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Q.1.

Current Capacity of the plant


Length of Shift (minutes)
Setup time for gear machining (minutes)
Total time available for H1 (minutes)
Time required for machining of a gear (H1)
Number of gears machined per shift (H1)
Setup time for gear machining (minutes)
Total time available for S1 (minutes)
Time required for machining of a gear (S1)
Number of gears machined per shift (S1)
Setup time for shaft machining (minutes)
Total time available H2 (minutes)
Time required for machining of a shaft (H2)
Number of shaft machined per shift (H2)
Setup time for gear machining (minutes)
Total time available for S2 (minutes)
Time required for machining of a shaft (S2)
Number of shafts machined per shift (S2)
Time available for heat treatment
Number of gears heat treated per shift (Max.)
Time available for heat treatment
Number of shafts heat treated per shift (Max.)
Setup time for gear finish grinding (minutes)
Total time available for finish grinding of a gear FG1+FG2 (minutes)
Time required for finish grinding of a gear (FG1+FG2)
Number of gears finished per shift (FG1+FG2)
Setup time for shaft finish grinding (minutes)
Total time available for finish grinding of a shaft FG1+FG2 (minutes)
Time required for finish grinding of a shaft (FG1+FG2)
Number of shafts finished per shift (FG1+FG2)

Therefore, capacity is constrained by number of gears and shaft which can be machined (H
Number of gears finished per day
Number of shafts finished per day
Number of gearboxes finished per day
Number of gearboxes finished per month
Number of gearboxes finished per year
Taking 85% efficiency into account, revised capacity
Therefore, current capacity of plant is 14790 gearboxes per year.

Assumptions: The machines HI, S1, H2, S2 and FG1 and FG2 have to be set up once every day (for all

The capacity can be increased in the following manner


1. The number of required sets of shafts is less compared to the gears needed for a gear box, so we ca

ABC DEMM LTD CASE

Morning Shifts
Evening Shift Night shift
450
450
390
120
0
0
330
450
390
5
5
5
66
90
78
60
0
0
390
450
390
3
3
3
130
150
130
120
0
0
330
450
390
8
8
8
41
56
48
60
0
0
390
450
390
5
5
5
78
90
78
450
450
390
250
250
250
450
450
390
100
100
100
30
0
0
840
900
780
2
2
2
420
450
390
30
0
0
840
900
780
6
6
6
140
150
130

234

410

145

246
750
300

1260

420

ich can be machined (Hobber) per shift as it is the lowest capacity machine on the floor layout (H1
234
145
58
1450
17400
14790

up once every day (for all three shifts). Hence, available time for working is reduced by setup time in every shift

d for a gear box, so we can choose to convert H2 and S2 to gear hobbing and shaving machines after every few

ne on the floor layout (H1 - 234 gears, H2 - 145 shafts).

ed by setup time in every shift.

ving machines after every few shifts

Q2.
Gear Box Manufacturing Cost

Sr.No Item
1 Gear Blanks
2 Cost of Gear Shaft blanks
3 Grear Housing
4 Gear Box Assembly Kit
5 Other Tools and consumables
6 Packaging material
Total Cost Price of Gear Box
Selling Price of the Gear Box

Cost
2400
2800
6000
800
340
160
12500
20000

Sr.No Worker
Cost
1 Regular
792000
2 Temporary
18000
3 Supervisor
90000
4 Executive
80000
Total Monthly Direct Labor Cost
980000
Capacity (current)
Sales 2013-14
Increased capacity
Expected Sales (2014-15)

14790
11700
16320
13455

S.No
1
2.a
b
c
d
3
a
b
4
5
6
7
8
9
10
11

Factor
Sales Realization
Raw Material Cost
Bought out items
Rejections
Packing material costs
Manpower
Direct
Indirect
Other cost tools and consumables
Plant O H and Power etc.
Repairs and Maintenance
Depreciation
Interest
Administrative and selling costs
Welfare costs
[1-(2 to 10)] PBT
Profitability (PBT/Sales)
Increase in profitability

After Changes(for
25% increase in
Current
profitability
234000000
269100000
60840000
69966000
79560000
91494000
1216800
1399320
1872000
2152800
11760000
0
3978000
12240000
4680000
7480000
7200000
4680000
1000000
37493200

11760000
0
4574700
10836000
5382000
7480000
7200000
5382000
1000000
50473180

16.02%
17.06%

18.76%

Q3.
We propose to convert H2 and S2 to gear machining and use 10% of time on H2 and S2 for gear machining. Rest 90% time will be use
0.1
New capacity of the plant after conversion of H2 and S2 in gear machining
Morning Shifts
Evening Shift
Length of Shift (minutes)
450
450
Setup time for gear machining (minutes)
120
0
Total time available for H1 (minutes)
330
450
Time required for machining of a gear (H1)
5
5
Number of gears machined per shift (H1)
66
90
Setup time for gear machining (minutes)
60
0
Total time available for S1 (minutes)
390
450
Time required for machining of a gear (S1)
3
3
Number of gears machined per shift (S1)
130
150
Setup time for gear machining (minutes)
120
0
Total time available for H2 (minutes)
33
45
Time required for machining of a gear (H2)
5
5
Number of gears machined per shift (H2)
6
9
Setup time for gear machining (minutes)
60
0
Total time available for S2 (minutes)
39
45
Time required for machining of a gear (S2)
3
3
Number of gears machined per shift (S2)
13
15
Setup time for shaft machining (minutes)
120
0
Total time available H2 (minutes)
297
405
Time required for machining of a shaft (H2)
8
8
Number of shaft machined per shift (H2)
37
50
Setup time for gear machining (minutes)
60
0
Total time available for S2 (minutes)
351
405
Time required for machining of a shaft (S2)
5
5
Number of shafts machined per shift (S2)
70
81
Time available for heat treatment
450
450
Number of gears heat treated per shift (Max.)
250
250
Time available for heat treatment
450
450

Number of shafts heat treated per shift (Max.)


Setup time for gear finish grinding (minutes)
Total time available for finish grinding of a gear FG1+FG2 (minutes)
Time required for finish grinding of a gear (FG1+FG2)
Number of gears finished per shift (FG1+FG2)
Setup time for shaft finish grinding (minutes)
Total time available for finish grinding of a shaft FG1+FG2 (minutes)
Time required for finish grinding of a shaft (FG1+FG2)
Number of shafts finished per shift (FG1+FG2)

100
30
840
2
420
30
840
6
140

100
0
900
2
450
0
900
6
150

Therefore, capacity is constrained by number of gears and shaft which can be machined (Hobber) per shift as it is the l
Number of gears finished per day
Number of shafts finished per day
Number of gearboxes finished per day
Number of gearboxes finished per month
Number of gearboxes finished per year
Taking 85% efficiency into account, revised capacity
Therefore, increased capacity of plant is 16320 gearboxes per year.

256
130
64
1600
19200
16320

ning. Rest 90% time will be used for shaft machining.

Night shift
390
0
390
5
78
0
390
3
130
0
39
5
7
0
39
3
13
0
351
8
43
0
351
5
70
390
250
390

234

410

22

41

130

221
750

100
0
780
2
390
0
780
6
130

300

1260

420

obber) per shift as it is the lowest capacity machine on the floor layout (H1+H2 - 234+22 - 256 gears, H2 - 130 shafts).

30 shafts).