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A Course Material on

Engineering Economics & Cost Analysis

By
Mr. R.Siby., M.E
ASSISTANT PROFESSOR
DEPARTMENT OF MECHANICAL ENGINEERING
SASURIE COLLEGE OF ENGINEERING
VIJAYAMANGALAM 638 056

QUALITY CERTIFICATE

This is to certify that the e-course material


Subject Code

: MG 2451

Subject

: Engineering Economics & Cost Analysis

Class

: IV Year Mech

Being prepared by me and it meets the knowledge requirement of the university curriculum.

Signature of the Author


Name

: R. SIBY., M.E

Designation

: ASSISTANT PROFESSOR

This is to certify that the course material being prepared by Mr. R.Siby., M.E is of adequate quality. He
has referred more than five books among them minimum one is from abroad author.

Signature of HD
Name: E.R. SIVAKUMAR., M.E

SEAL

CONTENTS
SL NO

TOPICS

PAGE NO

UNIT I INTRODUCTION TO ECONOMICS


1.1

Introduction to economics

1.2

Flow in an economy

1.3

Law of supply and demand

1.4

Concept of engineering economics

1.5

Engineering efficiency

1.6

Economic efficiency

1.7

Scope of engineering economics

1.8

Marginal cost

1.9

Marginal revenue

1.10

Sunk cost

1.11

Opportunity cost

1.12

Break-even analysis

1.13

P\V ratio

10

1.14

Elementary economic analysis

10

1.15

Material selection for product design selection for a product

11

1.16

Design selection for a product

12

1.17

Process planning

14

UNIT-II VALUE ENGINEERING


2.1

Make or buy decision

18

2.2

Value engineering

18

2.3

Function

25

2.4

Aims

26

2.5

Value engineering procedure

26

2.6

Interest formulae and their applications

27

2.7

Time value of money

27

2.8

Single payment compound amount factor

28

2.9

Single payment present worth factor

28

2.10

Equal payment series sinking fund factor

29

2.11

Equal payment series payment present worth factor

29

2.12

Equal payment series capital recovery factor

30

2.13

Uniform gradient series annual equivalent factor

30

2.14

Effective interest rate

31

CONTENTS
UNIT III CASH FLOW
SL NO
3.1

TOPICS

PAGE NO

Methods of comparison of alternatives

32

Present worth method (Revenue dominated cash flow diagram),

32

3.1.2.1

Future worth method (Revenue dominated cash flow diagram)

33

3.1.2.2

Future worth method (Cost dominated cash flow diagram)

34

3.1.3.1

Annual equivalent method (Revenue dominated cash flow diagram)

35

3.1.3.2

Annual equivalent method (Cost dominated cash flow diagram)

35

Rate of return method

36

3.1.1

3.1.4

UNIT IV REPLACEMENT AND MAINTENANCE ANALYSIS


4.1

Replacement and maintenance analysis

46

4.2

Types of maintenance

47

4.3

Types of replacement problem

48

4.4

Determination of economic life of an asset

48

4.5

Replacement of an asset with a new asset

52

4.6

Capital recovery with return and concept of challenger and defender

53

4.7

Simple probabilistic model for items which fail completely

55

UNIT V DEPRECIATION
5.1

Depreciation- introduction

59

5.2.1

Straight line method of depreciation

59

5.2.2

Declining balance method of depreciation

61

5.2.3

Sum of the years digits method of depreciation

64

5.2.4

Sinking fund method of depreciation

66

5.2.5

Service output method of depreciation

69

5.3

Evaluation of public alternatives

70

5.4

Inflation adjusted decisions

70

5.5

Procedure to adjust inflation

70

5.6

Comparison of alternatives and determination of economic life of asset

70

*****
6

Tutorial problems and Worked out examples

71

Question Bank

84

Previous year University questions

92

TEXT BOOKS:
1. Panneer Selvam, R, Engineering Economics, Prentice Hall of India Ltd, New Delhi, 2001.

MG2451 ENGINEERING ECONOMICS AND COST ANALYSIS

LT P C
3 0 0 3

OBJECTIVES:
To learn about the basics of economics and cost analysis related to engineering so as to take economically sound
decisions.
UNIT I INTRODUCTION TO ECONOMICS
8
Introduction to Economics- Flow in an economy, Law of supply and demand, Concept of Engineering Economics
Engineering efficiency, Economic efficiency, Scope of engineering economics- Element of costs, Marginal cost,
Marginal Revenue, Sunk cost, Opportunity cost, Break-even analysis- V ratio, Elementary economic Analysis
Material selection for product Design selection for a product, Process planning.
UNIT II VALUE ENGINEERING
10
Make or buy decision, Value engineering Function, aims, Value engineering procedure. Interest formulae
and their applications Time value of money, Single payment compound amount factor, Single payment present
worth factor, Equal payment series sinking fund factor, Equal payment series payment Present worth factorequal payment series capital recovery factor-Uniform gradient series annual equivalent factor, Effective interest rate,
Examples in all the methods.
UNIT III CASH FLOW
9
Methods of comparison of alternatives present worth method (Revenue dominated cash flow diagram), Future
worth method (Revenue dominated cash flow diagram, cost dominated cash flow diagram), Annual equivalent
method (Revenue dominated cash flow diagram, cost dominated cash flow diagram), rate of return method,
Examples in all the methods.
UNIT IV REPLACEMENT AND MAINTENANCE ANALYSIS
9
Replacement and Maintenance analysis Types of maintenance, types of replacement problem, determination of
economic life of an asset, Replacement of an asset with a new asset capital recovery with return and concept of
challenger and defender, Simple probabilistic model for items which fail completely.
UNIT V DEPRECIATION
9
Depreciation- Introduction, Straight line method of depreciation, declining balance method of depreciation-Sum
of the years digits method of depreciation, sinking fund method of depreciation/ Annuity method of
depreciation, service output method of depreciation-Evaluation of public alternatives- introduction, Examples,
Inflation adjusted decisions procedure to adjust inflation, Examples on comparison of alternatives and
determination of economic life of asset.
TOTAL: 45 PERIODS
TEXT BOOKS:
1. Panneer Selvam, R, Engineering Economics, Prentice Hall of India Ltd, New Delhi,
2001.
2. Suma Damodaran, Managerial economics, Oxford university press 2006.
REFERENCES:
1. Chan S.Park, Contemporary Engineering Economics, Prentice Hall of India, 2002.
2. Donald.G. Newman, Jerome.P.Lavelle, Engineering Economics and analysis Engg.
Press, Texas, 2002
3. Degarmo, E.P., Sullivan, W.G and Canada, J.R, Engineering Economy, Macmillan,
New York, 1984
4. Grant.E.L., Ireson.W.G., and Leavenworth, R.S, Principles of Engineering
Economy, Ronald Press, New York,1976.
5. Smith, G.W., Engineering Economy, Lowa State Press, Iowa, 1973.
6. Truett & Truett, Managerial economics- Analysis, problems & cases Wiley India 8
Th edition 2004.
7. Luke M Froeb / Brian T Mccann, Managerail Economics A problem solving
approach Thomson learning 2007.

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ENGINEEERING ECONOMICS & COST ANALYSIS

UNIT I - INTRODUCTION TO ECONOMICS


1.1 Introduction
Efficient functioning of any business organization would enable it to provide
goods/services at a lower price.
In the process of managing organizations, the managers at different levels should take
appropriate economic decisions which will help in minimizing investment, operating and
maintenance expenditures besides increasing the revenue, savings and such other gains of the
organization.
These can be achieved through Engineering Economics which deals with the methods
that enable one to make economic decisions towards minimizing costs and/or maximizing
benefits to business organizations.
This chapter discusses the elements of economics and the interaction between its
various components.
This is followed by an analysis of the need and scope of engineering economics. Later,
elements of cost and break-even analysis are presented.
1.2 Economics - is a study of economic problems of the people concerning production,
consumption, exchange and distribution of wealth.
Economics is the science that deals with the production and consumption of goods and
services and the distribution and rendering of these for human welfare.
The following are the economic goals.

A high level of employment


Price stability
Efficiency
An equitable distribution of income
Growth

1.3 Flow in economy The flow of goods, services, resources and money payments in a simple
economy
Households and businesses are the two major entities in a simple economy.
Business organizations use various economic resources like land, labour and capital
which are provided by households to produce consumer goods and services which
will be used by them.
Business organizations make payment of money to the households for receiving
various resources.

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The households in turn make payment of money to business organizations for


receiving consumer goods and services.
This cycle shows the interdependence between the two major entities in
a simple economy.
Money payments for consumer goods and services
Consumer goods, services

Households

Businesses
1. Provide goods and services to
consumers
2. Use resources, inputs
provided by households

1. Consume final goods


and services produced
by businesses and services
2. Provide productive
inputs to businesses

Money payments for resources, rents, wages,


salaries, interest and profit
Economic Resources: Land, labour, capital

Fig.

Flow of goods, services, resources and money payments in a simple economy.

1.4 Laws of supply and demand


1.3.1 Laws of supply - states that the quantity of a commodity supplied varies directly with
the price, other determinants of supply remaining constant.
If the cost of inputs increases, then naturally, the cost of the product will go up. In
such a situation, at the prevailing price of the product the profit margin per unit
will be less.
The producers will then reduce the production quantity, which in turn will affect
the supply of the product.
For instance, if the prices of fertilizers and cost of labour are increased
significantly, in agriculture, the profit margin per bag of paddy will be reduced.
So, the farmers will reduce the area of cultivation, and hence the quantity of
supply of paddy will be reduced at the prevailing prices of the paddy.
If there is an advancement in technology used in the manufacture of the product in
the long run, there will be a reduction in the production cost per unit.
This will enable the manufacturer to have a greater profit margin per unit at the
prevailing price of the product. Hence, the producer will be tempted to supply
more quantity to the market.
Weather also has a direct bearing on the supply of products. For example, demand
for woollen products will increase during winter. This means the prices of woollen
goods will be incresed in winter.
So, naturally, manufacturers will supply more volume of woollen goods during
winter.

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Factors influencing supply


The shape of the supply curve is affected by the following factors:

Cost of the inputs


Technology
Weather
Prices of related goods

1.3.2 Law of demand states that other things being equal demand when price falls and
contracts when price rises.

Market demand is the total quantity demanded by all the purchasers together.

Elasticity of Demand - Elasticity of demand may be defined as the degree of


responsiveness of quantity demanded to a Change in price.

An interesting aspect of the economy is that the demand and supply of a product
are interdependent and they are sensitive with respect to the price of that
product. .
From Fig. it is clear that when there is a decrease in the price of a product, the
demand for the product increases and its supply decreases.
Also, the product is more in demand and hence the demand of the product
increases.
At the same time, lowering of the price of the product makes the producers restrain
from releasing more quantities of the product in the market.
Hence, the supply of the product is decreased. The point of intersection of the
supply curve and the demand curve is known as the equilibrium point.
At the price corresponding to this point, the quantity of supply is equal to the
quantity of demand. Hence, this point is called the equilibrium point.

Price

Supply

Demand

Quantity

Fig. Demand and supply curve.

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Factors influencing demand


The shape of the demand curve is influenced by the following factors:

Income of the people


Prices of related goods
Tastes of consumers

1.5 Concept of Engineering Economics


Science is a field of study where the basic principles of different physical
systems are formulated and tested.
Engineering is the application of science. It establishes varied application
systems based on different scientific principles.
From the discussions in the previous section, it is clear that price has a major role
in deciding the demand and supply of a product.
Hence, from the organizations point of view, efficient and effective functioning of
the organization would certainly help it to provide goods/services at a lower cost
which in turn will enable it to fix a lower price for its goods or services.
The following section discusses the different types of efficiency and their impact
on the operation of businesses and the definition and scope of engineering
economics.
.
1.5 Types of Efficiency
Efficiency of a system is generally defined as the ratio of its output to input. The
efficiency can be classified into technical efficiency and economic efficiency.
1. Technical efficiency
It is the ratio of the output to input of a physical system. The physical
system may be a diesel engine, a machine working in a shop floor, a furnace,
etc.
Output
Technical efficiency (%) =
100
Input
The technical efficiency of a diesel engine is as follows:
Heat equivalent of mechanical
energy produced
Technical efficiency (%) =
Heat equivalent of fuel used

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In practice, technical efficiency can never be more than 100%.


This is mainly due to frictional loss and incomplete combustion of fuel, which
are considered to be unavoidable phenomena in the working of a diesel engine.
2. Economic efficiency
Economic efficiency is the ratio of output to input of a business system.
Economic efficiency (%) =

Output
Input

Worth
100 =
100
Cost

Worth is the annual revenue generated by way of operating the business


and cost is the total annual expenses incurred in carrying out the business.
For the survival and growth of any business, the economic efficiency
should be more than 100%.
Economic efficiency is also called productivity. There are several ways
of improving productivity.

Increased output for the same input

Decreased input for the same output

By a proportionate increase in the output which is


more than the proportionate increase in the input
By a proportionate decrease in the input which is
more than the proportionate decrease in the output
Through simultaneous increase in the output with decrease in the
input.

1.6 Definition and Scope of Engineering Economics


As stated earlier, efficient functioning of any business organization would
enable it to provide goods/services at a lower price.
In the process of managing organizations, the managers at different levels
should take appropriate economic decisions which will help in minimizing
investment, operating and maintenance expenditures besides increasing the
revenue, savings and other related gains of the organization.
1.6.1 Definition
Engineering economics deals with the methods that enable one to take
economic decisions towards minimizing costs and/or maximizing benefits to
business organizations.

