Rod Support Systems Cost Comparison

Size: px

Start display at page:

Download "Rod Support Systems Cost Comparison"

Vivien Murphy
5 years ago
Views:

1 Rod Support Systems Cost Comparison Ref. Time Estimation Booklet Nov 2, 2016, T. Gutowski 1

2 Example Problem Job Shop to large scale production 2

3 Picking Manufacturing Systems Job Shops very flexible, low volumes, high variety Flow shops arrange dedicated equipment in order of operations, balance flow, deskill jobs Transfer Lines automated transfer, hardwired flow shop Flexible Mfg. Systems (FMS) automate transfer between machines, allow skipping and double back Toyota cell special arrangement of flow shop with many machines per operator 3

4 Job shops - flexible 4

5 Flow Shop - dedicated L L M D G A A Receiving L M G G L M D Shipping 5

6 Toyota Mfg Cell HM VM Part movement L VM L Decoupler (Kanban square) G S Worker position Worker path Final inspection Raw material cart Finished part cart 6 OUT

7 Machining Systems Classification Ref J T. Black 7

8 Designing a cell for the Rod Support Goal one part every 2.5 minutes Material; Aluminum extrusion Tolerance , except for the two 0.50 radius corners which have + 1/64 8

9 Process planning How would you machine this part? Assumption: 1. We begin with a stock size of 2.5 X 2.25 X This will be manufactured in a job shop for very low quantity We will use: - A bandsaw to roughly cut the stock to size - A manual vertical mill to create the planar features and the holes - A belt sander to sand the radii ( assuming the tolerance is not very high) 9

10 10

11 Process plan Machine Operation Horizontal band saw Saw stock to ~4.125 Mill two ends to length 4 Mill width to 2 Manual vertical mill Mill out 2 X1.5 X4 Drill hole 1 diameter Bore 1 radius Belt sender Sand 0.5 radii 11

12 Time estimation (minutes) Machine Operation (V = Volume, A = Area, P = Perimeter) Horizontal band saw Saw stock to ~4.125 A = in 2, P = 9 in Fixture Tool Change Run (R=Rough, F=Finish) Deburr/Inspect/ Measure D, 0.05I Mill two ends to length 4 V = in 3 A = in 2, P = 19in R 0.75F 0.63D, 0.05I, 0.13M Mill width to 2 V = 2.5 in 3 A = 10 in 2, P = 13in R 0.67F 0.43D, 0.05I, 0.13M Manual vertical mill Mill out 2 X1.5 X4 V = 12 in 3 A = 14 in 2, P = 15in Drill hole 1 diameter - Center drill - Pilot drill ½ - Pilot drill 63/64 - Ream R 0.93F D, 0.05I 0.13M, 0.13M 0.21D, 0.05I 0.17M Bore 1 radius V = 0.79 in 3 A = 1.57 in 2, P = 7.28in R 0.01F 0.24D, 0.05I 0.06M Belt sender Sand 0.5 radii V = 0.05 in 3 A = 0.79 in 2, P = 3.14in R 0.21F 0.10D, 0.05I M, 0.06M

13 Summary Times (minutes) fixture tool change cutting inspect Saw Mill -ends width hog out hole bore Sand TOTAL Total = 25.6 minutes 13

14 Summary Times (minutes) fixture tool change cutting inspect Saw Mill -ends width hog out hole bore Sand TOTAL Total = 25.6 minutes 14

15 Cell Features 1. Start with extrusion (eliminate milling) 2. Use form drill 3. Use hole cutter for 1 dia 15

16 Cellular Layout (One operator) Radial Arm Drill Press w/ hole saw Cold Saw Belt Sander Drill Press w/ form drill 16

17 Cellular Layout (One operator) # Machine 10 Cold Saw 20 Radial Arm Drill Press Ope ration (V = volume, A=Are a, P = pe rime te r) Saw extrusion to 4", A=2, P=9 without D+I+M 1" Rad half hole use hole cutter Fixture 0.32 Tool Change Run (R= rough, F = finish) De burr, Inspe ct, Me asure (Time ) Manual Time 0.32 Machine Time Drill Press 1" dia from drill Belt Sander Sand 2*0.5" rad Note; Times in minutes 17

