Production and Quality Management(PQM) - Unit 1 PPT - Chapter 3 : Topic Process Selection - Diploma 4th Semester - Mechanical Engineering - N Scheme - 4020440 020-Diploma in Mechanical Engineering - 4020440- IV Semester - Production and Quality Management - Unit 1 PPT - Process Selection Prepared By… U. ARAVIND, B.E., M.I.S.T.E., LECTURER / MECHANICAL ENGINEERING LAKSHMI AMMAL POLYTECHNIC COLLEGE K.R. NAGAR, KOVILPATTI - 628 503 THOOTHUKUDI DISTRICT, TAMIL NADU Mobile No: 9943244068 Email Id: aravindulaganathanmech@gmail.com aravindmech@lapc.in

1. U.Aravind, Lecturer, Department of Mechanical Engineering, Lakshmi Ammal Polytechnic College, Kovilpatti.
UNIT 1 : PROCESS PLANNING AND SELECTION
4020440 PRODUCTION AND QUALITY
MANAGEMENT
உற்பத்தி மற்றும் தர மமலாண்மம
PROCESS SELECTION (செயல்முமை
சதரிவு செய்தல் )

2. Topics
Introduction
1/7 U.Aravind, Lecturer, Department of Mechanical Engineering, Lakshmi Ammal Polytechnic College, Kovilpatti.
Unit 1: Process
Planning and
Selection
1.Production
2.Process
Planning
3. Process
Selection

3. Introduction
Process Selection
1/7 U.Aravind, Lecturer, Department of Mechanical Engineering, Lakshmi Ammal Polytechnic College, Kovilpatti.

4. Classification
of
manufacturing
processes
Forming from
Liquid
Casting,
Moulding
Forming from Solid
by Deformation
Hot working
Cold Working
Forming from
powder
Forming from
solid by material
removal
Forming by
joining parts
Forming by
Assembly
Forming by
Material Addition

5. Process Selection
1/7 U.Aravind, Lecturer, Department of Mechanical Engineering, Lakshmi Ammal Polytechnic College, Kovilpatti.

6. Major Technological Choice
1/7 U.Aravind, Lecturer, Department of Mechanical Engineering, Lakshmi Ammal Polytechnic College, Kovilpatti.
• Whether technology is available to make the
product or component.
• What are the various technology available to
manufacture the product.
• What is the technology to be selected among the
alternatives.
• If the technology is not available, whether the
technology to manufacture the given component
can be developed in the country itself.
• Whether the technology can be imported from
foreign countries.

7. Minor Technological Choice
1/7 U.Aravind, Lecturer, Department of Mechanical Engineering, Lakshmi Ammal Polytechnic College, Kovilpatti.
• Whether the process can be done continuously for
24 hours a like steel or chemical industries.
• Whether manufacturing can be done in an assembly
line ie. by mass production process for 24 hours a
day continuously like ready made garment
manufacturing or automobile assembly.
•Whether the manufacturing can be done o a job-
shop process ie. made to order for customers.
•Selecting a suitable basic process for the
manufacturing of the product among the various
alternatives - casting, forging, forming, rolling. A
combination of processes has to be found out to
produce the product with minimum cost.

8. Specific Component Choice
1/7 U.Aravind, Lecturer, Department of Mechanical Engineering, Lakshmi Ammal Polytechnic College, Kovilpatti.
• Once the manufacturing process is determined, the
specific machine or equipment to be used is to be
selected. The following factors are analysed before
selecting the correct machine or equipment,
•Degree of automation required
•Whether single purpose or general purpose machine
is to be used.
•What are the activities to be done by the operator
and what activities are to be done by automatic
means.

