FPB-1800 Justification - Peddinghaus · FPB-1800 Justification A real calculation from a fabricator...
Transcript of FPB-1800 Justification - Peddinghaus · FPB-1800 Justification A real calculation from a fabricator...
FPB-1800 Justification
A real calculation from a fabricator analyzing his costs, and justifying the purchase of a Peddinghaus FPB-1800
Gussets – A Fabricators’ Cost Analysis
•A Fabricator in North America needed to run a large amount of gussets similar to the drawing to the right.
•They did their own cost analysis in justifying the Peddinghaus FPB‐1800 purchase.p
•They asked several employees to estimate the time it took them to make the part manually and thenmake the part manually, and then calculated time and costs involved.
Employee One - Time EstimateT k Ti t P fTask Time to Perform
Template 1 min
Layout 2 min
Burn 11 min
Drill/clean 4 min
Handling 2 ming
Total 20 Min + indirect time factors (25%) =25 min/plate25 min/plate
TOTAL MAN HOURS = 1,327 for Project
Employee Two - Time EstimateT k Ti t P fTask Time to Perform
Template 1 min
Layout 2 min
Burn 15 min
Drill/clean 4 min
Handling 3 ming
Total 25 Min + indirect time factors (25%) =31 25 min/plate31.25 min/plate
TOTAL MAN HOURS = 1,658 for Project
Employee Three - Time Estimate (Fabtrol Adjusted)
Task Time to Perform
Template 0 min
Layout 5 minLayout 5 min
Burn 12.5 min
Drill/clean 5 min
Handling 3 min
Paint 1 min
Total 26 5 Min + indirectTotal 26.5 Min + indirect time factors (25%) =33.125 min/plate
TOTAL MAN HOURS = 1,758 for Project
Average Hours from 3 Estimates for this Project Done Manually:
1581 HOURS29.8 MIN/PLATE
Peddinghaus Estimate (based on 72×240” Plate)
Task Number of Repetitions Time Performed
Punch 120 holes 6 Minutes
Plasma 30 pierces 3 Minutes
Plasma cut 2554.7 inches 17.62 Minutes
Total Process Times 26.62 min for 30 parts .89 minutes per gusset plate
Total Time After Handling (2 min. per plate from 4.06 min/Gusset + (25% f g ( p p ftruck to machine)
/ (indirect) = 5.08 min/plate
TOTAL TIME WITH PEDDINGHAUS
The Peddinghaus Difference:
Hours to do Manually: 1581TOTAL LABOR SAVINGS FOR PROJECT:
y‐ Hours to do with FPB‐1800: 270SAVED SHOP HOURS 1311SAVED SHOP HOURS: 1311
Material Cost Savings
Material Cost Analysis
Current Materials Rectangular cut plates: 3184 $139,452.83Current Materials Rectangular cut plates: 3184 pieces×71.8 lbs. @$.61
$139,452.83
Materials with FPB‐1800 72×240 plates30 Gussets per plate =
$119,123.6830 Gussets per plate 106.133 plates @ 122 plf ×20 @ $.46
Material Cost Savings $20,329.15
Total Cost Savings for this Project:
Total Labor Savings for Gusset Plates
Labor @ $30.00 / hr × 1311 $39,330.00 saved
Material $20.329.15 savedMaterial $20.329.15 saved
TOTAL $59,659.00 TOTAL SAVINGS
/ $60,000/129.5 TONS $463.32 SAVED PER TON OF GUSSET PLATES
Approximate Annual Labor and Plate M i l C S i C l l iMaterial Cost Savings Calculation:•Assuming average yearly plate projects = 10%
•Assuming yearly production is on average from 8,000 to 10,000 tons
•Average yearly plate content therefore is 800‐1000 tonsAverage yearly plate content therefore is 800 000 tons
•Average yearly base plate content = 50% of plate content
•Therefore annual gusset plate requirements = 400 to 500 tons•Therefore annual gusset plate requirements = 400 to 500 tons
•Yearly savings with weight at $463.32 = $185,328 to $231,660
•Less estimated consumable costs annually = $10,800…..
Estimated Yearly Savings:
$174 528 t$174,528 to $220,860$220,860
Estimated Payback Period:
2 5 3 22.5 to 3.2 YearsYears