ME8793 Process Planning Cost Estimation 5

ME8793 L T P C 3 0 03
PROCESS PLANNING AND COST ESTIMATION
OBJECTIVES
 To introduce the process planning concepts to make cost estimation for
various products after process planning
UNIT I INTRODUCTION TO PROCESS PLANNING 9
Introduction- methods of process planning-Drawing interpretation-Material

evaluation – steps in process selection-.Production equipment and tooling
selection
UNIT II PROCESS PLANNING ACTIVITIES 9
Process parameters calculation for various production processes-Selection jigs

and fixtures election of quality assurance methods - Set of documents for
process planning-Economics of process planning- case studies
UNIT III INTRODUCTION TO COST ESTIMATION 9
Importance of costing and estimation –methods of costing-elements of cost

estimation –Types of estimates – Estimating procedure- Estimation labor
cost, material cost- allocation of over head charges- Calculation of
depreciation cost
UNIT IV PRODUCTION COST ESTIMATION 9
Estimation of Different Types of Jobs - Estimation of Forging Shop, Estimation

of Welding Shop, Estimation of Foundry Shop
UNIT V MACHINING TIME CALCULATION 9
Estimation of Machining Time - Importance of Machine Time Calculation-

Calculation of Machining Time for Different Lathe Operations ,Drilling and
Boring - Machining Time Calculation for Milling, Shaping and Planning -
Machining Time Calculation for Grinding.
TOTAL : 45 PERIODS
OBJECTIVE TYPE QUESTIONS
1. To convert “the product design into a product”, a manufacturing

plan is called as
A. Production Planning B. Process Planning
C. Manufacturing Planning D. All the above
2. The systematic determination of the engineering process and

systems to manufacturing a product is called as
A. Operation Planning B. Process Planning
C. Operational Research D. (A) & (B)
3. The process of determining the portable cost of the product

before the start of its manufacture is called as
A. Documentation B. Quality Assurance
C. Cost Estimation D. Process Planning
4. The operational Sheets is also called as

A. Route Sheet B. Instruction Sheet
C. Traveller D. All the above
5. The Manual Process planning approaches are

A. Work Book ApproachB. Traditional Approach
C. (A) & (B) D. Generative Approach
6. CAPP Approaches are categorizes as

A. Retrieval B. Variant
C. Generative D. All the above
7. With the use of computers in the process planning one can reduce
the routine clerical work of the manufacturing engineers is called as
A. CAPP B. Work Book
C. Generative D. Designing
8. The process plan created based on the decision logics and pre
coded algorithms is called as
A. CAPP B. Work Book
C. Generative D. Designing
9. Advantages of manual process planning

A. Suitable for small companies
B. Highly Flexible
C. Low Investment
D. all the above
10. Commercially available generative CAPP systems are
A. APPASB. CMPP
C. EXCAP & X PLAND. All the above
11. The first step in preparing the process plan for any component /
product is
A. Process PlanningB. Production Planning
C. Drawing InterpretationD. All the above
12. The main property requirements while selecting the
material in process planning
A. Mechanical B. Physical
C. Service Environment D. All the above
13. The important factors of process selection
A. Material FromB. Component size and Weight
C. Economic ConsiderationsD. All the above
14. The important factors to be considered during the selection of
production euipments
A. Component sizeB. Cost
C. Physical size of the machineD. (A) & (C)
15. The technical factors considered for machine selection
A. Batch SizeB. Availability
C. Physical Size of the work PieceD. Capacity
16. The “term tooling” in the manufacturing generally refers to
A. Machine accuracyB. Surface Finishing
C. Cutting tools & AccessoriesD. Cutting Force
17. How to calculate the Machine power required for each operation
A. Cutting Force * Cutting Speed
B. Cutting Force / Cutting Speed
C. Cutting Force + Cutting Speed
D. Cutting Force - Cutting Speed
18. Two important capability factors to be considered for tool
selection are:
A. Dimensional and geometric accuracy requiredB. Surface finish
specifications
C. Cutting Force & Cutting Speed
D. (A) & (B)
19. The machine Selection involves the following four stages in
sequential order. i) Operational analysis ii) first-cut selection iii)
Capability Analysis iv) Power or Force Analysis.
A. ii-iv-iii-i B. ii-iv-i-iii C. iv-i-iii-ii D. iv-i-ii-iii
20. Expand the terms MPS.
A. Master Production Schedule B. Material and Production Schedule
C. Manufacturing and Production Schedule D. Master Process Schedule

21. The cutting Speed also known as
A. Surface cutting speed B. surface speed
C. (A) & (B) D. None of the above
22. The unit for cutting speed

