INDUSTRIAL ENGINEERING AND ESTIMATION AND COSTING
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Chapter 1:-
WORK STUDY. (2x3=6, 1×8-8: Total 14 marks)
Short answer questions
1. Write Objectives of work study
2. State the techniques of work study
3. Define the terms production and productivity
METHOD STUDY
1. Write Objectives of Method study
2. Draw the process chart symbols
3. What is THERBLIGS? Give any six symbols of them.
WORK MEASUREMENT
1. Write objectives of work measurement?
2. State the different incentive plans
3. State the differences between wages and incentives.
4. The observed time for an element is 0.7 min. The rating factor is 90%. All the allowances put
together are 20% of normal time. Calculate the standard time.
5. The observed time for activity is 5 minutes and rating is 110%. Find normal time. If the allowance
of 15% of normal time is allowed for operation, determine the standard time.
Essay answer questions
1. Describe the procedure of Method study step by step.
2. Write short note on (a) SIMO Chart (b) String diagram
3. Briefly explain cycle graph and Chrono cycle graph. What is the difference between them?
4. What are the objectives of work sampling? And explain work sampling procedure.
5. Explain standard time and its components. Highlighting with allowances.
(l.e- observed time, normal time, rating factor, and allowances)
6. Explain the techniques of PMTS and mention the advantages and limitations.
Chapter 2:-
STATISTICAL QUALITY CONTROL. (2x3=6, 1x8-8, total 14 marks)
Short answer questions
1. State the principle of random sampling.
2. List the basic quality control tools?
3. Difference between random sampling and 100% inspection
4. Define the terms quality and quality control
5. What are the advantages of statistical quality control?
6. State the difference between attribute data (discrete data) and variable data (continues data)
7. State the objectives of six Sigma
Essay answer questions
1. The daily production in machine shop is 1000 items. These items are inspected by Go and No Go
gauge. A sample of 100 is inspected daily for 10 days. The samples are taken at random. Compute
the control limits for: (a) p-chart (b) np-chart (c) 100 p chart and draw the charts.
Date 1 2 3 4 5 6 7 8 9 10
Rejection 2 10 6 20 18 14 15 12 8 6
2. In a production process a lot of 250 products has been manufactured in a day. Five samples have been collected at random in a day as a SQC measure. Each sample size is 5. Five samples A,B,C,D and E have been shown in the table below for a particular dimension of the product.
Sample
A 43,42,42,44,43
B 45,40,39,39,46
C 40,40,41,42,43
D 43,42,40,40,46
E 40,41,43,46,43
Calculate the control limits and plot and R charts. Take A, for control limits of X as 0.577 and D, and D4 for control limits of R as 2.11 and 0 respectively
3. The values of means and ranges for 10 samples of size 5 each is given below. Draw charts for means and ranges. Comment on the state of control of process. For n=5; take A2= 0.58; D3 = 0;D4= 2.11.
Sample no. 1 2 3 4 5 6 7 8 9 10
Mean(X) 7 7.5 8 10 9.5 11 11.5 4 3.5 4
Range(R) 2 3 2 2 3 4 3 2 3 2
4. The inspection result of a sheet metal part produced is given below
DATE 1 2 3 4 5 6 7 8 9 10 11 12
Lot size 300 300 300 300 300 300 300 300 300 300 300 300
No. of defectives 24 15 21 15 42 0 24 30 30 9 9 15
Apply the following charts and discuss the results
(i) p-chart; (ii) np-chart; (iii) 100p chart
5. Find X (mean) and σ (Standard deviation) from the following data
X 5 7 10 12 15 18 20
f 5 10 15 20 14 11 6
6. Explain floor inspection and centralized inspection? Write advantages and disadvantages.
Chapter 3:-
FUNDAMENTALS OF ESTIMATION AND COSTING (2x3=6, 1x8-8, total 14 marks)
Short answer questions
1. Difference between estimating and costing
2. Write objectives of estimation
3. What are the various causes of depreciation?
4. List out the methods of calculating depreciation.
5. What are the main elements of costing?
6. Give the examples of administrative overheads
7. Give the examples of factory overheads.
8. Give the examples of administrative overheads
Essay answer questions
1. A certain product is manufactured in batches of 200. The Direct material cost for this batch is
found to be Rs. 50. Direct Labour cost is Rs. 60 and overhead expenses are Rs. 40. If the selling
expenses are 50% of the factory cost, what will be the selling price of each product to earn the
profit of 15% of the selling cost?
