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## GUJARAT TECHNOLOGICAL UNIVERSITY

## Program Name: Diploma Engineering Level: Diploma

Branch: Mechanical  Engineering Subject Code: DI04019031

Subject Name  : Engineering Costing and Plant Maintenance

w. e. f. Academic Year:

2025-26

Semester:

4 th

Category of the Course:

Professional Elective - II

| Prerequisite:   | Mathematics                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                               |
|-----------------|---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------|
| Rationale:      | This  course  is  designed  to  develop  students'  ability  to  evaluate  materials,  consumables,  and  process  costs  in  monetary  terms.  By  doing  so,  it  contributes  to  improving  organizational  productivity  and  promoting  the  conservation  of  valuable  resources. The course also helps students build essential decision-making skills and  learn how to plan, use, monitor, and control resources efficiently and economically.  In  addition,  it  provides  fundamental  knowledge  and  skills  related  to  industrial  maintenance problems, including their causes and possible remedies. |

## Course Outcome:

After Completion of the Course, Student will able to:

|   No | Course Outcomes                                                                                                      |
|------|----------------------------------------------------------------------------------------------------------------------|
|   01 | Understand the concept of estimation, costing and depreciation.                                                      |
|   02 | Apply break even analysis to get optimum production level.                                                           |
|   03 | Calculate cost for various conventional manufacturing processes.                                                     |
|   04 | Explain various maintenance practices, machine diagnostics methods, and fault analysis        techniques.            |
|   05 | Demonstrate understanding of industrial safety standards, hazard identification, and preventive    safety practices. |

## Teaching and Examination Scheme:

| Teaching scheme  (in Hours)   | Teaching scheme  (in Hours)   | Teaching scheme  (in Hours)   | Total Credits  L+T+ (PR/2)   | Total Credits  L+T+ (PR/2)   | Assessment Pattern and Marks   | Assessment Pattern and Marks   | Assessment Pattern and Marks   |       |
|-------------------------------|-------------------------------|-------------------------------|------------------------------|------------------------------|--------------------------------|--------------------------------|--------------------------------|-------|
| L                             | T                             | PR                            | C                            | Theory                       | Theory                         | Tutorial / Practical           | Tutorial / Practical           | Total |
| L                             | T                             | PR                            | C                            | ESE(E)                       | PA (M)                         | PA (I)                         | ESE (V)                        | Marks |
| 3                             | 0                             | 2                             | 4                            | 70                           | 30                             | 20                             | 30                             | 150   |

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## GUJARAT TECHNOLOGICAL UNIVERSITY

## Program Name: Diploma Engineering Level: Diploma

## Branch: Mechanical  Engineering Subject Code: DI04019031

Subject Name  : Engineering Costing and Plant Maintenance

## Course Content:

|   Unit  No. | Content                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                               |   No. of  Hrs |   % of  Weightage |
|-------------|-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------|---------------|-------------------|
|           1 | Introduction of Costing  1.1 Terminology  associated  with  various  cost  elements  and  their  classification.  1.2 Terminology  associated  with  overheads,  their  classification  and  allocation.  1.3 Determination of selling price and catalogue price.  1.4 Depreciation and obsolescence: Definition, types, Different methods  of calculating depreciation.  1.5 Numerical problems                                                                                                                                                                      |            06 |                14 |
|           2 | Break even analysis  2.1 Classification  of  costs  as  fixed  and  variable  costs.  Relationship  between the costs and quantity of production.  2.2 Definition of Break Even Point (BEP) and its needs in industry.  2.3 Procedure of construction of Break Even Chart, Assumptions made in  constructing  Break  even  chart,  Calculation  of  BEP  analytically  and  graphically.  2.4 Numerical problems                                                                                                                                                      |            06 |                14 |
|           3 | Costing in Welding, Fabrication and Machining shop  3.1 Cost terminology and procedure associated with welding and  machining shop.  3.2 Calculate  cost  of  consumables  and  production  for  gas  cutting  and  welding (Gas & Arc) of a given job.   3.3 Calculate fabrication cost of real time object.   3.4 Calculation of Solar Roof Top costing for various capacities. It includes,  cost of welding, framing, solar panel, labour, taxes, subsidies, etc.  3.5 Calculate machining cost in lathe, drilling and milling machines.  3.6 Numerical problems. |            10 |                21 |
|           4 | Costing in forging and casting shop.  4.1 Cost terminology and procedure associated with forging and casting  shop.  4.2 Calculate volume of various shapes.    4.3 Calculate mass and material cost of given component.  4.4 Calculate various forging losses and forging cost for given data.  4.5 Calculate pattern making cost (for given data).  4.6  For a given component, calculate casting cost including all losses.  4.7 Numerical problems.                                                                                                               |            08 |                18 |
|           5 | Maintenance Concepts and Practices  5.1 Introduction to Maintenance - Need, objectives, types of maintenance                                                                                                                                                                                                                                                                                                                                                                                                                                                          |            05 |                11 |

