UNIT-I

(WORKSTUDY AND ERGONOMICS)

Part-A (2 Marks)
1. What is !a"t #$ W%rk St&'$(
Work Study is the systematic examination of the methods of carrying out activities
such as to improve the effective use of resources and to set up standards of
performance for the activities carried out.
2 What is !a"t #$ M!th%' St&'$(
Method Study is the systematic recording and critical examination of ways of doing
things in order to make improvements.
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3 What is Pr%)!ss Charts(
Graphical representation of the seuence of steps or tasks !workflow" constituting a
process# from raw materials through to the finished product. $t serves as a tool for
examining the process in detail to identify areas of possi%le improvements. &lso
called process map.
' What is SIMO Charts(
& %asic motion(time chart used to show the simultaneous nature of motions)
commonly a ther%lig chart for two(hand work with motion sym%ols plotted
vertically with respect to time# showing the ther%lig a%%reviation and a %rief
description for each activity# and individual times values and %ody(mem%er detail.
&lso known as simultaneous motion(cycle chart.
* What is &*ti+*! a)ti,it$ )harts(
Multiple &ctivity +harts !or Multi(&ctivity +harts" are a very useful tool for
understanding the flow of work in a cyclical process and as a conseuence
understanding which resource is controlling the overall progress of the work. ,he
tool can %e used to model different scenarios to determine the optimum mix of
resources for the work. ,he example %elow is %ased on using a tower crane to lift
concrete from the street to a high floor for placing. -ach resource is represented %y
a column) time is on the vertical axis.
. What ar! th!r#*i-s(
,he ther%lig is used in the study of motion economy in the workplace. & workplace
task is analy/ed %y recording each of the ther%lig units for a process# with the
results used for optimi/ation of manual la%or %y eliminating unneeded movements.
,he word therblig was the creation of 0rank 1unker Gil%reth and 2illian Moller
Gil%reth# &merican industrial psychologists who invented the field of time and
motion study. $t is a reversal of the word Gilbreth# with 3th3 treated as one letter.
4 What is tra,!* )hart(
& Travel Chart is a simple ta%le that is useful where there are multiple !and
possi%ly irregular" movement %etween places. $t is a variation on the +heck Sheet#
indicating movements from and to any com%ination of a given set of locations.
5 What is !a"t #$ .%rk !as&r!!"t(
&pplication of time and motion study and activity sampling techniues to determine
the time for a ualified worker to complete a specific 6o% at a defined level of
performance. Work measurement is used in %udgeting# manpower planning#
scheduling# standard costing# and in designing worker incentive schemes. See also
ther%lig.
7 What is a**%.a")!(
1. & sum set aside for an occurrence that may or may not come to pass. 0or
example# funds earmarked for expenses associated with potential %ad weather.
2. 0unds allocated periodically for a stated purpose# such as a per diem.
3. & discount# especially one offered as a result of specific circumstances.
2
18 What is !a"t #$ !r-%"%i)s(
9efinition: -rgonomics is the science of work. -rgonomics derives from two Greek
words: ergon# meaning work# and nomoi# meaning natural laws. +om%ined they
create a word that means the science of work and a person;s relationship to that
work.
UNIT-II
(PROCESS P/ANNING)
Part-A (2 Marks)
1 What is !a"t #$ +r%)!ss +*a""i"-(
& process is something in which the forms of material undergo some changes %y
doing some manual or mechanical work. 2ots of steps are involved under a
process. <rocess planning can %e defined as a planning of facts of a process %efore
starting that process.
2
What ar! th! 0a)t%rs a00!)t +r%)!ss +*a""i"-(
,he three classic factors that affect the planning process in %usiness are inputs#
processes and outcomes. $nputs are raw materials# resources# knowledge and
anything else %rought to the planning process. <rocesses are what you do to the
inputs to create outcomes. =utcomes are partly profits# %ut also 6o%s created for
employees# and the use and pleasure that consumers receive from finished
products or services.
3 What ar! th! r!as%"s 0%r +r%)!ss '%)&!"tati%"(
& process consists of inputs and outputs that are created and used to produce
significant outcomes. +ompanies rely on processes %ecause they %ring value and
cohesiveness. >ou will find different types of processes in the marketplace#
including management# support# and operations. =ne of the methods you want to
apply when it comes to documenting a process is identifying and interviewing the
right individuals or groups.
' Stat! th! -!"!ra* a++r%a)h!s t% +r%)!ss +*a""i"-(
<rocess planning is a key element in pro6ect management that focuses on selecting
resources for use in the execution and completion of a pro6ect. $n a manufacturing
setting# this aspect of planning also includes esta%lishing the general seuence of
steps that %egin with the acuisition of materials and end with the creation of a
finished product. <rocess planning is often closely associated with pro6ect
planning# although the specific functions of each tool are used differently in the
overall strategic planning.
