LOGO Capstone Design Economic analysis through line balancing.
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Transcript of LOGO Capstone Design Economic analysis through line balancing.
LOGO
Capstone DesignEconomic analysis through line balancing
LOGO
Contents
Introduction to Team members & Topic1
Reason of topic selection2
Market conditions3
Progress direction of project4
Schedules5
LOGO
Introduction toTeam members & Topic1
Economic analysis through line balance
LOGO
Capstone Design
Engineering Economics
Quality Control
Production Management
Senior
Junior
Reason of topic selection
2
Productivity, Line-Balance,
Plant Management
Reliability, Defective ratio
Investment analysis
Utilize all of IE’s tools
LOGO
Market conditions3
Increase over last year 27.1 %
Increase over last year 27 %
<Market present condition of domestic family washing machine>
자료출처 : 통계청 광업ㆍ제조업 통계조사 보고서
LOGO
Market conditions3
Distinction
Number of companiesProduction
Amount(1million won)shipment
Amount(1million won)
Yearlyaverage
Yearlyaverage
Growth rate
Yearlyaverage
Yearlyaverage
Growth rate
Yearlyaverage
Yearlyaverage
Growth rate
2004-2007 9 19.35% 1,822,261 10.05% 1,825,660 9.88%
<Market present condition analysis of domestic family washing machine>
자료출처 : ( 주 ) 밸류애드
LOGO
Error process
ProcessFormGrasp Line-Balance
Productivity
DefectiveRatio
Analysis
Analysis of economy
The direction of project4
LOGO
Week 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Report the plan
Visit to field
Process form
grasp
Error process
analysis
Productivity
analysis
Line-Balance
analysis
Simulation modeling
Economical
evaluation
Resultant
report
Schedules5
LOGO
LOGO
Capstone DesignEconomic analysis through line balancing
LOGO
Contents
Introduce to Company1
Production Flow2
Analysis by Process3
4 Schedules
LOGO
Company Introduction1
Company Name :
Dongyang Inotek
Owner : Yang jong-hyeon
History : Established in 2007
Manufactured Items :
Washing machine Shaft
Last year Sales : 6 billion
Location :
1235-21 ok-dong, gwangsangu
LOGO
Production Flow
Factory inside photo
2
LOGO
Production Flow
Materials Centering Process Lathe turning Process
Heat treatment Process Press-in Process Form rolling Process
Polishing Process TAP Process Product
2
LOGO
Analysis by Process3
Process Name :
Centering Process
Drill holes on both sides of materials center
LOGO
Analysis by Process3
Process Name :
Lathe turning Process
Using a CNC lathe machining
LOGO
Analysis by Process3
Process Name :
Heat treatment Process
Heat treatment
LOGO
Analysis by Process3
Process Name :Press-in process
Put the bearings
LOGO
Analysis by Process3
Process Name :Form rolling Process
Screw Machining
LOGO
Analysis by Process3
Process Name :Polishing Process
Trim surface
LOGO
Analysis by Process3
Process Name :TAP Process
Screw Machining
LOGO
Week 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Report the plan
Visit to field
Process form
grasp
Error process
analysis
Productivity /
Defective ratio
analysis
Line-Balance
analysis
Simulation modeling
Economical
evaluation
Resultant
report
Schedules4
4Plan Run
LOGO
LOGO
Capstone DesignEconomic analysis through line balancing
LOGO
Contents
Working time & Production volume 1
Error process analysis2
Defective ratio & Productivity analysis3
4 Schedules
LOGO
Working time & Production volume1
Weekday = 36,600 sec / day(10hour 10min)
