DIRECTORATE OF TECHNICAL EDUCATION, CHENNAI - 600 025

BOARD EXAMINATIONS – APRIL 2018

ANSWER KEY
COURSE : MECHANICAL ENGINEERING MAXIMUM MARKS : 75
SEMESTER : V SEM QUESTION PAPER CODE : 832
SUBJECT : PROCESS PLANNING AND COST ESTIMATION
Part – A
1. What is manual process planning?
Process of preparation of process plans manually is called as manual process
planning. The task involves examining and interpreting engineering drawings,
making decisions on machining process selection, equipment selection, operation
sequence and shop practices. … 2 marks
2. What is machine capacity?
Machine capacity may be defined as the time available for work at a machine,
expressed in machine hours. If overtime is worked, these extra hours per week
should be added to the machine capacity to find the planned machine capacity.
… 2 marks
3. What are the factors influencing choice of machinery?

• The size and shape of the work piece.

• The work material.
• The accuracy and surface quality required.
• The quantity of parts.
• The sizes of lots required.
• Rate of output.
• Cost of production.
• Personal preferences. (Any 4) … 2 marks
4. Define Ergonomics.
It is defined as the application of human biological sciences along with
Engineering sciences to achieve optimum mutual adjustment of men and work, the
benefits being measured in terms of human efficiency and well being. … 2 marks
5. Name the various constituents of cost.
• Prime cost
• factory cost
• manufacturing cost
• total cost
• sellingprice (Any 4) … 2 marks
6. What do you mean by inspection time?
Time required to inspect the product dimensions at regular intervals to maintain
uniform quality. …1 mark
 Inspection time depends on (Any 1) …1 mark
• Type of operation performed.
• Type of measuring or checking device.
• The precision of the work surface.

7. Define Tool approach and tool over travel.

Tool approach:
Tool approach is the distance a tool is fed from the time it touches the work piece
until it is cutting to the full depth. … 1 mark
Tool over travel
Over travel is the distance the tool is fed while it is not cutting. it is the distance
over which the tool idles before it enters and after it leaves the cut. … 1 mark

8. What is the objective of line balancing?

• To distribute tasks evenly to workers.
• To distribute tasks evenly over the workstations.
• To minimize the idle time of men and machine.
• To improve the production rate. (Any 2) … 2 marks
PART-B
9. State the advantages of computer aided process planning (CAPP).
• Reduces the process planning time.
• Reduces the skill required of a planner.
• Creates more consistent plans.
• Produces more accurate plans.
• Increases productivity.
• Reduces both process planning and manufacturing costs. (Any 3)… 3 marks
10. Explain the uses of jigs and fixtures.
• Reduces the cost of production per piece
• Gives higher production rate
• Reduces production time … 3 marks
11. What are the objectives of work study?
• To establish standards of performance.
• To evaluate human work.
• To reduce work content of the product. ,materials , tools and equipments.
• To reduce material handling.
• To improve product quality.
• To simplify and standardize the methods. (Any 3) … 3 marks
12. Give the name, explanation, abbreviation and symbol of any three
therblig.

(Any 3) … 3 marks
13. What data are required for making a cost estimate?
• Brief design specifications such as description of the product, its function,
performance and purpose.
• Rate of production.
• Assembly or layout drawings.
• Quantity.
• Operation analysis.
• Standard time data.
• List of sub-assemblies of the product.
• Detailed drawings and a bill of materials for the product.
• Material release data.
• Machine tool and equipment required.
 • Tools , gauges and special fixtures , jigs or dies , required
• Manufacturing routings.
• Test and inspection equipment and procedures. (Any 3)… 3 marks

