P.A COLLEGE OF ENGINEERING AND TECHNOLOGY, POLLACHIDEPARTMENT OF MECHANICAL ENGINEERING

ME2027 - PROCESS PLANNING AND COST ESTIMATIONTwo mark questions and answers

UNIT-I – WORK STUDY AND EROGONOMICS

1. Define method study.Method study is the systematic recording and critical examination of existing and

proposed ways of doing work as a means of developing and applying easier and more effective methods and reducing cost.

2. What are the objectives of method study?(a) To present and analyze true facts concerning the situation.(b) To examine those facts critically.(c) To develop the best answer possible under given circumstances based on critical examinations of facts.

3. What are the various charts used for method study?(a). Out line process chart(b). Flow process chart(c). Two handed process chart(d). Multiple activity chart(e). Gang chart(f). Simo chart

4. Write short note on outline process chart.The outline process chart gives an overall view of the process, from the beginning to

the end. It is a graphic representation of the sequence of all the operations and inspections carried out in the entire process and the stage at which the materials are introduced.

5. Write short note on flow process chart.A flow process chart is a graphical representation of the sequence of all operations,

transportations, inspections, delay and shortages occurring during a process and includes information considered desirable for analysis such as time required and distance moved.

6. What are the various diagrams used for method study?(a) Flow diagram, b) String diagram, c) Travel chart

7. Write short note on flow diagram.Flow diagram is a drawing, made to a scale of the workplace showing the location of

various equipment and machines, activities carried out and the followed by workers and materials.

8. Write short on string diagram.String diagram is a scale layout drawing on which the length of string is used to

record the extent as well as pattern of movement of a worker for materials or equipment working within limited area over a certain period time

9. Write short note on travel chart.Travel chart is a tabular record for presenting quantitative data about the movement

of workers, materials or equipment between any numbers of places over a given period of time.

10. Define Ergonomics.The application of human biological sciences along with engineering sciences to

achieve optimum mutual adjustment of men and his work, the benefits being measured in terms of human efficiency and well-being.

Ergonomics also known as human engineering and human factors engineering is the scientific study of the relationship between man and his working environments.

11. What are principles of motion economy?(a) Use of the human body.(b) Arrangement of workplace.(c) Design of tools and equipment.

12. What are the various techniques of work measurement?(a) Time study(b) Synthesis(c) Work sampling(d) Analytical estimating(e) Predetermined motion and time study

13. Define time study.The application of techniques designed to establish the time for a qualified worker to

carry out a specified job at a defined level of performance.

14. What are the various time study equipment?(a) Stop watch(b) Time study board(c) Time study forms(d) Motion picture camera

15. What are the application of work measurement various techniques? Techniques Applicationsa) Time study Short cycle repetitive jobs(b) Synthesis Short cycle repetitive jobs(c) Work sampling Long cycle jobs(d) Analytical estimating Short cycle repetitive jobs.(e) Predetermined motion. Manual operations confined to one work centre time study.

.16. What are the objectives of ergonomics?

(a). To enhance the efficiency and effectiveness with which the activities is carried out so as to increase the convenience of use, reduced errors and increase in productivity.

(b). To enhance certain desirable human values including safety, reduced stress and fatigue and improved quality of life.

17. What are therbligs?

Therbligs are the symbols used to denote the various activities and movements done for different purposes.

Therbligs refer primarily to motions of the human body at the work place and to the mental activities associated with them.

18. Draw the symbols representing (a) Inspection and (b) Storage.Inspection - □Storage -˅

19. Define work measurement?Work measurement is the application of techniques designed to establish the time for

a qualified worker to carry out a specified job at a defined level of performance.

20. What are the benefits of motion study? It eliminates unnecessary and wasteful motion. It makes the work faster and better. It increases productivity.

21. Mention the important applications of work study?Scope of work study is not restricted to manufacturing industries only. It can

effectively be used in service sector as well. It can be applied in offices, hospitals, banks and other service organizations.

22. Mention any two objectives of method study? The work study is mainly carried out to fulfill the following objectives:

i. To find the most economical way of doing the work.ii. To simplify and standardize the methods, materials, tools and equipment.

23. Mention few applications of work study?Besides in manufacturing industries, the work study can also be applied in offices,

hospitals, banks, and other service organizations.

24. Define SIMO chart?SIMO stands for Simultaneous Motion cycle chart.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.

UNIT-II – PROCESS PLANNING

1. Define process planning.It is defined as the systematic determination of methods by which a product is to be

manufactured economically and competitively. It consists of selecting the proper machines, determining the sequence of operations,

specifying the inspection stages, and tools, jigs and fixtures such that the product can be manufactured as per the required specifications. The detailed process planning is done at each component level.

2. What are the considerations to be given while selecting a process or machine?a. Economic considerationsb. Production rate and unit cost of production.c. Durability and dependability. d. Lower process rejection.e. Minimum set-up and put away times. f. Longer productive life machines or equipment.g. functional versatility.

3. What are the information’s required for process planning? a. Assembly and component drawings and bill of materials b. Machine or equipment details c. The standard times for, operation and details of set-up time for each job d. Availability of tooling.

4. What are the factors that influencing process planning? a. Volume of production. b. Delivery date for components or products. c. Accuracy and process capability of machines. d. The skill and expertise of manpower. f. Materials specifications. g. Accuracy requirements of components or parts.

5. Explain the process planning sheet.The whole information determined by the process planning is recorded in a tabular

form in a sheet.