A. mpm B. rpm
C. rpsD. spm
23.The cutting speed for shaping, planning and slotting operations

A. S= (LN S)/ (1000C)B. S= ( 𝜋 DN)/ (1000)
C. S= (C NS)/ (1000L) D. S= ( 𝜋 DL)/ (1000)
24. Calculate the cutting speed for a shaping operation, if the

shaper is capable of 20strokes per minute over a stroke length of
1.5 meter, with a cutting time ratio of 3:2
A. 25 mpm B. 40 mpm
C. 50 mps D. 50 mpm
25. Feed rate is usually expressed in

A. mm/revB. mm/min
26. The purpose of jigs are

A. To locate the work pieceB. To clamp the work piece
C. To guide the tool. D. All the above
27. Drill jigs are used for

A. Drilling B. Chamfering
C. Counter sinking D. All the above
28. The statement who told “quality is fitness for use”

A. juran B. crospy
C. ISO D. Demming
29. Break even analysis is also known as

A. Cost- profit analysis B. volume- profit analysis
C. profit analysis D. Cost- volume- profit analysis
30. It is concerned with finding the point at which revenues and

cost are exactly equal. This point is also known as
A. Beak even pointB. No profit No loss point
C. None of the aboveD. (A) & (B)
31. profit-volume ratio is
A. contribution and profit B. contribution and loss
C. contribution and salesD. All the above
32. Break –even chart is graphical representation of the
relationship between
A. volume and revenue B. cost and volume
C. volume and profit D. Cost and revenue
33. The important process parameters to be calculated for each

operation during process planning
A. Cutting speed B. Feed rate
C. Depth of cut D. All the above
34. The relative speed between the tool and the work piece
35. The thickness of the layer of metal removed in one cut or pass,
measured in a direction perpendicular to the machined surface.
36. The speed at which the cutting tool penetrate the work piece
37. The work holding device which Locate and hold the work piece
for a specific operation is called as.
A. Fixture B. jig
38. The work holding device which only holds the work piece for a
specific operation is called as.
A. Fixture B. jig
39. The Basic elements of jigs and fixtures are

A. Clamping elements B. Locating elements
C. Tool guiding and setting elements D. All the above
40. Find the odd man out

A. Tapping fixture B. Plate Fixtures
C. Angle plate Fixtures D. Vice – jaw Fixtures
41. For a taper turning operation (D=60 mm, d=40 mm, spindle speed
=500rpm, Length of taper =25 mm) find the cutting speed.
A. 7.854 m/min B. A. 785.4 m/min
C. 78.54 m/minD. A. 7.847 m/min
42. The spindle speed required to turn a 60mm diameter SS
Shaft using a HSS Tool is 185.68 rpm. If a carbide tool is used
instead of HSS Tool then the spindle speed is 663.15rpm. find
the resulting percentage increase in the spindle speed .
A. 35.15% B. 3.57%
C. 35.75% D. 357.15%
43. The important process parameters to be calculated for each

operation during process planning
44. The relative speed between the tool and the work piece
45. The thickness of the layer of metal removed in one cut or pass,
measured in a direction perpendicular to the machined surface.
46. The speed at which the cutting tool penetrate the work piece
47. The work holding device which Locate and hold the work piece
for a specific operation is called as.
A. Fixture B. jig
C. (A) & (B)D. None of the above
48. The work holding device which only holds the work piece for a
specific operation is called as.
A. Fixture B. jig
49. The Basic elements of jigs and fixtures are

A. Clamping elements B. Locating elements
C. Tool guiding and setting elements D. All the above
50. Find the odd man out

A. Tapping fixture B. Plate Fixtures
C. Angle plate Fixtures D. Vice – jaw Fixtures
51. is the speed at which the metal is removed by the tool from
the work piece.
a) feed
b) cutting speed
c) depth of cut
d) none of the mentioned
52. Which of the following represents the formula for cutting speed? cs =cutting
speed, D= diameter of work, N= rpm.
a) cs = (3.14*D*N)
b) cs = (D*N)
c) cs = (3.14*D)/N
53. Which of the following represent the unit of cutting speed?

a) meter*minute
b) meter*meter*minute
c) meter / minute
54. is the distance the tool advances for each revolution of the work.
a) feed
b) depth of cut
c) metal removal rate
55. Which of the following is the unit of the feed?