14. List the various steps of cost estimating.

• Make a complete and through analysis of the cost required to understand it fully.
• Make an analysis of the part or product and make separate lists of standard parts
and the parts to be fabricated within the plant.
• Make a manufacturing process plan for the parts to be fabricated.
• Determine the material costs for the standard and the fabricated parts.
• Estimate the total production time for each operation.
• Apply the labour and burden rates to each operation.
• Add the material costs and the labour and burden costs. This will give the total
manufacturing cost.
• Apply the profit factors to arrive at the selling price. (Any 3)… 3 marks

15. Define feed. What are the factors influencing for the selection of feed?

Feed is defined as the relatively small movement per cycle of the cutting tool,
relative to the Work piece in a direction which is usually perpendicular to the
cutting speed direction. … 2 marks
Factors influencing the selection of feed.
• Smoothness of the finish required.
• Power available
• Condition of machine and its drive.
• Type of cut.
• Tool life (Any 1) … 1 mark

16. The handle of a gauge of 30mm diameter has 80mm length. it is to be knurled
in lathe. find the machining time for knurling the handle, if the cutting speed
is 20m/min and the feed is 0.3mm per rev.

Given :
Length (L) : 80 mm
Diameter (D) : 30 mm
Cutting speed (S) : 25 m/min
Feed (F) : 0.3 mm/rev
To find :
Time required for knurling.
Solution:
1000 × s
N= 𝜋 ×D
1000 ×25
= = 265.25 RPM ... 1 mark
π ×30
Length of cut, L = 80mm
 Time for knurling T,
𝐿
T = F×S
80
= 0.3 × 265.25
= 1.00 min
= 60 sec. … 1 mark

PART – C (5 x 10 = 50)
17) a. Explain the generative process planning and state its advantages.
Generative process planning may be defined as a system that synthesis process
information in order to create a process plan for new component automatically.
In generative approach, a process plan is created from scratch for each part
without human intervention. These systems contain the logic to use
manufacturing database and suitable part description schemes to generate
process plan for particular part.
In this generative approach the computer is used to generate each individual
process plan automatically and without reference to any prior plan.
Some of the generative systems used in practice are CPPP, AUTAP, APPAS, TIPPS,
EXCAD, SIPP and TOM.

… 3 marks
OPERATION OF GENERATIVE CAPP SYSTEM
• The generative CAPP system uses a branch of artificial intelligence called expert
system.
• Expert system is a computer program that is capable of solving complex
problem.
• The problem solving procedure by using an expert system is termed as inference
engine.
• The technical knowledge of manufacturing and logic used by successful process
planners are captured and coded into programs, these programs are called
knowledge base.
• By using this knowledge base and inference engine, the CAPP system synthesis
new process plan from scratch for new part. … 2 marks
STEPS INVOLVED IN PREPARING A PROCESS PLAN IN GENERATIVE CAPP SYSTEM:
• The machinable volumes, called packets, are identified by taking the difference of
blank size and the finished component size.
• The packets are stored in order of levels that clearly indicate the same sequence
in the final process plan.
• Examine the packets for possibility of combining so that the machining
operations could be reduced.
• Select the machine tool to be used for each packets.
• Identify the process sequence required for machining each packet.
• Select the suitable cutting tools for each packet and operation decided.
• Obtain the optimum cutting process parameters such as speed, feed, depth of cut
and number of passes for each part.
• Sequence the operations on the basis of machine tool and cutting tool.
• Calculate the machine time and idle time involved in the production of the part.
• The final process plan is selected on the basis of lowest cost of machining time.
• The results are documented in any of the form such as process sheet, machining
simulation steps or CNC part program. … 3 marks

ADVANTAGES OF GENERATIVE PROCESS PLANNING:

• It can generate consistent process plans rapidly.
• New components can be planned as easily as existing components.
• It can potentially be interfaced with an automated manufacturing facility to
provide detailed and up to date control information.
… 2 marks

17. b. A company is buying one of the component that go into their product at a
total purchase cost of Rs.20 per unit. Their annual requirement of the
component is 6000 units. One of the supervisors had put up a proposal for
making the component in the shop itself because the variable cost per unit
comes to Rs.2 only. It was found that it requires sophisticate machines and
the accounts department had worked out and estimated the annual fixed
cost of Rs.1,40,000. Should the proposal be accepted? Draw the break even
chart and find the minimum level of annual requirements of the component
above which making the component would be profitable.