6. List the process planning activities?Analyse, determine, select, calculate, document, communicate.

7. What are the parameters for material selection?Function, Appearance, Reliability, Service life, environment, compactability, cost

8. What are the types of CAPP?a. Retrieval CAPP systemb. Generative CAPP system

9. What are the factors affecting process planning?Volume of production, Man Power, Delivery dates of products, Material

specification, accuracy of process and machines.

10. What are the approaches for process planning?a) Manual process planning b) Computer Aided process planning.

11. List the benefits of CAPP. a) Process standardization. b) Productivity improvement.

c) Product cost reduction. d) Elimination of human error e) Reduction in time. f) Reduced paper work.

12. What is PMTS?A work measurement technique whereby times established for basic human motions

are used to build up the time for a job at the defined level of performance.

13. What is the information required for process planning? i) Assembly and component drawings and bill of materials. ii) Machine or equipment details. iii) The standard times for operation and details of set-up time for each job. iv) Availability of tooling.

14. List the demerits of retrieval CAPP System. a) The components to be planned are limited to similar components previously planned. b) Experienced process planers are still required to modify the standard plan for specific

component.

15. List the advantages of generative CAPP. It can generate consistent process plans rapidly. New components can be planned as easily as existing components.

16. What are the tools for acquiring and documenting and Knowledge? Flow charts, Decision tables, experts system shells.

17. Explain the term normal time.Normal time is the time for carrying out a work or an element of work at standard

rating.

18. What are the various allowances added in normal time?a. Relaxation allowance.b. Fatigue allowance.c. Personal allowance.d. Process delay allowance.e. Special allowance such as interference and contingency allowance.

19. Brief about scope of process planning? 1. Process rationalization and standardization. 2. Faster response to engineering changes. 3. Standard plans leads to achieve six sigma levels.

20. Define the term route sheet?The route sheet, also known as operation sheet or instruction sheet or planner or

traveler, lists the production operations and associated machine tools for each component and subassembly of the product.

21. What do you understand by process planning?Process planning is the systematic determination of the methods by which a product

is to be manufactured, economically and competitively.22. What are the types of production?

Job shop production Batch production Mass production

23. What are the materials selection parameters? Function Appearance Reliability service life Environment Compatibility.

24. What are the functions of process planning? Process planning, through route sheet, provides: i. part identification ii. operation sequence and machine.

34. What is sequencing?Sequencing can be defined as the selection of an order for a series of jobs to

be done on a finite number of service facilities (machines).

25. What are the types of process planning? Manual process planning. Computer aided process planning Retrieval CAPP system Generative CAPP system

26. What is computer Aided Process Planning?In CAPP, the Process plan is prepared with the use of computers. CAPP overcomes

the drawbacks of manual process planning.

27. What does the term process planning mean?Process planning is an act of preparing a detailed processing documentation for the

manufacture of a piece part or assembly.28. What are all the documents necessary for process planning? i. Assembly and component drawings. ii. Bill of materials.

iii. Machine and equipment details.

29. What are the documents used in process planning? Process sheet Operation sheet Route sheet.

UNIT-III – INTRODUCTION TO COST ESTIMATION

1. Define cost estimating.Cost estimating is the estimation of the expected cost of producing a job or

manufacturing order before the actual production is taken up or predicting what new things will cost, before they are made. The expected expenditure on all the items used to make a product is added to give the estimated cost of final product.

2. Define cost accounting.Cost accounting means classify, recording and allocating the appropriate expenditure

for determining the cost of production and is achieved by keeping a continuous record of all the costs involved in manufacturing.

3. Write the common method costing. a. Job costing

b. Batch costingc. Process costingd. Operating cost methode. Unit cost methodf. Multiple cost method

4. Define Job costing. The is method is concerned with finding the cost of each individual job or contracts.

In this method, the total cost for each order is obtained from the daily cost sheet. The method is adopted in job order industries such as ship building, machine manufacturing, fabrication, building contract.

5. What are the components of a cost estimate? a. Cost design b. Cost drafting c. Cost of research and development d. Cost of materials. e. Cost of labour f. Cost of inspection. g. Cost of tools, jigs and fixtures.

6. Define overhead expenses.

Overhead expenses include all other expenditure made on the product except direct materials cost, direct labour charges and direct other expenses. Administrative expenses, sales and advertisement costs etc., form a part of overhead expenses.

7. What are the two major groups of total cost of the product?a. Direct costs b. Indirect costs

9. What are the usual three elements of costing?a. Material cost.b. Labour cost.c. Other expenses.

10. Write short notes on direct labour cost. Direct labourer is one who actually works and processes the materials to convert it

into the final shape. The cost associated with direct labour is called direct labour cost.

11. Write short notes on indirect labour cost.Indirect labourer is one who is not directly employed in the manufacturing of the

product but his services are used in some indirect manner. The indirect labour includes supervisors, inspectors, foremen, storekeeper gatekeeper, maintenance staff crane driver etc. The cost associated with indirect labour is called indirect labour cost.

12. What are the direct expenses?Cost of special jigs, patterns, tooling made for job, or cost of research and

development work done for that specific job.

13. What are the indirect expenses?a. Factory expensesb. Administrative expenses.c. Selling and distribution expenses.

14. What are the components of Primary cost?a. Direct material cost, b. Direct labour cost, c. Direct expenses.

12. What are the components of Production cost?a. Factory cost, b. Administrative expenses.

15. List any two objectives of cost estimation .a. To establish the selling price of product.b. To veryfiy the quotations submitted by vendors.c. To take make or buy decisions.d. To prepare production budget.