* What is CAPP(
C%+&t!r-ai'!' +r%)!ss +*a""i"- !CAPP" is the use of computer technology to
aid in the process planning of a part or product# in manufacturing. +&<< is the link
%etween +&9 and +&M in that it provides for the planning of the process to %e
used in producing a designed part.
3
. What ar! th! a',a"ta-!s %0 CAPP(
$nvestment in hardware and software is not much.
,he system offers a shorter development time and lower manpower
consumption to develop process plan.
,he system is very relia%le and reasona%le in real production
environments for small and medium si/e companies.
?uality of process plan depends on knowledge and %ackground of process
planner.
4 What is 1*%. Chart(
& 0*%.)hart is a type of diagram that represents an algorithm or process# showing
the steps as %oxes of various kinds# and their order %y connecting these with
arrows. ,his diagrammatic representation can give a step(%y(step solution to a
given pro%lem. <rocess operations are represented in these %oxes# and arrows
connecting them represent flow of control. 9ata flows are not typically represented
in a flowchart# in contrast with data flow diagrams) rather# they are implied %y the
seuencing of operations. 0lowcharts are used in analy/ing# designing#
documenting or managing a process or program in various fields.
5 What ar! th! 'isa',a"ta-!s %0 0*%. )harts(
+omplex logic: Sometimes# the program logic is uite complicated. $n that
case# flowchart %ecomes complex and clumsy.
&lterations and Modifications: $f alterations are reuired the flowchart may
reuire re(drawing completely.
@eproduction: &s the flowchart sym%ols cannot %e typed# reproduction of
flowchart %ecomes a pro%lem.
,he essentials of what is done can easily %e lost in the technical details of how
it is done.
7 What is '!)isi%" ta#*!(
& decision ta%le is a ta%le composed of rows and columns# separated into four
separate uadrants.
+onditions +ondition &lternatives
&ctions &ction -ntries
,he upper left uadrant contains the conditions. ,he upper right uadrant contains
the condition rules ofr alternatives. ,he lower left uadrant contains the actions to
%e taken and the lower right uadrant contains the action rules.
18 Stat! th! #!"!0its %0 '!)isi%" ta#*!(
-asy to understand
Map nicely to a set of %usiness rules
&pplied to real pro%lems
Make no prior assumptions a%out the data
&%le to process %oth numerical and categorical data
'
UNIT-III
(INTRODUCTION TO COST ESTIMATION)
Part-A (2 Marks)
1 D!0i"! C%st Estiati%"
&n approximation of the pro%a%le cost of a product# program# or pro6ect#
computed on the %asis of availa%le information. 0our common types of cost
estimates are: !1" <lanning estimate: a rough approximation of cost within a
reasona%le range of values# prepared for information purposes only. &lso called
%all park estimate. !2" 1udget estimate: an approximation %ased on well(defined
!%ut preliminary" cost data and esta%lished ground rules. !3" 0irm estimate: a
figure %ased on cost data sound enough for entering into a %inding contract. !'"
Aot(to(exceed BAot(less(than estimate: the maximum or minimum amount
reuired to accomplish a given task# %ased on a firm cost estimate.
2 What ar! th! t$+!s %0 Estiati%"(
=rder of Magnitude -stimate
Suare 0oot and +u%ic 0oot -stimates
&ssem%lies !or Systems" -stimate
Cnit <rice -stimate
3 What ar! th! !th%'s %0 Estiati%"(
-stimation methods %roadly follow evaluation designs# with the determination of
the counterfactual %eing the core of the evaluation design. 9ifferent ways to
esta%lish controls under different evaluation designs determine the methods to %e
used to measure the counterfactual:
' Stat! th! i+%rta")! %0 r!a*isti) !stiat!s.
-ffective pro6ect managers cultivate the courage and competency to push %ack
against ar%itrary %udgets and deadlines to negotiate realistic win(win cost and
schedule estimates for their pro6ects. ,his article explores how to negotiate
realistic estimates to set realistic expectations.
* What is '!si-" )%st(
9esign(to(cost is a strategic management commitment to invest in the present for
a significantly greater reward in the future. 9esign(to(cost is one of the strongest
levers in the cost improvement tool%ox.
9esign(to(cost simply means designing a product from scratch to meet the Dtarget
costE or the market price which customers are willing to pay# for a particular !or
specified" level of functionality and uality# while returning a profit to the
enterprise.
. What is *a#%&r )%st(
,he cost of wages paid to workers during an accounting period on daily# weekly#
*
monthly# or 6o% %asis# plus payroll and related taxes and %enefits.
4 What '% $%& !a" #$ %,!rh!a' )%st(
,he ongoing administrative expenses of a %usiness which cannot %e attri%uted to
any specific %usiness activity# %ut are still necessary for the %usiness to function.