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1.6.2 Scope
The issues that are covered in this book are elementary economic analysis,
interest formulae, bases for comparing alternatives, present worth method, future
worth method, annual equivalent method, rate of return method, replacement
analysis, depreciation, evaluation of public alternatives, inflation adjusted
investment decisions, make or buy decisions, inventory control, project
management, value engineering, and linear programming.
1.7 Elements Of Costs
Cost can be broadly classified into variable cost and overhead cost.
Variable cost varies with the volume of production while overhead cost is fixed,
irrespective of the production volume.
Variable cost can be further classified into direct material cost, direct labour
cost, and direct expenses. The overhead cost can be classified into factory
overhead, administration overhead, selling overhead, and distribution
overhead.
Direct material costs are those costs of materials that are used to produce
the product. Direct labour cost is the amount of wages paid to the direct labour
involved in the production activities.
Direct expenses are those expenses that vary in relation to the production
volume, other than the direct material costs and direct labour costs.
Overhead cost is the aggregate of indirect material costs, indirect labour
costs and indirect expenses. Administration overhead includes all the costs that are
incurred in administering the business.
Selling overhead is the total expense that is incurred in the promotional
activities and the expenses relating to sales force. Distribution overhead is the total
cost of shipping the items from the factory site to the customer sites.
The selling price of a product is derived as shown below:
(a) Direct material costs + Direct labour costs + Direct
expenses = Prime cost
(b) Prime cost + Factory overhead = Factory cost
(c) Factory cost + Office and administrative overhead
= Costs of production
(d) Cost of production + Opening finished stock Closing finished
stock
= Cost of goods sold

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(e) Cost of goods sold + Selling and distribution overhead = Cost of


sales
(f) Cost of sales + Profit = Sales
(g) Sales/Quantity sold = Selling price per unit
In the above calculations, if the opening finished stock is equal to the closing
finished stock, then the cost of production is equal to the cost of goods sold.
1..8 Other Costs/Revenues
The following are the costs/revenues other than the costs which are presented in the
previous section:
Marginal cost
Marginal revenue
Sunk cost
Opportunity cost
1. Marginal Cost
Marginal cost of a product is the cost of producing an additional unit of that
product. Let the cost of producing 20 units of a product be Rs. 10,000, and the cost of
producing 21 units of the same product be Rs. 10,045. Then the marginal cost of
producing the 21st unit is Rs. 45.
2. Marginal Revenue
Marginal revenue of a product is the incremental revenue of selling an additional
unit of that product. Let, the revenue of selling 20 units of a product be Rs. 15,000
and the revenue of selling 21 units of the same product be Rs. 15,085. Then, the
marginal revenue of selling the 21st unit is Rs. 85.
3. Sunk Cost
This is known as the past cost of an equipment/asset. Let us assume that an
equipment has been purchased for Rs. 1,00,000 about three years back. If it is considered
for replacement, then its present value is not Rs. 1,00,000. Instead, its present market
value should be taken as the present value of the equipment for further analysis.
So, the purchase value of the equipment in the past is known as its sunk cost.
The sunk cost should not be considered for any analysis done from now onwards.

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4. Opportunity Cost
In practice, if an alternative (X ) is selected from a set of competing alternatives
(X,Y ), then the corresponding investment in the selected alternative is not available
for any other purpose. If the same money is invested in some other alternative (Y ), it may
fetch some return. Since the money is invested in the selected alternative (X ), one has
to forego the return from the other alternative (Y ).
The amount that is foregone by not investing in the other alternative (Y ) is known
as the opportunity cost of the selected alternative (X ). So the opportunity cost of an
alternative is the return that will be foregone by not investing the same money in another
alternative.
1.9 Break-Even Analysis
The main objective of break-even analysis is to find the cut-off production volume from
where a firm will make profit.
Let
s = selling price per unit
v = variable cost per unit
FC = fixed cost per period
Q = volume of production
The total sales revenue (S) of the firm is given by the following formula:
S=s

The total cost of the firm for a given production volume is


given as
TC = Total variable cost + Fixed
cost
=v

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Q + FC

The linear plots of the above two equations are shown in Fig. .

The intersection point of the total sales revenue line and the total
cost line is called the break-even point.

The corresponding volume of production on the X-axis is known as


the break-even sales quantity.

At the intersection point, the total cost is equal to the total revenue.
This point is also called the no-loss or no-gain situation.

For any production quantity which is less than the break-even


quantity, the total cost is more than the total revenue.

Hence, the firm will be making loss.

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Sales (S)

Profit

Break-even
sales

Total cost (TC)


Variable cost (VC)
Fixed cost (FC)

Loss

BEP(Q*) Production quantity

Fig.

Break-even chart.

For any production quantity which is more than the break-even quantity, the
total revenue will be more than the total cost. Hence, the firm will be making profit.
Profit = Sales (Fixed cost + Variable costs)
= s Q (FC + v Q)
The formulae to find the break-even quantity and break-even sales quantity
Fixed cost

Break-even quantity =

Selling

price/unit Variable cost/unit

FC
s-v (in units)

=
Break-even sales =

Fixed cost
Selling price/ unit
Selling price/ unit Variable cost / unit

FC

s (Rs.)

sv

The contribution is the difference between the sales and the variable costs. The
margin of safety (M.S.) is the sales over and above the break-even sales. The
formulae to compute these values are
Contribution = Sales Variable costs
Contribution/unit = Selling price/unit Variable cost/unit
M.S. = Actual sales Break-even sales
=

Profit

sales

Contribution
M.S. as a per cent of sales = (M.S./Sales)

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1.10 Profit/Volume Ratio (P/V Ratio)


P/V ratio is a valid ratio which is useful for further analysis.
The different formulae for the P/V ratio are as follows:
P/V ratio =

Contribution Sales Variable costs


Sales
=
Sales

The relationship between BEP and P/V ratio is as follows:


BEP =

Fixed cost
P/V ratio

1.11 Elementary Economic Analysis


Whether it is a business situation or a day-to-day event in somebodys personal life,
there are a large number of economic decision making involved. One can manage
many of these decision problems by using simple economic analysis.
For example, an industry can source its raw materials from a nearby place or from a
far-off place. In this problem, the following factors will affect the decision:
Price of the raw material
Transportation cost of the raw material
`Availability of the raw material
Quality of the raw material
Consider the alternative of sourcing raw materials from a nearby place
with the following characteristics:
The raw material is more costly in the nearby area.
The availability of the raw material is not sufficient enough to
support the operation of the industry throughout the year.
The raw material requires pre-processing before it is used
in the production process. This would certainly add cost to the
product.
The cost of transportation is minimal under this alternative.
On the other hand, consider another alternative of sourcing the
raw materials from a far-off place with the following characteristics:
The raw material is less costly at the far off place.
The cost of transportation is very high.
The availability of the raw material at this site is abundant and it
can support the plant throughout the year.
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processing before using it for production.

1.12 Material Selection For A Product/Substitution Of Raw Material


The cost of a product can be reduced greatly by substitution of the raw materials.
Among various elements of cost, raw material cost is most significant and it forms
a major portion of the total cost of any product.
So, any attempt to find a suitable raw material will bring a reduction in the total
cost in any one or combinations of the following ways:
Reduced machining/process time
Enhanced durability of the product
Cheaper raw material price

Therefore, the process of raw material selection/substitution will result in finding an


alternate raw material which will provide the necessary functions that are provided by
the raw material that is presently used.
In this process, if the new raw material provides any additional benefit, then it
should be treated as its welcoming feature. This concept is demonstrated with numerical
problem given below
Example
In the design of a jet engine part, the designer has a choice of specifying either an
aluminium alloy casting or a steel casting. Either material will provide equal service, but
the aluminium casting will weigh 1.2 kg as compared with 1.35 kg for the steel casting.
The aluminium can be cast for Rs. 80.00 per kg. and the steel one for Rs. 35.00 per
kg. The cost of machining per unit is Rs. 150.00 for aluminium and Rs. 170.00 for steel.
Every kilogram of excess weight is associated with a penalty of Rs. 1,300 due to
increased fuel consumption. Which material should be specified and what is the
economic advantage of the selection per unit?
Solution
(a) Cost of using aluminium metal for the jet
engine part:
Weight of aluminium casting/unit = 1.2 kg
Cost of making aluminium casting = Rs. 80.00 per kg
Cost of machining aluminium casting per unit = Rs. 150.00
Total cost of jet engine part made of aluminium/unit
= Cost of making aluminium casting/unit
+ Cost of machining aluminium
casting/unit
= 80 1.2 + 150 = 96 + 150
= Rs. 246
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(b) Cost of jet engine part made of steel/unit:


Weight of steel casting/unit = 1.35 kg
Cost of making steel casting = Rs. 35.00 per kg
Cost of machining steel casting per unit = Rs. 170.00
Penalty of excess weight of steel casting = Rs. 1,300 per kg
Total cost of jet engine part made of steel/unit
= Cost of making steel casting/unit
+ Cost of machining steel
casting/unit
+ Penalty for excess weight of steel
casting
= 35 1.35 + 170 + 1,300(1.35 1.2)
= Rs. 412.25
DECISION
The total cost/unit of a jet engine part made of
aluminium is less than that for an engine made of steel. Hence,
aluminium is suggested for making the jet engine part. The
economic advantage of using aluminium over steel/unit is Rs.
412.25 Rs. 246 = Rs. 166.25
1.12.1 Design Selection for a Product
a. The design modification of a product may result in reduced raw
material requirements, increased machinability of the materials and
reduced labour.
b. Design is an important factor which decides the cost of the product for a
specified level of performance of that product.
Example
(Design selection for a process industry). The chief engineer of refinery
operations is not satisfied with the preliminary design for storage tanks to be
used as part of a plant expansion programme. The engineer who submitted
the design was called in and asked to reconsider the overall dimensions in the
light of an article in the Chemical Engineer, entitled How to size future
process vessels?
The original design submitted called for 4 tanks 5.2 m in diameter and 7
m in height. From a graph of the article, the engineer found that the present
ratio of height to diameter of 1.35 is 111% of the minimum cost and
that the minimum cost for a tank was when the ratio of height to diameter was
4 : 1. The cost for the tank design as originally submitted was
estimated to be Rs. 9,00,000. What are the optimum tank dimensions if the
volume remains the same as for the original design? What total savings may be
expected through the redesign?
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Solution
(a) Original design
Number of tanks = 4
Diameter of the tank = 5.2 m
Radius of the tank = 2.6 m
Height of the tank = 7 m
Ratio of height to diameter = 7/5.2 = 1.35
Volume/tank = (22/7)r 2h = (22/7)(2.6) 2 7
= 148.72 m3
(b) New design
Cost of the old design = 111% of the cost of the new design (optimal
design)
Optimal ratio of the height to diameter = 4:1
h:d=4:1
4d = h
d = h/4
r = h/8
Volume = (22/7)r2h = 148.72 (since, the volume remains the same)
(22/7)(h/8)2h = 148.72
h3 = 148.72
(22/7)
h = 14.47 m

64 = 3,028.48

r = h/8 = 14.47/8 = 1.81 m


Therefore,
Diameter of the new design = 1.81

= 3.62 m
Cost of the new design = 9,00,000

(100/111)

= Rs. 8,10,810.81
Expected savings by the redesign = Rs. 9,00,000 Rs. 8,10,810.81
= Rs. 89,189.19

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1.13 Process Planning /Process Modification


While planning for a new component, a feasible sequence of operations with
the least cost of processing is to be considered.
The process sequence of a component which has been planned in the past is
not static.
It is always subject to modification with a view to minimize the cost of
manufacturing the component.
So, the objective of process planning/process modification is to identify the
most economical sequence of operations to produce a component.
The steps in process planning are as follows:
1. Analyze the part drawing to get an overall picture of what is
required.
2. Make recommendations to or consult with product engineers
on product design changes.
3. List the basic operations required to produce the part to
the drawing or specifications.
4. Determine the most practical and economical manufacturing
method and the form or tooling required for each operation.
5. Devise the best way to combine the operations and put them
in sequence.
6. Specify the gauging required for the process.
Steps 35 aim to determine the most practical and economical sequence of
operations to produce a component. This concept is demonstrated with a
numerical problem.
Example
The process planning engineer of a firm listed the sequences of operations as
shown in Table to produce a component.
Table Data for Example
Sequence
Process sequence
1
2
3

Turning Milling Shaping Drilling


Turning Milling Drilling
All operations are performed with CNC machine

The details of processing times of the component for various operations and
their machine hour rates are summarized in Table below

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Machine Hour Rates and Processing Times (minutes) for Example


Operation

Machine hour
sequence rate
(Rs.)

Turning

Process
1

200

Milling

400

14

Shaping

350

10

Drilling

300

CNC operations

1,000

Find the most economical sequence of operations to manufacture the


component.
Solution (a) Cost of component using process sequence 1.
sequence 1 of the component is as follows:

The process

Turning Milling Shaping Drilling


The calculations for the cost of the above process sequence are summarized in Table.
Table
Operation

Workings for Process Sequence 1

Operation

Time

Machine

No.

Cost

hour rate
(min)

(hr)

(Rs.)

(Rs.)

Turning

0.083

200

16.60

Milling

0.133

400

53.20

Shaping

10

0.167

350

58.45

Drilling

0.050

300

15.00

Total: 143.25
(b) Cost of component using process sequence 2.
of the component is as follows:

The process sequence 2

Turning Milling Drilling


The calculations for the cost of the above process sequence are given in
Table
Table Workings for Process Sequence 2
Operation

Operation

Time

Machine

No.
1

2
3

Turning

Milling
Drilling

(min)

(hr)

Cost

hour rate
(Rs.)