16. Name the types of material cost .a. Direct materials cost b. Indirect material cost.

17. Who are called indirect lab our ?Indirect lab our are the non productive staff who helps the productive lab our in

performing their duties..

18. What are the knowledge required for cost estimation.

a. Design time. b. amount and cost of materials required. c) production time requird. d) labour charges.e) cost of machinery f) previous estimates g) volume h) change of cost.

19. What are the types of estimates ?a) preliminary estimates b) final estimates.

20. What is meant by indirect material? Indirect material is the one which cannot be traced as a part of the product. It is the material required for maintaing and operating the plant and equipment but cannot be the part of product.

21. Give examples for indirect materials.Grease, lubricating oil used to lubricate the equipments, coolants, cotton wastes,

kerosene.

22. What is indirect labour cost?It is the wages paid to the indirect labour.

23. What are the types of expenses?Direct expenses, Indirect expenses.

24. List the factory expenses.Factory on cost, works on cost, factory overhead, production overhead.

25. What is selling expenses? These are the expenses which are incurred for creating and enhancing the demand

for the products.

UNIT-IV – COST ESTIMATION

1. What are the data required for estimation of cost of any product? a. Machining operations b. Machining time required for each operation

2. What are the elements consisting of estimating total time required to perform an operation.

a. Set-up time b. Handling time c. Machining time d. Tear down time e. Down time f. Allowance

3. Explain the term set-up time.This is the time taken to prepare the machine for operation.

4. Explain the term unit time operation.The sum of handling time and machining time for a job is called unit operation time.

5. Write short note on machining time.

It is the time for which the machine works on the components, i.e. From the time when the tool touches the work to when the tool leaves the component after completion of operation.

6. Write short note on tear down time.It is the time taken to remove the tools, jigs fixtures from the machine and to clean

the machine and tools after the operation has been done on the last component of batch.

7. Write short note on down time.It is the time wasted by the operator due to break down, non-availability or delay in

supply of tools and materials etc. 8. What are the various allowances in estimation?

a. Personal allowance b. Fatigue c. Tool sharpening/Change allowance d. Checking allowance

9. Define the term fatigue allowance.The long working hours and poor working conditions such as poor lighting, poor

ventilation etc., causes fatigue and effect the efficiency of worker i.e. fatigue decreases the workers capacity to work.

10.Write short note on tool sharpening/change allowance. This allowance is provided for the time taken by the operator to get the tool changed

or to resharpen the tool when it becomes dull. This time varies from machine to machine and depends upon the type of tool being used.

11. Define design cost.The cost of design of a product is estimated by ascertaining the expected time for the

design of the that product.

12.Define drafting cost . After the completion of the design the drawing have to be prepared by drafts man.

13.List the components of job estimate. Design cost , drafting cost, R&D cost, Materials cost , labour cost , Inspection cost.

Overhead cost, cost of tools and jigs and fixtures.

14. Name the types of estimate.a. preliminary estimation. b. Final estimation.

15. What are the method of estimation?a. Conference method.b. Comparision method.c. Detailed analysis method

16. What is cost of research?Considerable time and money has to be spent on research and development work.

17. What is tool cost per unit produced ?Estimated cost / number of job.

18. Define inspection cost .Estimating the inspection cost , one should consider the cost of inspection

equipments, gauges and consumables, wages to the Inspectors.

19. What is overhead cost ?Overhead expenses are those which cannot be charged directly to a particular

product manufactured.

20. What is prime cost ?The sum of direct labour cost and direct material cost and direct expenses.

21. What is total cost?The sum of prime cost and factory overheads and administrative expenses and

selling and distribution expenses.

22. What is unit cost method?This method is adopted by the firms ,which supply a uniform product rather than a

varity of products such as mines,quries,etc.

23. What is manufacturing cost?Sum of factory cost and administrative expenses.

24. What is selling price?Total cost + profit.

25. What is market price ?Selling price + discount.

UNIT-V – PRODUCTION COST ESTIMATION

1. What are the various elements considered while calculating the cost of a welded joint? a. Direct material cost. b. Direct labor cost. c. Direct other expenses. d. Overheads.

2. Explain the terms direct material in costing of welded joint. a. Cost of base materials to be welded i.e., sheet, plate, rolled section, casting or forging.

This cost is calculated separately. b. Cost of electrodes/filler materials used. The electrode consumption can be estimated

by using the charts supplied by the suppliers. Another way to find the actual weight of weld metal deposited is to weigh the component before and after the welding and making allowance for stub end and other losses during welding.Also the weight of weld metal = Volume of weld X Density of weld material.

3. Explain the terms direct other expenses in costing of welded joint.

The direct other expenses include the cost of power consumed, cost of fixtures used for a particular job etc.

4. Explain the terms overheads expenses in costing of welded joint.

The overheads include the expenses due to office and supervisory staff, lighting charges of office and plant, inspection, transport, cost of consumables and other charges. The cost of equipment is also apportioned to the individual components in the form of depreciation.

5. What are the various losses considered while calculating the materials cost for a forged component.

a. Shear loss. b. Tonghold loss.c. Scale loss. d. Flsh loss. e. Sprued loss.

6. Explain the term Shear loss. The blank required for forging a component is cut from billet or long bars. The material equal to the product of thickness of sawing blade and cross-section of bar is lost for each cut. Similarly, if the small pieces left at the end are not of full length, these also go as waste. Shear loss is generally taken as 5% of net weight.

7. Explain the term Tonghold loss. Drop forging operations are performed by holding the stock at one end with the help

of tongs. A small length, about 2.0-2.5cm and equal to dia of stock is added to the stock for holding.