-xamples include rent# utilities# and insurance.
5 D!0i"! )%sti"-.
System of computing cost of production or of running a %usiness# %y allocating
expenditure to various stages of production or to different operations of a firm.
7 What ar! th! !th%'s %0 )%sti"-(
&s per the nature and peculiarities of the %usiness# different $ndustries follow
different methods to find out the cost of their product. ,here are different
principles and procedure for doing the costing. Fowever the %asic principle and
procedure of costing remain the same. Some of the methods are mentioned %elow:
1. Cnit +osting
2. Go% +osting
3. +ontract +osting
'. 1atch +osting
*. =perating +osting
.. <rocess +osting.
4. Multiple +osting
5. Cniform +osting.
UNIT-I2
(COST ESTIMATION)
Part-A (2 Marks)
1 What ar! th! !*!!"ts %0 )%st(
,here are %roadly three elements of cost ( !1" material# !2" la%our and !3"
expenses.:
,he su%stance from which the product is made is known as material. $t may
%e in a raw state(raw material# e.g.# tim%er for furniture and leather for shoe#
etc. $t may 6 also %e in manufactured state(components# e.g.# %attery for car#
speaker for radio# etc# Materials can %e direct and indirect.
2 What ar! th! t$+!s %0 )%st(
,he different types of costs:
opportunity cost
accounting cost or historical costs
transaction cost
sunk cost
marginal cost
3 What is !a"t #$ 'ir!)t at!ria*(
&ll items such as raw materials# standard and speciali/ed parts# and su%(
assem%lies reuired to assem%le or manufacture a complete product. 9irect
.
material costs are assigna%le to a specific product# cost center# or work
order.
' What ar! th! t$+!s %0 'ir!)t at!ria*(
Manufacturing a product needs input of raw materials. @aw materials are
main component of the product. ,here are two types of materials.
1. Direct Materials
,he materials reuired for producing a product are called direct materials.
9irect materials are also known as raw materials or input materials. 9irect
raw materials constitute the main component or part of a finished product. $t
is identified in terms of cost per unit of output. Wood for furniture industry#
sugarcane for sugar mills. textile for garment industry are some of the
examples of direct materials.
2. Indirect Materials
,he materials that can not %e form as the main part of a finished product are
called indirect materials. ,herefore# such materials can not %e easily
identified with the product. Aails used in furniture industry and threads used
in garment industry are some example of indirect materials.
* Stat! s%! !3a+*!s 0%r 'ir!)t at!ria*.
0rom the perspective of a manufacturer# 9irect Material is any o%6ect that
will %ecome part of the product that is sold to the end customer. $ndirect
Material is considered and o%6ect that is used in the creation of your end
product %ut does not %ecome part of the end product. 0or example an Hair
toolH used to assem%le a car is indirect material. & H%earingH used to
maintain a conveyor system is considered an indirect material. While a Hgas
pedalH that leaves the dealership with a car# for example# is direct material.
. What is !a"t #$ i"'ir!)t at!ria*(
+onsuma%les !such as cleaning chemicals# disposa%le tools# protective
devices" not used as raw materials# %ut which make the production of a
good or service possi%le# more efficient# or safer. $ndirect material costs are
not readily identifia%le with a specific product or 6o%. ,hey are termed
indirect costs and are charged to overhead accounts.
4 Wh% ar! )a**!' 'ir!)t *a#%&r(
Workers such as those who operate machines# who are directly involved in
the production of goods or services# rather than those involved in organi/ing
or managing the cost of employing workers to make a particular product or
provide a particular service. ,his does not include other costs such as the
amount spent on materials etc in 1ritain# workers who are employed
directly %y an organi/ation such as a local government authority# rather than
%eing employed through a separate company.

5 Stat! s%! !3a+*!s 0%r 'ir!)t *a#%&r(
H9irect la%orH refers to the work done %y those employees who actually
make the product on the production line. !H$ndirect la%orH is work done %y
4
employees who work in the production area# %ut do not work on the
production line. -xamples include employees who set up or maintain the
euipment."
Cnlike direct materials !which are o%tained prior to %eing used" direct la%or
is o%tained and used at the same time. ,his means that for any given good
output# we can compute the direct la%or rate variance# the direct la%or
efficiency variance# and the standard direct la%or cost at the same time.
7 Wh% ar! )a**!' i"'ir!)t *a#%&r(
Wages paid to the indirect la%orer is called indirect la%or cost# or indirect
wages# or unproductive wages. ,hese la%orers are not directly engaged in
manufacturing of goods or services. ,hey are engaged generally in office I
maintenance activities# selling I distri%ution of goods I services. -xample
of indirect la%or are wages or salary paid to the office peon# clerk# watch
man# store keeper etc.