(Rs.)
16.60

0.083

200

14

0.233

400

0.050

300

93.20
15.00
Total: 124.80

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(c) Cost of component using process sequence 3. The process sequence


3 of the component is as follows:
Only CNC operations
The calculations for the cost of the above process sequence are summarized
in Table
Table
Operation

Workings for Process Sequence 3

Operation

Time

Machine

No.
1

Cost

hour rate
CNC operations

(min)

(hr)

(Rs.)

(Rs.)

0.133

1,000

133

The process sequence 2 has the least cost. Therefore, it should be selected for
manufacturing the component.

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UNIT-II VALUE ENGINEERING


2.1 INTRODUCTION
Value analysis is one of the major techniques of cost reduction and cost
prevention. It is a disciplined approach that ensures necessary functions for minimum
cost without sacrificing quality, reliability, performance, and appearance. According
to the Society of American Value Engineers (SAVE),
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 the lowest overall cost.
It is an organized approach to identify unnecessary costs associated with any
product, material part, component, system or service by analysing the function and
eliminating such costs without impairing the quality, functional reliability, or the
capacity of the product to give service
2.1.1 WHEN TO APPLY VALUE ANALYSIS
One can definitely expect very good results by initiating a VA programme if one
or more of the following symptoms are present:
1. Companys products show decline in sales.
2. Companys prices are higher than those of its competitors.
3. Raw materials cost has grown disproportionate to the volume of production.
4. New designs are being introduced.
5. The cost of manufacture is rising disproportionate to the
volume of production.
6. Rate of return on investment has a falling trend.
7. Inability of the firm to meet its delivery commitments.
2.1.2 Value
The term value is used in different ways and, consequently, has different
meanings. The designer equates the value with reliability; a purchase person with
price paid for the item; a production person with what it costs to manufacture, and a
sales person with what the customer is willing to pay.
Example
Cost value. It is the summation of the labour, material, overhead and all other
elements of cost required to produce an item or provide a service compared to a base.
Exchange value. It is the measure of all the properties, qualities and
features of the product, which make the product possible of being traded for another
product or for money.
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Value analysis/value engineering


It is a special type of cost reduction technique. It critically investigates and
analyses the different aspects of materials, design, cost and production of each and
every component of the product in produce it economically without decreasing its
utility, function or reliability.
Applications
The various application areas of value engineering are machine tool
industries, industries making accessories for machine tools, auto industries, import
substitutes, etc.

2.2 INTRODUCTION
In the process of carrying out business activities of an organization, a
component/product can be made within the organization or bought from a subcontractor.
Each decision involves its own costs.
So, in a given situation, the organization should evaluate each of the above make or
buy alternatives and then select the alternative which results in the lowest cost. This is an
important decision since it affects the productivity of the organization
In the long run, the make or buy decision is not static. The make option of a
component/product may be economical today; but after some time, it may turn out to be
uneconomical to make the same.
Thus, the make or buy decision should be reviewed periodically, say, every 1 to 3
years. This is mainly to cope with the changes in the level of competition and various
other environmental factors.
Make or Buy Decisions - is a determination whether to produce a component part
internally or to buy it from an outside supplier. The Organization should evaluate the
costs and benefits of manufacturing a product or product component against purchasing it
and then select the alternative which results in the lower cost.

2.2.1 CRITERIA FOR MAKE OR BUY


In this section the criteria for make or buy are discussed.
1. Criteria for make
The following are the criteria for make:
1. The finished product can be made cheaper by the firm than by
outside suppliers.
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2. The finished product is being manufactured only by a limited


number of outside firms which are unable to meet the
demand.
3. The part has an importance for the firm and requires extremely
close quality control.
4. The part can be manufactured with the firms existing
facilities and similar to other items in which the company has
manufacturing experience.
2. Criteria for buy
The following are the criteria for buy:
1. Requires high investments on facilities which are already
available at suppliers plant.
2. The company does not have facilities to make it and there
are more profitable opportunities for investing companys
capital.
3. Existing facilities of the company can be used more
economically to make other parts.
4. The skill of personnel employed by the company is not readily
adaptable to make the part.
5. Patent or other legal barriers prevent the company for making the part.
6. Demand for the part is either temporary or seasonal.
2.3 APPROACHES FOR MAKE OR BUY DECISION
Types of analysis followed in make or buy decision are as follows:
1. Simple cost analysis
2. Economic analysis
3. Break-even analysis
1. Simple Cost Analysis
The concept is illustrated using an example problem.
EXAMPLE
A company has extra capacity that can be used to produce a sophisticated
fixture which it has been buying for Rs. 900 each. If the company makes the
fixtures, it will incur materials cost of Rs. 300 per unit, labour costs of Rs. 250
per unit, and variable overhead costs of Rs. 100 per unit. The annual fixed cost
associated with the unused capacity is Rs. 10,00,000. Demand over the next year
is estimated at 5,000 units. Would it be profitable for the company to make the
fixtures?
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Solution
We assume that the unused capacity has alternative use.

Cost to make
Variable cost/unit = Material + labour + overheads
= Rs. 300 + Rs. 250 + Rs. 1 0 0
= Rs. 650
Total variable cost = (5,000 units) (Rs. 650/unit)
= Rs. 32,50,000
Add fixed cost associated
with unused capacity
Total cost

Cost to buy
Purchase cost

+ Rs. 10,00,000
= Rs. 42,50,000

= (5,000 units) (Rs. 900/unit)


= Rs. 45,00,000

Add fixed cost associated


with unused capacity
Total cost

+ Rs. 10,00,000
= Rs. 55,00,000

The cost of making fixtures is less than the cost of buying fixtures from
outside. Therefore, the organization should make the fixtures.

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2. Economic Analysis
The following inventory models are considered to illustrate this concept:
Purchase model
Manufacturing model
The formulae for EOQ and total cost (TC) for each model are
given in the following table:
Purchase model

Manufacturing model

2Co D
Q1 =

TC = D

P+

2CD
-------Cc (1 r/k)

Q2 =

Cc
DCo
Q1 Cc
+
Q1
2

TC = D

P+

DCo
Q2

+ Cc (k r)

Q2
2*k

where
D = demand/year
P = purchase price/unit
Cc = carrying cost/unit/year
Co = ordering cost/order or set-up cost/set-up
k = production rate (No. of units/year)
r = demand/year
Q1 = economic order size
Q2 = economic production size
TC = total cost per year

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EXAMPLE
An item has a yearly demand of 2,000 units. The different costs in
respect of make and buy are as follows. Determine the best option.
Buy
Item cost/unit
Procurement cost/order
Set-up cost/set-up
Annual carrying cost/
item/year
Production rate/year

Rs. 8.00
Rs. 120.00

Make
Rs. 5.00
Rs. 60.00

Rs.

1.60

Rs. 1.00
8,000 units

Solution
Buy option
D = 2,000 units/year
Co = Rs. 120/order
Cc = Rs. 1.60/unit/year
Q1 =

2Co D
=
Cc

2 2,000 120
1.60

= 548 units (approx.)


TC = DP +

DCo
Q1Cc
+
Q1
2

548 1.60
2,000 120
+
2
548
= Rs. 16,876.36
= 2,000

8+

Make option
Co = Rs. 60/set-up
r = 2,000 units/year
Cc = Re 1/unit/year
k = 8,000 units/year
Q2 _

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2Cor
Cc[1 (r/k)]
2 60 2,000
= 566 units (approx.)
1.0(1 2,000/8,000)

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TC = DP +

Q2
D Co
+ Cc (k r)
2k
Q2

= 2,000

5.00 +

566
2,000 60
+ 1.0 (8,000 2,000)
2 8,000
566

= Rs. 10,424.26

Result: The cost of making is less than the cost of buying.


Therefore, the firm should go in for the making option.
3. Break-even Analysis
The break-even analysis chart is shown in Fig.

Sales (S)

Profit

Total cost (TC)

B
Variable cost (VC)
Loss
Fixed cost (FC)

C
Production quantity
Fig. 13.1

Break-even chart.

TC = total cost
FC = fixed cost
TC = FC + variable cost
B = the intersection of TC and sales (no loss or no gain situation)
A = break-even sales
C = break-even quantity/break-even point (BEP)
The formula for the break-even point (BEP) is
FC
BEP =

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Selling price / unit Variable cost / unit

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EXAMPLE
There are three alternatives available to meet the demand of a
particular product. They are as follows:
(a) Manufacturing the product by using process
A (b) Manufacturing the product by using
process B (c) Buying the product
The details are as given in the following table:
Cost elements

Manufacturing
the product by
process A

Fixed cost/year (Rs.)


Variable/unit (Rs.)

Manufacturing
the product by
process B

5,00,000

6,00,000

175

150

Purchase price/unit (Rs.)

Buy

125

The annual demand of the product is 8,000 units. Should the company make the
product using process A or process B or buy it?
Solution
Annual cost of process A = FC + VC Volume
= 5,00,000 + 175 8,000
= Rs. 19,00,000
Annual cost of process B = FC + VC Volume
= 6,00,000 + 150 8,000
= Rs. 18,00,000
Annual cost of buy

= Purchase price/unit
= 125 8,000
= Rs. 10,00,000

Volume

Since the annual cost of buy option is the minimum among all the alternatives, the company
should buy the product

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2.4 Function
Function is the purpose for which the product is made. Identification of the basic
functions and determination of the cost currently being spent on them are the two major
considerations of value analysis.
Function identifies the characteristics which make the product/component/
part/item/device to work or sell. Work functions lend performance value while sell
functions provide esteem value.
Verbs like support, hold, transmit, prevent, protect, exhibits, control,
etc., are used to describe work functions, while attract, enhance, improve, create,
etc., are used to describe sell functions. For example, in a bus driver cabin, the
functional analysis of some of the parts are given in Table

Functional Analysis of Some Parts of a Bus Driver Cabin


Component of study

Functional analysis
Verb

Noun Steering

wheel

Control

Direction Gear box

Change

Speed Brake system

Stop

Vehicle Wiper

Clear

Water

Horn

Make

Sound

Side mirror

Show

Side traffic

2.4.1Classification of the functions


Rarely do all functions assume equal importance. Usually, some functions are more important than
others. Functions can be classified into the following three categories:
1. Primary function
2. Secondary function
3.Tertiary function
1. Primary functions are the basic functions for which the product is specially designed to achieve. Primary
functions, therefore, are the most essential functions whose non-performance would make the product
worthless, e.g. a photo frame exhibits photographs, a chair supports weight, a fluorescent tube gives light.
2. Secondary functions are those which, if not in-built, would not prevent the device from performing its
primary functions, e.g., arms of a chair provide support for hands. Secondary functions are usually related to
convenience. The product can still work and fulfill its intended objective even if these functions are not inbuilt and yet they may be necessary to sell the product.
3. Tertiary functions are usually related to esteem appearance. For example, Sunmica top of a table gives
esteem appearance for the table.

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Examples
Let us consider a single example of painting a company bus to explain all the above three functions. Here, the
primary function of painting is to avoid corrosion.
The secondary function is to identify the company to which the bus belongs by the colour ofthe paint (e.g. blue
colour for Ashok Leyland Ltd.).
The tertiary function is to impart a very good appearance to the bus by using brilliant colours.
2.5 Aims The aims of value engineering are as follows:
Simplify the product.
Use (new) cheaper and better materials.
Modify and improve product design.
Use efficient processes.
Reduce the product cost.
Increase the utility of the product by economical means.
Save money or increase the profits.
2.6 Value Engineering Procedure
The basic steps of value engineering are as follows:
(a) Blast (i) Identify the product.
(ii) Collect relevant information.
(iii) Define different functions.
(b) Create (iv) Different alternatives.
(v) Critically evaluate the alternatives.
(c) Refine (vi) Develop the best alternative.
(vii) Implement the alternative.
Step 1: Identify the product. First, identify the component for study. In future, any design change should add
value and it should not make the product as obsolete one. Value engineering can be applied to a product as a whole or to
sub-units.
Step 2: Collect relevant information. Information relevant to the following must be collected:

Technical specifications with drawings


Production processes, machine layout and instruction sheet
Time study details and manufacturing capacity
Complete cost data andmarketing details
Latest development in related products

Step 3: Define different functions. Identify and define the primary, secondary and tertiary functions of the
product or parts of interest. Also, specify the value content of each function and identify the high cost areas.
Step 4: Different alternatives. Knowing the functions of each component part and its manufacturing details,
generate the ideas and create different alternatives so as to increase the value of the product.Value engineering should be
done after a brain storming session. All feasible or non-feasible suggestions are recorded without any criticism; rather,
persons are encouraged to express their views freely.

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2.7 Interest Formulas Interest rate can be classified into simple interest rate and compound
interest rate.
In simple interest, the interest is calculated, based on the initial deposit for every
interest period. In this case, calculation of interest on interest is not applicable.
In compound interest, the interest for the current period is computed based on the
amount (principal plus interest up to the end of the previous period) at the
beginning of the current period.
The notations which are used in various interest formulae are as follows:
P = principal amount
n = No. of interest periods
i = interest rate (It may be compounded monthly, quarterly,
semiannually or annually)
F = future amount at the end of year n
A = equal amount deposited at the end of every interest period
G = uniform amount which will be added/subtracted period after period
to/from the amount of deposit A1 at the end of period 1
2.8 Time Value of Money - . It represents the growth of capital per unit period. The period
may be a month, a quarter, semiannual or a year.
An interest rate 15% compounded annually means that for every hundred
rupees invested now, an amount of Rs. 15 will be added to the account at the
end of the first year. So, the total amount at the end of the first year will be Rs.
115.
At the end of the second year, again 15% of Rs. 115, i.e. Rs. 17.25
will be added to the account.
Hence the total amount at the end of the second year will be Rs. 132.25. The
process will continue thus till the specified number of years.
If an investor invests a sum of Rs. 100 in a fixed deposit for five years with an
interest rate of 15% compounded annually, the accumulated amount at the end of
every year will be as shown in Table

Compound Amounts
(amount of deposit = Rs. 100.00)
Year end
0
1
2
3
4
5

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Interest
(Rs.)

