/Production-Cost-Comparison> * 2.8.4.4 Process Cost Comparison <http://www.scribd.com/doc/49636090/57/Process-Cost-Comparison> * 2.9 SET OF DOCUMENTS FOR PROCESS PLANNING <http://www.scribd.com/doc/49636090/58/SET-OF-DOCUMENTS-FOR-PROCESS-PLANNING > * 2.10 DEVELOPING MANUFACTURING LOGIC AND KNOWLEDGE <http://www.scribd.com/doc/49636090/59/DEVELOPING-MANUFACTURING-LOGIC-AND-KN OWLEDGE> * 2.11 PROCESS TIME CALCULATION <http://www.scribd.com/doc/49636090/60/PROCESS-TIME-CALCULATION> * 2.12 SELECTION OF COST OPTIMAL PROCESS <http://www.scribd.com/doc/49636090/61/SELECTION-OF-COST-OPTIMAL-PROCESS> * 3.0 INTRODUCTION <http://www.scribd.com/doc/49636090/62/INTRODUCTION> * 3.1 REASONS FOR DOING ESTIMATES <http://www.scribd.com/doc/49636090/63/REASONS-FOR-DOING-ESTIMATES> * 3.2 DEFINITION <http://www.scribd.com/doc/49636090/64/DEFINITION> * 3.2.1 Importance of Estimating <http://www.scribd.com/doc/49636090/65/Importance-of-Estimating> * 3.3 OBJECTIVES OR PURPOSE OF ESTIMATING <http://www.scribd.com/doc/49636090/66/OBJECTIVES-OR-PURPOSE-OF-ESTIMATING> * 3.4 FUNCTIONS OF ESTIMATING <http://www.scribd.com/doc/49636090/67/FUNCTIONS-OF-ESTIMATING> * 3.5 COST ACCOUNTING OF COSTING <http://www.scribd.com/doc/49636090/68/COST-ACCOUNTING-OF-COSTING> * 3.6 IMPORTANCE OF COSTING <http://www.scribd.com/doc/49636090/69/IMPORTANCE-OF-COSTING> * 3.7 AIMS OF COST ACCOUNTING <http://www.scribd.com/doc/49636090/70/AIMS-OF-COST-ACCOUNTING> * 4.4 MATERIALS AVAILABLE TO DEVELOP AN ESTIMATE <http://www.scribd.com/doc/49636090/71/MATERIALS-AVAILABLE-TO-DEVELOP-AN-EST IMATE> * 4.5.2 Group Technology <http://www.scribd.com/doc/49636090/72/Group-Technology> * 4.5.3 Parametric Estimating <http://www.scribd.com/doc/49636090/73/Parametric-Estimating> * Use of parametric estimating <http://www.scribd.com/doc/49636090/74/Use-of-parametric-estimating> * 4.5.4 Statistical Estimating <http://www.scribd.com/doc/49636090/75/Statistical-Estimating> * 4.6 IMPORTANCE OF REALISTIC ESTIMATES <http://www.scribd.com/doc/49636090/76/IMPORTANCE-OF-REALISTIC-ESTIMATES> * 4.7 ESTIMATING PROCEDURE <http://www.scribd.com/doc/49636090/77/ESTIMATING-PROCEDURE> * 4.8 DIVISION OF ESTIMATING PROCEDURE <http://www.scribd.com/doc/49636090/78/DIVISION-OF-ESTIMATING-PROCEDURE> * 4.9 CONSTITUENTS OF A JOB ESTIMATE <http://www.scribd.com/doc/49636090/79/CONSTITUENTS-OF-A-JOB-ESTIMATE> * 4.10 COLLECTION OF COST <http://www.scribd.com/doc/49636090/80/COLLECTION-OF-COST> * 4.11 ALLOWANCES IN ESTIMATION <http://www.scribd.com/doc/49636090/81/ALLOWANCES-IN-ESTIMATION> * 5.0 INTRODUCTION PRODUCTION COST ESTIMATION <http://www.scribd.com/doc/49636090/82/INTRODUCTION-PRODUCTION-COST-ESTIMATI