Saturday = 27,600 sec / day(7hour 40min)
A month Working hours
= 22(day) X 36,600(sec) + 4(day) X 27,600(sec)
= 805,200(sec) + 110,400(sec)
= 915,600(sec)=254hour 20min
Average monthly production = 8,100 EA
Average daily production = 312 EA
Heat treatment process
Press – in process
Form rolling process
Polishing process
TAP process
Lathe turning process
Centering process (1 machine)
(2 machine)
(1 machine)
(1 machine)
(1 machine)
(1 machine)
(1 machine)
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Error process analysis
One Process – One machine
Total work time per 1EA 25 200 40 25 35 18 50 393Efficiency (E) = = = 0.2807 = 28.07%
Number of workplace Cycle-Time 7 200 1400
Time(sec)
Process name
2
Unbalance Rate(D) = 1 - Efficiency = 1 - 0.2807 = 0.7193 = 71.93%
( ) (Number of workplace Cycle-Time) - Total work time per 1EA = (7 200) - 393 = 1007(sec) = 16min 47secIdle Time IT
LOGO
Error process analysis
Actual Process : Used 2 lathe turning machine
Time(sec)
Process name
Total work time per 1EA 25 100 40 25 35 18 50 293Efficiency (E) = = = 0.4186 = 41.86%
Number of workplace Cycle-Time 7 100 700
2
Unbalance Rate(D) = 1 - Efficiency = 1 - 0.4186 = 0.5814 = 58.14%
( ) (Number of workplace Cycle-Time) - Total work time per 1EA = (7 100) - 293 = 407(sec) = 6min 47secIdle Time IT
LOGO
Defective ratio & Productivity analysis
3
Number of defective 1Defective ratio = = = 0.00125 = 0.125%
Number of good products 800
Productivity = 1 - Defective ratio = 1 - 0.00125 = 0.99875 = 99.875%
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Week 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Report the plan
Visit to field
Process form
grasp
Error process
analysis
Productivity /
Defective ratio
analysis
Line-Balance
analysis
Simulation modeling
Economical
evaluation
Resultant
report
Schedules4
4Plan Run
LOGO
LOGO
Capstone DesignEconomic analysis through line balancing
LOGO
Contents
Calculation of objectives cycle-time1
Calculate the minimum workplace2
Relationship between number ofequipment and line efficiency3
4 Schedules
LOGO
Calculation of objectivescycle-time
Process flow photo
1
LOGO
Calculation of objectivescycle-time
1
(Day at work)
3,125 EA
per
month
5,625 EA
per
month
(Day and night work)(Day at work)(Day at work)
3,125 EA
per
month
3,125 EA
per
month
14,580 EA
per
month
8,100 EA
per
month
8,100 EA
per
month
8,100 EA
per
month
LOGO
Calculation of objectivescycle-time
1
1month production : 8,100 EA
Sum of production day work : 8,100 EA X 9 month = 72,900 EA
Sum of production night work : (8,100 EA X 1.8) X 3 month= 43,740 EA
1year total production : 72,900 EA + 43,740 EA = 116,640 EA
Currently cycle-time : 293 sec per 1EA
Objective tact-time : 915,600 sec / 9,720 EA = 94.19 sec per 1EA
1month production objectives : 116,640EA / 12month = 9,720 EA
Day and night 1month production work : 8,100 EA X 1.8= 14,580 EA
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Calculate the minimum workplace2
..
Currently cycle-time 293Minimum workplace = = = 3.1 = 4
Objective tact-time 94.19
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Calculate the minimum workplace2
Process name
Time(Sec)
1machine
4machine
1machine
1machine
1machine
1machine
1machine
※ Note : Currently Efficiency = 41.86 %
Total work time per 1EA 25 50 40 25 35 18 50 243Efficiency (E) = = = 0.6942 = 69.42%
Number of workplace Cycle-Time 7 50 350
..