a) mm / minute
b) mm / revolution
c) mm * minute
56. The depth of cut is the distance measured from the machined surface
to the surface of the work piece, which is uncut.
a) parallel
b) perpendicular
c) at 45 degree
57. Which of the following represents the formula for the depth of cut?
d1=diameter of work surface before machining and d2=diameter of the
machined surface
a) d1+d2
b) d1-d2
c) (d1+d2)/2
d) (d1-d2)/2
58. Which of the following represents the formula for metal removal rate?
a=cutting speed, b=depth of cut, c=feed, d=revolution
a) (a*b*d)/c
b) (a*b)/(c*d)
c) (a*b*c)/d
59. Which of the following represents the unit of metal removal rate?
a) mm/revolution
b) mm*mm/revolution
c) mm*mm*mm/revolution
60. Which of the following represents the unit for machining time?
a) mm / minute
b) minute / revolution
c) minute
View Answer
61. Which of the following represents the formula for the machining time?
s=feed of the job per revolution, l=length of the job, n=rpm.
a) l / (s*n)
b) (s*n) / l
c) (l*s) / n
View Answer
62. For general purposes, ratio of the depth of cut to the feed varies from
a) 10:1
b) 1:10
c) 100:1
d) 1:100
63. Table top drilling machine can be categorized as

a) general purpose drilling machine
b) specific purpose drilling machine
c) can’t say anything
64. Which type of feed can be given in table top drilling machine?
a) manual
b) power
c) both manual and power feed
65. Power produced by table top drilling machine is comparatively low.
a) true
b) false
66. In table top drilling machine, feed can be operated by

a) gear mechanism
b) lever
c) spindle
67. Generally, table top drilling machine can produce diameters up to

a) 1 mm
b) 10 mm
c) 100 mm
68. Table top drilling machine can be mounted on the table.

a) true
b) false
View Answer
69. Table top drilling machine is generally in terms of height.

a) small
b) big
70. In table top drilling machine, belt-pulley system operates

a) lever
b) spindle
c) both lever and spindle
71. Drill is mounted on lever in table top drilling machine.

a) true
b) false
View Answer
72. Which of the following is not true for table top drill machine?
a) it is used in only small jobs
b) it is used for mass production
c) odd shape jobs are not machined
73. Multi spindle drilling machine is used for lot production.

a) true
b) false
74. Multi spindle drilling machine can be categorized as
a) general purpose drilling machine
b) special purpose drilling machine
75. Multi spindle drilling machines can have spindles up to 10 to 12.

a) true
b) false
76. Which of the following is true for multi spindle drill machine?
a) it can’t make number of holes at different location and of different size
b) it is able to make number of holes at different location and of
different size
c) it can’t make number of holes at different location , but can make holes of
different size
d) it can make number of holes at different location , but can not make holes of
different size
View Answer
77. Multi spindle drill machines can produce holes of different

a) shapes
b) depth
c) both shapes and depth
78. In multi spindle drill, for each type of job separate jig should be used.
a) true
b) false
View Answer
79. Which of the following is the part of multi spindle drill machine?
a) motor
b) central gear
c) planetary gear
d) all of the mentioned
80. In multi spindle drill,the circular angular rotation, position and location of
the spindle can’t be changed.
a) true
b) false
81. In multi spindle drill, the drills are used at

a) same height
b) different height
82. The movement of entire head is little difficult and not economical in
this machine.
a) true
b) false
83. In shaper, the tool head consists of

a) tool post
b) tool slide
c) clamper box
84. The main parts of shaper are

a) base and body
b) ram and tool head
c) crossrail and body
85. The body of the shaper comprises of

a) pillar
b) column
c) frame
86. The base of the shaper is a heavy cast iron casting.

a) true
b) false
87. Which of the following part of shaper supports the entire load of the
machine?
a) base
b) crossrail
c) frame
88. The base of the shaper is not able to withstand the vibration.
a) true
b) false
89. Drive mechanism consists of

a) main drives
b) the gear box
c) quick return mechanism
90. Quick return mechanism is responsible for ram movement.
a) true
b) false
91. Quick return mechanismprovides guideways for

a) ram
b) crossrail
92. Saddle slides along the ram.

a) true
b) false
View Answer
93. Milling machine is a machine tool that removes the metal as the work is fed
against a rotating singlepoint cutter.
a) true
b) false
94. In milling machine, cutter rotates at high speed and removes metal at very
high speed.
a) true
b) false
95. Milling machine can hold cutters at a time.

a) only one
b) only two
c) only three
96. Which of the following machine is superior to other machines as regards

accuracy and better surface finish?
a) lathe
b) drill
c) shaper
d) milling
97. Milling machines find wide application in production work.

a) true
b) false
98. Which type of machining can be done by milling machine?