9. Process flow Choice
1/7 U.Aravind, Lecturer, Department of Mechanical Engineering, Lakshmi Ammal Polytechnic College, Kovilpatti.
•The next step in process planning is to decide the
path of flow of material / product during production.
The material and product movement generally
depends upon the process selected. The process
flow is analyzed with the help of assembly
drawings, charts, route sheet, and flow process
charts.
•The main aim should be to reduce material handling,
and storage costs. We may have to change the
production sequence or combine or eliminate some
operations in order to get the free flow of material
during production.

10. U.Aravind, Lecturer, Department of Mechanical Engineering, Lakshmi Ammal Polytechnic College, Kovilpatti.
UNIT 1 : PROCESS PLANNING AND SELECTION
4020440 PRODUCTION AND QUALITY
MANAGEMENT
உற்பத்தி மற்றும் தர மமலாண்மம
MACHINE CAPACITY

11. Analysis of Machine Capacity
1/7 U.Aravind, Lecturer, Department of Mechanical Engineering, Lakshmi Ammal Polytechnic College, Kovilpatti.

12. Analysis of Machine Capacity
1/7 U.Aravind, Lecturer, Department of Mechanical Engineering, Lakshmi Ammal Polytechnic College, Kovilpatti.
• Machine Availability =
𝐀𝐯𝐚𝐢𝐥𝐚𝐛𝐥𝐞 𝐦𝐚𝐜𝐡𝐢𝐧𝐞 𝐭𝐢𝐦𝐞
𝐓𝐨𝐭𝐚𝐥 𝐌𝐚𝐜𝐡𝐢𝐧𝐞 𝐓𝐢𝐦𝐞
𝐱 𝟏𝟎𝟎
• Machine Utilization =
𝐀𝐜𝐭𝐮𝐚𝐥 𝐫𝐮𝐧𝐧𝐢𝐧𝐠 𝐭𝐢𝐦𝐞
𝐀𝐯𝐚𝐢𝐥𝐚𝐛𝐥𝐞 𝐦𝐚𝐜𝐡𝐢𝐧𝐞 𝐭𝐢𝐦𝐞
𝐱 𝟏𝟎𝟎
• Machine Efficiency =
𝐒𝐭𝐚𝐧𝐝𝐚𝐫𝐝 𝐫𝐮𝐧𝐧𝐢𝐧𝐠 𝐭𝐢𝐦𝐞
𝐀𝐜𝐭𝐮𝐚𝐥 𝐫𝐮𝐧𝐧𝐢𝐧𝐠 𝐓𝐢𝐦𝐞
𝐱 𝟏𝟎𝟎
• Machine Effective utilization
=
𝐒𝐭𝐚𝐧𝐝𝐚𝐫𝐝 𝐫𝐮𝐧𝐧𝐢𝐧𝐠 𝐭𝐢𝐦𝐞
𝐀𝐜𝐭𝐮𝐚𝐥 𝐦𝐚𝐜𝐡𝐢𝐧𝐞 𝐓𝐢𝐦𝐞
𝐱 𝟏𝟎𝟎

13. PROCESS SELECTION PROCEDURE
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1. Collect the following Details
• The Specifications of the finished product from part and
assembly drawings
• The quantity of products to be made and the date of delivery
from the sales department
• Size, shape and properties of raw materials and Details of
surface finish, hardness
2. Improving the specifications
3. Listing the various operations to be done recorded in
process sheet
4. Determining the most practical and economical process
5. Detailed Processing

14. PROCESS SHEET
1/7 U.Aravind, Lecturer, Department of Mechanical Engineering, Lakshmi Ammal Polytechnic College, Kovilpatti.

15. Determination of Sequence of operations
1/7 U.Aravind, Lecturer, Department of Mechanical Engineering, Lakshmi Ammal Polytechnic College, Kovilpatti.
• For manufacturing any product, first we
have to make the component from raw
material using basic processes like
forging, casting, extrusion.
• After this we have to carry out the
operations like turning, drilling, reaming,
tapping, facing, threading, milling,
shaping, heat treating, etc. to bring the
required shape, dimensions and properties
in the components.