Currently cycle-time 293Minimum workplace = = = 3.1 = 4
Objective tact-time 94.19
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Relationship between number ofequipment and line efficiency
3
30 60 90 120 150 180 210 270240 330 360300
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Cycle-time
Number ofequipment
Efficiency
41.86 %
69.42 %
79.51 %
244.16 sec
159.1 sec
243 sec
293 sec
208 sec 74.29 %
Centering : 25 sec (1 machine) Lathe turning : 40 sec (5 machine) Heat treatment : 40 sec (1 machine) Press-in : 25 sec (1 machine) Form rolling : 35 sec (1 machine) Polishing : 18 sec (1 machine) TAP : 25 sec (2 machine)
Total : 208sec (12 machine)
2080.7429 74.29%
7 40E
Centering : 25 sec (1 machine) Lathe turning : 28.6 sec (7 machine) Heat treatment : 20 sec (2 machine) Press-in : 25 sec (1 machine) Form rolling : 17.5 sec (2 machine) Polishing : 18 sec (1 machine) TAP : 25 sec (2 machine)
Total : 159.1sec (16 machine)
159.10.7951 79.51%
7 28.6E
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Week 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Report the plan
Visit to field
Process form
grasp
Error process
analysis
Productivity /
Defective ratio
analysis
Line-Balance
analysis
Simulation modeling
Economical
evaluation
Resultant
report
Schedules4
4Plan Run
LOGO
LOGO
Capstone DesignEconomic analysis through line balancing
LOGO
Contents
Correction contents1
2
Simulation modeling3
4 Result & Analyze
Raw data for simulation
Schedules5
LOGO
Correction contents1
Average monthly production = 8,100 EA
Working time per month = 915,600 / sec
Net working time per month 915,600Tact time = 113 / sec
Production per month 8,100
Total production of 1 year = 116,640 EA
Objective monthly production = 116,640 / 12 = 9,720 EA
Net working time per month 915,600Objective tact time = 94.20 94.12sec
Production per month 9,720
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Correction contents1
(Day at work)
3,125 EA
per
month
5,625 EA
per
month
(Day and night work)(Day at work)(Day at work)
3,125 EA
per
month
3,125 EA
per
month
8,100 EA
per
month
8,100 EA
per
month
8,100 EA
per
month
14,580 EA
per
month
14,580 EA
per
month
8,100 EA
per
month
8,100 EA
per
month
8,100 EA
per
month
8,100 EA
per
month
8,100 EA
per
month
8,100 EA
per
month
14,580 EA
per
month
Used 2 lathe turning machines
LOGO
Correction contents1
(Day at work)
3,125 EA
per
month
5,625 EA
per
month
(Day at work)(Day at work)(Day at work)
3,125 EA
per
month
3,125 EA
per
month
8,100 EA
per
month
8,100 EA
per
month
8,100 EA
per
month
14,580 EA
per
month
14,580 EA
per
month
8,100 EA
per
month
8,100 EA
per
month
8,100 EA
per
month
9,720 EA
per
month
9,720 EA
per
month
9,720 EA
per
month
9,720 EA
per
month
Used 3 lathe turning machines
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Raw data for simulation
Number of equipment to satisfy 94.12 seconds
Time(sec)
Process name
2
94.12 / sec
Used 3 Lathe turning machines cycle time = 66.67 sec
<Used 3 Lathe turning machines>
3,125 EA
per
month
8,100 EA
per
month
LOGO
Raw data for simulation
3,125 EA
per
month
8,100 EA
per
month
9,720 EA
per
month
Each process cycle time & process form
Working hours a day
3,125 EA
per
month 8,100 EA
per
month
<Used 2 lathe turning machine>
Week : 36,600 sec
Weekend : 27,600 sec
Objective Tact-time = 94.12 sec
Centering : 25sec Lathe turning : 200sec Heat treatment : 40sec
Press-in : 25sec Form rolling : 35sec Polishing : 18sec Tap : 50sec
2
LOGO
Simulation modeling
Used 2 lathe turning machines