8. Explain the term Scale loss.As the forging process is performed at very high temperature, the oxygen from air

forms iron oxide by reacting with hot surface. The iron oxide forms a thing film called scale, and falls off from surface at each stroke of hammer. Scale loss is taking as 6% of net weight.

9. Explain the term Flash loss. When dies are used for forging, some metals come out of the die at the parting line

of the top and bottom halves of the die. This extra metal is called flash. Flash is generally taken as 20mm wide and 3mm thick. The circumference of component at parting line multiplied by cross-sectional area of flash gives the volume of flash. The flash lioss is then calculated by multiplying the volume of flash by density of the material.

10. Explain the term sprue loss. When the component is forged by holding the stock with tongs, the tonghold and metal in the die even when metal is squeezed in dies, are in contact through a portion of metal called sprue or runner. The cut off when product is completed. Sprue loss taken as 7% of net weight.

11. Explain the terms direct material cost in costing of forged component.

a. Calculate the net weights of forging. Net weight = Volume of forging X Density of materials.b. Calculate the gross weight. Gross weight = Net weight + Materials loss in the process.

c. Direct materials cost = Gross weight X Piece per Kg.

12. Discuss the various constituents of cost of a forged component.a. Cost of direct materials.

b. Cost of direct labour. c. Direct expenses such as due to cost of die and cost of press.d. Overheads.

13. Explain the terms direct labour cost in costing of forged component. Direct labout cost is estimated as follows.

Direct labour cost = tX l Where t = Time for forging per piece (in hours) l = Labour rate per hour14. Explain the distribution of die cost on individual components.

Apportioning of Die cost:Let cost of die = Rs. XNo. of components that can be produced using this die = Y components.Cost of die/component = Rs. X/Y

15. Explain the terms overheads expenses in costing of forged component.The over heads include supervisory charges, depreciation of plant and machinery,

consumable, power and lighting charges, office expenses etc. The overheads are generally expressed as p[percentage of direct labour cost.

16. Explain the distribution of machine cost on individual components.Apportioning of Machine Cost:Let cost of press = Rs. ALife of press = B = n year = nX12X4X5X8 = 1920n hoursHourly cost of production =A/BNo. Components produced per hour = NCost of using press per component = A/BN Rs.

17. Define bending.Bending is the operation by which a metal rod or pipe can be bent to form various

shapes without damaging its internal gain structure.

18. What is drifting ?After a hole is punched it may be opened out to any size and shape by driving a

tapered drift through it .this operation is known as drifting .

19. Define swaging.Swaging is the process of removing the irregularities on the surface of the work

piece produced by the process of drawing down.

20. What is net weight of forging?Volume of forging X density of material used.

21. What is filler material ?The filler material has a similar composition and melting point as the base metal.

The filler rod is used to make up losses during welding.

22. What is flux ?A flux is required for the welding process, so as to remove the oxide layers in the

form of fusible slag which floats on the molten metal.

23. What is non pressure welding ?

In fusion welding the metal at the joint is heated to molten state. Then it is allowed to solidify. Pressure is not applied in welding process.

24. What is butt joint ?Butt joint is used to join the ends of two sheets or plates kept in the same plane.

25. What is lap joint ?It is used to join two overlapping sheets or plates.

26. What is welding cost ?It is the cost of labor in actual welding operation.

PART B – QUESTIONS

UNIT-I

1. Explain the significance, construction and applications of the following recording techniques: (i). Out line process chart; (ii). Flow process chart; (iii). Two handed process chart; and (iv). Multiple activity chart.2. Explain the various techniques of work measurement.3. What is meant by ergonomics? Describe the objectives of the study of ergonomics.

UNIT-II

1. Define CAPP. Explain the various types of CAPP approaches.2. What is process planning? What are the activities associated with it.3. Compare and contrast the features of variant and generative CAPP systems.4. Name the three commonly used tools for acquiring and documenting knowledge.5. What are the requirements to analyze finished parts.

UNIT -III

1. What the main functions of estimation?2. What is meant by preparation of a realistic estimate?3. Define floor to floor time.4. What is aim of costing?5. Differentiate costing and estimation.6. Describe with a block diagram how the selling price of a product is arriving at?7. Illustrate the relationship between ‘elements of cost’ and ‘component cost’ with the help of a block diagram.

UNIT-IV

1. What are the causes for depreciation?2. How is the gross weight in forging operation determined?3. What are the various allowances required in pattern making operation?4. How can you determine the size of the stock in forging?5. Discuss the various constituents of cost of forged components.

6. How can you estimate the grinding time for a cylindrical grinding operation?7. Explain the procedure on estimating the machining time for plain milling a flat

surface when the width of the job to be milled is more than the width of the plain milling cutter.

UNIT-V

1. What are the various losses in forging? 2.. What are the different types of labour cost involved welding? 3. Estimate the milling time to cut 60 teeth on a gear blank 60mm thick, 35mm/min and take overall set up time as 10 minutes. 4. How can you estimate the cost of the wooden pattern for sand molding?

ME1015 - PRODUCTION PLANNING AND CONTROL

UNIT-I INTRODUCTION

1. What is production?Production consists of a series sequential operations to produce a desirable product acceptable to customer and meets the customer demand, with respect to the quality and intended function.

2. Define the term production planning and control.Direction and coordination of firm’s resources towards attaining the prefixed goals.

4. What are the functions of production planning and control?a. Material function, b. Machines and equipment, c. Methods, d. Routing, e. Estimating f. Loading and scheduling, g. Dispatching, h. Expediting i. Inspection.