Given:
Buying cost (s) = Rs.20/- unit
Annual fixed cost (F) = Rs.1,40,000.
Variable cost (V) = Rs.2/-unit
Annual requirement (Q) = 6000 units
To find:
Break even quantity.
 Solution:
Total cost of purchase
= Q×S … 1 mark
= 6000×20
= Rs 1,20,000/- … 1 mark
Total cost of manufacturing
= F+(Q×V) … 1mark
= 1,40,000 + (6000 × 2)
= Rs 1,52,000/- … 1mark
As the cost of manufacturing is more, it is decided to buy. … 1mark
Break even quantity
Q×S = F+(Q×V) … 1mark
F
Q = S−V
140000
Q = … 1mark
20−2

= 7778 units … 1mark

250000

200000 Break even Buying cost

Quantity (Q) Manufacturing cost
150000 Fixed cost
100000

50000

0
(7778)
0 2000 4000 6000 8000 10000 12000

X axis - quanity of product ; Yaxis - cost in rupees … 2marks

18. a.Construct suitable operation planning sheet for manufacture of spur gear
having 24 teeth using a 2 module gear cutter. The spur gear is to be made
for a total quantity of pieces. The material of the gear is medium of the gear
is medium carbon steel

Step:1 Study and analysis of the part drawing: …1 mark

In study of the part drawing the shape and size of the bar stock are considered.
Pitch diameter (dp) = z×m
= 24 × 2
= 48 mm
Tip diameter(Da) = d + 2×m
= 48 + (2×2)
= 52 mm
 Here the maximum diameter of 52 mm and assuming tolerance of 0.20mm, we
can select 55mm diameter bar stock.
Step:2 Consult with the product designer: …1 mark
The process planner will discuss with the product designer regarding the
dimensions and tolerances. After clarifying everything, the process planner will
proceed further.
Step:3 List the basic operations, required to produce the part: …1 mark
• Facing & turning
• Drilling
• Gear hobbing
Step:4 Select the machines and tools: …1 mark
• For the given part, it is required to select lathe.
• Depending upon quantity to be produced the machine tool may be engine
lathe, turret lathe or automatic lathe and gear hobbing machine.
• Select the single point cutting tool ,drill bit and gear hob.
Step:5 Sequencing the operations: …1 mark
• Fix the circular blank in the lathe chuck.
• Facing operation is to be done on both ends.
• Turning operation for 52mm diameter is to be carried out by using a
single point cutting tool.
• Drilling operation is to be carried out for a diameter of 12mm throughout
the width of the circular blank.
• Circular blank is to be held in a hobbing machine and based on depth of
tooth and number of teeth, gear teeth is generated in the circular blank.
Step:6 Specifying the measuring instruments or gauging: …1 mark
• Vernier Caliper or Snap Gauge
• Plug Gauge
• Pitch Diameter Gear Gauge
 Step:7 Operation Planning Sheet …4 marks

OPERATION PLANNING SHEET

Part name : Gear Material : Medium carbon steel
Part No. : Specification :
Description Cutting
OP. No. Machine Gauges
of Operation Tools
10 Facing Turret lathe
20 Facing Turret lathe
Vernier
30 Inspection
Caliper
40 Turning Turret lathe
Vernier
50 Inspection Caliper , Snap
Gauge
60 Drilling Turret lathe Drill bit
Vernier
70 Inspection Caliper , Plug
Gauge
Gear Gear hobbing
80 Hob
generation machine
Pitch
90 Inspection Diameter
Gear Gauge

18.b. A component can be produced on either a turret lathe or an automatic lathe.

The different cost factors for the two machines are given below.

