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ME6005 – PROCESS PLANNING
AND COST ESTIMATION
ELECTIVE SUBJECT
3 CREDIT PAPER
DICTIONARY MEANING
A series of actions or steps taken in
order to achieve a particular end.
Example :
To go to your native place from
our college after applying leave
To attend one workshop or
conference
To win a medal in a race
A series of actions or steps taken in order to achieve a
particular end.
Courtesy :
http://www.oatly.com/process/
Case Study:
MILLING
During the first stage of the
process, we mix oats with water
and mill the soft mixture in our
milling room.
Enzyming
In the enzyming tanks, we add
natural enzymes that break the oat
starch down into smaller
components, primarily maltose
(also called malt sugar), which
sweetens our products naturally.
SEPARATION
During the separation, we remove bran,
that is to say, the loose shells from the
oats. That leaves the loose fibers, the beta-
glucans. Now we have our oat base, an
excellent source of nutrition. It contains
macronutrients from the oats, in other
words, protein, fat, and carbohydrates.
INGREDIENTS
We add different ingredients,
depending upon the product we
are manufacturing. It may be
rapeseed oil (when we make
iKaffe) or rapeseed oil, calcium and
vitamins (when we make our
enriched oat drink).
HEAT TREATMENT
We heat-treat the products prior to
packaging – with UHT or pasteurization
– to extend the life.
STERILE TANK
Once the product has been heat-
treated, we collect it in the sterile
tank before we send it further for
packaging.
PACKAGING
Some of our products wind up in
small packages, others in large
packages. When we fill liter size
packages, our machines have the
capacity to produce 7,500 – 8,000
packages per hour.
Marketing
• Promotion of existing products to increase the
sales
• Identifying the possible gaps for a new
product through market research
• If need is identified give idea to the design and
R&D department for promoting a new product
R&D
• New product idea from marketing
• Development of PDS (Product Design
Specification)
• PDS is a statement of constraints and
conditions to control the design and
manufacturing department.
– Say some specifications for a smart phone
Design department
• Conceptual design
– All possible solutions are gathered
– The solutions are forwarded for synthesis.
– Then all ideas will be evaluated and one best idea
is selected to pursue.
• Detailed design
• PDS and conceptual design are used here to finalize the
design
Contd..
• Detailed design
– Information about parts
– Information about assembly
– Information about bill of materials
Cost analysis
Modify
Prototype
• It is a first or preliminary version of a device
from which other forms are developed.
• With all the informations from the detailed
design prototype is made
• This is for evaluating the function of the
product and manufacturing difficulties.
Test run
• If prototype is cleared and evaluated for
different performance aspects and
manufacturing aspects a trial batch of
products are to be produced
• This is called as pilot and test run stage.
• The products are marketed for creating
demand
Production planning
• Once the manufacturing methods was fully
established production plans will be
developed.
• In production plan stage demand is enabled
by the manufacturing of products at right time
and right quantities.
• At last the manufacturing commences and then sales are also
started.
Formulating strategies to achieve the
process.
PROCESS PLANNING
• Process planning comprises the selection and
sequencing of processes and operations to
transform a chosen raw material into a
finished component.
PROCESS PLANNING
• It is not only the selection of manufacturing
processes
• It comprises of selection of machines
• Selection of tools
• Manufacturing sequence selection
• Allotment of machining time and setup time
Etc.,
PROCESS PLANNING
Concurrent Engineering
• Concurrent engineering requires the
integration of all aspects of the product life
cycle.
– Design
– Manufacturing
– Assembly
– Distribution
– Service
– disposal
Process planning serves as an
integration link between design and
manufacturing
PROCESS PLANNING – Definitions
• Process planning is set of instructions that
describe how to fabricate a part or build an
assembly which will satisfy the entire engg
specifications.
• An act of preparing a detailed processing
documentation for the manufacturing of
pieces or building an assembly.
Contd....
• Systematic determination of the methods by
which a product is manufactured in
economically and competitively.

