PROCESS PLANNING AND COST ESTIMATION

100

UNIT I PROCESS PLANNING 8 Introduction- Place of process planning-economics- Process & Production Planning, Process Planning & Concurrent Engineering-Types of production- standardization- Production design & selection. UNIT II DESIGN AND CONCEPTS OF PROCESS PLAN 8 Selection of processes, tools, cutting parameters & machine tools- Jigs and Fixtures Grouping of processes- Sequencing of operations- Selecting primary manufacturing processes for rough & refined needs- Process capability, Process Charts. UNIT III MANUAL AND COMPUTER AIDED PROCESS PLANNING 7 Retrieval type/variant approach, group technology generative approach, logics decision tress and tables, axiomatic approach AI expert systems feature recognition applications. UNIT IV DIRECT AND INDIRECT COST COMPONENTS 12 Labour costdirect, indirectestimationlabour normstime study rating labour cost variances; material costdirect, indirectestimationmaterial issue valuation material cost variancesproblems. Overhead cost - Elements factory, administrative, sales and distribution expensesmethods of absorbing overheads Direct Labour, Direct Material, Machine Hour Rate methods depreciation methods accounting for service department expenses problems. UNIT V BREAK EVEN ANALYSIS & COST MANAGEMENT 10 make or buy decision, assumptions, merits and demerits of break even analysis. Applications. Linear, multi product break-even analysis. Learning curves, product life cycle cost analysis Tools and techniquesactivity based costing - concepts, cost drivers; introduction to target costing - need and applications LECTURE : 45 TUTORIAL : 0 TOTAL : 45 REFERENCES 1 R.K.Rajput, Thermal Engineering , Laxmi Publications, New Delhi, Sixth edition, 2005 2 Kothandaraman C.P, Domkundwar and A.V. Domkundwar, A course in Thermal Engineering, Dhanpat Rai & Sons, Fifth Edition, 2002 3 Holman J.P. Thermodynamics, McGraw-Hill, 1985. 4 Arora C.P., Refrigeration and Air conditioning, Tata McGraw-Hill, New Delhi, 1994 5 Sarkar B.K., Thermal Engineering, Tata McGraw-Hill, New Delhi New Delhi, 1998 6 V.Ganesan, Internal Combustion Engines, Tata McGraw-Hill, New Delhi, 1994

PROCESS PLANNING AND COST ESTIMATION 3 0 0 3

PROCESS PLANNING: Introduction- Place of process planning-economics- Process & Production Planning, Process Planning & Concurrent Engineering-Types of productionstandardization- Production design & selection. (4) DESIGN AND CONCEPTS OF PROCESS PLAN: Selection of processes, tools, cutting parameters & machine tools- Jigs and Fixtures - Grouping of processes- Sequencing of operations- Selecting primary manufacturing processes for rough & refined needs- Process capability, Process Charts. (5) MANUAL AND COMPUTER AIDED PROCESS PLANNING: Retrieval type/variant approach, group technology generative approach, logics decision tress and tables, axiomatic approach AI expert systems feature recognition applications. (6) ESTIMATING AND COSTING: Concepts, differences, different costing methods classification of costs cost grid-problems (4) DIRECT AND INDIRECT COST COMPONENTS: Labour costdirect, indirect estimationlabour normstime study rating labour cost variances; material costdirect, indirectestimationmaterial issue valuation material cost variancesproblems. Overhead cost Elements factory, administrative, sales and distribution expensesmethods of absorbing overheads Direct Labour, Direct Material, Machine Hour Rate methods depreciation methods accounting for service department expenses problems. (10) COST CALCULATIONS: Machined componentswelded components, forged components, powder metallurgy parts, calculation of sales cost, case studies, use of computers in cost estimation, cost of rejection. OPTIMUM MACHINING CONDITIONS: Taylors equation, deriving the equation for optimum economic cutting velocity selection of cutting speed for optimum cost, problems process capability analysis. (9) BREAK EVEN ANALYSIS: Concept, make or buy decision, assumptions, merits and demerits of break even analysis. Applications. Linear, multi product break-even analysis. (3) COST MANAGEMENT: Learning curves, product life cycle cost analysis -Tools and techniquesactivity based costing - concepts, cost drivers; introduction to target costing - need and applications. (4) Total 45 TEXT BOOKS: 1. Kannappan D, Mechanical Estimating and Costing, Tata McGraw Hill, New Delhi, 2003. 2. Frederic C Jelen and James H Black, Cost and Optimization Engineering, McGraw Hill Inc., New York, 1983. REFERENCES: 1. Thomas E.Vollmann et all, Manufacturing Planning and Control Systems, Galgotia Publications Pvt. Ltd., New Delhi, 1998. 2. Haslehurst M, Manufacturing Technology, ELBS, 1985. 3. Kesavon R Process Planning and Cost Estimation, New Age International Pvt. Ltd., Chennai, 2005.