For turret lathe

Fixed cost (F) = 400.
Variable cost (V) = 2 per piece

For automatic lathe

Fixed cost (F) = 1600.
Variable cost (V) = 0.50 per piece

Assume that the cycle time for production of the component is same for both
machines. Which machine will you select for producing (i) 900 (ii) 700
components? Also determine the break even quantity.

Given:
Turret lathe
Fixed cost (F) = Rs.400
Variable cost (v) = Rs.2/piece
Automatic lathe
Fixed cost (F) = Rs.1600
Variable cost (v) = Rs.0.5/piece

To Find:
Break even quantity (Q)

Solution:
a) Let Q1 = 900
For turret lathe
Total cost = F1+(Q1×V1) … 1 mark
= 400 + (900×2)
= Rs.2200 … 1 mark
For automatic lathe
Total cost = F2+(Q2×V2)
= 1600 + (900×0.5)
= Rs.2050 … 1 mark

We select automatic lathe as the total cost is less. … 1 mark

b) Let Q2 = 700
For turret lathe
Total cost = F1+(Q1×V1) … 1 mark
= 400 + (700×2)
= Rs.1800 … 1 mark

For automatic lathe

Total cost = F2+(Q2×V2)
= 1600 + (700×0.5)
= Rs.1950. … 1 mark

In this case, turret lathe may be selected ,because total cost is less
compare to automatic lathe … 1 mark

BREAK EVEN QUANTITY (Q)

F1 + (Q1×V1) = F2 + (Q2×V2) … 1 mark
Q1 = Q2 = Q
(Q × V1) – (Q × V2) = F2 – F1
Q = (𝐹2 − 𝐹1)/(𝑉1 − 𝑉2)
1600−400
Q = 2−0.5

Q = 800 Units … 1 mark

19) a. What are the objectives of method study? Explain the basic procedure
followed for conducting method study.

Objectives of method study

• To improve plant layout
• To improve manufacturing processes
• To improve working conditions
• To reduce human effort and fatigue
• To reduce material handling
• To improve plant and equipment design
• To improve the use of material , machines and manpower
• To improve in safety standard
• To ensure safety (Any 3 )… 2 marks

Procedure for method study

The various steps involved are

1. SELECT
(The job to be studied)

2. RECORD
(all facts about job)

3. EXAMINE
(all facts critically)

4. DEVELOP
(most economical , efficient method)

5. INSTALL
(the new method into practice)

6. MAINTAIN
(the new method by controlling)
… 2 marks
1. SELECT
The job should be selected for the method study based upon the following
considerations.
• Economic aspect
• Technical aspect
• Human aspect

ECONOMIC ASPECTS
The method study involves cost and time. The following guidelines can be used
for selecting a job:
• Bottle neck operations which are holding up other production
operations.
• Operations involving excessive labour.
• Operations producing lot of scrap or defectives.
• Operations having poor utilization of resources.
• Backtracking of materials and excessive movement of materials.

TECHNICAL ASPECTS
The factors which favour selection in technical aspects are:
• Job having inconsistent quality.
• Operations generating lot of scraps.
• Frequent complaints from workers regarding the job.

HUMAN ASPECTS
These are some of the situations where human aspect should be given due
importance.
• Workers complaining about unnecessary and tiring work.
• More frequency of accidents.
• Inconsistent earnings.

2. RECORD
After selecting the work to be studied the next step is to record all the relevant
facts pertaining to the existing method. Recording can be done with the help of
following aids:
a) Process charts
i) Outline process chart
ii) Flow process chart: man , material and equipment type
iii) Two handed process chart
iv) Multiple activity chart.
b) diagrams
i) flow diagram
ii) string diagram
iii) cyclegraph
iv) chronocyclegraph
 c) motion and film analysis
i) simo char
d) models , etc.

