Process planning and cost estimation

Preface to the Second Edition
......Page 10
Preface to the First Edition
......Page 12
Contents
......Page 14
1.1 Improving Plant Layout......Page 20
1.2 Importance of Working Conditions
......Page 21
1.4 Basic Procedure for Method Study......Page 23
1.5 Charts and Diagrams Used in Method Study (Tools and Techniques)......Page 27
1.5.1 Process Chart Symbols......Page 28
1.5.2 Operation Process Chart......Page 29
1.5.3 Flow Process Chart......Page 30
1.5.4 Two-Handed Process Chart (or) Right Hand, Left Hand Chart......Page 31
1.5.5 Man-Machine Chart......Page 32
1.5.6 Flow Diagram......Page 33
1.5.7 String Diagram......Page 35
1.6 Work Measurement......Page 36
1.7.1 Stop Watch Time Study......Page 37
1.7.1.1 Breaking a Job into Elements......Page 38
1.8 Rating Factor......Page 40
1.10 Allowances......Page 41
1.11 Calculation of Standard Time......Page 42
1.12 Production Study......Page 43
1.13 Ratio Delay Study......Page 44
1.14 Synthesis from Standard Data......Page 45
1.15.4 Application......Page 47
1.16.3 Table Preparation......Page 48
1.17.1 Objectives......Page 49
1.17.2 Applications......Page 50
Review Questions......Page 52
2.1.1 Purpose of Process Planning......Page 54
2.1.2 Concept of Process Planning......Page 55
2.3 Scope of Process Planning......Page 56
2.5.1 Concept of Process Planning......Page 57
2.5.3 Process Planning Procedure......Page 58
2.6.1 Manual Process Planning......Page 63
2.6.2 Computer Aided Process Planning......Page 64
2.6.2.1 Retrieval Type Approach......Page 66
2.6.2.2.1 Process Planning Logic
......Page 69
2.7 Selection Processes......Page 73
2.7.1 Factors Affecting Selection Process......Page 74
2.7.2 Machine Capacity......Page 75
2.7.3 Analysis of Machine Capacity......Page 76
2.7.4 Process and Equipment Selection Procedure......Page 77
2.7.6.1 Manpower Requirement......Page 78
2.8 Material Requirement......Page 80
2.8.1 Bill of Material......Page 81
2.8.3 Factors Influencing Choice of Machinery......Page 82
2.8.4.1 Selection among Suitable Machines......Page 83
2.8.4.2 Break Even Point Analysis......Page 85
2.8.4.3 Production Cost Comparison......Page 90
2.8.4.4 Process Cost Comparison......Page 92
2.11 Process Time Calculation......Page 94
Review Questions......Page 95
3.1 Reasons for Doing Estimates......Page 96
3.2.1 Importance of Estimating......Page 97
3.5 Cost Accounting of Costing......Page 98
3.8 Difference Between Cost Estimating and Cost Accounting......Page 99
3.9 Difference Between Financial Accounting and Cost Accounting......Page 100
3.10 Methods of Costing......Page 101
3.11 Elements of Cost Introduction......Page 103
3.12.2 Indirect Material Cost......Page 104
3.13.2 Determination of Direct Labour Cost......Page 105
3.13.3 Indirect Labour Cost......Page 107
3.14.2 Indirect Expenses (Overheads)......Page 108
3.15 Cost of Product (Ladder of Cost)......Page 109
Review Questions......Page 110
4.1.2 Budgetary......Page 111
4.2 How Estimates are Developed?......Page 112
4.3.1 How Standard Data are Developed?......Page 113
4.4 Materials Available to Develop an Estimate
......Page 114
4.5.1 Computer Estimating
......Page 115
4.5.2 Group Technology......Page 116
4.5.3 Parametric Estimating......Page 117
4.5.4 Statistical Estimating......Page 118
4.7 Estimating Procedure......Page 119
4.9 Constituents of A Job Estimate......Page 121
4.11 Allowances in Estimation......Page 123
Review Questions......Page 124
5.1.2 Mensuration in Estimating......Page 125
5.1.3 Solved Problems in Material Cost......Page 130
5.2 Estimation of  Labour Cost......Page 143
5.3.1 Introduction......Page 152
5.4.1 Percentage on Direct Material Cost......Page 153
5.4.2 Percentage on Direct Labour Cost......Page 154
5.4.3 Percentage on Prime Cost......Page 155
5.4.4 Man-Hour Rate......Page 156
5.4.5 Machine-Hour Rate......Page 157
5.4.8 Space Rate Method......Page 159
5.5.1.1 Losses in Forging......Page 160
5.5.1.2 Forging Cost......Page 161
5.5.1.3 Solved Problems......Page 162
5.5.2.1 Welding Cost......Page 171
5.5.2.2 Solved Problems......Page 172
5.5.3.2 Foundry Losses......Page 183
5.5.3.4 Solved Problems......Page 184
5.5.4.1 Introduction......Page 195
5.5.4.2 Importance of Machine Time Calculation......Page 196
5.5.4.3 Calculation of Machining Time for Different Lathe Operations......Page 197
5.5.4.4 Machining Time Calculation for Drilling Lathe and Boring......Page 198
5.5.4.5 Machining Time Calculation for Milling Operation......Page 199
5.5.4.6 Machining Time Calculation for Shaping and Planing......Page 202
5.5.4.8 Solved Problems......Page 203
Review Questions......Page 239
Index......Page 246