6. Define the term durability.Durability refers to the length of the active life of the product under given working condition.

7. Define the term dependability. Dependability refers to the reliability with which the product serves its intended function.

8. Define the term Standardization. Standardization is a process of defining and applying the conditions necessary to ensure

that given range of requirements can normally be met with a minimum of variety and in a reproducible and economic manner on the basis of the best current techniques.

9. What are the objectives of Standardization? i) Interchangeability of parts, components, etc. ii) Keeping the variety minimum. iii) Helps to achieve a better control due to reduced variety.

10. What are the advantages of Standardization?

i)Reduction of waste and obsolescence. ii)Reduction in inventory iii)Reduced efforts in book keeping and accounting. iv)Standardization reduces the price because of economy of scale. v) Ease in procurement because of availability.

11. What is simplification? It is a process of reducing types of products within a definite range.

12. What is specialization? It is a process where in particular firms concentrate on the manufacture of limited

number of product types.

13. What are the disadvantages of simplification? i) Not able to meet the needs of wide range of customer preferences. ii) Possibility of loosing orders to competitors iii) Creates a constant source of conflict between marketing and production.

14. Define the term break-even point. Break-even point refers to the level of sales at which the sale income equal the total costs.

15. What is margin of safety? It is the difference between the existing level of output and the level of output at BEP.16. What are the levels of production palnning ?

factory planning , process planning , operation planning.17.what are the factors control the production planning ? volume production , nature of process, nature of operations.

18.What are the phases involves in PPC ? a. pre planning phase . 2. planning phase. 3. control phase.

19.What is meant by productivity?Productivity is measure of how effectively the resources of an enterprise are being

managed. It is defined as the ratio of output to the input.

20.What are methods for determining the financial feasibility?Payback period, rate of return, present worth, and uniform annual cost

21.What is meant by payback period?The payback period is the time during which benefits from the investment equal to

the cost of investment. It can be expressed as PP = C / (S-A), where C=required investment

S=annual savingsA=annual cost of utilizing the investment

22.What are the methods available to improve the productivity?Increasing the output for a given input

Decreasing the input for a given outputVarying both the output and input in such a way that their ratio increases

23.What is meant by mass production?In mass production of discrete parts or assemblies, the production volume is high.

Here the dedicated special purpose machine can be used for mass production.Eg. Manufacturing of bicycles, washing machines, and video games

24.What is meant by batch production?In batch production of parts or assemblies, the volume is lower, and variety higher

than in mass production. Here goods are manufactured in batches that be repeated as required. It is some times referred to as mid volume, mid variety operation. Eg. Books, apparels etc

25.What is meant by job shop production?The job shop represents the most versatile production facility. With in the limitations

of machine and the operators, it can manufacture almost any product. With a low production volume , the cost of product design and set up time is high.

Eg Production facilities for aircrafts, ships, and special machine tools.

26. What is meant by product life cycle? An expression to describe the length of time a product lasts in the market. It

comprises the period of conception, design, production, use, and finally termination when not needed by the market. Flexible technologies allow shorter product life cycles, which mean more frequent design and model changes

UNIT-II WORK STUDY

1. What is method study?It is the systematic recording and critical examination of existing and proposed ways of doing work, as a means of developing and applying easier and more effective method reduced costs.

2. What are the objectives of method study? i) To present and analyze true facts concerning the situation. ii) To examine those facts critically. iii) To develop the best answer possible under given circumstances based on critical

examination of facts.

3. What are the charts used for method study? i) Operation process chart, ii). Flow process chart. iii). Multiple activity chart,

iv) Two handed process chart, v). Travel chart, vi). Simo chart.

4. What are the diagrams used for method study?

i) Flow and string diagram, ii). Models and templates, iii). Cycle graph and chronocycle graph.

5. What is outline process chart? The chart gives the bird’s-eye view of the whole process by recording only the major

activities and inspections involved in the process.

6. What is time study? The application of techniques designed to establish the timer for a qualified worker to

carry out a specified job at a defied level of performance.

7. What is work sampling? A technique in which a statistically competent number of instantaneous observations are

taken, over a period of time, of group of machines, process or workers. Each observations recorded for a particular activity or delay is a measure of the percentage of time observed by the occurrence.

8. What is multiple activity chart? It is a chart on which the activities of more than one subject are each recorded on a

common time scale to show their interrelationship.

9. What is Simo chart? It is used to record simultaneously on a common time scale the activities of two hands or

other parts of worker’s body during the performance of single cycle of operation being investigated.

10. What are therbligs? Therbligs are the symbols used to denote the various activities and movements done for

different purposes.

11. What is memo motion study? Memo motion study is a form of time-lapse photography which records activity by the

use of cine camera adapted to take picture at longer intervals than normal.

12. What is PMTS? A work measurement technique whereby times established for basic human motions are

used to build up the time for a job at the defined level of performance.

13. What are the various templates and models used for method study? (a) 2-dimensional templates (b) 2-dimensional models (c) 3-dimensional models

14. What are principles of motion economy?(a) Use of the human body.(b) Arrangement of workplace.(c) Design of tools and equipment.

15. What are the various techniques of work measurement?(a) Time study

(b) Synthesis(c) Work sampling(d) Analytical estimating(e) Predetermined motion and time study

16. Explain the term normal time.Normal time is the time for carrying out a work or an element of work at standard

rating.

17. Why some allowances have to be added in normal time?There is no provision, in the normal time, for the interruptions that occur on every

job each day, such as time required by the workers for personal needs and rest and for delay due to reasons beyond his control. To compensate for theses delays, the normal time is increased by adding some allowances.

