Modern Manufacturing — Process to Cost

Description

This Modern Manufacturing eBook from 3D-LABS is written for engineers and students who want a clear, practical reference they can apply immediately.

Modern Manufacturing — Process to Cost covers engineering and economic analysis of manufacturing processes including machining, casting, forging, sheet metal, welding, AM, and surface treatment with process capability (Cpk), production rate, tooling cost, and total unit cost calculations. Written for manufacturing engineers, process planners, and product cost engineers.

What format and standards does this book reference?

Process-physics-to-cost-model structure: each process is explained from material-removal or forming physics, then a cost model is derived with fixed cost (tooling, setup), variable cost (material, labour, energy), and quality-related cost (scrap, rework). Standards referenced include ISO 286-1:2010 (tolerance grades achievable by process), CMTI Machining Data Handbook for Indian cutting data, and ASTM B117 (salt spray test for surface treatment validation).

What process capability formula is used?

Cpk = min((USL – x-bar)/(3*sigma), (x-bar – LSL)/(3*sigma)), where USL/LSL are specification limits, x-bar is process mean, and sigma is standard deviation. Targets: Cpk >= 1.33 for standard production, Cpk >= 1.67 for safety-critical parts. By process: grinding Cpk typically 2.0+, CNC turning 1.3-1.7, sand casting 0.5-1.0.

What unit cost model is used for process selection?

Unit cost = C_material + C_tooling/N_parts + C_setup/N_parts + C_labour + C_energy + C_overhead x (1 + scrap rate). Break-even analysis: N_breakeven = fixed cost savings / variable cost difference per unit. Decision matrix: process capability, unit cost, lead time, and quality risk scored and weighted for systematic process selection.

How do I access this book after purchase?

eBook PDF: After your payment is confirmed, our team emails the PDF to the address on your order. No shipping wait, and no subscription — if you need another copy later, email info@3d-labs.com and we will resend it. Paper Book: Printed and shipped worldwide. Shipping within India is free; international shipping is charged at checkout.

Contents

1. How to Use This Book: From Drawing to Quoted Price — p. 1–14
2. Reading the Part: Features, Tolerances and Cost Drivers — p. 15–36
3. Machining Routes: Turning, Milling and Multi-Axis Work — p. 37–62
4. Sheet Metal and Fabrication: Cutting, Forming and Joining — p. 63–86
5. Casting, Forging and Powder Metal Routes — p. 87–110
6. Plastics, Moulding and Tooling Amortisation — p. 111–132
7. Additive Manufacturing Where It Actually Pays — p. 133–152
8. Heat Treatment, Plating and Finishing Costs — p. 153–172
9. Cycle Time Estimation and Machine Hour Rates — p. 173–198
10. Material Cost, Scrap, Yield and Nesting — p. 199–218
11. Tooling, Fixtures and Setup Cost Across Batch Sizes — p. 219–240
12. Cost of Quality: Inspection, Rework and Rejection — p. 241–260
13. Building the Quotation: Overheads, Margin and Costing Sheets — p. 261–280

What’s Included

An instant PDF download covering the core concepts, practical examples, and key references — ready to read on any device.

Related Reading

• Construction Project Management — India Edition
• From Sketch to Production — Mechanical Design in Practice
• Indian Workshop Handbook — Threads, Fits, Cutting Data

Download the Modern Manufacturing — Process to Cost e-book from 3D-LABS — instant PDF access with lifetime re-downloads.

About Modern Manufacturing — Process to Cost

Modern Manufacturing — Process to Cost is part of the 3D-LABS Manufacturing series — a focused e-book library for manufacturing engineers, production managers, and quality professionals. This title covers lean manufacturing, Six Sigma, quality control, industry 4.0, and process optimisation, with worked examples and industry-current best practices drawn from real manufacturing projects.

Written by practising 3D-LABS engineers and reviewed by senior specialists, Modern Manufacturing — Process to Cost is designed to move you from concept to competence quickly — not to be a comprehensive academic reference, but a working reference you actually use.