3. EXAMINE
Once all the relevant information’s and procedure pertaining to the present
or existing method have been recorded the next step is to critically examine the
recorded facts. Critical examination is the means by which each activity
subjected to systematic and progressive series of questions.
The basic questions are ,
Purpose what is done?
Person who does it?
Place where it is done?
Means how is it done?
Sequence when is it done?
The above mentioned five basic questions, individually are further subjected to
enquiries like,

Why
Why is it necessary, why he does it , why it is done there , why is it done by that
method and why is it done at that time?

Alternative ways of doing

What else could be done, who else could do it, where else it could be done, how
else it could be done and when else it could be done.

Best method of doing

What should be done, who should do it, where it should be done, how it should
be done and when it should be done.

4. DEVELOP
After the questions have been answered, it is the job of the method study man
to put the improvements in practice. The developed method should be,
i) Practical and feasible.
ii) Safe and effective.
iii) Economical and
iv) Acceptable to design, production control, quality control and sales
departments.

5. INSTALL
The next step in the method study is to install the proposed method as the
standard method. installation involves three phases ,
Namely- planning, arranging and implementing for this purpose the following
procedure may be followed.

i) Get the proposed method accepted by all the supervisors, workers

and management.
 ii) Train the supervisors and workers to work according to the new
method.
iii) Minimize the hardship or inconvenience to all concerned.

6. MAINTAIN
Once the proposed method is installed, then it should be maintained in its
specified form and is not allowed to slip back to old form.

i) Ensure the proper functioning of the installed method by periodic

checks and verifications.
ii) The purpose of checks and reviews is to find if the method being
practiced is the same or it has deviated from the authorized one.
iii) Reason or deviation, if any should be explored and take suitable
corrective actions.
… 6 marks

19. b) The mean observed time and the rating factor for 5 elements of
a job are given below.

Mean observed time in

Elements Rating factor in %
Minutes
1 0.3 120
2 0.6 100
3 2.2 80
4 1.5 110
5 1.4 90

Fatigue allowance – 5% ; personal allowance – 10% ;

Contigency allowance – 5%. Calculate the allowed time for the job.

GIVEN:
Fatigue allowance – 5% ;personal allowance – 10% ; contigency allowance – 5%.
Calculate the allowed time for the job.

TO FIND:
Determine the allowed time for the job.
 SOLUTION

Basic time Basic

Observed Observed Observed rating
Element time
time rating 100
× Observed time (mins)

1. 0.3 120 O.T =

0.3×120
0.36
100

0.6×100
2. 0.6 100 O.T = 0.60
100

3. 2.2 80 O.T =
2.2×80 1.76
100

4. 1.5 110 O.T =

1.5×110 1.65
100

1.4×90
5. 1.4 90 O.T = 1.26
100

Total basic time 5.63

… 6 marks

Total allowance = fatigue allowance + personal allowance + contingency allowance

= 5 + 10 + 5 = 20%
20 × 5.63
= 100

= 1.126mins … 2 marks

Allowed time = total basic time + total allowances

= 5.63 + 1.12
= 6.75mins … 2 marks

20) a. Estimate the sales price to be quoted for the product from the
following given data.

Direct material cost per piece = 14/-

Direct labour cost per piece = 18/-
Factory overhead = 100 % of prime cost
General overhead = 25% of factory cost
Profit = 10% of total cost

GIVEN:
Direct material cost per piece = 14/-
Direct labour cost per piece = 18/-
Factory overhead = 100 % of prime cost
General overhead = 25% of factory cost
Profit = 10% of total cost
 TO FIND:
Sales price of the product.

