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Lecture 33: Process Selection: Assistant Professor, Department of Applied Mechanics, IIT Delhi, Hauz Khas, 110016

The document discusses different manufacturing processes and their economic batch sizes. It compares die casting, pressure casting, and sand casting processes for aluminum connecting rods. It explains that the most economical process depends on the production size, with fixed costs dominating at small batches and variable costs at larger batches. A process-economic batch size chart shows the range of batch sizes each process is economically competitive for.

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Tarun Gupta
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36 views11 pages

Lecture 33: Process Selection: Assistant Professor, Department of Applied Mechanics, IIT Delhi, Hauz Khas, 110016

The document discusses different manufacturing processes and their economic batch sizes. It compares die casting, pressure casting, and sand casting processes for aluminum connecting rods. It explains that the most economical process depends on the production size, with fixed costs dominating at small batches and variable costs at larger batches. A process-economic batch size chart shows the range of batch sizes each process is economically competitive for.

Uploaded by

Tarun Gupta
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Lecture 33: Process

Selection

Jayant Jain

Assistant Professor,
Department of Applied Mechanics,
IIT Delhi, Hauz Khas, 110016

Cost Model

Material cost independent of batch size and


production rate
n = Batch size/production volume
= Production rate

C-n curves

An example: Three competing


processes for the manufacturing of
Al connecting rods
Die casting
Pressure casting
Sand casting

The most economical process for a part depends on the


production size at small batch sizes the unit cost is
dominated by the fixed costs of tooling as batch size
increases, the variable costs of material, labor, and
other overhead become dominant
Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

So we have seen for each process there can


be economic batch size
This is the size of batch for which process
is likely to be economical
Think of summarising this in chart form
Create process-economic batch size chart

Process Economic Batch Size

Note coloured
bar

Each process has a range of batch sizes for which


it is likely to be economically competitive
Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Problem 1

Solution: - for 1000 units: sand casting (plus machining),


investment casting; forging; machining.
- for 10,000 units: the same, plus powder forming.

Problem 3

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

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