Compound amount
(Rs.)

15.00
17.25
19.84
22.81
26.24

100.00
115.00
132.25
152.09
174.90
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The formula to find the future worth in the third column is
F=P

(1 + i)n

where
P = principal amount invested at time 0,
F = future amount,
i = interest rate compounded annually,
n = period of deposit.
The maturity value at the end of the fifth year is Rs. 201.14. This means that the
amount Rs. 201.14 at the end of the fifth year is equivalent to Rs. 100.00 at time 0
(i.e. at present). This is diagrammatically shown in Fig. 3.1. This explanation assumes
that the inflation is at zero percentage.
2.9 Single-Payment Compound Amount - Here, the objective is to find the single future sum (F) of
the initial payment (P) made at time 0 after n periods at an interest rate i compounded every
period.
F

0
P

2
3
i%

. .
.

Cash flow diagram of single-payment compound amount.


The formula to obtain the single-payment compound amount is
F = P(1 + i)n = P(F/P, i, n)
where
(F/P, i, n) is called as single-payment compound amount factor.
2.10 Single-Payment Present Worth Amount - Here, the objective is to find the present worth
amount (P) of a single future sum (F) which will be received after n periods at an interest rate of
i compounded at the end of every interest period.
F
. .
.

.
2
3
4
n
i%
P
Cash flow diagram of single-payment present worth amount.
0 1

The formula to obtain the present worth is


P=

= F(P/F, i, n)

(1 + i)n

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Where
(P/F, i, n) is termed as single-payment present worth factor.

2.11 Equal-Payment Series Sinking Fund


In this type of investment mode, the objective is to find the equivalent
amount (A) that should be deposited at the end of every interest period for n interest
periods to realize a future sum (F) at the end of the nth interest period at an interest
rate of i.
n
i%
.
1
2
3
4 .
0

A
A
A
i%
A = equal amount to be deposited at the end of each interest period
n = No. of interest periods
i = rate of interest
F = single future amount at the end of the nth period

The formula to get F is


A=F

i
= F(A/F, i, n)
(1 + i)n 1

Where
(A/F, i, n) is called as equal-payment series sinking fund factor.
2.12 Equal-Payment Series Present Worth Amount The objective of this mode of investment is to
find the present worth of an equal payment made at the end of every interest period for n
interest periods at an interest rate of i compounded at the end of every interest period.
The corresponding cash flow diagram is shown in Fig. 3.8. Here,
P = present worth
A = annual equivalent payment
i = interest rate
n = No. of interest periods
The formula to compute P is
P=A

(1 + i)n 1
= A(P/A, i, n)
i(1 + i)n

Where
(P/A, i, n) is called equal-payment series present worth factor

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2.13 Equal-Payment Series capital recovery The objective of this mode of investment is
to find the annual equivalent amount (A) which is to be recovered at the end of every
interest period for n interest periods for a loan (P) which is sanctioned now at an interest
rate of i compounded at the end of every interest period
P
i%
1

Cash flow diagram of equal-payment series capital recovery amount.


P = present worth (loan amount)
A = annual equivalent payment (recovery amount)
i = interest rate
n = No. of interest periods
The formula to compute P is as follows:
A=P

i(1 + i)n
= P(A/P, i, n)
(1 + i)n 1

Where,
(A/P, i, n) is called equal-payment series capital recovery factor.

2.14 Uniform Gradient series annual equivalent The objective of this mode of investment is to
find the annual equivalent amount of a series with an amount A1 at the end of the first year
and with an equal increment (G) at the end of each of the following n 1 years with an
interest rate i compounded annually.
The corresponding cash flow diagram is shown in Fig
0

A1

A1+G

.
.

10

A1+2G
A1+3G
A1+ (n 1)G

Cash flow diagram of uniform gradient series annual equivalent amount.


The formula to compute A under this situation is
(1 + i)n in 1
A = A1 + G
i(1 + i)n i
= A1 + G (A/G, i, n)
here
Where
(A/G, i, n) is called uniform gradient series factor.
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2.15 Effective Interest rate Let i be the nominal interest rate compounded annually. But, in
practice, the compounding may occur less than a year. For example, compounding may
be monthly, quarterly, or semi-annually. Compounding monthly means that the interest is
computed at the end of every month. There are 12 interest periods in a year if the
interest is compounded monthly. Under such situations, the formula to compute the
effective interest rate, which is compounded annually, is Effective interest rate, R = 1 +
i/C C 1
where,
i = the nominal interest rate
C = the number of interest periods in a year.

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UNIT III CASH FLOW


3.1 Introduction
In this method of comparison, the cash flows of each alternative will be reduced to time
zero by assuming an interest rate i. Then, depending on the type of decision, the best
alternative will be selected by comparing the present worth amounts of the alternatives.
The sign of various amounts at different points in time in a cash flow diagram is to be
decided based on the type of the decision problem.
In a cost dominated cash flow diagram, the costs (outflows) will be assigned with positive
sign and the profit, revenue, salvage value (all inflows), etc. will be assigned with negative
sign.
In a revenue/profit-dominated cash flow diagram, the profit, revenue, salvage value (all
inflows to an organization) will be assigned with positive sign. The costs (outflows) will be
assigned with negative sign.
In case the decision is to select the alternative with the minimum cost, then the alternative
with the least present worth amount will be selected. On the other hand, if the decision is to
select the alternative with the maximum profit, then the alternative with the maximum present
worth will be selected.
3.2 BASES FOR COMPARISON OF ALTERNATIVES
In most of the practical decision environments, executives will be forced to select the
best alternative from a set of competing alternatives.
Let us assume that an organization has a huge sum of money for potential investment and
there are three different projects whose initial outlay and annual revenues during their lives
are known. The executive has to select the best alternative among these three competing
projects.
There are several bases for comparing the worthiness of the projects. These bases are:
1. Present worth method
2. Future worth method
3. Annual equivalent method
4. Rate of return method
3.2.1 PRESENT WORTH METHOD
In this method of comparison, the cash flows of each alternative will be reduced to
time zero by assuming an interest rate i.
Then, depending on the type of decision, the best alternative will be selected by
comparing the present worth amounts of the alternatives.

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In a cost dominated cash flow diagram, the costs (outflows) will be assigned with
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positive sign and the profit, revenue, salvage value (all inflows), etc. will be assigned
with negative sign.
In a revenue/profit-dominated cash flow diagram, the profit, revenue, salvage value
(all inflows to an organization) will be assigned with positive sign. The costs
(outflows) will be assigned with negative sign.
3.1.1.1 Revenue-Dominated Cash Flow Diagram
A generalized revenue-dominated cash flow diagram to demonstrate the
present worth method of comparison is presented in Fig.
S

R1
.

R2

R3

Rj

Rn

To find the present worth of the above cash flow diagram for a given
interest rate, the formula is
PW(i) = P + R1[1/(1 + i)1] + R2[1/(1 + i)2] + ...
+ Rj [1/(1 + i) j] + Rn[1/(1 + i)n] + S[1/(1 + i)n]
3.1.1.2 Cost-Dominated Cash Flow Diagram
A generalized cost-dominated cash flow diagram to demonstrate the present worth
method of comparison is presented in Fig.
S

C1

C2

Cj

Cn

P
To compute the present worth amount of the above cash flow diagram for a given interest
rate i, we have the formula
PW(i) = P + C1[1/(1 + i)1] + C2[1/(1 + i)2] + ... + Cj[1/(1 + i) j]
+ Cn[1/(1 + i)n] S[1/(1 + i)n]

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EXAMPLE
Alpha Industry is planning to expand its production operation. It has identified three different
technologies for meeting the goal. The initial outlay and annual revenues with respect to each of the
technologies are summarized in Table 1. Suggest the best technology which is to be implemented
based on the present worth method of comparison assuming 20% interest rate, compounded
annually.
Table 1
Initial outlay
(Rs.)
Technology 1
Technology 2
Technology 3

Annual revenue
(Rs.)

12,00,000
20,00,000
18,00,000

Life
(years)

4,00,000
6,00,000
5,00,000

10
10
10

Solution
In all the technologies, the initial outlay is assigned a negative sign and
the annual revenues are assigned a positive sign.
TECHNOLOGY 1

Initial outlay, P = Rs. 12,00,000


Annual revenue, A = Rs. 4,00,000
Interest rate, i = 20%, compounded annually
Life of this technology, n = 10 years
The cash flow diagram of this technology is as shown in Fig. 4.3.
4,00,000 4,00,000 4,00,000

4,00,000

10

i =20%
12,00,000
Fig.

Cash flow diagram for technology 1.

The present worth expression for this technology is


PW(20%)1 = 12,00,000 + 4,00,000
= 12,00,000 + 4,00,000

(P/A, 20%, 10)


(4.1925)

= 12,00,000 + 16,77,000
= Rs. 4,77,000

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TECHNOLOGY 2

Initial outlay, P = Rs. 20,00,000


Annual revenue, A = Rs. 6,00,000
Interest rate, i = 20%, compounded annually
Life of this technology, n = 10 years
The cash flow diagram of this technology is shown in Fig. 4.4.
6,00,000

6,00,000 6,00,000

10

i = 20%
20,00,000
Fig.

Cash flow diagram for technology 2.

The present worth expression for this technology is


PW(20%)2 = 20,00,000 + 6,00,000

(P/A, 20%, 10)

= 20,00,000 + 6,00,000

(4.1925)

= 20,00,000 + 25,15,500
= Rs. 5,15,500
TECHNOLOGY 3

Initial outlay, P = Rs. 18,00,000


Annual revenue, A = Rs. 5,00,000
Interest rate, i = 20%, compounded annually
Life of this technology, n = 10 years
The cash flow diagram of this technology is shown in Fig. 4.5.
5,00,000

5,00,000 5,00,000

10

i =20%

18,00,000
Fig.

Cash flow diagram for technology 3.

The present worth expression for this technology is


PW(20%)3 = 18,00,000 + 5,00,000
= 18,00,000 + 5,00,000

(P/A, 20%, 10)


(4.1925)

= 18,00,000 + 20,96,250
= Rs. 2,96,250
From the above calculations, it is clear that the present worth of technology 2
is the highest among all the technologies. Therefore, technology 2 is suggested
for implementation to expand the production.

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Department of Mechanical Engineering

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ENGINEEERING ECONOMICS & COST ANALYSIS

3.1.2 FUTURE WORTH METHOD


In the future worth method of comparison of alternatives, the future worth of various alternatives
will be computed.
Then, the alternative with the maximum future worth of net revenue or with the minimum future
worth of net cost will be selected as the best alternative for implementation.
3.1.2.1 Revenue-Dominated Cash Flow Diagram
A generalized revenue-dominated cash flow diagram to demonstrate the future worth
method of comparison is presented in Fig.
S

R1

R2

R3

Rj

Rn

P
Fig Revenue-dominated cash flow diagram.
In Fig. P represents an initial investment, Rj the net-revenue at the end of the jth year, and S
the salvage value at the end of the nth year.
The formula for the future worth of the above cash flow diagram for a given interest rate, i is
FW(i) = P(1 + i)n + R1(1 + i)n1 + R2(1 + i)n2 + ...
+ R j(1 + i)nj + ... + Rn + S
In the above formula, the expenditure is assigned with negative sign and the revenues are
assigned with positive sign.

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ENGINEEERING ECONOMICS & COST ANALYSIS

3.1.2.2 Cost-Dominated Cash Flow Diagram


A generalized cost-dominated cash flow diagram to demonstrate the future worth method
of comparison is given in Fig.
S
0

C1 C2
P

Cj

Cn

Fig. Cost-dominated cash flow diagram.


In Fig. 5.2, P represents an initial investment, Cj the net cost of operation and
maintenance at the end of the j th year, and S the salvage value at the end of
the nth year.
The formula for the future worth of the above cash flow diagram
for a given interest rate, i is
FW(i) = P(1 + i)n + C1(1 + i )n1 + C2(1 +
i)n2 + ...
+ Cj(1 + i)nj + ... + Cn S

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ENGINEEERING ECONOMICS & COST ANALYSIS

EXAMPLE
Consider the following two mutually exclusive alternatives:
End of year
Alternative

A (Rs.)

50,00,000

20,00,000

20,00,000

20,00,000

20,00,000

B (Rs.)

45,00,000

18,00,000

18,00,000

18,00,000

18,00,000

At i = 18%, select the best alternative based on future


worth method of comparison.
Solution Alternative A
Initial investment, P = Rs. 50,00,000
Annual equivalent revenue, A = Rs. 20,00,000
Interest rate, i = 18%, compounded annually
Life of alternative A = 4 years
The cash flow diagram of alternative A is shown in Fig.
20,00,000

20,00,000

20,00,000

20,00,000

i =18%
50,00,000

Fig. Cash flow diagram for alternative A.


The future worth amount of alternative B is computed as
FWA(18%) = 50,00,000(F/P, 18%, 4) + 20,00,000(F/A, 18%, 4)
= 50,00,000(1.939) + 20,00,000(5.215)
= Rs. 7,35,000

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Department of Mechanical Engineering

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ENGINEEERING ECONOMICS & COST ANALYSIS

Alternative B
Initial investment, P = Rs. 45,00,000
Annual equivalent revenue, A = Rs. 18,00,000
Interest rate, i = 18%, compounded annually
Life of alternative B = 4 years
The cash flow diagram of alternative B is illustrated in Fig..
18,00,000

18,00,000

18,00,000

18,00,000

i =18%
45,00,000

Fig.

