UNIVERSITY OF BOTSWANA

FACULTY OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING
Bachelor of Industrial Engineering
COURSE CODE: COURSE TITLE:
IMB 423 PROCESS PLANNING AND COST ESTIMATION
DATE: 16 MAY 2022 FINAL EXAMINATION
TIME ALLOWED: READING TIME: MAXIMUM MARKS: 100
2 HOURS 10 Minutes
INSTRUCTIONS TO CANDIDATES:
1. This paper has 12 pages excluding the cover page
2. This paper contains FIVE (5) QUESTIONS. Attempt ANY FOUR [4]
QUESTIONS.
3. The marks for each question are clearly indicated.
4. Make sure that you understand what the question requires before attempting it.
5. Any additional examination material is to be placed in the answer book and must
indicate clearly the question number, your full name and the Student I.D. number.
6. Assume any missing data appropriately.
INSTRUCTIONS TO INVIGILATORS:
1. Programmable calculators are not allowed.
2. Additional Materials: formulae sheets, tables.
QUESTION 1

(a) Write any TWO (2) activities of process planning. [3 marks]

(b) The design details of a shaft of motor being manufactured in BMC workshop is
shown in Fig Q1(b). Prepare the best sequence of the operation to
manufacturing the spindle. [12 marks]

Figure Q1(b)

(c) State any THREE (3) disadvantages of manual process planning. [3 Marks]

(d) List any THREE (3) factors that are considered in the selection of materials
during process planning. [3 Marks]

(e) List any TWO (2) types of production system based on the type of flow and
give ONE (1) example to each. [4 Marks]

(f) State any ONE (1) type of information that you would expect to find contained
in a typical route sheet used in the manufacturing industry. [1 Mark]

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QUESTION 2

(a) A company produces steel bolts with nuts. The different costs to make a lot of
1500 bolts with nuts are presented below in Table Q2(a):

Table Q2(a): Costs to make a lot of 1 500 bolts with nuts

# Cost of material P 4,000
1 Direct labour cost
(a) Forging shop
• Cutting the rods to P 700
length:

• Setting up P1 500
2 (b) Machine shop
• Milling heads of bolts P 800
and nuts

• Threading P 700
3 Cost of tools P 900
4 Overhead expenditure:
(a) Forging shop 175% of the
labour cost
(b) Machine shop 150% of the
labour cost
5 Establishment charges of office
expense is 20% of factory cost
6 Package and transport P1 500

The competitive price realized for the bolts is P18 per unit. Check whether the
company makes profit for making 1500 units. If so, find the profit/loss per bolt
with nut. [9 Marks]

(b) A company manufactures electronic gadgets. The details of its monthly

expenditure to produce the gadgets are as follows: Direct material = P15,000;
direct labour = 250 hours at the rate of P6 per hour and 125 hours at the rate
of P5 per hour; factory overheads = 15% of prime cost; Other overheads = 12%

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 of works cost; profit = 25% of total cost; number of units manufactured per
month = 250; Estimate the selling price per unit. [10 Marks]

(c) Provide THREE (3) reasons for process documentation in process planning.
[3 Marks]

(d) State THREE (3) causes of under estimation. [3 Marks]

QUESTION 3

(a) Explain the difference between plastic and fusion welding and give ONE (1)
example of each of the techniques. [4 Marks]

(b) In the estimation of material losses in forging, list at least TWO (2) material
losses that an estimator should consider in estimation. [2 Marks]

(c) A machinist manufactures 25 jobs in 7 hours. If this time includes the time for
setting his machine, calculate the machinist’s efficiency. Take the allowed
standard time and standard production time per piece as 45 minutes and 10
minutes respectively. [4 Marks]

(d) U shaped link shown in Figure Q3(d) are to be forged from a bar of 10 mm
diameter and 5 m length. Neglecting the possible losses, estimate the total
number of links which can be produced. [5 Marks]

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 Figure Q3(d)

(e) A butt joint between two square metal plates of 250 cm x 250 cm is made using
electric arc welding. If the rate of welding is 5 metres/hour, calculate the time
required to compete ten such welding operations. [3 Marks]

(f) The output of an electric bulb factory is 5000 bulbs per month. Its variable cost
is P2.75 each and the fixed overheads are P7000 per month. The selling price
is P6.25 per bulb. Work out the minimum monthly production which may not
cause any loss to the owner. [7 Marks]

QUESTION 4

(a) Explain the difference between hot forging and cold forging and give ONE [1]
example of a component that can be made by each technique. [4 Marks]

(b) Estimate the welding cost for making a lap welded joint through electric arc
welding shown in Figure Q4(b) given the information below: [13 Marks]

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 Figure Q4(b) Lap joint
Length of joint = 1 metre;
Electrode diameter = 6 mm;
Minimum arc voltage = 30 volts;
Current used = 250 amperes;
Welding speed = 10m/hr;
Electrode used = 0.35kg/m of welding;
Labour rate = P12/hr;
Power rate = P0.70 per kWhr;
Electrode rate = P36 per kg;
Efficiency of welding machine = 60%;
Connecting ratio = 0.5;
Overhead charges = 40% of direct charges;
Hint: Power Cost = (Vx A)/1000 x t/60 x 1/n x 1/r x C

(c) Estimate the total time taken to turn a 15 cm long, 2.5 cm diameter mild steel rod
to a diameter of 2.3 cm in a single cut. Take cutting speed as 30m/min, feed as
0.1mm/rev and the mounting time in a self-centering 3-jaw chuck as 45 seconds.
Neglect time taken for setting up tools, etc. [8 Marks]

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QUESTION 5

(a) A mild steel bolt 24 mm diameter is rotating at 370 rpm. How much machining
time is required to make 45° chamfer by 8 mm, as shown in Figure Q5(a). Take
feed as 0.25 mm/rev. [4 Marks]

Figure Q5(a)

(b) A foundry unit produces tractor components as cast. Calculate the selling price of
producing a component weighing 50 kg from the following data: [15 Marks]
Material of component is cast iron with density 7.2 gm/cc
Cost of molten iron at cupola = P2.50 per kg
Process scrap = 17% of net weight
Scrap return value = P1.10 per kg
Administrative and sales overheads = P5 per piece
Profit = 10% of total cost
Other important information is given in Table Q5(b):

Table Q5(b)
Labour cost Shop
Time/Component per component overheads/hr
Operation (mins) (Pula) (Pula)
Moulding and pattern
making 6 2.6 4.25
Core making 8 2.4 3.5
Fettling and cleaning 10 2.75 3

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(c) An 80 mm diameter shaft is to be reduced to 60 mm diameter. If the depth of cut
is 2.5 mm per pass, calculate the minimum number of passes required. [3 Marks]

(d) Estimate the machining time to turn a 4 cm diameter mild steel bar 10 cm long
down to 3.5 cm diameter in a single cut, using high speed steel tool. Assume the
cutting speed of the tool to be 30m/min and a feed of 0.30 mm per revolution.
[3 Marks]

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ADITIONAL MATERIAL

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Material Formulae Tables

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