Professional Documents
Culture Documents
Prepared by:
M. Sundra Pandian, M.E., M.B. A.
Assistant Professor, Department of Mechanical Engineering,
Sri Ramakrishna Institute of Technology,
Coimbatore - 641010
Course Content
Module II
Process Planning, Aims of Process Planning, Steps to
.B . A.
, M
prepare the detailed Work Sheets for Manufacturing a
NDIA N,M .E .
A PA
S UN DR
M.
given Component, Break Even Analysis, Forecasting,
Purpose and Methods of Forecasting, Time Series,
Regression and Correlation.
Process Planning - Definition
PA ND
N DR A
M. S U
product as per the design.
Aims of Process Planning
Process Plan
Steps for Process Planning
The following are the steps involved in manual process
planning.
• Interpretation of design drawings
• Choice of processes and sequence
.B . A.
• Choice of equipment IAN, M.E., M
PA ND
• Choice of tools,Ndies,
DRA molds, fixtures, and gauges
M. SU
• Analysis of methods
• Setting of work standards
• Choice of cutting tools and cutting conditions
Steps for Process Planning
• Interpretation of Design Drawings
The planner must analyze the part or product design
(materials, dimensions, tolerances, surface finishes, etc.).
• Choice of Processes and Sequence., M.B.A.
, M .E
The process planner A
must
PA NDIAselect the processes and their
N
NDR
U
sequence required,
M. S and prepare a brief description of all
processing steps.
Steps for Process Planning
• Choice of Equipment
In general, process planners must develop plans that
utilize existing equipment in the plant. Otherwise, the
company must purchase the component A.
M .B .
or invest in new equipment.DIAN, M.E.,
PA N
• Choice of Tools,
S UNDies,
DR Molds, Fixtures, and Gauges
A
M.
The process planner must decide what tooling is
required for each processing step. The actual design and
fabrication of these tools is usually delegated to a tool
design department and tool room, or an outside vendor
specializing in that type of tooling.
Steps for Process Planning
• Analysis of Methods
Workplace layout, small tools, hoists for lifting heavy
parts, even in some cases hand and body motions must be
specified for manual operations. The industrial
M .B . A. engineering
.E .,
department is usually responsible
PA NDIA N, Mfor this area.
DRA
• Setting of MWork
. SU Standards
N
.B . A.
.E ., M
IA N,M
PA ND
N DR A
M. S U
.B . A.
.E ., M
RM IA N,M
PA ND
N DR A
Note: M. S U
.B . A.
.E ., M
IA N,M
PA ND
N DR A
M. S U
Processes Planning for Assembly Parts
The type of assembly method used for a given product
depends on factors such as:
. A.
• Anticipated production quantities
,M .E ., M .B
DIA N
PA N
DRA
• Complexity
M. SUof the assembled product,
N for ex. the
number of distinct components and
• Assembly processes used, for ex. mechanical assembly
versus welding.
Processes Planning for Assembly Parts
The Process planning for assembly involves development
of detailed assembly instructions.
For high production on an assembly line, process
planning consists of allocating work Aelements .
to the
M .B .
individual stations of the line,DIAaNprocedure
, M .E., called
PA N
N DR“Line
A Balancing”.
M . S U
10 s 10 s 14 s 6s
M/c 1 M/c 2 M/c 3 M/c 4 M/c 5
4s
10 s 10 s 14-4 6+4
M/c 1 M/c 2 M/c 3 M/c 4 M/c 5
10 s 10 s
Make or Buy
Not all components or sub-assemblies of a product are to
be manufactured by the parent organization.
In a normal industrial scenario, less critical or standard
components are procured or boughtM.from B .A. suppliers and
.E.,
critical components are manufactured
PA NDIA N, M in-house.
DR A
So, there should
M . S UNbe a basic understanding on which of the
Reliability of Supplier
Availability of Plant
capacity
Alternative source of
Supplies
Make or Buy
Not all components or sub-assemblies of a product are to
be manufactured by the parent organization.
In a normal industrial scenario, less critical or standard
components are procured or boughtM.from B .A. suppliers and
.E.,
critical components are manufactured
PA NDIA N, M in-house.
DR A
So, there should
M . S UNbe a basic understanding on which of the
APA N P
S UN DR
M. B Variable Cost (VC)
A
S=s*Q
a) Contribution b) Profit
c) BEP d) M.S.
Problem for Practice
Solution:
= 1 25 000 – 55 000 M .B . A.
.E .,
IA N,M
= Rs. 70 000 PA ND
N DRA
M. SU
b) Profit = Contribution – Fixed Cost
= 70 000 – 35 000
= Rs. 35 000
Problem for Practice
Solution:
c) BEP
= Rs. 62 500
Problem for Practice
Solution:
= { 35 000 / 56 } * 100 M .B . A.
.E .,
IA N,M
= Rs. 62 500DRA PAND
. S UN
M
Forecasting
A forecast is a prediction of future events used for
planning purposes.
.B . A.
.E ., M
IA N,M
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N DR A
M. S U
Forecasting - Features
• Relates to future events which needs planning
• Used best available data to provide the best informed guess with
min. errors .B . A.
.E ., M
IA N,M
PA ND
• Abnormalities RA
M .in
S the
UN Dtrend should be taken into consideration.
• Various statistical tools can be incorporated during analysis
SMA = D1+D2+D3+…+D .B . A.
.E.n, M ,M
DIA N
A N
S UN
N DR A P
M.
where SMA = Simple Moving Average
Dn = Demand for nth previous or
past data
N = No. of all previous data
Problem for Practice
2.
Fa= D (a -1) + (1- ) D (a-2) +M.E.(1-, M ) D (a-3)
.B . A
I A N ,
PA ND
+. SUN(1-
DRA ) D
3
(a-4) + … + (1- ) n-1
F (a-(n-1))
M
+ (1- ) n F (a-n)
Problem for Practice
C= (x- x ) * (y-y)
(x-x)2 * (y-y)2
Problem for Practice
A company’s monthly sales against the total no. of
visits made by the salesman during a particular period
are given below.
.B . A.
Sales : 15 40 50 85 100 A N,M .E ., M
A NDI
P
Visits : M.2SUN4DRA6 8 10
.E ., M
IA N,M
15 2
PA ND
N DR A
40 S
M. 4U
60 6
85 8
100 10
2 2
x (x-x) (x -x) 2 y (y -y) (y - y) 2 (x - x)(y - y) (x-x) (y-y)
Quantitative Methods - Econometric Analysis
a) Correlation Analysis
If C > 0, i.e., If C assumes a positive value, it means that
the factors a have a positive or directly proportional
influence on the demand. i.e., If C is.Apositive . the sales
, M .B
increases with the increaseDinIANno. , Mof
.E visits.
.
A PA N
R
S U N D
Similarly,Mif. C <0, or negative, the factor has negative
influence. i.e., no. of visits is inversely proportional.
If C = 0, then there is no correlation or no effect or
relationship between no. of visits and the sales of the
product.
Quantitative Methods - Econometric Analysis
b) Regression Analysis
The regression analysis attempts to develop logical
linear relationship between two variables.
This relationship developed, not.Bonly. A. provide useful
.E ., M
forecast but also indicateAthe
NDIAcauses
N, M and factors leading the
RA P
forecasted value.
M. SU
N D