Cash flow diagram for alternative B.

The future worth amount of alternative B is computed as


FWB(18%) = 45,00,000(F/P, 18%, 4) + 18,00,000 (F/A, 18%, 4)
= 45,00,000(1.939) + 18,00,000(5.215)
= Rs. 6,61,500

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Department of Mechanical Engineering

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ENGINEEERING ECONOMICS & COST ANALYSIS

3.1.3 ANNUAL EQUIVALENT METHOD


In the annual equivalent method of comparison, first the annual equivalent cost or
the revenue of each alternative will be computed.
Then the alternative with the maximum annual equivalent revenue in the case of
revenue-based comparison or with the minimum annual equivalent cost in the
case of cost- based comparison will be selected as the best alternative.
3.1.3.1 Revenue-Dominated Cash Flow Diagram
A generalized revenue-dominated cash flow diagram to demonstrate the annual
equivalent method of comparison is presented in Fig.
S
R1
0

R2

R3

Rj

Rn

P
Fig. Revenue-dominated cash flow diagram.
In Fig. P represents an initial investment, Rj the net revenue at the end of the
j th year, and S the salvage value at the end of the nth year.
The first step is to find the net present worth of the cash flow diagram using the
following expression for a given interest rate, i:
PW(i) = P + R1/(1 + i)1 + R2/(1 + i)2 + ...
+ Rj/(1 + i) j + ... + Rn/(1 + i)n + S/(1 + i)n
In the above formula, the expenditure is assigned with a negative sign and the
revenues are assigned with a positive sign.

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Department of Mechanical Engineering

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ENGINEEERING ECONOMICS & COST ANALYSIS

3.1.3.2 Cost-Dominated Cash Flow Diagram


A generalized cost-dominated cash flow diagram to demonstrate the annual
equivalent method of comparison is illustrated in Fig.
S
0

C1

C2

Cj

Cn

P
In Fig, P represents an initial investment, Cj the net cost of operation and maintenance at
the end of the jth year, and S the salvage value at the end of the nth year.
The first step is to find the net present worth of the cash flow diagram using the following
relation for a given interest rate, i.
PW(i) = P + C1/(1 + i)1 + C2/(1 + i)2 + ...
+ Cj/(1 + i) j + ... + Cn/(1 + i)n S/(1 + i)n

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Department of Mechanical Engineering

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ENGINEEERING ECONOMICS & COST ANALYSIS

EXAMPLE
A company provides a car to its chief executive. The owner of the
company is concerned about the increasing cost of petrol. The cost per litre
of petrol for the first year of operation is Rs. 21. He feels that the cost of petrol
will be increasing by Re.1 every year. His experience with his company car
indicates that it averages 9 km per litre of petrol. The executive expects to
drive an average of 20,000 km each year for the next four years. What is the
annual equivalent cost of fuel over this period of time?. If he is offered
similar service with the same quality on rental basis at Rs. 60,000 per year,
should the owner continue to provide company car for his executive or
alternatively provide a rental car to his executive? Assume i = 18%. If the
rental car is preferred, then the company car will find some other use within
the company.
Solution
Average number of km run/year = 20,000 km
Number of km/litre of petrol = 9 km
Therefore,
Petrol consumption/year = 20,000/9 = 2222.2 litre
Cost/litre of petrol for the 1st year = Rs. 21
Cost/litre of petrol for the 2nd year = Rs. 21.00 + Re. 1.00
= Rs. 22.00
Cost/litre of petrol for the 3rd year = Rs. 22.00 + Re. 1.00
= Rs. 23.00
Cost/litre of petrol for the 4th year = Rs. 23.00 + Re. 1.00
= Rs. 24.00
Fuel expenditure for 1st year = 2222.2 21 = Rs. 46,666.20
Fuel expenditure for 2nd year = 2222.2 22 = Rs. 48,888.40
Fuel expenditure for 3rd year = 2222.2 23 = Rs. 51,110.60
Fuel expenditure for 4th year = 2222.2 24 = Rs. 53,332.80
The annual equal increment of the above expenditures is Rs. 2,222.20
(G). The cash flow diagram for this situation is depicted in Fig.
0

A1
A1 +G
A1 +2G
A1 +3G

Fig. Uniform gradient series cash flow diagram.

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In Fig., A1 = Rs. 46,666.20 and G = Rs. 2,222.20


A = A1 + G(A/G, 18%, 4)
= 46,666.20 + 2222.2(1.2947)
= Rs. 49,543.28
The proposal of using the company car by spending for petrol by the
company will cost an annual equivalent amount of Rs. 49,543.28 for four
years. This amount is less than the annual rental value of Rs. 60,000.
Therefore, the company should continue to provide its own car to its
executive.

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ENGINEEERING ECONOMICS & COST ANALYSIS

3.1.4 RATE OF RETURN METHOD


The rate of return of a cash flow pattern is the interest rate at which the present worth of that
cash flow pattern reduces to zero.
In this method of comparison, the rate of return for each alternative is computed. Then the
alternative which has the highest rate of return is selected as the best alternative.
A generalized cash flow diagram to demonstrate the rate of return method of comparison is
presented in Fig
S
R1

R2

R3

Rj

Rn

.
j
n
0 1
2
3
P
Fig. Generalized cash flow diagram.
In the above cash flow diagram, P represents an initial investment, Rj the net revenue at the
end of the jth year, and S the salvage value at the end of the nth year.
The first step is to find the net present worth of the cash flow diagram using the following
expression at a given interest rate, i.
PW(i) = P + R1/(1 + i)1 + R2/(1 + i)2 + ...
+ Rj/(1 + i) j + ... + Rn/(1 + i)n + S/(1 + i)n

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Department of Mechanical Engineering

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ENGINEEERING ECONOMICS & COST ANALYSIS

EXAMPLE
A person is planning a new business. The initial outlay and cash
flow pattern for the new business are as listed below. The expected
life of the business is five years. Find the rate of return for the
new business.
Period
Cash flow
(Rs.)

1,00,000

30,000

30,000

30,000

30,000

30,000

Solution
Initial investment = Rs. 1,00,000
Annual equal revenue = Rs. 30,000
Life = 5 years
The cash flow diagram for this situation is illustrated in Fig.

30,000

30,000

30,000

30,000
4

30,000
5

1,00,000

Fig. Cash flow diagram.

The present worth function for the business is


PW(i) = 1,00,000 + 30,000(P/A, i, 5)

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When i = 10%,
PW(10%) = 1,00,000 + 30,000(P/A, 10%, 5)
= 1,00,000 + 30,000(3.7908)
= Rs. 13,724.
When i = 15%,
PW(15%) = 1,00,000 + 30,000(P/A, 15%, 5)
= 1,00,000 + 30,000(3.3522)
= Rs. 566.
When i = 18%,
PW(18%) = 1,00,000 + 30,000(P/A, 18%, 5)
= 1,00,000 + 30,000(3.1272)
= Rs. 6,184
i = 15% +

566 0
566 ( 6184)

(3%)

= 15% + 0.252%
= 15.252%
Therefore, the rate of return for the new business is 15.252%.

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Department of Mechanical Engineering

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ENGINEEERING ECONOMICS & COST ANALYSIS

UNIT IV REPLACEMENT AND MAINTENANCE ANALYSIS


4.1 Introduction
Organizations providing goods/services use several facilities like equipment and
machinery which are directly required in their operations. In addition to these facilities,
there are several other items which are necessary to facilitate the functioning of
organizations.
All such facilities should be continuously monitored for their efficient functioning;
otherwise, the quality of service will be poor. Besides the quality of service of the
facilities, the cost of their operation and maintenance would increase with the passage of
time.
Hence, it is an absolute necessity to maintain the equipment in good operating
conditions with economical cost. Thus, we need an integrated approach to minimize the
cost of maintenance. In certain cases, the equipment will be obsolete over a period of time.
If a firm wants to be in the same business competitively, it has to take decision on
whether to replace the old equipment or to retain it by taking the cost of maintenance and
operation into account.
There are two basic reasons for considering the replacement of an equipment physical
impairment of the various parts or obsolescence of the equipment.
Physical impairment refers only to changes in the physical condition of the machine
itself. This would lead to a decline in the value of the service rendered, increased
operating cost, increased maintenance cost or a combination of these.
Obsolescence is due to improvement of the tools of production, mainly improvement
in technology.
So, it would be uneconomical to continue production with the same machine
under any of the above situations. Hence, the machines are to be periodically replaced.
Sometimes, the capacity of existing facilities may be inadequate to meet the current
demand. Under such situation, the following alternatives will be considered.
Replacement of the existing equipment with a new one.
Augmenting the existing one with an additional equipment.

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4.2 Types of Maintenance


Maintenance activity can be classified into two types:
Preventive maintenance and
Breakdown maintenance.
Preventive maintenance (PM) is the periodical inspection and service activities which
are aimed to detect potential failures and perform minor adjustments or repairs which will
prevent major operating problems in future.
Breakdown maintenance is the repair which is generally done after the equipment has
attained down state. It is often of an emergency nature which will have associated penalty
in terms of expediting cost of maintenance and down time cost of equipment.
Preventive maintenance will reduce such cost up to a point. Beyond that point, the cost
of preventive maintenance will be more when compared to the breakdown maintenance
cost.
The total cost, which is the sum of the preventive maintenance cost and the breakdown
maintenance cost, will go on decreasing with an increase in the level of maintenance up to
a point.
Beyond that point, the total cost will start increasing. The level of maintenance
corresponding to the minimum total cost is the optimal level of maintenance. The
concepts are demonstrated in Fig.

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ENGINEEERING ECONOMICS & COST ANALYSIS

4.3 Types of Replacement Problem


Replacement study can be classified into two categories:
(a) Replacement of assets that deteriorate with time
(Replacement due to gradual failure, or wear and tear of the
components of the machines).
This can be further classified into the following types:
(i) Determination of economic life of an asset.
(ii) Replacement of an existing asset with a new asset.
(b) Simple probabilistic model for assets which fail completely
(replacement due to sudden failure).

4.4 Determination of Economic Life of an Asset


Any asset will have the following cost components:
Capital recovery cost (average first cost), computed from the first cost
(purchase price) of the machine.
Average operating and maintenance cost (O & M cost)
Total cost which is the sum of capital recovery cost (average first cost)
and average maintenance cost.

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Department of Mechanical Engineering

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ENGINEEERING ECONOMICS & COST ANALYSIS

EXAMPLE
A firm is considering replacement of an equipment, whose first cost is Rs.
4,000 and the scrap value is negligible at the end of any year. Based on experience,
it was found that the maintenance cost is zero during the first year and it increases
by Rs. 200 every year thereafter.
(a) When should the equipment be replaced if i = 0%?
(b) When should the equipment be replaced if i = 12%?
(a) When i = 0%. In this problem
(i)

First cost = Rs. 4,000

(ii)

Maintenance cost is Rs. 0 during the first year and it increases


by Rs. 200 every year thereafter.

This is summarized in column B of Table

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Column C summarizes the summation of maintenance costs for each


replacement period. The value corresponding to any end of year in this column
represents the total maintenance cost of using the equipment till the end of that
particular year.
Average total cost =
=

First cost (FC) + Summation of maintenance cost


Replacement period
+

first cost
= Average
+ Average maintenance
he
t given period
cost for the given
for
period
Column F = Column E + Column D
The value corresponding to any end of year (n) in Column F represents
the average total cost of using the equipment till the end of that particular
year.
For this problem, the average total cost decreases till the end of year 6
and then it increases. Therefore, the optimal replacement period is six
years, i.e. economic life of the equipment is six years.
(b) When interest rate, i = 12%. When the interest rate is more than
0%, the steps to be taken for getting the economic life are summarized with
reference to Table
Table Calculations to Determine Economic Life (First cost = Rs. 4,000,
Interest = 12%)
End of
year

Maintenance
cost at end of
year

P/F, 12%,
n

(n)

Present worth as of
Summation of
Present worth of
present worth
beginning of year 1
cumulative
of maintenance
of maintenance
maintenance cost
costs
costs through year
& first cost
given

(B

D (Rs.)

E (Rs.)

B (Rs)

0.8929

0.00

0.00

200

0.7972

159.44

400

0.7118

600

0.6355

800

C)

A/P, 12%,
n

E + Rs. 4,000
F (Rs.)

Annual
equivalent
total
cost through
year given

H (Rs.)

4,000.00

1.1200

4,480.00

159.44

4,159.44

0.5917

2,461.14

284.72

444.16

4,444.16

0.4163

1,850.10

381.30

825.46

4,825.46

0.3292

1,588.54

0.5674

453.92

1,279.38

5,279.38

0.2774

1,464.50

1,000

0.5066

506.60

1,785.98

5,785.98

0.2432

1,407.15

1,200

0.4524

542.88

2,328.86

6,328.86

0.2191

1,386.65*

1,400

0.4039

565.46

2,894.32

6,894.32

0.2013

1,387.83

1,600

0.3606

576.96

3,471.28

7,471.28

0.1877

1,402.36

10

1,800

0.3220

579.60

4,050.88

8,050.88

0.1770

1,425.00

*Economic life of the machine = 7 years

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ENGINEEERING ECONOMICS & COST ANALYSIS

The steps are summarized now:


1. Discount the maintenance costs to the beginning of year 1.
1

Column D = Column B

(1 + i)n

= Column B

(P/F, i, n) = Column B

Column C.

2. Find the summation of present worth of maintenance costs


through the year given (Column E = Column D).
3. Find Column F by adding the first cost of Rs. 4,000 to
Column E.
4. Find the annual equivalent total cost through the years given.