Time constraints
Constraints for
only one hour’s operation
Input the raw material
throughout the
lathe turning process
Finished product
from heat treatment
3
LOGO
Simulation modeling
Used 3 lathe turning machines
3
LOGO
Result & Analyze
3,125 EA
per
month
5,625 EA
per
month
3,125 EA
per
month
3,125 EA
per
month
8,100 EA
per
month
8,100 EA
per
month
8,100 EA
per
month
9,720 EA
per
month
Used 2 lathe turning machine
4
LOGO
Result & Analyze
3,125 EA
per
month
5,625 EA
per
month
3,125 EA
per
month
3,125 EA
per
month
8,100 EA
per
month
8,100 EA
per
month
8,100 EA
per
month
9,720 EA
per
month
Used 3 lathe turning machine
4
LOGO
Week 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Report the plan
Visit to field
Process form
grasp
Error process
analysis
Productivity /
Defective ratio
analysis
Line-Balance
analysis
Simulation modeling
Economical
evaluation
Resultant
report
Schedules4 Plan Run5
LOGO
Simulation model
3,125 EA
per
month
8,100 EA
per
month
Show the simulation model
LOGO
LOGO
Capstone DesignEconomic analysis through line balancing
LOGO
Contents
Raw data for economical analyze1
2
Economical analyze3
4 Result
Method of economical analyze
Schedules5
LOGO
Row data foreconomical analyze
1
Machine investment cost
New Lathe Turning machine
66,000,000 won
Payment (Unit : won)
Minimum wage : 4,320
Weekend / Over time : 4,320 x 1.5 = 6,480
Night at work : 4,320 x 2 = 8,640
LOGO
Row data foreconomical analyze
1
Wage calculation
Weekday(1worker) : 34,560(8h) + 16,200(2h 30m) = 50,760
50,760 x 22(day/month) = 1,116,720
Weekend(1worker) : 6,480 x 8 = 51,840
51,840 x 4(day/month) = 207,360
1year = 10,592,640 x 12(month) = 127,111,680
1month = 1,324,080 x 8(worker) = 10,592,640
1worker wage / month = 1,116,720 + 207,360 = 1,324,080
Increase machine / year = 1,324,080 x 9(worker) = 143,000,640
LOGO
Row data foreconomical analyze
1
Night at work wage calculation
PM 20:00 ~ PM 22:00 : (4,320 x 1.5) x 2 = 12,960
PM 22:00 ~ AM 06:00 :(4,320 x 2) x 8 = 69,120
Sum = 82,080 / day
(82,080 x 8(worker)) x 22(weekday) = 14,446,080(month) x 3(month)
= 43,338,240
1year(day at work + night at work) = 127,111,680 + 433,338,240
= 170,449,920
Minimum wage increase rate
Year 2008 2009 2010 2011
Increase rate 8.3 % 6.1 % 2.8 % 5.1 %
LOGO
Row data foreconomical analyze
1
Warehouse cost estimate
Warehouse area : 20(pyeong)
Cost : 15,000,000
Incidental expenses
middle rack(10EA) = 250,000 x 10 = 2,500,000
Total cost = 15,000,000 + 2,500,000 = 17,500,000
LOGO
Method ofeconomical analyze
Depreciation(Decline-balance method)
2
1 1
N 10Depreciation factor ( ) = 1-(0.05) = 1-(0.05) 0.2588
N D-factor Dn Bn
0 0 0 66,000,000
1 0.2588 Bn x factor = 17,085,126 Bn – Dn1 =48,914,874
2 0.2588 Dn1 x factor = 12,662,376 Bn1 – Dn2 = 36,252,498
.
.10
0.2588.0.2588
.
.Dn9 x factor
.Bn 8 – Dn9 3,300,000(Salvage value)
N=Machine’s durable years(10)0.05 = Salvage value
A Compound Interest
(1 )NF P i i = interest rate
N = term
P = present value
F = future value
LOGO
Method ofeconomical analyze
Wages calculated according to the wage increase
4ponit moving average
2
t t-1 t-2 t-3 t-N+1t
D + D + D + D + + DAverage : A =
N
t tForecast : F +1 = A
t
t
t+1
N = Term
D = Actual value of T-term
A = Average of T-term
F = Value of T+1 term
LOGO
Economical analyze3
Actual
N YearForecast increase
Pay
0 2011 - ₩170,449,920
1 2012 5.56% ₩179,926,936
2 2013 4.88% ₩188,707,370
3 2014 4.57% ₩197,331,297
4 2015 5.03% ₩207,252,128
5 2016 5.01% ₩217,634,164
6 2017 4.87% ₩228,236,688
7 2018 4.87% ₩239,351,013