a) cutting keyways
b) slots and grooves
c) gears
99. Which of the following motion does a milling machine has?
a) vertical motion
b) crosswise motion
c) longitudinal motion
100. For milling, the work is fixed on a table which controls the feed against the
cutter.
a) true
b) false
101. Generally in workshop, column and knee type milling machine is used.
a) true
b) false
102. Milling machine is designed for manufacturing a variety of tool room work.
a) true
b) false
103. The various milling process may be classified in categories.

a) 1
b) 2
c) 3
104. Upmilling and downmilling are the subtype of milling process.

a) peripheral milling
b) face milling
c) both peripheral milling and face milling
d) none of the mentione
105. Which of the following milling is known as conventional milling?

a) upmilling
b) downmilling
c) both upmilling and downmilling
106. Which of the following process is also known as climb milling?

a) upmilling
b) downmilling
c) both upmilling and downmilling
107. The thickness of the chip in upmilling is at the beginning of the
cut.
a) minimum
b) maximum
c) zero
108. The thickness of the chip in upmilling is in when the cut

terminates.
a) minimum
b) maximum
c) zero
109. The upmilling operation is not safe.

a) true
b) false
110. Machine vibration isn’t there in upmilling process.

a) true
b) false
111. The cutting force is directed and this tends to lift the work from the
fixture in upmilling.
a) upward
b) downward
112. In upmilling, the surface milled appears to be slightly wavy.

a) true
b) false
113. The cutting action can be done from both sides of the table to finish the
job. This is the advantage of process.
a) upmilling
b) downmilling
114. Smooth cut can be obtained in downmilling process.

a) true
b) false
115. More depth of cut can be used in milling process.
a) upmilling
b) downmilling
116. In downmilling, clamping difficulty is not high.

a) true
b) false
117. Difficulty is experienced in pouring coolant just on the cutting edge from
where the chip begins. This is the disadvantage of process.
a) upmilling
b) downmilling
118. The work is pulled by cutter teeth and hence the job may get spoiled or
breakaway. This is the disadvantage of process.
a) upmilling
b) downmilling
119. As the cutter progress, the chip accumulate at the cutting zone, spoils the
work surfaces. This is the disadvantage of process.
a) upmilling
b) downmilling
120. Cutter teeth wears out soon as in the beginning itself the teeth comes in
contact with the hard surface of the workpiece. This is the disadvantage of
process.
a) upmilling
b) downmilling
121. The burr on the surface cleans during the cutting operation. This is the
advantage of process.
a) upmilling
b) downmilling
122. Downmilling is the process of removing metal by a cutter which is rotated
direction of the travel of the workpiece.
a) in the same
b) against the
123. The thickness of the chip is when the tooth begins its cut in
downmilling.
a) maximum
b) minimum
c) zero
d) can’t say anything
124. The thickness of the chip is when the cut terminates in

downmilling.
a) maximum
b) minimum
c) zero
d) can’t say anything
125. For downmilling, machines are used.

a) light
b) moderate
c) rigid
126. In downmilling, the machine must have fixed on it a backlash error

eliminator.
a) true
b) false
127. In downmilling, more springing actions are there in cutter.

a) true
b) false
128. Narrow slots can be milled in milling process.

a) upmilling
b) downmilling
129. Downmilling is easily used on flexible, thin and flat jobs.
a) true
b) false
130. In forging process, metals are shaped by

a) impact
b) cohesion
c) tense
131. Which method is considered as one of the oldest methods of giving

required shapes to the metals ?
a) casting
b) forging
c) forming
132. Smithy forging can also be termed as open die forging.

a) true
b) false
133. Which of the following is the example of impact pressure forging ?

a) striking a blow
b) shaping by press
c) all of the mentioned
134. Cold forging is also known as simply forging.

a) true
b) false
135. Which type of forging is done by deforming the metal at room

temperature?
a) cold forging
b) simply forging
c) hot forging
136. Hot forging is also known as simply forging.

a) true
b) false
137. The upset type of forging makes increment in the diameter of the
workpiece.
a) true
b) false
138. Which type of forging is done by blacksmith?
a) hand forging
b) machine forging
c) both hand forging and machine forging
139. For which purpose, hand forging is used?

a) maintenance work
b) production of small articles tools
c) repair work
140. In which forging process, parts are heated in open hearth?

a) machine forging
b) hand forging
c) both hand forging and machine forging
141. In which forging process, parts are heated in closed hearth?

a) machine forging
b) hand forging
c) hand forging and machine forging both
142. Press forgings are churlish in surface.