2. The market Price of a product is Rs. 200. The discount allowed is 20% of the market price. The
selling expenses are equal to factory cost and the relation between material cost, labour cost and
factory expenses is 1 : 3:2. If the labour cost is Rs. 30/- What profit is being made on this product.
3. A machine was purchased for Rs. 11,00,000. And its life was estimated as 10 years. Its scrap value
was Rs. 1,00,000. Find the value of the machine at the end of 5 years.
4. Describe the estimation procedure.
Chapter 4:-
ESTIMATION OF WEIGHTS AND MACHINING TIMES. (2x3=6, 1x8=8, total 14 marks)
Short answer questions
1. Write the volume formula for different elements
2. Determine the volume of solid of revolution of circular fillet about x-x axis at a distance of R from C.G.
3. State procedure to calculate the weight of material of a component.
4. Define the terms cutting speed, depth of cut and feed and also writes their formulae?
5. List out any six machining operations.
6. Estimate the machining time to turn M.S. rod 25 mm dia to 22 mm dia bar a length of 200mm in a spindle cut. Assume cutting speed 25m/min and feed 0.4mm/rev
7. Find the time required to drill six holes in a casted flange each of 8cm depth if the hole diameter is 1cm. assume cutting speed as 20m/min and feed as 0.02 cm/rev.
8. A hollow spindle is bored to enlarge its hole diameter from 2.5 to 3 cm upto 12 cm depth in single cut. Estimate the boring time, if cutting speed is 30m/min and feed is 0.02 cm/rev
Essay answer questions
1. The shaft shown below is to be manufactured by turning out of 85 mm steel rod. Find out the minimum machining time if the job is to be turned at 300 rpm with feed 0.5 mm/rev and depth of cut 3 mm. All dimensions are in mm.
2. Find the time taken to prepare a job according to the dimensions shown in figure from a bar of 4.0 cm diameter and 6 cm long. Assume following data
Cutting speed for turning and boring = 20m/min
Cutting speed for drilling = 30 m/min
Feed for turning and boring = 0.02 cm/rev
Feed for drilling = 0.023 cm/rev
Depth of cut not to exceed = 3mm
3. Estimate the time required to turn a 50 mm bar to the dimensions as shown in figure, Owith cutter speed 20 m/min and feed 0.7 mm/rev. Assume that all cuts are 2.5 mm deep. Neglect the facing time. All dimensions are in mm.
4. Calculate the weight and cost of material of the 100 lathe centres shown in figure. Assume density of material as 7.8 gm/cc and the cost of material is Rs 20 per kg.
5. Estimate the volume of material required for manufacturing 100 pieces of shafts as shown in Figure. The shafts are made of mild steel which weighs 7.8 gm/cc and costs Rs 30/kg. Also, calculate the material cost for 100 such shafts. All dimensions are in mm.
6. Estimate the volume of material required for producing 1000 parts as shown in figure. Assume that 15% of the finished material is wasted during finishing. All dimenisons are in mm.
7. Calculate the number of rivets of dimensions shown in fig., which can be manufactured from 45 kgs of mild steel. Assume that there is no wastage of material. Density ofmild steel is 7.8 gm/cc.
8. Determine the cost of brass casting shown in figure. Density of brass may be taken as 8.6 gm/cc and cost may be taken as Rs. 40 per kg.