18. What are the various allowances added in normal time?a. Relaxation allowance.b. Fatigue allowance.c. Personal allowance.d. Process delay allowance.e. Special allowance such as interference and contingency allowance.

19. What are the various time study equipment?(a) Stop watch(b) Time study board(c) Time study forms(d) Motion picture camera

20. What are the application of work measurement various techniques? Techniques Applicationsa) Time study Short cycle repetitive jobs(b) Synthesis Short cycle repetitive jobsI Work sampling Long cycle jobs(d) Analytical estimating Short cycle repetitive jobs.(e) Predetermined motion. Manual operations confined to one work centre time study.

21. Define process allowancesThese are allowances provided to compensate for enforced idleness during a process.

22. Name the special allowances .i) startup allowances. ii) shut down allowances.iii) Cleaning allowances. iv) Tool allowances.v) Changeover allowance.

23. what are the basic procedure for method study ?select, record , examine, develop, define, install, maintain.

24. List the objectives of work measurements ? To reduce or eliminate non productive time.

To fix standard time for doing a job. To develop standard data for future reference. To improve methods.

25. What is work study ?

work study is 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.

UNIT-III PRODUCTION PLANNING AND PROCESS PLANNING

1. What is production planning? It is the determination, acquisition and arrangement of all facilities necessary for future

production products.

2. What are the factors affecting production planning?i) Non-availability of materialsii) Plant, equipment and machine breakdown

iii) Changes in demand and rush orders. iv) Absenteeism of workers. v) Lack of coordination and communication between various functional areas of business.

22. What is value analysis? Value analysis is the systematic application of recognized techniques which identify the

function of a product or service, establish a monetary value for the function and provide the necessary function reliably at that lowest overall cost.

4. When to apply value analysis? i) Company’s products are loosing in the market and there is a decline in sales. ii) Compny’s products are priced higher than the competitors. iii) New design of products being undertaken. iv) Symptoms of disproportionate increase in cost of production. v) Decreasing profitability and return on investment. vi) Company failing to meet its delivery commitment.

5. What is process planning? It is defined as the systematic determination of methods by which a product is to be

manufactured economically and competitively.

6. What are the activities associated with process planning? * List of operations to be performed and their sequence. * Specifications of the machines and equipment required

* Necessary toolings jigs and fixtures. * Gives the manufacturing details with respect to feed, speed, and depth of cut for each

operation to be performed. * It gives the estimated or processing times of operations.

7. What is the information required for process planning? i) Assembly and component drawings and bill of materials. ii) Machine or equipment details. iii) The standard times for operation and details of set-up time for each job. iv) Availability of toolings.

8. What are the factors affecting process planning? i) Volume of production ii) Delivery dates for components iii)Accuracy and process capability of machines. iv) The skill and expertise of manpower.

v) Material specifications vi) Accuracy requirements of components or parts.

9. What are the steps in process planning? i) Detailed study of the component drawings, process and machine selection, inspection

stages and toolings required. ii) List the surfaces to be machined. iii) Determine the work centre, tools, cutting tools, jigs and fixtures and inspection

stages and equipment required. iv) Determine the speed, feed and depth of cut for each operation. v) Estimate the operation time. vi) Find the total time to complete the job. vii) Represent the details on the process sheet.

10. What is machine capacity? MC- Machine capacity MP-Max production UC-Utilization capacity N – Number of machines ST-Standard time MC = ST X MP/N X UC.

11. What is Use value ?It is the measure of properties, qualities, and features which make the product accomplish a use.use value is the fundamentals form of economic value.

12.what is cost value ? It is the measure of sum of all costs incurred in producing the product.

13.what are the reasons for unnecessary costs ?failure to utilize specialized knowledge.poor design of the component.lack of ideas and relevant information.lack of standardization and exaggerated specification.unavoidable delivery constraints.Advances in technology is not considered.

14.what are the steps involved in value analysis ? Blast—(i) Identify the product. (ii) Collect relevant information (iii) Define different functions. create—iv) Create different alternatives. v) critically evaluate alternatives. refine—vi) Develop the best alternative. vii) implement the alternative.

15.what are factors affecting the selection of batch sizes ?1 setup costs of machines and other costs of preparation for the run.2.consumption rate.3.production rate.4.interest charges per piece per unit time.5.Average storage costs.6.sales price per unit.

16.what are the criteria for slection of batch sizes ?1.minimum costs per piece.2.maximum profit for the batch.3.maximum ration of profit to cost of production.4. maximum rate of return per unit time.

17. What is meant by machine loading ?machine loading is the process of the assigning specific jobs to machines , men or work centers based on relative priorities and capacity utilization.

18. list the information required for machine loading ?i) Number and identification of work order.ii) symbol and identification of part.iii)number of parts in each lot.iv) list of operations to be performed.v) sequences in which operations., specifications of machines.

19.what is master production program?The various information’s required for machine loading and sequence are usually presented in a graphical form known as master production programme.

20.Define machine output machine output is inversely proportional to cycle time.

21. what is meant by balancing ?balancing refers to the procedure of adjusting the times at work centers to conform as much as possible to required cycle time.

22.What are the process planning techniques used in the modern manufacturing technologies?

Manual approach

Computer aided process planning techniquesRetrieval type CAPP system (Variant type CAPP system)Generative type CAPP system

23.What is meant by CAPP?Computer aided process planning system offers the potential for reducing the routine

clerical work of manufacturing engineers. It provides the opportunity to generate routings which are rational, consistent and perhaps even optimal.