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Process planning and cost estimation introduction

  • 1. ME6005 – PROCESS PLANNING AND COST ESTIMATION ELECTIVE SUBJECT 3 CREDIT PAPER
  • 2.
  • 3. DICTIONARY MEANING A series of actions or steps taken in order to achieve a particular end.
  • 4. Example : To go to your native place from our college after applying leave To attend one workshop or conference To win a medal in a race A series of actions or steps taken in order to achieve a particular end.
  • 6.
  • 7. MILLING During the first stage of the process, we mix oats with water and mill the soft mixture in our milling room. Enzyming In the enzyming tanks, we add natural enzymes that break the oat starch down into smaller components, primarily maltose (also called malt sugar), which sweetens our products naturally.
  • 8. SEPARATION During the separation, we remove bran, that is to say, the loose shells from the oats. That leaves the loose fibers, the beta- glucans. Now we have our oat base, an excellent source of nutrition. It contains macronutrients from the oats, in other words, protein, fat, and carbohydrates. INGREDIENTS We add different ingredients, depending upon the product we are manufacturing. It may be rapeseed oil (when we make iKaffe) or rapeseed oil, calcium and vitamins (when we make our enriched oat drink).
  • 9. HEAT TREATMENT We heat-treat the products prior to packaging – with UHT or pasteurization – to extend the life. STERILE TANK Once the product has been heat- treated, we collect it in the sterile tank before we send it further for packaging.
  • 10. PACKAGING Some of our products wind up in small packages, others in large packages. When we fill liter size packages, our machines have the capacity to produce 7,500 – 8,000 packages per hour.
  • 11.
  • 12. Marketing • Promotion of existing products to increase the sales • Identifying the possible gaps for a new product through market research • If need is identified give idea to the design and R&D department for promoting a new product
  • 13. R&D • New product idea from marketing • Development of PDS (Product Design Specification) • PDS is a statement of constraints and conditions to control the design and manufacturing department. – Say some specifications for a smart phone
  • 14. Design department • Conceptual design – All possible solutions are gathered – The solutions are forwarded for synthesis. – Then all ideas will be evaluated and one best idea is selected to pursue. • Detailed design • PDS and conceptual design are used here to finalize the design
  • 15. Contd.. • Detailed design – Information about parts – Information about assembly – Information about bill of materials Cost analysis Modify
  • 16. Prototype • It is a first or preliminary version of a device from which other forms are developed. • With all the informations from the detailed design prototype is made • This is for evaluating the function of the product and manufacturing difficulties.
  • 17. Test run • If prototype is cleared and evaluated for different performance aspects and manufacturing aspects a trial batch of products are to be produced • This is called as pilot and test run stage. • The products are marketed for creating demand
  • 18. Production planning • Once the manufacturing methods was fully established production plans will be developed. • In production plan stage demand is enabled by the manufacturing of products at right time and right quantities. • At last the manufacturing commences and then sales are also started.
  • 19. Formulating strategies to achieve the process.
  • 20. PROCESS PLANNING • Process planning comprises the selection and sequencing of processes and operations to transform a chosen raw material into a finished component.
  • 21.
  • 22.
  • 24. • It is not only the selection of manufacturing processes • It comprises of selection of machines • Selection of tools • Manufacturing sequence selection • Allotment of machining time and setup time Etc., PROCESS PLANNING
  • 25. Concurrent Engineering • Concurrent engineering requires the integration of all aspects of the product life cycle. – Design – Manufacturing – Assembly – Distribution – Service – disposal
  • 26. Process planning serves as an integration link between design and manufacturing
  • 27. PROCESS PLANNING – Definitions • Process planning is set of instructions that describe how to fabricate a part or build an assembly which will satisfy the entire engg specifications. • An act of preparing a detailed processing documentation for the manufacturing of pieces or building an assembly.
  • 28. Contd.... • Systematic determination of the methods by which a product is manufactured in economically and competitively.