Light Duty Technology Cost Analysis, Power - US Environmental ...

Project Process Requirement
Minimum Calculated Cycles Time
MANUFACTURING ASSUMPTIONS
Projected Operating Pattern
Process Information
Costs Broken Out Into Categories with Quantity per Assembly Taken into Account
Manufacturing Cost Mark-up Cost
Total Number of Direct
Operators
Resulting Cycle Time/
Part
"Sec.
2.00
7.50
Resulting Pieces/Hour 480
Number of Equivalent
Machines Required
Multiplier, If Required for
Parallel Processing
(1=Nothing)
Tack Time/Machine/Cycle
"Seconds"
Piece/Cycle/Machine
Parallel
Operations/Machine or
Stations/Line
Lean Design Calculation
for Complete Process
Time "Sec."
1.0
6.0
15
2
7
-
Cycle Time/Operation @
Stated Efficiency "Sec." 7.99
Pcs./ Hr.
@ Stated Efficiency 451
Efficiency %
85%
Cycle Time/Operation
"Sec." 9.40
Pcs./ Hr. (100% Eff.) 383
Hrs./
Yr.
Wks./
Yr.
Hrs./
Wk
Days/ Shifts./ Hrs./
Week Day Shift
Process & Equipment Assumptions
Total Markup Cost
(Component/ Assembly)
ED&T­
R&D
SG&A Profit
End Item
Scrap
Total Mfg'ing Cost
(Component/ Assembly)
Material Labor Burden
4700
47
100
10
2
5
Semi Automated Line with Operator load and unload. St#1, Operator load injector assembly w. face seal., St#2, install
circlip face seal, S#3Press Screen Stop and filter, S#4 Install Compression Limiter Oring and Oring Injector, S#5, Install
Bracket Hold Down, S# 6Test & Label, #7 Operator Unload & Pack
$0.00 $0.16 $0.19 $0.34 $0.00 $0.00 $0.00 $0.00 $0.00
1.00
8.00
450
1.0
1.0
16
2
1
-
7.99
451
85%
9.40
383
4700
47
100
10
2
5
Operator Load and Unload, Single Station, tip seal install and size.
$0.02 $0.08 $0.07 $0.17 $0.00 $0.00 $0.00 $0.00 $0.00
2.00
8.00
450
1.0
5.0
16
2
5
-
7.99
451
85%
9.40
383
4700
47
100
10
2
5
4.00
8.00
450
1.5
8.0
12
1
12
-
7.99
451
85%
9.40
383
4700
47
100
10
2
5
Linear Transfer line feeding 2 Vertical Injection Press. Both 4 Cavities (2x2). Linear Transfer Line, St#1 Press Needle
Body Assembly into Solenoid Body, St#2, Insert Coil and Ring Locator and Press Home, St#3 Load into Mold, ST# 4
Overmold., ST#5 Transfer to secondary overmold.
Automated Rotary Laser weld table with operator load assist and unload. S# 1 & 2 load pallet, S# 3 Fixture & Weld, S5
Fixture&Weld, S#6 Cool, S#7 Re-orientate, S#8 Insert Valve Assembly/Spring and Sleeve, S#9 Install Inlet Tube, S#10
laser Weld, S#11 Cool, Station 12 Test and Pack.
$0.05 $0.17 $0.50 $0.71 $0.00 $0.00 $0.00 $0.00 $0.00
$0.00 $0.33 $0.80 $1.13 $0.00 $0.00 $0.00 $0.00 $0.00
1.00
8.00
450
1.0
4.0
8
1
4
32
7.99
451
85%
9.40
383
4700
47
100
10
2
5
Semi automated load to pallet, automatic fixture and press. Operator assistance on load and unload.
$0.00 $0.08 $0.27 $0.35 $0.00 $0.00 $0.00 $0.00 $0.00
1.00
7.00
514
1.0
3.0
7
1
3
21
7.99
451
85%
9.40
383
4700
47
100
10
2
5
Automated component feed and laser weld assembly station (load, fixture & clamp, weld#1, weld#2, unload)
$0.00 $0.07 $0.18 $0.25 $0.00 $0.00 $0.00 $0.00 $0.00
1.00
7.00
514
1.0
2.0
7.0
1
2
13
7.99
451
85%
9.40
383
4700
47
100
10
2
5
Automated component feed and laser weld assembly station (load, fixture&clamp, weld, unload)
$0.00 $0.07 $0.12 $0.19 $0.00 $0.00 $0.00 $0.00 $0.00
0.50
0.50
0.50
0.50
0.50
0.25
0.25
7.20
7.33
7.43
7.82
10.00
8.00
6.67
500
491
485
460
360
450
540
5.0
4.5
3.5
5.5
1.0
1.5
1.5
1.0
1.0
1.0
1.0
1.0
1.0
1.0
36
33
26
43
10
12
10
1
1
1
1
1
1
1
1
1
1
1
4
1
3
46
43
36
53
33
-
-
7.99
7.99
7.99
7.99
7.99
7.99
7.99
451
451
451
451
451
451
451
85%
85%
85%
85%
85%
85%
85%
9.40
9.40
9.40
9.40
9.40
9.40
9.40
383
383
383
383
383
383
383
D
4700
4700
4700
4700
4700
4700
4700
47
47
47
47
47
47
100
100
100
100
100
100
10
10
10
10
10
10
2
2
2
2
2
2
5
5
5
5
5
5
5
Multi Spindle CNC Turning Machine + Batch Wash
Multi Spindle CNC Turning Machine + Batch Wash
Multi Spindle CNC Turning Machine + Batch Wash
Multi Spindle CNC Turning Machine + Batch Wash
Cold Form Press with automated part handling
Automated CNC, Feed and Machine, Batch Wash
Hopper feed to centerless grinding
$0.64 $0.04 $0.45 $1.12 $0.01 $0.07 $0.07 $0.01 $0.16
$0.34 $0.04 $0.41 $0.79 $0.00 $0.05 $0.05 $0.01 $0.11
2 10 100 47
SECTION
Figure C-4: Sample MAQS Costing Worksheet (Part 2 of 2)
$0.19 $0.04 $0.33 $0.55 $0.00 $0.04 $0.03 $0.01 $0.08
$0.20 $0.04 $0.54 $0.77 $0.00 $0.05 $0.05 $0.01 $0.11
SECTION C
$0.02 $0.05 $0.28 $0.35 $0.00 $0.02 $0.01 $0.00 $0.04
$0.00 $0.02 $0.15 $0.17 $0.00 $0.01 $0.01 $0.00 $0.02
$0.00 $0.02 $0.13 $0.14 $0.00 $0.01 $0.01 $0.00 $0.02
Mark-up
Total
$0.25 $0.25
$0.08 $0.08
$0.01 $0.01
$0.03 $0.03
$0.01 $0.01
$0.05 $0.05
$0.02 $0.02
$0.03 $0.03
$0.00 $0.00
$0.00 $0.00
Material Labor Burden TMC Scrape SG&A Profit ED&T
$2.16 $1.47 $6.44 $10.07 $0.03 $0.41 $0.38 $0.06 $0.89
2
$10.95
Notes:
a) Items 1,2, & 3 must all equal same value otherwise there is a computation error.
47