a) true
b) false
143. Roll forging is done with the help of

a) cylindrical rolls
b) semi-cylindrical roll
c) both cylindrical and semi cylindrical rolls
144. Cast iron is forgeable.

a) true
b) false
145. is the speed at which the metal is removed by the tool from the
work piece.
a) feed
b) cutting speed
c) depth of cut
146. Which of the following represents the formula for cutting speed? cs
=cutting speed, D= diameter of work, N= rpm.
a) cs = (3.14*D*N)
b) cs = (D*N)
c) cs = (3.14*D)/N
147. Which of the following represent the unit of cutting speed?

a) meter*minute
b) meter*meter*minute
c) meter / minute
148. is the distance the tool advances for each revolution of the work.
a) feed
b) depth of cut
c) metal removal rate
149. Which of the following is the unit of the feed?

a) mm / minute
b) mm / revolution
c) mm * minute
150. The depth of cut is the distance measured from the machined
surface to the surface of the work piece, which is uncut.
a) parallel
b) perpendicular
c) at 45 degree
151. Which of the following represents the formula for the depth of cut?
d1=diameter of work surface before machining and d2=diameter of the
machined surface
a) d1+d2
b) d1-d2
c) (d1+d2)/2
d) (d1-d2)/2
152. Which of the following represents the formula for metal removal rate?
a=cutting speed, b=depth of cut, c=feed, d=revolution
a) (a*b*d)/c
b) (a*b)/(c*d)
c) (a*b*c)/d
153. Which of the following represents the unit of metal removal rate?
a) mm/revolution
b) mm*mm/revolution
c) mm*mm*mm/revolution
154. Which of the following represents the unit for machining time?
a) mm / minute
b) minute / revolution
c) minute
155. Which of the following represents the formula for the machining time?
s=feed of the job per revolution, l=length of the job, n=rpm.
a) l / (s*n)
b) (s*n) / l
c) (l*s) / n
156. For general purposes, ratio of the depth of cut to the feed varies
from
a) 10:1
b) 1:10
c) 100:1
d) 1:100
157. Amount of time during which the transformer will be used for welding
under normal loading condition is known as?
a) Hold time
b) Off time
c) Weld time
d) Duty cycle
158. Amount of voltage required to generate the arc under no load condition is
called?
a) Open circuit voltage
b) Closed circuit voltage
c) Short circuit voltage
d) Arc voltage
159. Amount of current required to generate the arc under no load condition is
called?
a) Open circuit current
b) Closed circuit current
c) Short circuit current
d) Arc current
160. If the open circuit voltage is 60 volt and the short circuit current is 20
amperes. Then determine the voltage required for welding if the current
required during welding is 10 amperes?
a) 30 V
b) 60 V
c) 20 V
d) 40 V
161. How does the arc voltage V depends upon the length of arc L?
a) V = f(L)
b) V = 1/f(L)
c) V = f(L2)
d) V = f(√L)
162. What is the function of flux in submerged arc welding?

a) To completely cover the welded zone
b) To prevent oxidation of joint
c) To prevent spattering of molten metal
d) To prevent sticking of molten metal
163. In which of the following gas welding process a non-consumable electrode

is used?
a) Submerged arc welding
b) Tungsten inert gas welding
c) Stud welding
d) Gas metal arc welding
164. What is the only difference between Plasma arc welding and TIG welding?
a) Flux is not used
b) Construction of torch is different
c) Gas is not used
d) Tungsten electrode is not used
165. In plasma arc welding the gas is?

a) Ionized
b) Heated
c) Magnetized
d) Vaporized
166. If the heat transfer efficiency is 0.5 and the melting efficiency is 0.6, then
the overall efficiency will be?
a) 0.83
b) 0.03
c) 0.30
d) 0.12
167. The deflection of the arc in arc blow is by?

a) Electric field
b) Magnetic field
c) Combination of both
d) Hydrostatic field
168. If the total efficiency is 0.35 in arc welding. Then what is the welding
speed in mm/sec if the cross-sectional area is 5mm2, welding power is 2 kW
and the heat required in melting the metal is 100 J/mm3.
a) 1.4
b) 14
c) 1400
d) 140
169. Which of the following gas welding process uses constant voltage?
a) Submerged arc welding
b) Tungsten inert gas welding
c) Stud welding
d) Gas metal arc welding
170. Which of the following inert gas is used with DC power supply only?
a) Argon
b) Helium
c) CO2
d) Nitrogen
171. In order to prevent oxidation and retain molten metal in stud welding
which of the following is used?
a) Ceramic rings
b) Metal rings
c) Non-metal rings
d) Flux
172. Jigs and Fixtures are used for
(A) Mass production
(B) Identical parts production
(C) Both ‘A’ and ‘B’
(D) None of the above