24.What is meant by retrieval type CAPP (Variant type) systems?For each part family a standard process plan is established and stored in computer

files and then it is retrieved for new work parts which belong to that family. Because of the alterations that are made in the retrieved process plan, the CAPP system is known as variant system.

25.What is meant by generative CAPP system?Generative process planning involves the use of computer to create an individual

process plan automatically without human assistance. The computer would employ a set of algorithms to progress through the various technical and logical decisions toward a final plan.

26.What are the types of variant type process planning systems?CAPP, MIPLAN, MITURN, MIAPP, UNIVATION, CINTURN, and COMCAPPV.

27.What are the types of generative type process planning systems?METCAPP, CPPP, AUTAP, and APPAS

28.What are the steps involved in the design for manufacturing?Guidelines for the general approach to DFMSelection of manufacturing processes (Choice of production process)Guidelines for particular processesGuidelines for assembly

29.What are the benefits of computer aided process planning (CAPP)?1. Process rationalization2. Increased productivity of process planners3. Reduced turn around time4. Improved legibility5. Incorporation of other application program.

UNIT-IV PRODUCTION SCHEDULING

1. What is loading?

It is defined as the assignment of work to a facility. The facility may be men, machine, a department, a group of men, group of machines of a plant.

2. What is scheduling? It is time phasing of loading. It is defined as the assignment of work to a facility

specifying the particular sequence of the work and the time of actual performance.

7. What is line balancing? Assembly line balancing is associated with a product layout in which products are

processed as they pass through a line of work centers. An assembly line can be considered as a production sequence where parts are assembled together to form an end product. The operations are carried out at different workstations situated along the line.

8. What are the advantages of assembly line? i) Uniform rate of production. ii) Less material handling iii) Less work-in-process. iv)Easy production control. v) Effective use of facilities/labour. vi) Less congesting.

9. What are the disadvantages of assembly line? i) More capital intensive. ii) Low flexibility. iii) Monotony of work for operators.

10. What are the steps in solving line balancing problems? i) Define task ii) Identify precedence requirements. iii) Calculate minimum number of workstations required to produce desired output. iv) Apply heuristics to assign task to each station. v) Evaluate effectiveness and efficiency. vi) Seek futher improvement.

11. What are the advantages of Gantt load chart? i) This system is quite simple. ii) This could be maintained even by electrical staff after some training. iii) Overall cost of operation is small.

12. What are the disadvantages of Gantt load chart? From the load chart it is not possible to learn the exact time of a work. It tells only the

total load ahead of a department or a facility.14. What is production sequencing? Determining the order of processing of all jobs at each work centre.

15. What is expediting?Monitoring progress, taking corrective actions to minimize deviations.

16.What is lot splitting ?In which a job order is split and only part of it is processed now and others are processed later.

17. what is operations splitting ?processing part of the job in one work centre and the rest at another.

18.what are the criteria for sequencing ?setup cost, process inventory, idle time, average time to complete job., average number of jobs waiting in que, average time the jobs are late.

19. What is LPT ?longest processing time.

20.what is PCO ? Preferred customer order.

21.what is critical ration for scheduling ?critical ratio = Demand time / supply lead time.

22. what are the advantages of critical scheduling ?

To fix up relative job priorities for scheduling . status of each job is determined.schedule can be adjusted automatically when there are changes in job demand and progress.

23. What is forward scheduling ?set forward is commonly used in job shops where customers place their orders on needed as soon as as possible basis. forward scheduling determines start and finish times of next priority job by assigning it the earliest available time slot and form that time, determines when the job will be finished in the work center.

24.what is job cards?card authorize the work man to sart the work on certain material, indicate what to do and also serves as a means of production progress.

25.what is shortage chasing ?It is the job of comparing the actual availability of material and parts with the quantities required for production and of reporting any shortages so that they can be produced quickly.

26.what is inventory turn over ?If the company maintains inventories equal to three months consumption. It means that inventory turnover is 4 times a year. The entire inventory is used up and replaced 4 times a year.

UNIT-V INVENTORY CONTROL AND RECENT TRENDS IN PPC

1. What are the types of inventories? i) Raw materials, ii) Bought out parts, iii) Work-in-process inventories, iv) Finished

goods inventories v) Maintenance, repair and operating stores.

2. What are the benefits of inventory control? i) Improvement in customer’s relationship because of the timely delivery of goods and

services.ii) Smooth and uninterrupted production and hence no stock out.

iii) Efficient utilization of working capital. iv) Helps in minimizing loss due to deterioration, obsolescence damage and preliferage. v) Economy in purchasing. vi) Eliminates the possibility of duplicate ordering.

3. What is inventory turnover? If the company maintains inventories equal to 3months consumption. It means that

inventory turnover is 4 times a year, i.e., the entire inventory is used up and replaced 4 times a year.

4. Define the term Re-order level. It is the point at which the replenishment action is initiated. When the stock level

reaches R.O.L., the order is placed for the item. 5. Define the term Re-order quantity. This is the quantity of material to be ordered at the re-order level. Normally this quantity

equals the economic order quantity.

6. What is demand?It is the number of items required per unit of time. The demand may be either deterministic or probabilistic in nature.

7. Define the term order cycle. The time period between two successive orders is called order cycle.

8. What is lead time?The length of time between placing an order and receipt of items is called lead time.

It is the time that elapses between placing of an order and the receiving the material to stock. It an order to placed today and material is received after one month, then the lead time is one month. the lead time determines the amount of material to be kept in stock.