Column H = Column F

= Column F

i(1 + i)n
(1 + i)n 1

(A/P, 12%, n) = Column F

Column G

5. Identify the end of year for which the annual equivalent


total cost is minimum.
For this problem, the annual equivalent total cost is minimum at the end of
year 7. Therefore, the economic life of the equipment is seven years.

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ENGINEEERING ECONOMICS & COST ANALYSIS

REPLACEMENT OF EXISTING ASSET WITH A NEW ASSET


In this section, the concept of comparison of replacement of an existing asset
with a new asset is presented. In this analysis, the annual equivalent cost of each
alternative should be computed first.
Then the alternative which has the least cost should be selected as the best
alternative. Before discussing details, some preliminary concepts which are essential
for this type of replacement analysis are presented.

Capital Recovery with Return


Consider the following data of a machine.
Let
P = purchase price of the machine,
F = salvage value of the machine at the end of machine life,
n = life of the machine in years, and
i = interest rate, compounded annually
The corresponding cash flow diagram is shown in Fig

The equation for the annual equivalent amount for the above
cash flow diagram is
AE(i) = (P F )

(A/P, i, n) + F

This equation represents the capital recovery with return.

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Concept of Challenger and Defender


o If an existing equipment is considered for replacement with a new
equipment, then the existing equipment is known as the defender and the
new equipment is known as challenger.
o Assume that an equipment has been purchased about three years back for
Rs. 5,00,000 and it is considered for replacement with a new equipment.
The supplier of the new equipment will take the old one for some
money, say, Rs. 3,00,000.
o This should be treated as the present value of the existing equipment and
it should be considered for all further economic analysis.
o The purchase value of the existing equipment before three years is now
known as sunk cost, and it should not be considered for further analysis.
EXAMPLE
Two years ago, a machine was purchased at a cost of Rs. 2,00,000 to be
useful for eight years. Its salvage value at the end of its life is Rs. 25,000. The
annual maintenance cost is Rs. 25,000.
The market value of the present machine is Rs. 1,20,000. Now, a new
machine to cater to the need of the present machine is available at Rs. 1,50,000 to
be useful for six years. Its annual maintenance cost is Rs. 14,000. The salvage
value of the new machine is Rs. 20,000.
Using an interest rate of 12%, find whether it is worth replacing the present
machine with the new machine.
Solution
Alternative 1
Present machine
Purchase price = Rs. 2,00,000
Present value (P) = Rs. 1,20,000
Salvage value (F) = Rs. 25,000
Annual maintenance cost (A) = Rs. 25,000
Remaining life = 6 years
Interest rate = 12%
The cash flow diagram of the present machine is illustrated in Fig.

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25,000

25,000 25,000 25,000 25,000 25,000 25,000


1,20,000
2,00,000
2,20,000

Fig. Cash flow diagram for alternative 1.


annual maintenance cost for the preceding periods are not shown
in this figure. The annual equivalent cost is computed as
AE(12%) = (P F)(A/P, 12%, 6) + F

i+A

= (1,20,000 25,000)(0.2432) + 25,000

0.12 + 25,000

= Rs. 51,104
Alternative 2
New machine
Purchase price (P) = Rs. 1,50,000
Salvage value (F) = Rs. 20,000
Annual maintenance cost (A) = Rs. 14,000
Life = 6 years
Interest rate = 12%
The cash flow diagram of the new machine is depicted in Fig.
20,000

14,000

14,000

14,000

14,000

14,000

14,000

1,50,000

Fig.

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Cash flow diagram for alternative 2.

Department of Mechanical Engineering

MG2451

ENGINEEERING ECONOMICS & COST ANALYSIS

The formula for the annual equivalent cost is


AE(12%) = (P F)(A/P, 12%, 6) + F

i+A

= (1,50,000 20,000)(0.2432) + 20,000

0.12 + 14,000

= Rs. 48,016
Since the annual equivalent cost of the new machine is less than that of the
present machine, it is suggested that the present machine be replaced with the
new machine.
Simple Probabilistic Model For Items Which Fail Completely
Electronic items like transistors, resistors, tubelights, bulbs, etc. could fail
all of a sudden, instead of gradual deterioration. The failure of the item may
result in complete breakdown of the system. The system may contain a
collection of such items or just one item, say a tubelight.
Therefore, we use some replacement policy for such items which would
avoid the possibility of a complete breakdown.
The following are the replacement policies which are applicable for this
situation.
(i) Individual replacement policy.
immediately after its failure.

Under this policy, an item is replaced

(ii) Group replacement policy. Under this policy, the following decision is
made:
At what equal intervals are all the items to be replaced simultaneously with
a provision to replace the items individually which fail during a fixed group
replacement period?
There is a trade-off between the individual replacement policy and the
group replacement policy. Hence, for a given problem, each of the replacement
policies is evaluated and the most economical policy is selected for
implementation. This is explained with two numerical problems.

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EXAMPLE
The failure rates of transistors in a computer are summarized in
Table .
Table Failure Rates of Transistors in Computers
End of week
Probability of
failure to date

0.07

0.18

0.30

0.48

0.69

0.89

1.00

The cost of replacing an individual failed transistor is Rs. 9. If


all the transistors are replaced simultaneously, it would cost Rs.
3.00 per transistor. Any one of the following two options can be
followed to replace the transistors:
(a) Replace the transistors individually when they fail
(individual replacement policy).
(b) Replace all the transistors simultaneously at fixed intervals
and replace the individual transistors as they fail in service
during the fixed interval (group replacement policy).
Find out the optimal replacement policy, i.e. individual
replacement policy or group replacement policy. If group
replacement policy is optimal, then find at what equal intervals
should all the transistors be replaced.
Solution
Assume that there are 100 transistors in use.
Let,
pi be the probability that a transistor which was new when
placed in position for use, fails during the ith week of its life.
Hence,
p1 = 0.07,

p2 = 0.11,

p5 = 0.21,

p3 = 0.12,

p6 = 0.20,

p4 = 0.18,

p7 = 0.11

Since the sum of pis is equal to 1 at the end of the 7th week, the
transistors are sure to fail during the seventh week.
Assume that
(a) transistors that fail during a week are replaced just before
the end of the week, and
(b) the actual percentage of failures during a week for a subgroup of transistors with the same age is same as the
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expected percentage of failures during the week for that sub-group of


transistors.
Let
Ni = the number of transistors replaced at the end of the ith week
N0 = number of transistors replaced at the end of the week 0 (or
at the beginning of the first week).
= 100
N1 =
=
N2 =
=
=
N3 =
=
=
N4 =
=
=
N5 =
=
=
N6 =
=
=
N7 =

number of transistors replaced at the end of the 1st week


N0 p1 = 100 0.07 = 7
number of transistors replaced at the end of the 2nd week
N0 p2 + N1 p1
100 0.11 + 7 0.07 = 12
N0 p3 + N1 p2 + N2 p1
100 0.12 + 7 0.11 + 12 0.07
14
N0 p4 + N1 p3 + N2 p2 + N3 p1
100 0.18 + 7 0.12 + 12 0.11 + 14 0.07
21
N0 p5 + N1 p4 + N2 p3 + N3 p2 + N4 p1
100 0.21 + 7 0.18 + 12 0.12 + 14 0.11 + 21 0.07
27
N0 p6 + N1 p5 + N2 p4 + N3 p3 + N4 p2 + N5 p1
100 0.2 + 7 0.21 + 12 0.18 + 14 0.12 + 21 0.11 + 27 0.07
30
N0 p7 + N1 p6 + N2 p5 + N3 p4 + N4 p3 + N5 p2
+ N6 p1
= 100 0.11 + 7 0.2 + 12 0.21 + 14 0.18 + 21 0.12
+ 27 0.11 + 30 0.07
= 25

Calculation of individual replacement cost


7

Expected life of each transistor =

pi

i=1

=1

0.07 + 2

+5

0.11 + 3

0.21 + 6

0.12 + 4

0.2 + 7

0.18

0.11

= 4.39 weeks

Average No. of failures/week = 100/4.39 = 23


(approx.) Therefore,
Cost of individual replacement
= (No. of failures/week
= 23

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Individual replacement cost/transistor)

9 = Rs. 207.

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Determination of group replacement cost


Cost of transistor when replaced simultaneously = Rs. 3
Cost of transistor when replaced individually = Rs. 9
The costs of group replacement policy for several replacement
periods are summarized in Table.
Table Calculations of Cost for Preventive Maintenance
End of Cost of replacing
week
100 transistors
at a time
B (Rs.)
A

Total cost

Cost of replacing transistors


individually during given
replacement period
C (Rs.)

1
2

300
300

7 9 = 63
(7 + 12) 9 = 171

300

(7 + 12 + 14)

300

(7 + 12 + 14 + 21)

300

(7 + 12 + 14 + 21 + 27)

300

(7 + 12 + 14 + 21 + 27 + 30)

300

(7 + 12 + 14 + 21 + 27 + 30 + 25)

(B + C)
D (Rs.)

9 = 297
9 = 486
9 = 729

Average
cost/week
(D/A)
E (Rs.)

363
471

363.00
235.50

597

199.00

786

196.50*

1,029

205.80

1,299

216.50

9 = 1,224 1,524

217.71

9 = 999

*Indicates the minimum average cost/week.

From Table it is clear that the average cost/week is minimum


for the fourth week. Hence, the group replacement period is four
weeks.
Individual replacement cost/week = Rs. 207
Minimum group replacement cost/week = Rs. 196.50
Since the minimum group replacement cost/week is less than
the individual replacement cost/week, the group replacement
policy is the best, and hence all the transistors should be replaced
once in four weeks and the transistors which fail during this fourweek period are to be replaced individually.

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UNIT V DEPRECIATION

5.1 Introduction
Any equipment which is purchased today will not work for ever. This may be
due to wear and tear of the equipment or obsolescence of technology.
Hence, it is to be replaced at the proper time for continuance of any
business.
The replacement of the equipment at the end of its life involves money. This
must be internally generated from the earnings of the equipment.
The recovery of money from the earnings of an equipment for its replacement
purpose is called depreciation fund since we make an assumption that the value
of the equipment decreases with the passage of time.
Thus the word depreciation means decrease in value of any physical asset
with the passage of time.
5.2 Methods of Depreciation
There are several methods of accounting depreciation fund. These are
as follows:
1. Straight line method of depreciation
2. Declining balance method of depreciation
3. Sum of the yearsdigits method of depreciation
4. Sinking-fund method of depreciation
5. Service output method of depreciation
1. Straight Line Method of Depreciation
In this method of depreciation, a fixed sum is charged as the
depreciation amount throughout the lifetime of an asset such that the accumulated
sum at the end of the life of the asset is exactly equal to the purchase value of the
asset.
Here, we make an important assumption that inflation is absent.
Let
P = first cost of the asset,
F = salvage value of the asset
n = life of the asset,
Bt = book value of the asset at the end of the period t,
Dt = depreciation amount for the period t.

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The formulae for depreciation and book value are as follows:
Dt = (P F)/n
Bt = Bt1 Dt = P t

[(P F)/n]

EXAMPLE
A company has purchased an equipment whose first cost is Rs. 1,00,000 with an
estimated life of eight years. The estimated salvage value of the equipment at the end of
its lifetime is Rs. 20,000. Determine the depreciation charge and book value at the end of
various years using the straight line method of depreciation.
Solution
P
F
n
Dt

= Rs. 1,00,000
= Rs. 20,000
= 8 years
= (P F)/n
= (1,00,000 20,000)/8
= Rs. 10,000
In this method of depreciation, the value of Dt is the same for all the years.
The calculations pertaining to Bt for different values of t are summarized
in Table .
Table

Dt and Bt Values under Straight line Method of Depreciation

End of year
(t)

Depreciation
(Dt)

Book value
(Bt = Bt1 Dt)
1,00,000

10,000

90,000

10,000

80,000

10,000

70,000

10,000

60,000

10,000

50,000

10,000

40,000

10,000

30,000

10,000

20,000

If we are interested in computing Dt and Bt for a specific period (t),


the formulae can be used. In this approach, it should be noted that the
depreciation is the same for all the periods.
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EXAMPLE
Consider Example and compute the depreciation and the book value for period 5.
P = Rs. 1,00,000
F = Rs. 20,000
n = 8 years
D5 = (P F)/n
= (1,00,000 20,000)/8
= Rs. 10,000 (This is independent of the time period.)
Bt = P t

(P F)/n

B5 = 1,00,000 5

(1,00,000 20,000)/8

= Rs. 50,000
2. Declining Balance Method of Depreciation
In this method of depreciation, a constant percentage of the book value
of the previous period of the asset will be charged as the depreciation
amount for the current period.
This approach is a more realistic approach, since the depreciation
charge decreases with the life of the asset which matches with the
earning potential of the asset.
The book value at the end of the life of the asset may not be exactly
equal to the salvage value of the asset. This is a major limitation of
this approach.
Let
P = first cost of the asset,
F = salvage value of the asset,
n = life of the asset,
Bt = book value of the asset at the end of the period t,
K = a fixed percentage, and
Dt = depreciation amount at the end of the period t.
The formulae for depreciation and book value are as follows:
Dt = K

Bt-1

Bt = Bt1 Dt = Bt1 K
= (1 K)

Bt1

Bt1

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The formulae for depreciation and book value in terms of P are


as follows:
Dt = K(1 K)t1
P Bt = (1 K)t
P
While availing income-tax exception for the depreciation
amount paid in each year, the rate K is limited to at the most 2/n. If
this rate is used, then the corresponding approach is called the
double declining balance method of depreciation.