ON> * 5.1 ESTIMATION OF MATERIAL COST <http://www.scribd.com/doc/49636090/83/ESTIMATION-OF-MATERIAL-COST> * 5.1.1 Determination of Material Cost <http://www.scribd.com/doc/49636090/84/Determination-of-Material-Cost> * 5.1.3 Solved Problems in Material Cost <http://www.scribd.com/doc/49636090/85/Solved-Problems-in-Material-Cost> * 5.4 ALLOCATION OR DISTRIBUTION OF OVERHEAD <http://www.scribd.com/doc/49636090/86/ALLOCATION-OR-DISTRIBUTION-OF-OVERHEA D> * 5.4.1 Percentage on Direct Material Cost <http://www.scribd.com/doc/49636090/87/Percentage-on-Direct-Material-Cost> * 5.4.2 Percentage on Direct Labour Cost <http://www.scribd.com/doc/49636090/88/Percentage-on-Direct-Labour-Cost> * 5.4.3 Percentage on Prime Cost <http://www.scribd.com/doc/49636090/89/Percentage-on-Prime-Cost> * 5.4.4 Man-Hour Rate <http://www.scribd.com/doc/49636090/90/Man-Hour-Rate> * 5.4.5 Machine-Hour Rate <http://www.scribd.com/doc/49636090/91/Machine-Hour-Rate> * 5.4.6 Combination of Man-Hour and Machine-Hour Method <http://www.scribd.com/doc/49636090/92/Combination-of-Man-Hour-and-Machine-H our-Method> * 5.4.7 Unit Rate Method <http://www.scribd.com/doc/49636090/93/Unit-Rate-Method> * 5.4.8 Space Rate Method <http://www.scribd.com/doc/49636090/94/Space-Rate-Method> * 5.5.1.1 Losses in Forging <http://www.scribd.com/doc/49636090/95/Losses-in-Forging> * 5.5.1.2 Forging Cost <http://www.scribd.com/doc/49636090/96/Forging-Cost> * 5.5.1.3 Solved Problems <http://www.scribd.com/doc/49636090/97/Solved-Problems> * 5.5.2 Estimation of Welding Shop <http://www.scribd.com/doc/49636090/98/Estimation-of-Welding-Shop> * 5.5.2.1 Welding Cost <http://www.scribd.com/doc/49636090/99/Welding-Cost> * 5.5.3 Estimation of Foundry Shop <http://www.scribd.com/doc/49636090/100/Estimation-of-Foundry-Shop> * 5.5.3.1 Estimation of Pattern Cost <http://www.scribd.com/doc/49636090/101/Estimation-of-Pattern-Cost> * 5.5.3.2 Foundry Losses <http://www.scribd.com/doc/49636090/102/Foundry-Losses> * 5.5.3.3 Steps for Finding Costing Cost <http://www.scribd.com/doc/49636090/103/Steps-for-Finding-Costing-Cost> * 5.5.4 Estimation of Machining Time <http://www.scribd.com/doc/49636090/104/Estimation-of-Machining-Time> * 5.5.4.1 Introduction <http://www.scribd.com/doc/49636090/105/Introduction> * 5.5.4.2 Importance of Machine Time Calculation <http://www.scribd.com/doc/49636090/106/Importance-of-Machine-Time-Calculati on> * 5.5.4.3 Calculation of Machining Time for Different Lathe Operations <http://www.scribd.com/doc/49636090/107/Calculation-of-Machining-Time-for-Di fferent-Lathe-Operations> * 5.5.4.4 Machining Time Calculation for Drilling Lathe and Boring <http://www.scribd.com/doc/49636090/108/Machining-Time-Calculation-for-Drill ing-Lathe-and-Boring> * 5.5.4.5 Machining Time Calculation for Milling Operation <http://www.scribd.com/doc/49636090/109/Machining-Time-Calculation-for-Milli

ng-Operation> * 5.5.4.6 Machining Time Calculation for Shaping and Planing (a) Shaping <http://www.scribd.com/doc/49636090/110/Machining-Time-Calculation-for-Shapi ng-and-Planing-a-Shaping> * 5.5.4.7 Machining Time Calculation for Grinding <http://www.scribd.com/doc/49636090/111/Machining-Time-Calculation-for-Grind ing> * 5.5.4.8 Solved Problems <http://www.scribd.com/doc/49636090/112/Solved-Problems> Share & Embed <http://www.facebook.com/sharer.php?u=http%3A%2F%2Fwww.scribd.com%2Fdoc%2F496360 90%2FProcess-Planning%23source%3Afacebook><http://twitter.com/home?source=scribd .com&status=Reading%20%22Process%20Planning%22%20on%20Scribd%20http%3A%2F%2Fwww. scribd.com%2Fdoc%2F49636090%20%23Readcast><http://www.google.com/buzz/post?url=h ttp%3A%2F%2Fwww.scribd.com%2Fdoc%2F49636090%2FProcess-Planning&message=> <#> Related Documents PreviousNext 1. p. <http://www.scribd.com/doc/47010089/Operation-Management-FULL-Without-Cutti ng-Mark> p. <http://www.scribd.com/doc/32888012/Paper-No-9-Operation-Management-FULL-Wi thout-Cutting-Mark> p. <http://www.scribd.com/doc/19463019/7/Time-Study-Work-Study-Method-Study-Jo b-Evaluation> 2. p. <http://www.scribd.com/doc/19463019/24/Linear-Programming> p. <http://www.scribd.com/doc/19463019/Operation-Management-FULL-Without-Cutti ng-Mark-> p. <http://www.scribd.com/doc/51271258/cost-estimation> 3. p. <http://www.scribd.com/doc/36215505/Cost-Sheet> p. <http://www.scribd.com/doc/51512627/30579378-MF-441-Prcess-Planning-and-Cos t-Estimation> p. <http://www.scribd.com/doc/37680193/2-Ethyl-2520Hexanol-Cost-2520Estimation -Economics> 4. p. <http://www.scribd.com/doc/27332664/Anil-Karanjkar> p. <http://www.scribd.com/doc/26260574/Cost-Accounting-DNRTmylove-infinite> p. <http://www.scribd.com/doc/6635467/2-Ethyl-2520Hexanol-Cost-2520EstimationE

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