18 What is !a"t #$ 0a)t%r$ %" )%st(
,otal cost of making a product at the production location# and comprising of
raw material# la%or# and overhead costs.
UNIT-2
(PRODUCTION COST ESTIMATION)
Part-A (2 Marks)
1
D!0i"! 0%r-i"-.
& process of working metal to a finished shape %y hammering or pressing and
is primarily a HhotH operation. $t is applied to the production of shapes either
impossi%le or too costly to make %y other methods or needing properties not
o%taina%le %y casting. +ategories of forgings include Fammer# <ress# 9rop or
Stamping.
2
Di00!r!"tiat! h%t 0%r-i"- a"' )%*' 0%r-i"-.
Fot forging is defined as working a metal a%ove its recrystalli/ation
temperature. ,he main advantage of hot forging is that as the metal is
deformed the strain(hardening effects are negated %y the recrystalli/ation
process.
+old forging is defined as working a metal %elow its recrystalli/ation
temperature# %ut usually around room temperature. $f the temperature is a%ove
8.3 times the melting temperature !on an a%solute scale" then it ualifies as
warm forging.
3 C%"trast sith 0%r-i"- a"' 'r%+ 0%r-i"-.
0orging worked %etween flat or simple contour dies %y repeated strokes and
manipulation of the workpiece. &lso known as HhandH or Hflat die H
forging.Feavy workpieces could %e processed using a smith(forging hammer#
and smaller forgings are die formed in drop hammers. Smith forging hammers
5
are typically steam or air(operated# consisting of a power actuated ram
supported %y a heavy cast iron frame. ,he final product is a result of the ram
%eing powered into the dies containing the workpiece.
&n operation in which a metal shape is formed %y forcing hot metal into
impressions formed in solid %locks of hardened alloy steel# the forging dies.
,he dies are made in halves# one attached to the rising and falling %lock of the
drop forge and the other to the stationary anvil. 9rop forgings are widely used
in the automotive industry for crankshafts# stu%(axles# gears# etc.
' I" .hat .a$s4 +r!ss 0%r-i"- a"' &+s!t 0%r-i"- ar! 'i00!r!"t(
<ress forging works %y slowly applying a continuous pressure or force# which
differs from the near(instantaneous impact of drop(hammer forging. ,he
amount of time the dies are in contact with the workpiece is measured in
seconds !as compared to the milliseconds of drop(hammer forges". ,he press
forging operation can %e done either cold or hot.
Cpset forging increases the diameter of the workpiece %y compressing its
length. 1ased on num%er of pieces produced this is the most widely used
forging process. & few examples of common parts produced using the upset
forging process are engine valves# couplings# %olts# screws# and other fasteners.
* D!0i"! a" h%&r a"' a)hi"! h%&r rat!.
&s the name indicates# this method is simply a com%ination of man(hour rate
and machine(hourrate methods. ,he man(hour rate method is suita%le only where work is
done %y hand# for example#in fitting and assem%ly shops etc. Similarly# machine hour rate
method is suita%le where almost allthe work is done %y machines. ,hus# in this way# %oth the
methods can %e applied in one factory.,his method is com%ination of man(hour and
machine(hour rate method of allocation.
. What is &"it rat!(
& rate is a ratio that is used to compare different kinds of uantities. &
unit rate descri%es how many units of the first type of uantity
corresponds to one unit of the second type of uantity. Some common
unit rates are miles !or kilometers" per hour# cost per item# earnings per
week# etc. $n each case the first uantity is related to 1 unit of the
second uantity.
4 What is s)a*! *%ss(
Scale loss is not normal for goldfish. ,hey do not molt. Most often scale loss is
the result of physical in6ury J %anging against hard o%6ects in the tank
!especially during %reeding season" or rough handling. $t may also result from
skin infections# %ut in this latter instance clear signs of skin deterioration#
%leeding and so on are o%vious.
5 What ar! th! t$+!s %0 .!*'i"-(
1. ,ig welding
2. Shielded metal arc welding also known as 6ust plain arc welding or stick
7
welding
3 Mig welding
7 What is th! +att!r"(
& +att!r"# from the 0rench patron# is a type of theme of recurring events or
o%6ects# sometimes referred to as elements of a set of o%6ects. ,he elements of
a pattern repeat in a predicta%le manner. <atterns can %e %ased on a template or
model which generates pattern elements# especially if the elements have
enough in common for the underlying pattern to %e inferred# in which case the
things are said to exhibit the uniue pattern.
18 What is shri"ka-! a**%.a")!(
& shrinkage allowance for metal casting is something that must %e figured into
a design from the very %eginning. &s the molten metal cools and solidifies it
will %egin to contract. ,his means that although the molten metal completely
filled up a mold# %y the time the casting was cold# the casting is smaller than
the mold.
18