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EXAMPLE
Consider Example 9.1 and demonstrate the calculations of the
declining balance method of depreciation by assuming 0.2 for K.
Solution
P = Rs. 1,00,000
F = Rs. 20,000
n = 8 years
K = 0.2
The calculations pertaining to Dt and Bt for different values of t
are summarized in Table 9.2 using the following formulae:
Dt = K

Bt1

Bt = Bt1 Dt
Table

Dt and Bt according to Declining Balance Method of Depreciation

End of year
(n)

Depreciation
(Dt)

0
1
2
3
4
5
6
7
8

20,000.00
16,000.00
12,800.00
10,240.00
8,192.00
6,553.60
5,242.88
4,194.30

Book value
(Bt)
1,00,000.00
80,000.00
64,000.00
51,200.00
40,960.00
32,768.00
26,214.40
20,971.52
16,777.22

If we are interested in computing Dt and Bt for a specific


period t, the respective formulae can be used.
EXAMPLE
Consider Example 9.1 and calculate the depreciation and the
book value for period 5 using the declining balance method of depreciation by
assuming 0.2 for K.
Solution
P = Rs. 1,00,000
F = Rs. 20,000
n = 8 years
K = 0.2

Dt = K(1 K)t 1 P
D5 = 0.2(1 0.2)4 1,00,000
= Rs. 8,192
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Bt = (1 K)t
B5 = (1 0.2)

P
5

1,00,000

= Rs. 32,768

3. Sum-of-the-Years-Digits Method of Depreciation


In this method of depreciation also, it is assumed that the book value of the
asset decreases at a decreasing rate. If the asset has a life of eight years, first the
sum of the years is computed as
Sum of the years = 1 + 2 + 3 + 4 + 5 + 6 + 7 + 8
= 36 = n(n + 1)/2
The rate of depreciation charge for the first year is assumed as the highest and then it
decreases. The rates of depreciation for the years 18, respectively are as follows:
8/36, 7/36, 6/36, 5/36, 4/36, 3/36, 2/36, and 1/36.
For any year, the depreciation is calculated by
multiplying the corresponding rate of depreciation with (P F).
Dt = Rate (P F)
Bt = Bt1 Dt
The formulae for Dt and Bt for a specific year t are
as follows:
Dt =

n t+1
(P F)
n(n + 1)/2

Bt = (P F)

(n t) (n t + 1)
+F
(n + 1)
n

EXAMPLE
Consider Example 9.1 and demonstrate the calculations of the
sum-of-the-years-digits method of depreciation.
Solution
P = Rs.
1,00,000
F = Rs.
20,000

Sum = n (n + 1)/2 = 8

9/2 = 36

n = 8 years
The rates for years 18, are respectively 8/36, 7/36, 6/36, 5/36, 4/36,
3/36,2/36 and 1/36.
The calculations of Dt and Bt for different values of t are summarized in

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Table using the following formulae:


Dt = Rate

(P F)

Bt = Bt1 Dt
Table

Dt and Bt under Sum-of-the-years-digits Method of Depreciation

End of year
(n)

Depreciation
(Dt)

Book value
(Bt)

0
1
2
3
4
5
6
7
8

17,777.77
15,555.55
13,333.33
11,111.11
8,888.88
6,666.66
4,444.44
2,222.22

1,00,000.00
82,222.23
66,666.68
53,333.35
42,222.24
33,333.36
26,666.70
22,222.26
20,000.04

If we are interested in calculating Dt and Bt for a specific t, then the usage


of the formulae would be better.
EXAMPLE 9.6 Consider Example 9.1 and find the depreciation and book
value for the 5th year using the sum-of-the-years-digits method of depreciation.
Solution
P = Rs. 1,00,000
F = Rs. 20,000
n = 8 years
Dt =

n t+1
(P F)
n(n + 1)/2

D5 =

8 5+1
(1,00,000 20,000)
8(8 + 1)/2

= Rs. 8,888.88
Bt = (P F)

n t n t+1
+F
n+1
n

B5 = (1,00,000 20,000)
= 80,000

(3/8)

85 85+1
+ 20,000
8
8+1

(4/9) + 20,000

= Rs. 33,333.33

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4. Sinking Fund Method of Depreciation


In this method of depreciation, the book value decreases at increasing rates with
respect to the life of the asset
Let
P = first cost of the asset,
F = salvage value of the asset,
n = life of the asset,
i = rate of return compounded annually,
A = the annual equivalent amount,
Bt = the book value of the asset at the end of the period t, and
Dt = the depreciation amount at the end of the period t.
The loss in value of the asset (P F) is made available an the form of cumulative
depreciation amount at the end of the life of the asset by setting up an equal
depreciation amount (A) at the end of each period during the lifetime of the asset.
A = (P F) [A/F, i, n]
The fixed sum depreciated at the end of every time period earns an interest at
the rate of i% compounded annually, and hence the actual depreciation amount
will be in the increasing manner with respect to the time period. A generalized
formula for Dt is
Dt = (P F) (A/F, i, n) (F/P, i, t 1)
The formula to calculate the book value at the end of period t is
Bt = P (P F) (A/F, i, n) (F/A, i, t)
The above two formulae are very useful if we have to calculate Dt and
Bt for any specific period.
If we calculate Dt and Bt for all the periods, then the tabular approach
would be better.

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EXAMPLE
Consider Example and give the calculations regarding the sinking fund
method of depreciation with an interest rate of 12%, compounded annually.
Solution
P = Rs.
1,00,000
F = Rs.
20,000
n = 8 years
i = 12%

A = (P F) [A/F, 12%, 8]
= (1,00,000 20,000) 0.0813
= Rs. 6,504

In this method of depreciation, a fixed amount of Rs. 6,504 will be


depreciated at the end of every year from the earning of the asset.
The depreciated amount will earn interest for the remaining period of life
of the asset at an interest rate of 12%, compounded annually.
For example, the calculations of net depreciation for some periods are as
follows:
Depreciation at the end of year 1 (D1) = Rs. 6,504.
Depreciation at the end of year 2 (D2) = 6,504 + 6,504
= Rs. 7,284.48

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Depreciation at the end of the year 3 (D3)


= 6,504 + (6,504 + 7,284.48)
= Rs. 8,158.62

.12

Depreciation at the end of year 4 (D4)


= 6,504 + (6,504 + 7,284.48 + 8,158.62)
= Rs. 9,137.65

0.12

These calculations along with book values are summarized in Table .


Table

Dt and Bt according to Sinking Fund Method of Depreciation

End of year
t

Fixed
depreciation
(Rs.)

Net depreciation
Dt
(Rs.)

Book value
Bt
(Rs.)

0
1
2
3
4
5
6
7
8

6,504
6,504
6,504
6,504
6,504
6,504
6,504
6,504
6,504

6,504.00
7,284.48
8,158.62
9,137.65
10,234.17
11,462.27
12,837.74
14,378.27

1,00,000.00
93,496.00
86,211.52
78,052.90
68,915.25
58,681.08
47,218.81
34,381.07
20,002.80

Bt = Bt1 Dt

EXAMPLE
Consider Example and compute D5 and B7 using the
sinking fund method of depreciation with an interest rate of 12%,
compounded annually.
Solution
P = Rs. 1,00,000
F = Rs. 20,000
n = 8 years
i = 12%
Dt = (P F) (A/F, i, n) (F/P, i, t 1)
D5 = (P F) (A/F, 12%, 8) (F/P, 12%, 4)
= (1,00,000 20,000) 0.0813 1.574
= Rs. 10,237.30

This is almost the same as the corresponding value given in


the table. The minor difference is due to truncation error.
Bt = P (P F) (A/F, i, n) (F/A, i, t)
B7 = P (P F) (A/F, 12%, 8) (F/A, 12%, 7)
= 1,00,000 (1,00,000 20,000)

0.0813

10.089

= 34,381.10
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5. Service Output Method of Depreciation


In some situations, it may not be realistic to compute depreciation
based on time period. In such cases, the depreciation is computed
based on service rendered by an asset. Let
P=
F=
X=
x=

first cost of the asset


salvage value of the asset
maximum capacity of service of the asset during its lifetime
quantity of service rendered in a period.

Then, the depreciation is defined per unit of service


rendered: Depreciation/unit of service = (P F)/X
Depreciation for x units of service in a period =

PF
(x)
X

EXAMPLE
The first coat of a road laying machine is Rs. 80,00,000. Its salvage value
after five years is Rs. 50,000. The length of road that can be laid by the
machine during its lifetime is 75,000 km. In its third year of operation, the
length of road laid is 2,000 km. Find the depreciation of the equipment for that
year.
Solution
P = Rs. 80,00,000
F = Rs. 50,000
X = 75,000 km
x = 2,000 km

PF
x
Depreciation for x units of service in a period = X
(80,00,000 50,000)
75,000
= Rs. 2,12,000

Depreciation for year 3 =

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5.3 Evaluation Of Public Alternatives


In evaluating alternatives of private organizations, the criterion is to select the
alternative with the maximum profit.
The profit maximization is the main goal of private organizations while
providing goods/services as per specifications to their customers.
But the same criterion cannot be used while evaluating public alternatives.
Examples of some public alternatives are
constructing bridges,
roads, dams,
establishing public utilities, etc.
The main objective of any public alternative is to provide goods/services to the
public at the minimum cost. In this process, one should see whether the benefits of the
public activity are at least equal to its costs.
5.4 Inflation Adjusted Decisions
Inflation is the rate of increase in the prices of goods per period. So, it has a
compounding effect. Thus, prices that are inflated at a rate of 7% per year will increase
7% in the first year, and for the next year the expected increase will be 7% of these new
prices.
If economic decisions are taken without considering the effect of inflation into
account, most of them would become meaningless and as a result the organizations
would end up with unpredictable return.
5.5 Procedure To Adjust Inflation
A procedure to deal with this situation is summarized
now.
1. Estimate all the costs/returns associated with an investment proposal in terms of
todays rupees.
2. Modify the costs/returns estimated in step 1 using an assumed inflation rate so that
at each future date they represent the costs/returns at that date in terms of the
rupees that must be expended/received at that time, respectively.
3. As per our requirement, calculate either the annual equivalent amount or future
amount or present amount of the cash flow resulting from step 2 by considering
the time value of money.
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WORKEDOUT PROBLEMS

Single-Payment Compound Amount


A person deposits a sum of Rs. 20,000 at the interest rate of 18% compounded
annually for 10 years. Find the maturity value after 10 years.
Solution
P = Rs. 20,000
i = 18% compounded annually
n = 10 years
F = P(1 + i)n = P(F/P, i, n)
= 20,000 (F/P, 18%, 10)
= 20,000 5.234 = Rs. 1,04,680
The maturity value of Rs. 20,000 invested now at 18% compounded yearly is equal
to Rs. 1,04,680 after 10 years.

Single-Payment Present Worth Amount


A person wishes to have a future sum of Rs. 1,00,000 for his sons education after 10
years from now. What is the single-payment that he should deposit now so that he gets the
desired amount after 10 years? The bank gives 15% interest rate compounded annually.
Solution
F
i
n
P

= Rs. 1,00,000
= 15%, compounded annually
= 10 years
= F/(1 + i)n = F(P/F, i, n)
= 1,00,000 (P/F, 15%, 10)
= 1,00,000 0.2472
= Rs. 24,720

The person has to invest Rs. 24,720 now so that he will get a sum of Rs.
1,00,000 after 10 years at 15% interest rate compounded annually.

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Equal-Payment Series Sinking Fund


A company has to replace a present facility after 15 years at an outlay of Rs. 5,00,000. It
plans to deposit an equal amount at the end of every year for the next 15 years at an interest
rate of 18% compounded annually. Find the equivalent amount that must be deposited at the
end of every year for the next 15 years.
Solution
F=
n=
i=
A=

Rs. 5,00,000
15 years
18%
?

The corresponding cash flow diagram is shown in Fig.


5,00,000

i = 18%
3
4

15

A
A
A
A
A
Fig. Cash flow diagram of equal-payment series sinking fund.
i
A=F

= F(A/F, i, n)
(1 + i)n
1

= 5,00,000(A/F, 18%, 15)


= 5,00,000

0.0164

= Rs. 8,200
The annual equal amount which must be deposited for 15 years is Rs. 8,200.

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Equal-Payment Series Present Worth Amount


A company wants to set up a reserve which will help the company to have an annual
equivalent amount of Rs. 10,00,000 for the next 20 years towards its employees welfare
measures. The reserve is assumed to grow at the rate of 15% annually. Find the singlepayment that must be made now as the reserve amount.
Solution
A = Rs. 10,00,000
i = 15%
n = 20 years
P=?
The corresponding cash flow diagram is illustrated in Fig.
P
i = 15%
0

.
..

20

10,00,000
1,00,00,00010000001000000 100000

Fig.

Cash flow diagram of equal-payment series present worth amount.

The formula to compute P is


(1 + i)n 1
P=A
= A(P/A, i, n)
n
i(1 + i)

= 10,00,000

(P/A, 15%, 20)

= 10,00,000

6.2593

= Rs. 62,59,300
The amount of reserve which must be set-up now is equal to Rs. 62,59,300.

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Department of Mechanical Engineering

MG2451

ENGINEEERING ECONOMICS & COST ANALYSIS

Equal-Payment Series Capital Recovery Amount


A bank gives a loan to a company to purchase an equipment worth Rs. 10,00,000 at an
interest rate of 18% compounded annually. This amount should be repaid in 15 yearly equal
installments. Find the installment amount that the company has to pay to the bank.
Solution
P = Rs. 10,00,000
i = 18%
n = 15 years
A=?
The corresponding cash flow diagram is shown in Fig..
10,00,000
i = 18%
1

.
A

.
.

