DI04019031 · Semester 4 · 5G scheme
Engineering Costing and Plant Maintenance
Notes and solutions following the Gujarat Technological University (GTU) syllabus for DI04019031. Independent material — not issued by the university.
Mechanical Engineering
Materials
Complete Book
The whole syllabus, unit by unit, written for the exam.
Complete Book
201 pages
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Syllabus units
Unit 1: Introduction of Costing
- Terminology associated with various cost elements and their classification.
- Terminology associated with overheads, their classification and allocation.
- Determination of selling price and catalogue price.
- Depreciation and obsolescence: Definition, types, Different methods of calculating depreciation.
- Numerical problems
Unit 2: Break even analysis
- Classification of costs as fixed and variable costs. Relationship between the costs and quantity of production.
- Definition of Break Even Point (BEP) and its needs in industry.
- Procedure of construction of Break Even Chart, Assumptions made in constructing Break even chart, Calculation of BEP analytically and graphically.
- Numerical problems
Unit 3: Costing in Welding, Fabrication and Machining shop
- Cost terminology and procedure associated with welding and machining shop.
- Calculate cost of consumables and production for gas cutting and welding (Gas & Arc) of a given job.
- Calculate fabrication cost of real time object.
- Calculation of Solar Roof Top costing for various capacities. It includes, cost of welding, framing, solar panel, labour, taxes, subsidies, etc.
- Calculate machining cost in lathe, drilling and milling machines.
- Numerical problems.
Unit 4: Costing in forging and casting shop.
- Cost terminology and procedure associated with forging and casting shop.
- Calculate volume of various shapes.
- Calculate mass and material cost of given component.
- Calculate various forging losses and forging cost for given data.
- Calculate pattern making cost (for given data).
- For a given component, calculate casting cost including all losses.
- Numerical problems.
Unit 5: Maintenance Concepts and Practices
- Introduction to Maintenance - Need, objectives, types of maintenance
- Preventive, Predictive and Breakdown Maintenance
- Condition-based maintenance - Vibration, temperature, lubrication checks
- Maintenance planning, scheduling and documentation
- Tools and equipment used in maintenance
- Maintenance records, history cards and checklists.
Unit 6: Machine Diagnostics and Fault Analysis
- Basics of machine diagnostics - Purpose and importance
- Common mechanical faults - misalignment, imbalance, wear, leakage and noise
- Vibration analysis - causes and interpretation
- Thermal analysis - overheating, friction, lubrication issues
- Fault tracing methods and troubleshooting procedure
- Root cause analysis (RCA) and corrective actions
Unit 7: Industrial Safety
- Industrial hazards - mechanical, electrical, chemical and fire hazards
- Personal Protective Equipment (PPE) and safe working practices
- Safety signs, signals and colour codes
- Machine guarding, lockout-tagout (LOTO)
- Workplace safety guidelines and emergency procedures
- Accident causes, reporting and prevention techniques
About this course
Study materials, question papers, and solutions for Engineering Costing and Plant Maintenance (DI04019031) - Mechanical Engineering, Semester 4