173- The use of jigs and fixtures
(A) Facilitates deployment of less skilled labour for production
(B) Eliminates pre-machining operations like marking, measuring, laying out

etc.
(C) reduced manual handling operations
(D) All of the above
174- The following is(are) the function(s) of a jig
(A) Holding
(B) Locating
(C) Guiding
175-A fixture does not
(A) Holds the workpiece
(B) Locate the workpiece
(C) Guide the tool
176- Jigs are not used in
(A) Drilling
(B) Reaming
(C) Tapping
(D) Milling
177- Fixtures are used in
(A) Milling
(B) Shaping
(C) Turning
178- Principle of states that “In order to achieve the maximum

accuracy in location the locating points should, therefore, be placed as
far apart from one another as it is possible”.
(A) Six point location
(B) Least points
(C) Extreme positions
(D) Mutually perpendicular planes
179- The following holds the workpiece securely in a jig or fixture

against the cutting forces
(A) Locating device
(B) Clamping device
(C) Guiding device
(D) Indexing device
180- The following is a quick acting clamp
(A) Hinged clamp
(B) Cam operated clamp
(C) Bridge clamp
(D) Edge clamp

181- The following material is commonly used for making locating and
clamping devices
(A) High carbon steel
(B) Low carbon steel
(C) High speed steel
(D) Die steel
182- The following type of jig is used for machining in more than one
plane
(A) Template jig
(B) Plate type jig
C) Open type jig
(D) Box type jig
183- The following type of jig suits best for drilling of holes in hollow
cylindrical components, with relatively smaller outside and inside
diameters, such as bushes
(A) Solid type jig
(B) Pot type jig
(C) Box type jig
(D) Open type jig
184- The following type of jig is used to drill a series of equidistant hole
along a circle
(A) Index jig
(B) Plate type jig
(C) Open type jig
(D) Pot type jig

185- This type of jig is employed on multi-spindle machines
(A) Index jig
(B) Universal jig
(C) Open type jig
(D) Multi-station jig
186- The following jig can be used for several different work pieces and
operations
(A) Template jig
(B) Multi-station jig
(C) Index jig
(D) Universal jig
187- The following is(are) the advantage(s) of cast jigs or fixtures
(A) No heat treatments are required for the cast jigs and fixtures
(B) It prevents the occurrence of tool chatter in milling
(C) if cast jigs or fixture drops down, they don’t get misaligned or de-shaped,
although it may break
188- The jigs and fixtures can be constructed through
(A) Casting
(B) Fabrication
(C) Welding
188. With the use of Jigs and fixture total cost of production
a) Increases
b) Decreases
c) Remains same
d) Jigs are not used in any production process
189. With the use of Jigs and fixture rate of production will
a) Increase
b) Decrease
c) Remains same
d) Jigs are not used in any production process
189. Jigs and fixture increases the accuracy of the parts.

a) True
b) False
190. Jigs And fixture are used to provide interchangeability.

a) True
b) False
191. With the use of Jigs and fixture quality control expenses will
a) Reduce
b) Increases
c) Jigs and fixture are not used in any production process
d) None of the mentioned
192. With the use of Jigs and fixture

a) Labour cost decreases
b) Labour cost increases
c) Labour cost decreases
193. Which of the following is not correct about fixture?

a) It is used to hold the work
b) It is used to position the work the work
c) It assures high accuracy of parts
d) It is used to guide the cutting tool
194. Which of the following is not correct about jig?

a) It is used to hold the work
b) It is used to position the work the work
c) It is used to guide the cutting tool
195. In which of the following operation jigs are preferred over fixture?
a) Drilling
b) Turning
c) Milling
d) Grinding
196. Number of degree of freedom of a workpiece in space is equal to
a) 10
b) 12
c) 14
d) 16
197. The basic difference between MRP and MRP-II is:

a) inventory
b) bom
c) finance
d) capacity planning
198. Inventory record file gives the following information

a) lot size
b) machine details
c) customer name
199. Bill of material structure is used to

a) calculate net requirements
b) calculate due dates
c) calculate man power requirements
200. Just in time manufacturing philosophy emphasizes on

a) man power
b) manufacturing
c) profit
d) inventory
201. Forecasting is used for

a) dependent demand items
b) independent demand items
202. CRP takes material requirements from MRP and converts to

a) standard hours of man power
b) standard hours of machine
c) standard hours of load
203. Capacity planning is concerned with