Who Modern Manufacturing — Process to Cost is for

Modern Manufacturing — Process to Cost is written for manufacturing engineers, production managers, and quality professionals. If you are:

• An early-career engineer wanting to accelerate your practical knowledge in manufacturing.
• An experienced practitioner looking for a compact reference on current practices.
• A student preparing for engineering exams, interviews, or your first professional role.
• A manager or team lead wanting to level-set your team on manufacturing fundamentals.

Then Modern Manufacturing — Process to Cost will earn its price back in the first project or exam you apply it to.

What is included in your download

• The complete PDF e-book — DRM-free, fully searchable, print-friendly formatting.
• Worked examples — real-world calculations, drawings, or case studies interspersed through the text.
• Reference charts and tables — quick-lookup material you will return to on the job.
• Further reading recommendations — curated pointers to codes, standards, and complementary resources.
• Free updates — when we revise the book, you get the updated PDF at no extra cost. We notify you by email.

Pricing and delivery

Modern Manufacturing — Process to Cost is priced at ₹2,500 (USD equivalent shown in cart). After payment is confirmed, our team emails your PDF to the address on your order. No subscriptions, no hidden fees, no expiring access.

Payment methods: Cashfree (Indian customers) or PayPal International (customers outside India). Bulk licensing available for corporate training programmes and educational institutions — contact sales@3d-labs.com.

How to get the most out of Modern Manufacturing — Process to Cost

1. Read the introduction and structure first — every book has a "how to use this book" section that maps chapters to the reader you are.
2. Work through the examples with pen and paper — passive reading is 10% retention; working the calculation yourself is 70%+.
3. Cross-reference with the 3D-LABS spreadsheet library — 900 Excel calculation tools that pair naturally with our e-books.
4. Apply the concepts to a real project immediately — the book will pay for itself the first time you avoid a design error.
5. Come back to the book after 6 months — with real project experience, you will read the same chapters differently.

Related titles and services

Readers of Modern Manufacturing — Process to Cost typically also work with:

• Other titles in the Manufacturing book series — currently 5 titles.
• The Skid Design & Detailing — for projects where you need experienced manufacturing engineers directly.
• Our 900 engineering calculation spreadsheets — Excel tools that complement the theory in this book.
• Our online training courses — instructor-led programmes on manufacturing topics.

Frequently asked questions

Can I read it on any device and print it?

Modern Manufacturing — Process to Cost is delivered as a DRM-free PDF file. The PDF is DRM-free, works on any device (desktop, tablet, phone, e-reader), and is fully searchable. Print-friendly formatting so you can print for offline reading.

How is this different from a paper textbook?

This e-book is a focused, practical guide — targeting a specific engineering skill or knowledge area. Unlike a 600-page academic textbook, it moves quickly to real-world applications with worked examples, industry practices, and current code references. Priced accordingly.

Who wrote this book?

These books are authored by 3D-LABS engineers and reviewed by senior specialists in the field. Every author has hands-on industry experience — this is not academic theory, it is applied practice from working engineers.

Can I use the material for teaching or training?

Purchase includes single-user rights. For classroom use, corporate training programmes, or bulk licensing, contact us at info@3d-labs.com — we offer institutional licensing and custom-branded editions for training programmes.

What if the content does not meet my expectations?

We offer a 7-day satisfaction guarantee. If Modern Manufacturing — Process to Cost does not deliver the value you expected, email us within 7 days of purchase for a full refund. No questions asked — we would rather have satisfied customers than unhappy ones.

About 3D-LABS engineering e-books

Modern Manufacturing — Process to Cost is one of 115 titles in the 3D-LABS e-book library — the largest collection of practitioner-authored engineering e-books available anywhere, spanning 14+ series from engineering fundamentals to future technology and urban air mobility. Every book is written and reviewed by 3D-LABS engineers who use the concepts daily on real client projects across the globe.

Browse the full e-book library, or explore other content options: 900 spreadsheets, 19 online courses, or our full engineering services.