8 2019 4.94% ₩251,185,868
9 2020 4.92% ₩263,553,823
10 2021 4.90% ₩276,474,386
SUM of payment
₩2,420,103,593
Calculate future wage 10 years trough 4point moving average forecast method (Wage increase)
LOGO
Economical analyze3
After
Year Forecast Increase Pay D-factor Dn Bn
2011 - ₩143,000,640 - - ₩66,000,000
2012 5.56% ₩150,951,476 0.258865551 ₩17,085,126 ₩48,914,874
2013 4.88% ₩158,317,908 0.258865551 ₩12,662,376 ₩36,252,498
2014 4.57% ₩165,553,036 0.258865551 ₩9,384,523 ₩26,867,975
2015 5.03% ₩173,876,215 0.258865551 ₩6,955,193 ₩19,912,782
2016 5.01% ₩182,586,326 0.258865551 ₩5,154,733 ₩14,758,049
2017 4.87% ₩191,481,419 0.258865551 ₩3,820,350 ₩10,937,698
2018 4.87% ₩200,805,891 0.258865551 ₩2,831,393 ₩8,106,305
2019 4.94% ₩210,734,860 0.258865551 ₩2,098,443 ₩6,007,862
2020 4.92% ₩221,111,077 0.258865551 ₩1,555,228 ₩4,452,633
2021 4.90% ₩231,950,911 0.258865551 ₩1,152,633 ₩3,300,000
SUM ₩2,030,369,757 ₩62,700,000 ₩66,000,000.00
SUM of pay and
total depreciation value (1)
₩2,093,069,757
SUM of (1) and
Warehouse investment
₩2,110,569,757
Machine’s cost basis : 66,000,000
1
101 (0.05)
66,000,000 x 0.258865551
48,914,874 x 0.258865551
36,252,498 x 0.258865551
26,867,975 x 0.258865551
19,912,782 x 0.258865551
14,758,049 x 0.258865551
10,937,698 x 0.258865551
8,106,305 x 0.258865551
6,007,862 x 0.258865551
4,452,633 x 0.258865551
66,000,000 - 17,085,126
48,914,874 - 12,662,376
36,252,498 - 9,384,523
26,867,975 - 6,955,193
19,912,782 - 5,154,733
14,758,049 - 3,820,350
10,937,698 - 2,831,393
8,106,305 - 2,098,443
6,007,862 - 1,555,228
4,452,633 - 1,152,633
2,030,369,757 + 62,700,000
2,093,069,757 + 17,500,000
LOGO
Result
Result
Actual
4
After
N YearForecast
FactorPay
0 2011 - ₩170,449,920
1 2012 5.56% ₩179,926,936
2 2013 4.88% ₩188,707,370
3 2014 4.57% ₩197,331,297
4 2015 5.03% ₩207,252,128
5 2016 5.01% ₩217,634,164
6 2017 4.87% ₩228,236,688
7 2018 4.87% ₩239,351,013
8 2019 4.94% ₩251,185,868
9 2020 4.92% ₩263,553,823
10 2021 4.90% ₩276,474,386
SUM of payment
₩2,420,103,593
YearForecast Factor
Pay D-factor Dn Bn
2011
-₩143,000,64
00 0 ₩66,000,000
2012
5.56%₩150,951,47
60.2588655
51₩17,085,1
26 ₩48,914,874
2013
4.88%₩158,317,90
80.2588655
51₩12,662,3
76 ₩36,252,498
2014
4.57%₩165,553,03
60.2588655
51₩9,384,52
3 ₩26,867,975
2015
5.03%₩173,876,21
50.2588655
51₩6,955,19
3 ₩19,912,782
2016
5.01%₩182,586,32
60.2588655
51₩5,154,73
3 ₩14,758,049
2017
4.87%₩191,481,41
90.2588655
51₩3,820,35
0 ₩10,937,698
2018
4.87%₩200,805,89
10.2588655
51₩2,831,39
3 ₩8,106,305
2019
4.94%₩210,734,86
00.2588655
51₩2,098,44
3 ₩6,007,862
2020
4.92%₩221,111,07
70.2588655
51₩1,555,22
8 ₩4,452,633
2021
4.90%₩231,950,91
10.2588655
51₩1,152,63
3 ₩3,300,000
SUM₩2,030,369,7
57 ₩62,700,0
00 ₩66,000,000.0
0SUM of pay
and total depreciation
value (1)
₩2,093,069,757
SUM of (1) and
Warehouse investment
₩2,110,569,757
Salvage Value 0.05%
Total Depreciation value
LOGO
Result
Result
4
Alternative A(Operation like present)
For worker wages during 10 years the future 2,420,103,593 won occurrence
Alternative B(1 Equipment and 1 workers increase)
As equipment investment expense, worker wages and warehouse investment expense during 10 years the future 2,110,569,757 won occurrence
So, it is reasonable that select alternative B
LOGO
Week 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Report the plan
Visit to field
Process form
grasp
Error process
analysis
Productivity /
Defective ratio
analysis
Line-Balance
analysis
Simulation modeling
Economical
evaluation
Resultant
report
Schedules4 Plan Run5
LOGO