a) how many machines required
b) how much labour required
204. MRP-II system is called a closed loop system because it considers
a) inventory
b) finance
c) man power
205. P.M.T.S( Predetermined Motion Time System) include

a) M.T.M (Method Time Measurement)
b) W.F.S (Work Factor Systems)
c) B.M.T.S (Basic Motion Time Study)
d) All of the mentioned
206. M.T.M is used to

a) improve existing methods
b) establish time standards
c) develop effective methods in advance of the beginning of production
207. For a small scale industry, the fixed cost per month is Rs. 5000. The
variable cost per product is Rs. 20 and sales price is Rs. 30 per piece. The
break even production per month will be
a) 300
b) 40
c) 500
d) 1000
208. Two alternatives can produce a product. First has a fixed cost of Rs. 2000
and a variable cost of Rs. 20 per piece. The second method has a fixed cost of
Rs. 1500 and a variable cost of Rs.30. The break even quantity between the
two alternatives is
a) 25
b) 50
c) 75
d) 100
209. Which of the following data is not required to prepare an estimate?

a) Amplitude
b) Drawings
c) Specifications
d) Rates
210. Estimating is the technique of calculating the various quantities and is

needed for controlling the expenditure during the execution of the work.
a) True
b) False
211. The process of working out the cost per unit of each item is known as
a) Work
b) Sheet
c) Data
d) Analysis
212. While fixing rate per unit of an item, the quantity of materials and labour
needed for one unit of an item are strictly per
a) Special Data Book
b) Standard Data Book
c) Special Data Record
d) Specific Data Record
213. In the case of works which require some special types of equipment, an
amount of percent of the estimated cost is given.
a) 1-2
b) 5-9
c) 12-18
d) 16-20
214. Which of the following is not a method used for preparing approximate
estimates?
a) Cubical contents method
b) Unit base method
c) Plinth area method
d) Cylindrical base method
215. In the plinth area method, the cost of construction is computed by the
multiplication of
a) Plinth length and rate
b) Plinth breadth and rate
c) Plinth area and plinth area rate
d) Plinth volume and plinth length rate
216. As per IS 3861-1966, which of the following areas should not be included
while calculating the plinth area of a building?
a) Porches of non-cantilever type
b) Area of barsati at terrace level
c) Area of walls at floor level
d) Area of lofts
217. For the preparation of approximate estimates, cubical contents method is

more accurate than the unit base method and plinth area method.
a) True
b) False
218. In the cubical contents method, the cost of a structure is computed by the
multiplication of total cubic contents and
a) Area of building
b) Volume of building
c) Local cubic rate
d) Length of building
219. Scope of automation in foundry process is

a) Low
b) High
c) Minimum
d) Maximum
220. Which of the following is an advantage of the Green sand molding process
used in a foundry?
a) Appropriate for long production run
b) Very low cost process
c) Sand is reusable
d) All of the mentioned
221. The castings in formed in foundry produced are accurate in dimensions.

a) True
b) False
222. The energy consumption is a drawback of the foundry.

a) High
b) Optimum
c) Intensive
d) Low
223. Majority parts in transportation vehicles are made by the foundry

processes.
a) True
b) False
224. defects in castings cannot be identified easily.

a) Internal
b) External
c) Chemical
d) Metallic
225. Castings are usually designed for distribution of loads.

a) Equal
b) Unequal
c) Maximum
d) Minimum
226. The directional properties are imparted to the castings made in
foundries.
a) Single
b) Double
c) Spherical
d) Multiple
227. In the foundry, the metal joining process is employed.

a) True
b) False
228. Foundry process is used to make intricate parts.

a) True
b) False
`
229. Which of the following are the cutting parameters used in drill?
a) cutting speed
b) feed
c) depth of cut
230. Which of the following is considered as the peripheral speed of the drill?
a) cutting speed
b) feed
c) depth of cut
231. Cutting speed generally express in

a) meter
b) meter/minute
c) meter*minute
232. Formula for cutting speed is

d=diameter of drill in mm, n=rpm of drill.
a) (d*n)/1000
b) (3.14*d*n)/1000
c) 3.14*d*n
233. The of a drill is the distance the drill moves into the work at each
revolution of the spindle.
a) depth of cut
b) feed
c) cutting speed
234. The feed may be expressed in
a) mm/revolution
b) mm*revolution
c) mm
235. is equal to half the diameter of the drill used.

a) feed
b) depth of cut
c) machining time
236. Depth of cut can be expressed in

a) mm
b) mm/revolution
c) mm/minute
237. The formula for depth of cut is

d=diameter of the drill.
a) d/4
b) d/2
c) d
d) 2d
238. If s2=feed per revolution, s1=feed per minute, n=rpm.

