LO Learning outcome (LO) AC In this assessment you will have the opportunity to present evidence that shows you are able to: Task no. Evidence (Page no) 3 3.1 calculate break-even points and identify suitable processes for given quantities 1 3.2 calculate cycle times for given components using specified equipment 2 3.3 specify CAM layouts for single spindle autos 3 3.4 make decisions based on the initial costs and running costs of Flexible Manufacturing Systems (FMS), Flexible Manufacturing Cells (FMC) and stand-alone machinery 4 Learning outcome (LO) AC In this assessment you will have the opportunity to present evidence that shows you are able to: Task no. Evidence (Page no) 4 4.1 Explain the technical requirements, uses and applications of special manufacturing processes. 5 4.2 Discuss the benefits and drawbacks of special manufacturing processes. 6 4.3 Identify the mix of manufacturing process equipment required to produce given components and assemblies Economically. 7 LO 3.1& 3.2 You are employed as a product engineer and have been asked to investigate the departmental costing in respect to fixed costs, Variable costs, contribution and breakeven point for a range of products and processes. Table of information Process Material Material Weight Material cost/tonne Material cost per component Operator cost/ Hour Hours per day Cycle times Quantity produced Total variable cost Pressings Mild steel Weight=9.5Kg £362/tonne From Table 2 shifts of 8 hrs 8.25 minutes 3 axis milling High carbon steel Weight=3.5Kg £578/tonne £13.50 2 shifts of 8 hrs 3.75 minutes Milling/turning centre Low carbon steel Weight=2.25Kg £501/tonne £15.50 2 shifts of 8 hrs 6.75 minutes CNC Turning Brass Weight=3.5 Kg £2,800/tonne From table 1 shift of 8hrs 4.25 minutes Casting Aluminium LM25 Weight=12.5Kg £1,501/tonne £12.50 3 shifts of 8hrs 15.5 minutes X-ray £10.00 3 shifts of 8hrs 2.25 minutes Calculate the Material cost per component and the operator cost per shift Complete the above table to work out the variable cost for Operator cost and material cost Operator cost Per Hour Pressing Operator cost Per Hour Brass £10.00 £11.45 Indirect fixed workforce Costs Managing director £75,000/Pa Finance accountant £55,000/Pa Engineering manager £45,000/Pa Office workers 6x16000/Pa= £96,000/Pa Purchase department 5x15000/Pa = £75,000/Pa Engineering department 4x15,000/Pa 2x22,000/Pa 1x28,000/Pa = £132,000/Pa Insurance £2100/Pa Advertising £1650/Pa IT Systems £4000/Pa Rent £6000/Pa Energy Costs Gas & Electric £20,000/Per Month From the table given calculate the monthly fixed cost Process Total Variable manufacturing cost per product Selling Price £ Weekly sales Total Contribution Total Revenue Pressing 120 x contribution = selling price x Qty 3 axis milling 240x contribution = selling price x Qty Milling/turning centre 137x contribution = selling price x Qty CNC Turning Brass 96x contribution = selling price x Qty Casting 90x contribution = selling price x Qty TOTAL £per wk = £= Calculate the variable manufacturing cost of Labour & Material cost per component. Calculation for the selling price of each product & the contribution that each component produces Selling price = (£variable Man cost÷ 80) × 100 = £0.00 Contribution = £selling price -£ variable Man cost = £0.00 contribution per pressing Selling price = ( £variable Man cost ÷ 80) × 100 = £0.00 Contribution = £selling price-variable Man cost = £0.00 contribution per 3 axis component. Selling price = (£variable Man cost ÷ 80) × 100 = £ Contribution = £ selling price-variable Man cost = £0.00 contribution per mill/turn component. Selling price = (£variable Man cost ÷ 80) × 100 = £ Contribution = selling price-variable Man cost = £0.00 contribution per brass component Selling price = (£variable Man cost ÷ 80) × 100 = £4.49 Contribution = selling price-variable Man cost = £0.00 contribution per cast component From the data derived, produce a Break-even graph with the following data included on the graph for a 12 month period 1/ Direct costs, variable costs, contribution and total revenue 2/ Using the formula for the breakeven point = Fixed costs per month / total contribution per month Calculate the payback period in months. LO 3.3 Specify CAM layouts for single spindle autos. Machining sequence and cycle times Machine 1 (1) Manual loading time including clamping = 1min 20sec (2) Rough machine from ø50 to ø 42 = 2min 45sec (3) Unclamp remove part and place on conveyor = 10sec Machine 2 (1) Manual loading time including clamping = 1min (2) Machine 4 flats on the shaft = 3min 15sec (3) Unclamp, remove part and place on conveyor = 15sec Machine 3 (1) Manual loading time including clamping = 1min 20 sec (2) Drill 4 holes equally spaced = 3min 10 sec (3) Unclamp, remove part and place on conveyor = 15sec Machine 4 (1) Manual loading time including clamping = 1min 10 sec (2) Machine 4 grooves 5mm wide 4mm deep = 1min 25sec (3) Unclamp, remove part and place on conveyor = 15sec Machine 5 (1) Manual loading time including clamping = 1min (2) Knurl ø 40 for 30mm = 1min 20sec (3) Unclamp, remove part and place on conveyor = 15sec For the above system calculate the cycle time for each process individually and identify where the bottle neck will be. Calculate the number of products produced in an 8 hour shift. Investigate the system to balance the quantities produced so that the system has no bottle neck and all machines are working with a similar cycle time by transferring operations between the machines. LO 3.4 Make decisions based on the initial costs and running costs of Flexible Manufacturing Systems (FMS), Flexible Manufacturing Cells (FMC) and stand-alone machinery You have been given three different manufacturing systems to produce the following product: - A machine vice, the volume required = 100,000 P/A, identify all the components that are required and determine how they will be manufactured. Develop a manufacturing solution for each of the above systems (FMS, FMC or Standalone machinery.) See moodle for solid models of all the components LO 4.1 Explain the technical requirements, uses and applications of special manufacturing processes. For the following, describe the process and identify suitable products that can be manufactured. Use suitable visual methods to help with your description. 1/ Chemical machining 2/ Electro discharge machining (die sinking, wire cutting) 3/ Laser machining 4/ Water jet cutting 5/ PCB routing and drilling 6/ Ultrasonic machining 7/ Rapid prototyping 8/ Flame cutting 9/ Plasma cutting 10/ Emerging technologies 11/ Economics of non-traditional manufacturing processes 4.2 Discuss the benefits and drawbacks of special manufacturing processes. From the list in LO4.1 Investigate 5 of the processes and identify a range of identifiable drawbacks and a range of tangible benefits. Use calculations if appropriate to validate your answers. 4.3 identify the mix of manufacturing process equipment required to produce given components and assemblies economically. For 2 of the products illustrated below suggest the most suitable forms of manufacturing equipment required identify suitable machine and show indicative costs, Look at all aspects of the product both mechanically and electrically if relevant. State any assumptions you make such as (quantity produced, material, costs, pay back period, and cycle time estimation etc.)