18 Cellular Layout (One operator) Cold Saw /.72 RA Drill Press /.24 manual Walking Time 0.2 Total Manual Time 2.34 Max. Machine Time 0.72 Cycle Time 2.34 Belt Sander /.4 Drill Press /.04 Note: times in minutes Walking time 18

19 Standard Work for Rod Support Cell PAR Rod Support Ope ra tors: PROCESS TIME {secs} # OPERATION Man Walk Auto Extrusion 3 2 Cold Saw Rad Arm Drill Press Drill Press Belt Sander Note; Times in Seconds 19

20 Cost Estimate Variable Costs labor and materials Fixed Costs equipment C/N C = F + V N N* N 20

21 Job shop (Small quantities, Aluminum block) # Machine Operation (V = volume, A=Area, P = perimeter) Saw stock to ~4.125", A=5.625, Mill two ends to length 4'', V=0.703, A=11.25, P=19 Fixture Tool Change Run (R= rough, F = finish) Deburr, Inspect, Measure (Time) Deburr, Inspect, Measure Deburr Inspect Deburr Inspect 0.13 Measure Deburr Mill width to 2", Inspect V=2.5 A=10 P= Measure Deburr 40 2 Mill out 2"*1.5"*4", Inspect V=12, A=14, P= Measure 0.13 Measure Drill hole 1" diameter Deburr * Center drill 0.2 *Pilot drill 1/2" Inspect *Pilot drill 63/64" Measure Ream Bore 1" radius, Deburr V=0.79, A=1.57, Inspect P= Measure Deburr Sand 0.5" radii, V=0.05, A=0.79, P= Inspect Measure 0.06 Measure Totals

22 Job shop (Large quantities, Aluminum extrusion) # Machine Operation (V = volume, A=Area, P = perimeter) Fixture Tool Change Run (R= rough, F = finish) Deburr, Inspect, Measure (Time) Deburr, Inspect, Measure 0.3 Deburr 10 1 Saw extrusion to 4", A=2, P= Inspect 0.13 Measure 20 2 Drill hole 1" diameter * Center drill *Pilot drill 1/2" Deburr Inspect *Pilot drill 63/64" Measure Ream Deburr Bore 1" radius, V=0.79, Inspect A=1.57, P= Measure Deburr 40 3 Sand 0.5" radii, V=0.05, A=0.79, P= Inspect Measure 0.06 Measure Totals

23 CNC production, aluminum block # Machine Operation (V = volume, A=Area, P = perimeter) Saw stock to 4", A=5.625, P=9 Mill out 2"*1.5"*4", V=12, A=14, P=15 Contour mill 0.5" radii, V=0.05, A=0.79, P=3.14 Fixture Tool Change Run (R= rough, F = finish) Deburr, Inspect, Measure (Time) Deburr, Inspect, Measure 0.3 Deburr Inspect 0.13 Measure Deburr Inspect 0.13 Measure 0.13 Measure Deburr Inspect 0.06 Measure 0.06 Measure Drill hole 1" diameter Deburr 40 2 * Center drill 0 *Pilot drill 1/2" Inspect *Pilot drill 63/64" Measure Ream Bore 1" radius, Deburr 50 2 V=0.79, A=1.57, Inspect P= Measure Totals

24 Flow shop (Unbalanced work load) # Machine 10 1 Ope ration (V = volume, A=Are a, P = pe rime te r) Saw extrusion to 4", A=2, P=9 Fixture 0.32 Tool Change Run (R= rough, F = finish) De burr, Inspe ct, Me asure (Time ) Deburr, Inspect, Measure 0.3 Deburr 0.05 Inspect 0.13 Measure Operation Time 1.52 Drill hole 1" 20 2A 0.12 diameter (R=6.28) Deburr 0.05 Inspect 0.17 Measure B Sand 0.5" radii, V=0.05, A=0.79, P=3.14 Drill with hole cutter 1" radius (use 0.82 in^3/min) V=0.196, P= Deburr Inspect Measure 0.06 Measure 0.24 Deburr Inspect 0.06 Measure Totals