Which of the following is mathematically right?
a) s1=s2*n
b) s2=s1*n
c) s1*s2=n
239. Machining time is expressed in

a) mm/minute
b) minute*minute
c) minute
240. If l=length of travel of the drill in mm, n=rpm of the drill, s= feed per
revolution of the drill in mm. Then machining time can be given as
a) (l*n)/s
b) (l*s)/n
c) l/(n*s)
241. Metal removal rate can be given as
a) (mm*mm*mm)/min
b) (mm*mm*m)/revolution
c) mm/revolution
d) mm/minute
242. Shaping can be performed more effectively by milling machine.

a) horizontal
b) vertical
243. surfacing can be performed more effectively by milling machine.

a) horizontal
b) vertical
244. Form cutting can be performed more effectively by milling

machine.
a) horizontal
b) vertical
245. Slab milling can be performed more effectively by milling

machine.
a) horizontal
b) vertical
246. Drilling can be performed more effectively by milling machine.

a) horizontal
b) vertical
247. Boring can be performed more effectively by milling machine.

a) horizontal
b) vertical
248. Dovetailing can be performed more effectively by milling machine.

a) horizontal
b) vertical
249. Straddle milling can be performed more effectively by milling
machine.
a) horizontal
b) vertical
250. Angular milling can be performed more effectively by milling

machine.
a) horizontal
b) vertical
251. Cutting T-slots can be performed more effectively by milling

machine.
a) horizontal
b) vertical
252. Slotting can be performed more effectively by milling machine.

a) horizontal
b) vertical
c) both horizontal and vertical

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ME8793 L T P C 3 0 03

PROCESS PLANNING AND COST ESTIMATION

UNIT I INTRODUCTION TO PROCESS PLANNING 9

Introduction- methods of process planning-Drawing interpretation-Material

UNIT II PROCESS PLANNING ACTIVITIES 9

Process parameters calculation for various production processes-Selection jigs

UNIT III INTRODUCTION TO COST ESTIMATION 9

Importance of costing and estimation –methods of costing-elements of cost

UNIT IV PRODUCTION COST ESTIMATION 9

Estimation of Different Types of Jobs - Estimation of Forging Shop, Estimation

UNIT V MACHINING TIME CALCULATION 9

Estimation of Machining Time - Importance of Machine Time Calculation-

1. To convert “the product design into a product”, a manufacturing

2. The systematic determination of the engineering process and

3. The process of determining the portable cost of the product

4. The operational Sheets is also called as

5. The Manual Process planning approaches are

6. CAPP Approaches are categorizes as

9. Advantages of manual process planning

A. ii-iv-iii-i B. ii-iv-i-iii C. iv-i-iii-ii D. iv-i-ii-iii

20. Expand the terms MPS.

A. Master Production Schedule B. Material and Production Schedule

C. Manufacturing and Production Schedule D. Master Process Schedule

22. The unit for cutting speed

23.The cutting speed for shaping, planning and slotting operations

24. Calculate the cutting speed for a shaping operation, if the

25. Feed rate is usually expressed in

26. The purpose of jigs are

27. Drill jigs are used for

28. The statement who told “quality is fitness for use”

29. Break even analysis is also known as

30. It is concerned with finding the point at which revenues and

33. The important process parameters to be calculated for each

39. The Basic elements of jigs and fixtures are

40. Find the odd man out

43. The important process parameters to be calculated for each

49. The Basic elements of jigs and fixtures are

50. Find the odd man out

53. Which of the following represent the unit of cutting speed?

55. Which of the following is the unit of the feed?

63. Table top drilling machine can be categorized as

66. In table top drilling machine, feed can be operated by

67. Generally, table top drilling machine can produce diameters up to

68. Table top drilling machine can be mounted on the table.

69. Table top drilling machine is generally in terms of height.

70. In table top drilling machine, belt-pulley system operates

71. Drill is mounted on lever in table top drilling machine.

73. Multi spindle drilling machine is used for lot production.

75. Multi spindle drilling machines can have spindles up to 10 to 12.

77. Multi spindle drill machines can produce holes of different

81. In multi spindle drill, the drills are used at

83. In shaper, the tool head consists of

84. The main parts of shaper are

85. The body of the shaper comprises of

86. The base of the shaper is a heavy cast iron casting.

89. Drive mechanism consists of

91. Quick return mechanismprovides guideways for

92. Saddle slides along the ram.

95. Milling machine can hold cutters at a time.