16. Classification of operations
1/7 U.Aravind, Lecturer, Department of Mechanical Engineering, Lakshmi Ammal Polytechnic College, Kovilpatti.
1.Critical Operations
2.Secondary Operations
3.Qualifying Operations
4.Supporting Operations

17. 1. Critical Operations
1/7 U.Aravind, Lecturer, Department of Mechanical Engineering, Lakshmi Ammal Polytechnic College, Kovilpatti.
• These operations require accurate
dimensions and good surface finish.
• These operations require regular
inspections for maintaining quality.
2. Secondary Operations
• These operations are productive
operations which are necessary to
produce the part.
• Its not critical operations`
• Ex: Rough turning, Drilling and Tapping

18. 3. Qualifying Operations
1/7 U.Aravind, Lecturer, Department of Mechanical Engineering, Lakshmi Ammal Polytechnic College, Kovilpatti.
• These operations required to prepare a
job for critical operations.
• Ex: Removal burrs, Annealing a
component, Casting
4. Supporting Operations
• Its not productive operations.
• Its carried out to protect the products
from the environment and handling.
• Ex: Testing, Inspection, Protective
Coating, Decorative Coating, Packaging.

19. SELECTION OF EQUIPMENTS
1/7 U.Aravind, Lecturer, Department of Mechanical Engineering, Lakshmi Ammal Polytechnic College, Kovilpatti.
• The selection of correct equipment
depends mainly on the selected process of
manufacture.
Factors considered while selecting the
correct equipment.
• Size and shape of work piece
• Work material
• Accuracy and surface quality required
• Quantity to be produced and size

20. SELECTION OF EQUIPMENTS
1/7
• The selection of correct
equipment depends
mainly on the selected
process of manufacture.
Factors considered while
selecting the correct
equipment.
• Size and shape of work
piece
• Work material
• Accuracy and surface

21. DETERMINATION OF MATERIAL REQUIREMENT
1/7
• Using the “Bill of Material” we can find
out the material requirement for producing
the required quantity.
• Bill of material is a Document from
which we can find out the quantity
requirement of different components.
• It indicates the list of parts too be
purchased from outside and parts to be
manufactured inside.
• Material requirement planning is done
based on the bill of material.

22. DETERMINATION OF MATERIAL REQUIREMENT
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23. SELECTION OF MATERIAL
1/7
• Selection of material should have
the right quality and chemical
composition.
• It should satisfy the complete
specification given by the product
design.
• Shape and size of the material
should be very close to the shape
and size of the final product.

24. SELECTION OF MACHINES
1/7
• If a particular product can be
produced by two or more
machines, we have to select the
machine which produces the
product with minimum total cost.
• Total cost is the sum of fixed cost
and variable cost.
• For given quantity of production
we must find out the total cost for

25. Problem 1
1/7
A component can be produced on either a
capstan lathe or an automatic lathe. The
different cost factors for the two machines
are given below.
Assume that the cycle time for production
of the component is same for both
machines. Which machine will you select
for producing a) 900 components b) 700
Machine I : Machine II :
Fixed Cost = Rs. 400 Fixed Cost = Rs. 1600
Variable Cost = Rs. 2 per
piece
Variable Cost = Rs. 0.50
per piece

26. Problem 2
1/7
A machine is purchased initially
for Rs. 2,00,000.
Annual interest rate = 18%
Depreciation = 15% annually
Insurance and taxes = 8%
annually
Annual maintenance = 5%
Find out the annual fixed cost.

27. Problem 3
1/7
Find out the annual variable
cost from the following data.
i) Annual Labour charges =
Rs. 20,000
ii) Labour overhead = 30% of
direct labour
iii) Annual power charge = Rs.
30,000

28. Any Q ?
1/7
U.Aravind,
Lecturer / Mechanical Engineering,
Lakshmi Ammal Polytechnic College.,
Kovilpatti, Thoothukudi.