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## GUJARAT TECHNOLOGICAL UNIVERSITY

## Program Name: Diploma Engineering Level: Diploma

Branch: Mechanical  Engineering Subject Code: DI04019031

Subject Name  : Engineering Costing and Plant Maintenance

|    | 5.2 Preventive, Predictive and Breakdown Maintenance  5.3 Condition-based maintenance - Vibration, temperature, lubrication  checks  5.4 Maintenance planning, scheduling and documentation  5.5 Tools and equipment used in maintenance  5.6 Maintenance records, history cards and checklists.                                                                                                                                                                        |    |     |
|----|-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------|----|-----|
| 6. | Machine Diagnostics and Fault Analysis  6.1 Basics of machine diagnostics - Purpose and importance  6.2 Common mechanical faults - misalignment, imbalance, wear, leakage  and noise  6.3 Vibration analysis - causes and interpretation  6.4 Thermal analysis - overheating, friction, lubrication issues  6.5 Fault tracing methods and troubleshooting procedure  6.6 Root cause analysis (RCA) and corrective actions                                               | 05 |  11 |
| 7. | Industrial Safety  7.1 Industrial hazards - mechanical, electrical, chemical and fire hazards  7.2 Personal Protective Equipment (PPE) and safe working practices  a. Fire triangle, fire extinguishers, PASS method  7.3 Safety signs, signals and colour codes  7.4 Machine guarding, lockout-tagout (LOTO)  7.5 Workplace safety guidelines and emergency procedures  7.6 Accident causes, reporting and prevention techniques  a. Factory Act 1948 - key provisions | 05 |  11 |
|    | Total                                                                                                                                                                                                                                                                                                                                                                                                                                                                   | 45 | 100 |

## Suggested Specification Table with Marks (Theory):

## Distribution of Theory Marks

|   R Level |   U Level |   A Level | N Level   | E Level   | C Level   |
|-----------|-----------|-----------|-----------|-----------|-----------|
|        21 |        21 |        28 | -         | -         | -         |

Where R: Remember; U: Understanding; A: Application, N: Analyze and E: Evaluate C: Create (as per Revised Bloom's Taxonomy)

## References/Suggested Learning Resources:

## (a) Books:

|   Sr.  No . | Title of Book                      | Author            | Publication        |
|-------------|------------------------------------|-------------------|--------------------|
|           1 | Mechanical estimating and costing. | Banga and Sharma  | Khanna Publishers  |
|           2 | Mechanical estimating and costing. | Shrimali and Jain | Khanna Publishers. |
|           3 | Mechanical costing and estimation. | Singh and Khan    | Khanna Publishers. |

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## GUJARAT TECHNOLOGICAL UNIVERSITY

## Program Name: Diploma Engineering Level: Diploma

Branch: Mechanical  Engineering Subject Code: DI04019031

Subject Name  : Engineering Costing and Plant Maintenance

|   4. | Maintenance Engineering and  Management   | R. C. Mishra & K.  Pathak   | PHI Learning Pvt. Ltd   |
|------|-------------------------------------------|-----------------------------|-------------------------|
|    5 | Maintenance Engineering                   | Er. S. K. Srivastava        | S. Chand & Company,     |

## (b) Open source software and website:

1. https://www.youtube.com/watch?v=KH-9VQbZxQE
2. https://youtu.be/7F1n5OgnK4I
3. https://youtu.be/btrxpgk4F-Q
4. https://youtu.be/hnfkUh3iYb4
5. https://www.youtube.com/watch?v=vRrBPuTHbM4
6. https://youtu.be/aTnDZF\_C-XM
7. https://www.youtube.com/watch?v=4ZXfpfs09g8
8. https://www.youtube.com/watch?v=7rKjN-wK83s&amp;list=PLSGws\_74K019n5sjannZRKcSpG25beMLl