25 Flow shop (Improved work load) # Machine A Ope ration (V = volume, A=Are a, P = pe rime te r) Saw extrusion to 4", A=2, P=9 without D+I+M Deburring+ Inspect+Measure of sawing +Drill hole 1" diameter (R=6.28) Fixture 0.32 Tool Change Run (R= rough, F = finish) De burr, Inspe ct, Me asure (Time ) Deburr, Inspect, Measure 0 N/A 0.3 Deburr 0.05 Inspect 0.13 Measure Deburr 0.05 Inspect 0.17 Measure Operation Time B Sand 0.5" radii, V=0.05, A=0.79, P=3.14 Drill with hole cutter 1" radius (use 0.82 in^3/min) V=0.196, P= Deburr Inspect Measure Measure 0.24 Deburr Inspect 0.06 Measure 0.71 Totals

26 Comparison Flow Shop 2 Time (Min./ part) Job Shop Job Shop 2 CNC Production Flow Shop 1 Cellular Labor 1 Experienced Machinist 1 Experienced Machinist 1 Experienced CNC Machinist 4 Medium skilled workers 4 Medium skilled workers 1 Multifunctional worker Labor cost ($/hr) Equipme nt Equipme nt cost ($) Mate rial Cost ($/part) Horizontal Bandsaw 1, Vetical Mill ,000 (Manual) Belt Sander 1,600 Cold Saw 15, Vetical Mill (Manual) 15, Belt Sander 1,600 Cold Saw 15, CNC Vertical Mill w/ Tool 125, Changer Auto Indexer 2,000 Cold Saw 15,000 Drill Press 10, Radial Arm ,000 Drill Press Sander 2,500 Cold Saw 15,000 Drill Press 10, Radial Arm ,000 Drill Press Sander 2,500 Cold Saw w/ feed 20,000 Drill Press w/ 7,500 feed Radial Arm Drill Press w/ 22,000 feed Sander 1,500 26

27 Comparison of Various System Job Shop 2 Time (Min./ part) Job Shop CNC Production Labor 1 Experienced Machinist 1 Experienced Machinist 1 Experienced CNC Machinist Labor cost ($/hr) Equipme nt Equipme nt cost ($) Mate rial Cost ($/part) Horizontal Bandsaw 1, Vetical Mill ,000 (Manual) Belt Sander 1,600 Cold Saw 15, Vetical Mill (Manual) 15, Belt Sander 1,600 Cold Saw 15, CNC Vertical Mill w/ Tool 125, Changer Auto Indexer 2,000 Cold Saw 15,000 Drill Press 10, Radial Arm Drill Press 17,000 Sander 2,500 Cold Saw 15,000 Drill Press 10, Radial Arm ,000 Drill Press Sander 2,500 Cold Saw w/ feed 20,000 Drill Press w/ 7,500 feed Radial Arm Drill Press w/ 22,000 feed 4 Medium Flow Shop skilled 1.92 workers Flow Shop 2 Cellular Medium skilled workers 1 Multifunctional worker 27

28 Cost Calculation without considering Inventory holding cost Cycle Time Material Fixed Cost Variable Cost Labor ($/hr) (min) ($/lb) ($) ($) Job Shop , Job Shop , CNC , Flow Shop , Flow Shop , Cellular ,

29 Cost for increasing production volume Unit cost vs. Number of Units Unit cost Job Shop1 Job Shop2 CNC production Flow Shop1 Flow Shop 2 Cellular Mfg Production number 29

30 Close-Up Job Shop Flow Shop Cell 30

31 Cost for increasing production volume Production Number Job Shop1 Job Shop2 CNC production Flow Shop1 Flow Shop 2 Cellular Mfg , , , , , , , Lowest variable cost Note: annual capacity for cell is >150,000 parts 31

32 COMMENTS (parts/shift) Job Shop (33) & CNC (52): flexible, skilled labor Flow Line (444): high output, 4 workers Cell (205): lowest variable cost, but demanding work 32

XEBEC AWARD 2008 Best Tip of the Year. How to operate XEBEC Cross-Hole Deburring Tool Alumina Fiber Rod Type with low speed lathes

XEBEC AWARD 2008 Best Tip of the Year. How to operate XEBEC Cross-Hole Deburring Tool Alumina Fiber Rod Type with low speed lathes AWARD 2008 Best Tip of the Year How to operate Cross-Hole Deburring Alumina Fiber Rod Type with low speed lathes When the spindle can bring up to max 4,000 rpm only, problem is solved by using the air