Chapter 5:-
ESTIMATION OF FORGING AND WELDING COSTS. (2x3=6, 1x8-8, Total 14 m)
Short answer questions
1. What is welding? Sketch any four welded joints?
2. List the various fabrication methods?
3. List the various forging operations?
4. List the various losses in forging operations?
5. Write the procedure for the estimation of the welding cost of a product. (Gas and arc welding)
Essay answer questions
1. A container, open on one side, of size 0.5 x 0.5 x 1.0 m height is to be fabricated form 6mm thick
plates. The plate metal weighs 8 gm/cc. If the joints are to be welded, estimate the cost of
container. The relevant data is :
(a) Cost of plate: Rs 30 /kg
(b) Sheet metal scrap: 5% of net volume of material
(c) Cost of labour: 10% of material cost
(d) Cost of welding material: Rs 40 /m of weld
2. Four plates of each 100 x 10 x 1 cm are to be welded together to form a plate of 100x 40x 1 cm.
Neglecting the cost of preparing edges, calculate the cost of material required for welding,
assuming:
• Consumption of O2 and C2 H2 each 1m³/hr
• Welding speed = 2m/hr
• Diameter of filler rod = 5mm
• Length of filler rod used/m of weld = 4.5 m
• Cost of O2 = Rs 7 / m³
• Cost of C2H2 = Rs 50 / m³
• Cost of filler metal = Rs 20/kg
• Density of filler metal = 8gm / cm³
3. Estimate the welding cost for butt welding two mild steel plates each 300 mm x 200 mm x 4 mm.
Assume that.
• Filler rod diameter = 3 mm
• Filler material lost during welding = 20%
• Oxygen consumed = 0.55 m³/hr
• C2 H2 consumed = 0.27 m³/hr.
- Filler rod length consumed = 3.4m/m of weld
• Welding time/ metre of weld = 20 min
• Density of filler material = 7.2 gm/cc
• Cost of filler material = Rs. 45 /kg
• Cost of oxygen = Rs 30/m³
• Cost of acetylene = Rs 150/m³
4. A Cylindrical boiler drum 3m x 1m dia is to be made from 15mm thick MS plates. Both the ends are
closed by welding circular plates to the drum. Cylindrical portin is welded along longitudanal seam.
Welding is done both on inner and outer sides. Caleculate electric welding cost using the follwing
data
(i) Rate of welding=2 m/hr on inner side and 2.5 m/hr on outer side
(ii) Length of electrode required= 1.5m/m of welding
(iii) Cost of electrode= Rs 6/m
(iv) Power consuption = 4 kWh/m of weld
(v) Power charges =Rs 15/kWh
(vi) Labour charges = Rs 10/hr
(vii) Other overhead charges = 200% of prime cost
5. Two 50 cm long MS plates of 10 mm thickness are to be welded by a lap joint on both sides with
the help of a 6 mm electrode. Calculate the cost of welding if:
(i) Current used = 250A
(ii) Voltage = 30V
(iii) Welding speed = 10 m/ hr
(iv) Electrode used = 0.4 kg/m of welding
(v) Labour charges = Rs 15/hr
(vi) Power charges = Rs 0.2 / kWh
(vii) Cost of Electrodes = Rs 5/kg
(viii) Efficiency of machine = 60%
6. Two 1m long M.S plates of 10 mm thick are to be welded by a double fillet lap joint with the help
of 6mm electrode. Assuming following data calculate the cost of welding:
(a) Current used = 250 amperes
(b) Voltage = 30 V
(c) Welding speed = 10 m/hr
(d) Electrode used = 0.5 kg/m of welding
(e) Labour charges = Rs 10/hr
(f) Power charges Re 12/- per kWh
(g) Cost of electrodes = Rs 15/kg
(h) Machine efficiency = 60%
7. 200 pieces of a component as shown in figure, are to be drop forged from a 4 cm diameter stock
bar. Calculate the cost of manufacturing, if.
• Material cost is Rs. 100 per metre
• Forging charges @ Re 0.10 per cm² of surface area to be forged.
• On cost is 10% of material cost.
Consider all possible losses during forging.