## Suggested Course Practical List:

|   Sr.  No. | Practical Exercises                                                                                                                                                                                                                                                                                                                                                                                |   Hrs |
|------------|----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------|-------|
|          1 | Calculate welding cost of various components.  a. Determine raw material volume of welded parts.  b. Select welding rod and estimate quantity of welding rod required.  c. Determine material and consumable costs.  d. Calculate welding cost. Show assumption and steps followed to estimate  welding cost.  e. Derive total cost of the component.                                              |    04 |
|          2 | Calculate cost of machining component.  a. Determine raw material volume of machined parts.  b. For each part, Tabulate operation, cutting tools to be used and cutting parameters  (Speed, Feed, Depth of cut) to be used.  c. Calculate raw material cost.  d. Calculate machining cost. Show assumption and steps followed to estimate  machining cost.  e. Derive total cost of the component. |    04 |
|          3 | Calculate volume of given component.                                                                                                                                                                                                                                                                                                                                                               |    02 |
|          4 | Calculate cost of given forging component.  a. Determine raw material volume of forged parts.  b. Prepare Die drawing (Production drawings with all dimensions, surface finishes,  allowances etc.) for all parts.                                                                                                                                                                                 |    02 |

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## GUJARAT TECHNOLOGICAL UNIVERSITY

## Program Name: Diploma Engineering Level: Diploma

## Branch: Mechanical  Engineering

## Subject Code: DI04019031

Subject Name  : Engineering Costing and Plant Maintenance

|    | c. Calculate Die cost.  d. Determine material and consumable costs.  e. Calculate forging cost. Show assumption and steps followed to estimate forging  cost.  f. Derive total cost of the component.                                                                                                                                                                                                                             |    |
|----|-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------|----|
|  5 | Calculate cost of given casting component.  a. Determine raw material volume of casted parts.  b. Prepare pattern drawing (Production drawings with all dimensions, surface  finishes, allowances etc.) for all parts.  c. Calculate pattern cost.  d. Determine material and consumable costs.  e. Calculate casting cost. Show assumption and steps followed to estimate casting  cost.  f. Derive total cost of the component. | 04 |
|  6 | Preparation of Preventive Maintenance Schedule  Tasks:  Select any workshop machine (lathe, milling, drilling, and compressor)  Identify machine parts requiring routine maintenance.  Prepare Preventive Maintenance (PM) schedule including:  o Daily / Weekly / Monthly PM tasks  o Lubrication chart  o Checklist format  o Spare parts required  Prepare machine maintenance history card.                                   | 04 |
|  7 | Machine Fault Identification & Root Cause Analysis (RCA)  Observe any rotating equipment (motor, pump, fan, lathe spindle).   Identify at least 3 possible faults, such as:  o Misalignment  o Bearing wear  o Imbalance  o Lubrication failure   Perform step-by-step fault tracing.   Prepare Root Cause Analysis (RCA) using:  o Fishbone diagram  o Fault tree   Suggest corrective actions.                              | 04 |

Page 5 of 6

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## GUJARAT TECHNOLOGICAL UNIVERSITY

## Program Name: Diploma Engineering Level: Diploma

## Branch: Mechanical  Engineering

## Subject Code: DI04019031

## Subject Name  : Engineering Costing and Plant Maintenance

|   8 | Demonstrate safety equipment and their methods use.   |   02 |
|-----|-------------------------------------------------------|------|
|   9 | Mini project and presentation.                        |   04 |

## List of Equipment:

- i. Tool kit.
- ii. Fire extinguishers.
- iii. Lubricants.
- iv. Cotton waste.
- v. Kerosene.
- vi. Measuring instruments.

## Suggested Activity for Students

1. Collect the finished parts from industries/market/scrap merchants consisting:
- i. Welded parts, ii. Casted parts, iii. Forged parts, iv. Machined Parts
- ii. Measure and prepare production drawings of all the parts using A4 size paper (Manually).
2. Do market survey and find prevailing hourly rates of CNC, Hacksaw cutter, lathe, milling, drilling, grinding and shaping machines and price of these machines.
3. Do market survey and find prevailing rates of commonly used engineering materials like MS, brass, copper, stainless steel, Aluminum, etc.
4. Estimate fabrication cost of real time objects like safety grill (e.g. windows, doors, etc.), gate, various shades, etc.
5. Estimate  solar  roof  top  costing  for  various  capacities.  It  includes  cost  of  welding,  framing,  solar panel, labour, taxes, subsidies, etc.
6. It includes cost of welding, framing, solar panel, labour, taxes, subsidies, etc.
7. Calculate cutting fluid cost. e.g. cost of lubricating oil, coolant, packaging oil, etc.
8. Calculate cutting tool cost. e.g. cost of drill, tips, carbide cutter, reamer, honing stick, etc.
9. Monitor functionality of machine element and try to judge fault in it.
10. Visit nearby Industry/plant/workshop/hospital and collect samples of periodic &amp; preventive maintenance format.

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