ME2027 - Process Planning and Cost Estimation

Model ANSWER KEY

Date : 29.10.14

Part - A

1. Work study - It is a generic term for those techniques, particularly method study and work
measurement, which are used in the examination of human work in all its contexts, and which
leads systematically to the investigation of all the factors which affect the efficiency and economy
of the situation being reviewed, in order to affect improvements.
2. Purpose of work measurement
- To determine the time required to do a job.
- To estimate the man and machine requirements and to assess the plant capacity
3. General rules : * Machine elements should be separated from machine elements * Each element
should be easily identifiable
4. Ergonomics: Ergonomics is a scientific study that deals with the interactions between the human
beings, the tools and the equipment (machinery) and the working environment.
5. Budgetary estimates: used for planning the cost of a piece part, assembly, or project. This type of
estimate is typically on the high side because the estimator understands that a low estimate
could create real problems.
6. Relaxation allowance, Fatigue allowance, Personal needs allowance, Process / unavoidable delay
allowance, Special allowances
7. By percentage ; By hourly rate ; By unit rate
8. M/c cost = 25,000 : Depreciation fund = 22,500 : Dep. Charges / hour = 22500/20000 = 1.25 /
hour
9. Overheads / machine = 800000/ 5,00000
10. Scale loss, Tonghold loss, and flash loss.
Part B
11.(a) Net weight = 56.76 7.86 = 446 gms ; Direct labor cost = Rs. 5 per piece
Overheads = 150 percent of labor cost
= 1.5 5 = Rs. 7.5
Cost per piece = 5.57 + 5 + 7.5
= Rs. 18
11. (b) Total length of weld = 200 mm ; Weight of filler rod = 8.5 7.2 = 61.2 gms ; Cost of making
the joint = 3.67 + 0.40 + 0.40 + 3.00 + 3.00
= Rs. 10.50
12. (a) Total man hours = 30 x 25 x 8 = 6000 hours
Lab. Cost = 6000 x 10 = 60,000; over time = 150 x2x 5 = 26,500
12. (b) No of products produced at 85 % capacity = 1000 * 0.85 = 850 shapers/annum
13. (a) Types of estimates : Computer Estimating , Parametric Estimating, Statistical Estimating
13. (b) various data requirements and sources for cost estimation;
General design specifications= product engg dept
Quantity and rate of production = Sales dept.
Assembly or layout drawing = product engg
14(a) (i) Method study
Select the work to be studied;Record all facts about the method by direct observation.

Examine the above facts critically;Develop the most efficient and economic method.
Define the new method; Install the new method
Maintain the new method by regular checking.
(ii) Two handed process chart & multiple activity chart

14 (b)

15. (a) (i) SIMO chart is used to record, simultaneously on a common time scale, the activities of
two hands or other parts of workers body during the performance of a single cycle of operation
being investigated.
(ii) Time study Select the job to be studied.
Note all the details about the operations and the operator being studied.
Split the work cycle into suitable elements. An element is a distinct part of a job, selected
for convenience of observation, measurement and analysis. Any non-repetitive and
occasional element in the manufacturing cycle should be noted separately.
(b) Applications : * Design of instruments and controls
* Design of workplace * Design of working environment