9. What are the various costs associated with inventory? i) Purchase cost, ii) Capital cost, iii) Ordering cost, iv) Holding costs, v) Shortage cost.

10. What is an Economic order quantity? It is the quantity to be ordered is one that strikes a balance between the inventory

carrying cost and the inventory carrying cost. This quantity is referred to as Economic order quantity.

11. What is safety stock? The additional stock of material to be maintained in order to meet the unanticipated

increase in demand arising out of uncontrollable factors.

12. What are the advantages of ABC analysis?

This approach helps the manager to exercise selective control and focus his attention only on a few items.

13. What are the limitations of ABC analysis? ABC analysis is a fundamental tool for exercising selective control over numerous

inventory items but in present for do not precise consideration of all relevant problems of inventory management.

It is not one time exercise and items are to be reviewed and recategorised periodically

14.Differentiate between MRP and Capacity planning?Materials Requirement Planning is used to plan the materials, while the capacity

planning is used to determine the man power and machine capacities required to meet the production schedule as well as long term future production need of the firm.

15 What is the use of order progress?The order progress is used to provide data for work-in-progress status report, shop

order status and capacity control.Order progress collects data from shop floor and generates reports to assist

production management.

16. what are the classification of inventory ?

Transit inventories cycle inventories buffer inventories. decoupling inventories.Inventory can also classified according to nature of items stocked namely raw materials, in process inventories, finished goods inventories and spare part inventories.

17. what are the factors affecting inventory control policy ? 1.Charaecteristics of the manufacturing system. 2.amount of production against shortages. 3.organizational factors.

18. Inventory carrying or holiday or storage cost ?cost of maintaining inventory.rent for the space, cost of depreciation.Interest on the capital.the wages and salaries of staff.Insurance, deterioration, obsolence cost etc.

19. What is Shortage cost ? It is the cost that arises due to unfailing of demand in the stock out period.

20. What is setup cost ?

This is the cost incurred in changing the inventory.

21. What is procurement cost ?

These are the costs incurred by inventory system itself in making a procurement of items or in receving the items to stock. Includes inspection costs also.

23. List the application of ABC analysis.

To evolve useful recording strategy.stock records.Information of items which require higher degree of control.priority treatment for different items.determination of safety stock limits.stores layout.value analysis.

24. What is PICS ? Production Inventory and control system.

25.What is waste of motion ?study motion for economy and consistency. economy improves productivity and consistency improves quality. first improve the motions , then mechanize or automate otherwise there is danger of automating waste.

26.what are the basic components of MRP system ?i) Master production schedule.(MPS) ii) Bill of materials (BOM) iii) Inventory status File.

ERODE SENGUNTHAR ENGINEERING COLLEGETHUDUPATHI, ERODE-57

DEPARTMENT OF MECHANICAL ENGINEERING ME-1015 PRODUCTION PLANNING AND CONTROL

Assignment 1 Questions

UNIT 1 INTRODUCTION TO PRODUCTION PLANNING AND CONTROL

Enumerate the activities involved in production planning and control function under ten convenient points?

Explain the different types of production systems. Differentiate between them.

Discuss the ten functions of production planning cycle?Explain Brake Even analysis.

Write detailed notes on1. standardization 2. simplification3. Specification.

ERODE SENGUNTHAR ENGINEERING COLLEGETHUDUPATHI, ERODE-57

DEPARTMENT OF MECHANICAL ENGINEERING ME-1015 PRODUCTION PLANNING AND CONTROL

Assignment II Questions

UNIT 2 WORK STUDYExplain the various types of time study?

Discuss pre determined time standards?

Explain micro motion time study?

Explain the work sampling process.

What are therbligs ? Explain any five therbligs with symbols?

ERODE SENGUNTHAR ENGINEERING COLLEGETHUDUPATHI, ERODE-57

DEPARTMENT OF MECHANICAL ENGINEERING ME-1015 PRODUCTION PLANNING AND CONTROL

Assignment III Questions

UNIT 3 PRODUCT PLANNING AND PROCESS PLANNING

Discuss in detail the different phases of applying value analysis?

Explain the steps involved in product planning and process planning?

What do you mean by minimum cost batch size? Also derive an expression for it?

What is mean by machine loading? Also enumerate the vriious methods to the cycle time to minimum?

Compare and contrast the manual and computer aided process planning?

ERODE SENGUNTHAR ENGINEERING COLLEGETHUDUPATHI, ERODE-57

DEPARTMENT OF MECHANICAL ENGINEERING ME-1015 PRODUCTION PLANNING AND CONTROL

Assignment IV Questions

UNIT 4 PRODUCTION SCHEDULING

Describe the information flow for master scheduling?

Explain Gantt chart with an example?

What is a priority sequence? Explain six priority rules used for job sequencing?

Write a detailed notes on flow production scheduling and batch production scheduling?

What is progressing? Explain its functions?

Explain the factors affecting scheduling .

ERODE SENGUNTHAR ENGINEERING COLLEGETHUDUPATHI, ERODE-57

DEPARTMENT OF MECHANICAL ENGINEERING ME-1015 PRODUCTION PLANNING AND CONTROL

Assignment V Questions

UNIT 5 INVENTORY CONTROL AND RECENT TRENDS IN PPC

Discuss the different costs associated with inventory?

Derive an expression for EOQ with uniform date of demand with out shortages?

Discuss in detail of JIT and ERP?

What is ABC analysis? Explain its significance in inventory control with a suitable example?

Describe the fixed period quantity inventory model then compare the P and Q system?

Explain MRP –II in Detail.

Explain the objectives of MRP.