2022_2026_Batch_MECH_III-II A.Y.
2024-2025
ASSIGNMENT - MID -1 5 marks
1. Applying & Creating:
a) Identify the key factors to consider when selecting production equipment.
b) Develop a case study on selecting production equipment for manufacturing a
precision gear used in robotics.
c) Justify tooling selection for a high-speed CNC milling process, considering
efficiency and accuracy.
2. Evaluating & Creating:
a) Assess the integration of quality assurance (QA) into process planning. Provide
an example of a QA method used in manufacturing an aerospace turbine blade.
b) Explain the methodology of cost estimation in process planning. Using an
example of injection moulding in plastic part production, analyse cost
considerations and optimization strategies.
3. A mild steel shaft needs to be manufactured in a workshop. The shaft has a
diameter of 50mm and a length of 200mm. It requires turning, facing, drilling and
threading operations.
Based on the given information, prepare a detailed process plan covering the
following:
a) Process Planning Activities: Describe the sequential steps involved in
planning the manufacturing process for this shaft.
b) Selection of Process Parameters: Determine cutting speed, feed rate and
depth of cut for turning and drilling operations.
c) Selection of Jigs and Fixtures: Recommend appropriate work-holding
devices to ensure accuracy and repeatability in machining.
d) Quality Assurance Methods: Identify inspection techniques to ensure that
the final product meets tolerance and surface finish requirements.
e) Break-even Analysis: If two different machining processes are available
(CNC lathe and manual lathe), analyze the break-even point to determine
the more cost-effective option.
f) Economics of Process Planning: Estimate the material cost, labour cost and
machine-hour cost required for manufacturing the shaft.
Instructions:
• Use relevant formulas for process parameter calculation.
• Include diagrams and tables wherever necessary.
• Justify your decisions with examples.
4. A small-scale manufacturing unit plans to produce 5000 custom-made metal
components for the automotive industry. The company wants to analyze the total
cost and determine the selling price for each unit.
Using the given information, perform the following tasks:
1. Cost Estimation Process:
o Outline the step-by-step procedure for estimating the total cost of
production.
2. Classification of Costs:
2022_2026_Batch_MECH_III-II A.Y. 2024-2025
o Differentiate between direct costs (e.g., material, labour) and
indirect costs (e.g., factory overhead, administrative expenses).
o Provide real-world examples of each cost type in the manufacturing
industry.
3. Methods of Costing:
o Identify the most suitable costing method (job costing, process
costing, batch costing, etc.) for this production.
o Justify your selection with a detailed explanation.
4. Cost Components Breakdown:
o Calculate and analyze the cost of raw materials, labour, tools and
overhead expenses using hypothetical values.
o Present your findings in a tabular format.
5. Break-even Analysis:
o Determine the minimum number of units required to reach the
break-even point.
o Explain how this analysis influences pricing strategy and profit
margins.
6. Comparison of Cost Estimation and Cost Accounting:
o Explain the differences between cost estimation and cost accounting
with examples.
o Discuss how businesses use both approaches for financial planning
and decision-making.
7. Case Study Comparison:
o Compare two real-world manufacturing businesses (one using job
costing and another using batch costing).
o Analyze their cost estimation strategies and discuss which one is
more efficient for automotive parts manufacturing.
Instructions:
• Use relevant formulas and calculations where necessary.
• Include diagrams, tables and flowcharts for better representation.
• Justify your answers with practical case studies and examples.