15

Fig. Cash flow diagram of equal-payment series capital recovery amount.

A=P

i(1 + i)n
(1 + i)n 1

= P(A/P, i, n)

= 10,00,000

(A/P, 18%, 15)

= 10,00,000

(0.1964)

= Rs. 1,96,400
The annual equivalent installment to be paid by the company to the bank is Rs. 1,96,400.

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Department of Mechanical Engineering

MG2451

ENGINEEERING ECONOMICS & COST ANALYSIS

Uniform Gradient Series Annual Equivalent Amount


A person is planning for his retired life. He has 10 more years of service. He would like to
deposit 20% of his salary, which is Rs. 4,000, at the end of the first year, and thereafter
he wishes to deposit the amount with an annual increase of Rs. 500 for the next 9 years
with an interest rate of 15%. Find the total amount at the end of the 10th year of the above
series.
Solution
Here,
A1 = Rs. 4,000
G = Rs. 500
i = 15%
n = 10 years
A=?&F=?
The cash flow diagram is shown in Fig.
1

4,000

i = 15%
3

4,000 + 500
4,000 + 1,000
4,000 + 1,500

4,000 + 4,500

Fig. Cash flow diagram of uniform gradient series annual equivalent amount.
A = A1 + G

(1 + i)n in 1
i(1 + i)n i

= A1 + G(A/G, i, n)
= 4,000 + 500(A/G, 15%, 10)
= 4,000 + 500

3.3832

= Rs. 5,691.60
This is equivalent to paying an equivalent amount of Rs. 5,691.60 at the end of every
year for the next 10 years. The future worth sum of this revised series at the end of the
10th year is obtained as follows:
F = A(F/A, i, n)

= A(F/A, 15%, 10)


= 5,691.60(20.304)
= Rs. 1,15,562.25
At the end of the 10th year, the compound amount of all his payments will be Rs.
1,15,562.25.

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Department of Mechanical Engineering

MG2451

ENGINEEERING ECONOMICS & COST ANALYSIS

Effective Interest Rate


A person invests a sum of Rs. 5,000 in a bank at a nominal interest rate of 12% for 10
years. The compounding is quarterly. Find the maturity amount of the deposit after 10
years.
Solution
P = Rs. 5,000
n = 10 years
i = 12% (Nominal interest rate)
F=?
METHOD 1
No. of interest periods per year = 4
No. of interest periods in 10 years = 10 4 = 40
Revised No. of periods (No. of quarters), N = 40
Interest rate per quarter, r = 12%/4
= 3%, compounded quarterly.
F = P(1 + r)N = 5,000(1 + 0.03)40
= Rs. 16,310.19
METHOD 2
No. of interest periods per year, C = 4
Effective interest rate, R = (1 + i/C )C 1
= (1 + 12%/4)4 1
= 12.55%, compounded annually.
F = P(1 + R)n = 5,000(1 + 0.1255)10
= Rs. 16,308.91

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Department of Mechanical Engineering

MG2451

ENGINEEERING ECONOMICS & COST ANALYSIS

UNIT I INTRODUCTION TO ECONOMICS


PART A (2 MARKS)
1. What is elasticity of Demand?
Elasticity of demand may be defined as the degree of responsiveness of quantity
demanded to a Change in price.
2.

Define the term `cost?


Cost may be defined as a total of all expenses incurred, whether paid of
outstanding in the manufacture and sale of a product.

3. What is opportunity cost?


Opportunity cost may be defined as the potential benefit that is given up as you
seek an alternative course of action. In other words, the expected return or benefit for
gone in rejecting one course of action for another.
4. What do you mean by marginal cost?
The institute of cost & works Accountants of India defined marginal cost as, the
amount at any given volume of output by which aggregate cost are changed, if the
volume of output is increased or decreased by one unit.
5. Explain marginal costing?
Marginal costing is defined by the ICWA as, the ascertainment by
differentiating between fixed costs, of marginal costs and of the effect on profit of changes
in volume or type of output.
6. What is meant by marginal revenue?
The revenue that can be obtained from selling one more unit of product is called
marginal revenue.
7. Give a short note on sunk cost?
A cost which was incurred or sunk in the past and is not relevant to the particular
decision making is a sunk cost or sunk loss. It may be variable or fixed or both.
8.

List out the elements of cost?


The elements of cost are:
V Materials
Labor cost
Expenses

9. Define the term costing?


Institute of costs and Management Accountants, (I.C.M.A) London has defines
costing as the ascertainment of costs. it refers to the techniques and process of
ascertaining costs and studies the principles and rules concerning the determination of
costs of products and services .

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Department of Mechanical Engineering

MG2451

ENGINEEERING ECONOMICS & COST ANALYSIS

10. What is Break-even point?


The Break-even point is, therefore, the volume of output at which neither a profit
is made nor a loss is incurred. It is a point where the total sales are equal to total cost.
11. Define P/V ratio.
Profit-Volume ratio expressed as a percentage indicates the relative profitability of
different products
PART: B (16 MARKS)
1. Explain in detail about flow in an economy?
2. Explain the concept of law of supply and demand with suitable example?
3. Briefly explain about element of cost and its classification?
4. Explain the concept of break even analysis with clear diagram?
5. Briefly explain about process planning and its various types?

UNIT-II VALUE ENGINEERING


PART A (2 MARKS)

12. What do you mean by `Make or Buy Decisions?


Make or buy decision is a determination whether to produce a component
part internally or to buy it from an outside supplier.
The Organization should evaluate the costs and benefits of
manufacturing a product or product component against purchasing it and
then select the alternative which results in the lower cost.
13. What are the different approaches followed in make or buy decision?
The following are the approaches followed in make or buy decision.
Simple cost analysis
Economic analysis
Break-even analysis
14. What is mean by value analysis/value engineering?
Value analysis is a special type of cost reduction technique.
It critically investigates and analyses the different aspects of materials,
design, cost and production of each and every component of the product in
produce it economically without decreasing its utility, function or
reliability.
15. What do you mean by value of a product?
Value differs from both price and cost in the sense that it is the cost proportionate
to the function. We can express value mathematically as Value =function or utility/ cost
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Department of Mechanical Engineering

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ENGINEEERING ECONOMICS & COST ANALYSIS

16. Explain `function.


Function specifies the purpose of the product or what the product does, what is its
utility etc.
17. What are the different types of values?
Cost value
Exchange value
Use value
Esteem value
18. What are the various functions of a product?
Functions can be classified into the following three categories:
Primary functions
Secondary functions
Tertiary functions
19. Write any four objectives of value analysis.
Reduce the cost of the product
Simplify the product
Use (new) cheaper and better materials
Modify and improve product design so as to make it acceptable to
consumer
20. List any four advantage of value engineering.
Value engineering/analysis identifies and reduces the product cost.
It modifies and improve the product design
It increases the performance/utility of the product by economical means.
It helps to generate new ideas.
PART :B (16 MARKS)
1. Explain in details about criteria for make or buy decision and its approaches? (Also see
problems)
2. Problems in single payment compound amount method?
3. Problems in single payment present worth factor?
4. Problems in equal payment series sinking fund factor method?
5. Problems in equal payment series present worth factor method?
6. Problems in equal payment series capital recovery factor method?

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Department of Mechanical Engineering

MG2451

ENGINEEERING ECONOMICS & COST ANALYSIS

UNIT-III CASH FLOW


PART A (2 MARKS)
21. What is revenue dominated cash flow?
The profit/revenue, salvage value of all inflows to an organization will be assigned
with positive sign and the cost outflows will be assigned with negative sign is called
revenue dominated cash flow.
22. What is cost of dominated cash flow?
The cost outflow will be assigned with positive sign and profit, revenue
salvage value all inflows etc,.
Will be assigned with negative sign is called cost dominated cash flow.
23. Mention the various rate of return method.
Internal rate of return(IRR)
Average rate of return(ARR)
Net present value method (NPV)
Pay-back period (PBP)
24. What is rate of return?
Rate of return is the break-even interest rate, I, which equates the present worth of
a projects cash outflows to the present worth its cash inflow
25. What is present worth method?
The present worth measures the surplus in an investments project at time zero (0).
The present worth of all cash inflows is computed the present worth of all cash
outflows associated with an investment of project is called present worth method.

PART: B (16 MARKS)


1. Problems in present worth method (Revenue dominated cash flow diagram)
2. Problems in future worth method (Revenue dominated cash flow diagram)
3. Problems in Annual equivalent method (Revenue dominated cash flow diagram)
4. Problems in Annual equivalent method (cost dominated cash flow diagram)
5. Problems in rate of return method

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Department of Mechanical Engineering

MG2451

ENGINEEERING ECONOMICS & COST ANALYSIS

UNIT-IV REPLACEMENT AND MAINTENANCE ANALYSIS


PART A (2 MARKS)
26. What is future worth analysis?
Net future worth measures the surplus at time period other then 0.
Future worth analysis is particularly useful in an investment situation where we
need to compute the equivalent worth of a project at the end of its investment
period.
27. What is annual equivalent method?
The criterion provide a basis for measuring investment worth by determining equal
payments on an annual basis is called annual equivalent method.
28. What is Replacement analysis?
Replacement analysis involves the Replacement of existing obsolete or worn-out
assets in order to avoid failure in operations.
The problems often faced by management of various industries are whether to
replace equipment or to continue to use existing equipment, and when existing
equipment should be replaced with efficient equipment.
This class of decision analysis is known as replacement analysis.
29. What is mean by gradual failure?
Gradual failure is progressive in nature.
It can be depicted in machine equipment, which is gradually depreciating or
deteriorating with the time resulting in very high operating and maintenance cost
and/or decreased residual value.
It is easier to predict such type of failure and taking the corrective measures by
providing a replacement policy for such machine equipment.
30. Define economic service life of an asset?
The economic service life of an asset is defined to be the period of useful life that
minimizes the annual equivalent cost of owning and operating the asset.
31. What are the types of replacement problem?
(a) Replacement of assets that deteriorate with time (replacement due to gradual
failure, or were and tear of the components of the machine).
This can be further classified in to the following types:
1. Determination of economic life an asset
2. Replacement of an asset with a new asset.
(b)Simple probabilistic model for assets which fails completely. (Replacement due
to sudden failure).
32. Explain annual equivalent total cost.
Annual equivalent total cost of owning and operating an asset is a
summation of the capital recovery cost (average first cost) and the annual equivalent
operating cost of the asset.
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Department of Mechanical Engineering

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ENGINEEERING ECONOMICS & COST ANALYSIS

33. Name the types of maintenance.


Corrective or Breakdown maintenance.
Scheduled maintenance
Preventive maintenance and
Predictive maintenance.
34. State the main causes of breakdown.
Failure to replace worn out parts
Lack of lubrication
Indifference towards minor faults
35. State any two disadvantages of break down maintenance.
1. Delays in production
2. Faster plant deterioration

36. Explain Predictive maintenance.


It is comparatively a newer maintenance technique.
Equipment conditions are measured periodically or on a continuous basis
and this enable maintenance men to take a timely action such as
equipment adjustments repair or overhaul.

UNIT-V DEPRECIATION
PART A (2 MARKS)
37. Define the term Depreciation.
Depreciation is the process of allocating the acquisition cost of the tangible assets
less salvage value, if any, in a systematic and a rational manner over the estimated life of
the asset.
38. Mention the various method used in depreciation calculation.
The various methods used in depreciation calculation are:
1. Straight line method
2. Declining method
3. Sum of the years digits method
4. Sinking fund or annuity method
5. Service output method
39. What is service output method of depreciation?
Service output method of depreciation is a type of computing depreciation base on
service rendered by an asset

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Department of Mechanical Engineering

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ENGINEEERING ECONOMICS & COST ANALYSIS

40. What are the causes of depreciation?


The causes of depreciation are:
Wear and tear
Depletion
Obsolescence
Lapse of time
41. Write five reasons for providing depreciation.
The reasons for providing depreciations are:
To know the correct profits
To show correct financial position.
To make provision for replacement of asset
To compute tax liability
To decide for show much to buy or sell the assets in the second hand
market
42. What is evaluation of public alternatives?
Evaluation of public alternatives is nothing but the selecting of best alternative
from the available alternatives.
43. Define the term inflation?
Inflation may be defined as a sustained in the general price level.
It is an economic condition where there is a rise in prices resulting in the
fall in the purchasing power of money
44. What is sinking fund?
A depreciation fund equal to be actual loss in the value of the asset is
estimated for each year.
This amount is invested outside the business in a separate account called
sinking fund.
45. What is amortization?
Amortization is a routine decrease in value of an intangible asset, or the
process of paying off a debt over time through regular payments.
Amortization refers to the expensing of intangible capital assets (intellectual
property: patents, trademarks, copyrights. Etc,) in order to show their
decrease in value as a result of use or passage of time.

PART B (16 MARKS)


1. Problems in different types of depreciation methods

(16)

2. Problems in inflation adjusted decision

(16)

3. Problems in finding the economic life of an asset

(16)

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Department of Mechanical Engineering

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ENGINEEERING ECONOMICS & COST ANALYSIS

4. (a) (i) How to adjust inflation in evaluating public alternatives? Explain the procedure.
(8)
(ii)Find the depreciation annuity by annuity method after three years, when the initial cost
of the machine is Rs 8,00,000 an salvage value at the end of three years is Rs 4,00,000.Rate of
interest 10 %
(8)
5. (i) What is economic life of an asset? How to determine it? Explain
(ii) The cost of a machine is Rs 1,60,000 and its scrap value is Rs 40,000 .Estimate life 5
years .Using sum of years digits method ,determine depreciation charges for each year.
(16)

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Department of Mechanical Engineering

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