4. Banga T R and Sharma S C, Mechanical Estimating and Costing, Khanna Publishers, New Delhi, 2002.

LEAN MANUFACTURING

3003

INTRODUCTION: Objectives of lean manufacturing-key principles and implications of lean manufacturing- Traditional Vs lean manufacturing Lean benefits. (6) LEAN MANUFACTURING CONCEPTS: Value creation and waste elimination- Major kinds of waste- pull production-different models of pull production-continuous flow-continuous improvement / Kaizen- Worker involvement. (7) GROUP TECHNOLOGY: Part family- Production flow analysis Composite part concept Machine cell design -Case studies. (5) LEAN MANUFACTURING TOOLS & METHODOLOGIES: Standard work communication of standard work to employees -standard work and flexibility -visual controlsquality at the source- 5S principles -preventive maintenance-total quality management-total productive maintenance -changeover/setup time -batch size reduction. (10) VALUE STREAM MAPPING: The as-is diagram-the future state map-application to the factory simulation scenario-line balancing -poke yoka- Kanban overall equipment effectiveness. (7) JUST IN TIME MANUFACTURING: Introduction - elements of JIT - Kanban system. (6) IMPLEMENTING LEAN: Road map-senior management Involvement-best practices. (4) TEXT BOOKS: 1. Mikell P. Groover (2002) Automation, Production Systems and CIM. REFERENCES: 1) Design and Analysis of Lean Production Systems, Ronald G. Askin & Jeffrey B. Goldberg, John Wiley & Sons, 2003 2. Rother M. and Shook J, 1999 Learning to See: Value Stream Mapping to Add Value and Eliminate Muda , Lean Enterprise Institute, Brookline, MA. 3)Richard B Chase F Robert Jacobs and Nicholas J Aquilano, Operations Management for Competitive Advantage, McGraw Hill/Irwin; Tenth Edition, 2003. 4) Poke - Yoke, "Improving Product Quality by Preventing Defects", Productivity Press, 1992.

MAINTENANCE ENGINEERING

3 0 0 3

UNIT I INTRODUCTION TO MAINTENANCE SYSTEMS 8 Introduction to repair and Maintenance -Maintenance as business - Maintenance systems such as reactive, preventive, predictive or proactive systems - Human resources management in Maintenance management -maintainability- Inherent and overall availability. - Mean time between failures, mean time to repairs and mean down time - Testability and supportability Design for Maintenance - Poor maintainability aspects - Design for reliability. UNIT II CONDITION BASED MAINTENANCE 7 Condition based monitoring of equipment and systems - condition monitoring techniques such as a) Vibration analysis, b) Ultrasonic detection techniques, c) Thermography, d) Oil and lubricant analysis, e) Motor condition monitoring (MCM) -Shaft alignments through laser Vibration instruments -Outline on Thermography UNIT III MAINTENANCE TECHNIQUES SUCH AS RELIABILITY CENTRED MAINTENANCE (RCM). 10 Reliability centred Maintenance-Failure Mode and Effect Analysis-Root cause Analysis- logic tree analysis-Criticality matrix - Total Productive Maintenance, Overall Equipment EffectivenessLean manufacturing- TPM and TPO- Relationship between OEE and world-class MaintenanceLadder of Maintenance improvement Computerized Maintenance management system in a business scenario- data Acquisition for effective management of CMMS. UNIT IV ASSET PLANNING AND SCHEDULING OF ACTIVITIES IN MAINTENANCE 10 Asset and spare part management, - Conventional spare Parts management techniques such as Economic Order Quantity, two bin systems - Latest trends in monitoring through bar codes, mobile computer and wireless data transmissions -. Different aspects of planning and scheduling of Maintenance, such as shutdowns Critical aspects of both routine and shut down Maintenance -. bar charts - PERT network during shut down -Man power Training and utilization of skilled manpower -Sequencing of activities. UNIT V SAFETY AND OTHER ASPECTS OF MAINTENANCE 10 Safety Engineering. - Hazard analysis -General rules and guidelines in safety and hazard prevention - Analytical tools - Hazard analysis- Fault Tree Analysis - Sneak Circuit analysis Integrated approach to Maintenance- Statistical distributions such as normal, gamma and Weibull in Maintenance- Maintenance effectiveness. TOTAL: 45 PERIODS TEXT BOOK: 1. Maintenance Engineering and Management: K.Venkataraman-PHI Learning2007 REFERENCES: 1. Kelly. A and Harris, M. J, Management of Industrial maintenance, Butter worth & Co., 1978 2. David J. Smith, Reliability and Maintainability in Perspective, McMillan,2 nd Edition, 1985. 3. Gwidon W Stachowiak and Andrew W. Batchelor, Engineering Tribology, Butterwork-Heinmann, 2001 4. John V.Grimaldi & Rollin H.Simonds, Safety Management, AITBS Publishers.