SOLUTION:
Prime cost = direct material cost + direct labour cost
= Rs.14 + Rs.18
= Rs.32 … 2 marks

Factory overhead = 100% of prime cost

100
= × 32 = Rs.32 … 1 mark
100

Factory cost = Prime cost + Factory overhead cost

= Rs.32 + Rs.32
= Rs.64 … 2 marks

General overhead = 25% of factory cost

25
= × 64 = Rs.16 … 1 mark
100

Total cost = factory cost + general overhead

= Rs.64 + Rs.16
= Rs.80 … 2 marks

Profit = 10% of total cost

10
= × 80 = Rs.8 … 1 mark
100

Selling price = total cost + profit

= Rs.80 + Rs.8
= Rs.88 … 1 mark

20.b) An electric immersion rod is being sold in the market for Rs.65 find its
production or manufacturing cost assuming 20% profit on the selling price
and selling expenses to be 40% of production cost. If the cost of material
used for the rod is Rs.15 and overheads of the department in which it is
being is 40% of labour cost. Find the time taken for its manufacture if the
labour rate is Rs.2 per hour.

GIVEN:
Selling price = Rs.65
Profit = 20% of selling price
Selling expenses = 40% of Production cost
Direct material = Rs.15
Factory overhead = 40% of labour cost
Labour cost = Rs.2
TO FIND:
Production cost
Time taken
 SOLUTION:
If ‘P’ is the production cost
Selling expenses = 0.4P … 1mark
20
Profit = 100 × 65 = Rs.13 … 1mark
Selling price = production cost + selling expenses + profit … 1mark
65 = P + 0.4 P + 13
65−13
P = = Rs.37.14 … 2marks
1.4

Now cost of raw material = Rs.15

If ‘W’ is the direct labour cost

Overheads = 0.4W … 1mark

Now P = Direct Material + Direct Labour + Overheads ... 1mark

37.14 = 15 + W + 0.4W

22.14
W = = Rs.15.81 …1mark
1.4

15.81
Time taken = = 7.905 hours …2marks
2

21) a). Estimate the machining time required on the shaper to complete one cut
on a plate 500 x 900 mm, if the cutting speed is 6m/min. The return time
to cutting time ratio is 1:3 and the feed is 2mm per stroke. The clearance
at each end is 70mm width wise allowance may be taken as 25mm.

GIVEN:
Length of plate (L) : 900mm
Width of plate (W) : 500 mm
Cutting time ratio(K) : 1:3
Cutting speed (S) : 6m/min
Feed (F) : 2mm per stroke
Clearance : 70 mm(each end)
Width allowance : 25 mm

TO FIND:
Estimate the machining time,T

SOLUTION:

Return time to cutting time ratio (K) = 1/3 = 0.33 … 1 mark

Length of stroke = length of block + clearance on both sides
 Length of stroke (L) = 900 + (2×70) = 1040 mm … 2 marks

Width + clearance (B) = 500 + (2×25) = 550 mm … 1 mark

L(1 + K) B
Machining time for one cut (T) = ×F ... 3
1000 S
marks

1040(1 + 0.33) 550

T= × … 2 marks
1000 ×6 2

T = 51.87 mins … 1 mark

21. b) A slot 25 mm deep is to be cut through a work piece 200mm long with the
help of a HSS side and face cutter whose diameter is 150 mm and that has
10 teeth. The cutting speed is 50m/min. and feed is 0.25 mm/tooth.
Determine (i) table feed in mm/min. (ii) total cutter travel and (iii) time
required to machine the slot.

GIVEN:
Slot deep (d) = 25 mm
Length (L) = 200 mm
Feed (F) = 0.25 mm/tooth
No. of teeth = 12
Cutting speed (S) = 50 m/min
Cutter diameter (D) = 150 mm

TO FIND:
i. Table feed in mm/min
ii. Total cutter travel
iii. Time required to machine the slot

SOLUTION:
1000 S
RPM (N) = πD
1000 ×50
= π ×150

= 106 RPM. … 2marks

a) Table feed
= Feed/tooth × No.of teeth ×RPM
= 0.25 × 10 × 106 … 2mark
= 265 mm/min. … 1mark

b) Table cutter travel = length of job + added table travel

= 200 +√Dd-d2 … 1 mark
= 200 +√150×25-252