Productivity and Cost Analysis Productivity and Cost Analysis Process Report

Mahle Metal Leve

Eixo Ford I4 Tornear Mancais 10 dezembro 2011

10/12/2011 Guilherme Guizi

Productivity and Cost Analysis

Customer Customer name Location Contact person Contact e-mail Contact phone Industry segment Automobilistico Mahle Metal Leve Mogi Guau Roberto Cesare

Operation Overview
Production Production type Parts per year/batch Machining hourly rate Mass 402000 pcs 50 R$

Cycle time Load-unload time Floor-to-floor time

0,583 min 0,0833 min 0,6663 min

Machine Machine name Machine type Year of manufacture Power Power efficiency Condition Coolant Holder Max rpm (cont.) Workpiece Workpiece name Workpiece type Part no Operation no Operation desc. Material Seco material grp. Heat treatment Surface properties Hardness Stability Results agreed by: Results Com a eliminao foi possivel obter um ganho de 29% em produtividade. J em custo foi possivel uma reduo de 20% comparado ao custo anterior. 6297 20 Tornear Mancais Fofo Cinzento 14 Eixo Ford I4 Solution Revisado programa CNC onde foi possivel eliminar 1 ferramenta do processo de usinagem. Isto foi possvel porque houve uma troca de mquina(torno) da linha com maior capacidade e rigidez 15 85% Good None 25x25 4000 kW Torno Romi Galaxy Objective Otimizar processo para aumento de produtividade

Date

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Productivity and Cost Analysis

Customer Mahle Metal Leve Workpiece name Eixo Ford I4

Summary
Operation desc. Tornear Mancais Seco rep. Guilherme Guizi

Stage 1
Cost per part

Stage 2
Cost per part

Stage 3
Cost per part

0,64 R$
Total cost

0,52 R$
Total cost Total cost

259.089 R$

207.053 R$
Total Cost Savings Total Cost Savings

52.035 R$ 20 %
259.089 207.053

52.035 0 0

Total cost

Total Cost Savings

Output per hour

Output per hour

Output per hour

88,5
Total hours required

114,7
Total hours required Total hours required

4.540

3.506
Total hours Saved Total hours Saved

1.034
Investment cost Investment cost

0 R$
Payback period Payback period

0h
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Productivity and Cost Analysis

Seco PCA Stage 1 - Original method

Machining efficiency Output per hour G50 [rpm] seq. Tool # POU # # 2 1 1 1 Turning Turning Operation type Operation desc.
Fechar Porta , Ponto e Placa
Desbastar Mancais, Acabar Canal

100% 88,5

Cycle time No.of tools

0,58 1 geometry

min

Total in-cut time Idle time

0,58 0,00 f [mm/rev] 0,15 0,1

min min Ap [mm] 1,5 0,3 Ae [mm] 66,25 32 In-cut time [min] 0,1 0,283 0,09 0,11 TCF [pcs] 250 600 Tool life [min] 0,00 70,75 54,00 0,00 0,00 0,00 Comment

Holder / Cutter

Insert / solid tool

Grade

Vc Dc [m/min] [mm] 131 320 27,8 29

n [rev/min] 1500 3512

CFIR2525M04 SDJCL2525M11

LCMF1604M0-0400 DCMT11T308

MP F2

TK150 TP2500

Acabar Diam. 29 e chanfro Abrir porta , ponto e placa

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Productivity and Cost Analysis

Seco PCA Stage 1 - Original Method - Cost Calculation

seq. # Tool # Operation desc. Holder / Cutter Insert / solid tool Grade In-cut time Machining cost Tool cost new Number of regrinds Cost per regrind Total tool cost No of cutting edges No. of inserts in cutter/holder Machine load cost Tool change frequency Tool life cost Parts per year/batch Tool change frequency Tool changes per year Tool change allowance Total time for tool changing Tool change cost Sub cost Total cost per part Output per hour min R$ R$ R$ R$ R$ pcs R$ pcs min h R$ R$ 0,64 88,5 0,08 0,31 0,10 0,083 Fechar Porta , Ponto e Placa 2 1 Desbastar Mancais, Acabar Diam. 29 e Acabar Canal chanfro CFIR2525M04 SDJCL2525M11 LCMF1604M0-0400DCMT11T308-F2 MP TK150 TP2500 0,28 0,09 0,236 0,075 31,59 19,95 Abrir porta , ponto e placa -

0,11 0,092

402.000

31,59 2,00 1,00 15,80 250,00 0,063 402.000 250,00 1608 2

53,60

19,95 2,00 1,00 9,98 600,00 0,017 402.000 600,00 670 2

22,33

402.000

402.000

402.000

0,007 0,09

0,003 0,09

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Productivity and Cost Analysis

Seco PCA Stage 2 - Proposed method 1

Machining efficiency Output per hour G50 [rpm] seq. Tool # POU # # 2 1 1 Turning Operation type Operation desc.
Fechar Porta, Placa e Ponto

100% 114,7

Cycle time No.of tools

0,43 1 geometry

min

Total in-cut time Idle time

0,43 min 0,00 min Ap [mm] 1,5

Process modification time Reason for process mod Ae [mm] 66,25 In-cut time [min] 0,10 0,22 0,11 0,00 0,00 0,00 TCF [pcs] 200,0 Tool life [min] 0,00 44,00 0,00 0,00 0,00 0,00

min

Holder / Cutter

Insert / solid tool

Grade

Vc Dc n f [m/min] [mm] [rev/min] [mm/rev] 163 27,8 0,16

Comment or Investment Cost

Acabar Mancais e Canal Abrir Porta, Ponto e Placa

CFIR2525M04

LCMF1604M0-0400

MP

TK150

1866

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Productivity and Cost Analysis

Seco PCA Stage 2 - Proposed method 1 - Cost Calculation

seq. # Tool # Operation desc. Holder / Cutter Insert / solid tool Grade In-cut time Machining cost Tool cost new Number of regrinds Cost per regrind Total tool cost No of cutting edges No. of inserts in cutter/holder Machine load cost Tool change frequency Tool life cost Parts per year/batch Tool change frequency Tool changes per year Tool change allowance Total time for tool changing Tool change cost Sub cost Total cost per part Output per hour min R$ R$ R$ R$ R$ pcs R$ pcs min h R$ R$ 0,52 114,7 0,08 0,27 0,10 0,083 Fechar Porta, Placa e Ponto 2 1 Acabar Mancais e Canal CFIR2525M04 LCMF1604M0-0400MP TK150 0,22 0,183 31,59 Abrir Porta, Ponto e Placa -

0,11 0,092

402.000

31,59 2,00 1,00 15,80 200,00 0,079 402.000 200,00 2010 2

67,00

402.000

402.000

402.000

402.000

0,008 0,09

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Cost per part

0,70

R$

0,60

0,50
Stage 1

0,40

Stage 2 Stage 3

0,30

0,20

0,10

0,00 Machining cost Tool life cost Tool change cost idle time cost Load-unload cost Down-time cost Total cost

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300.000

250.000

200.000 Stage 1 Stage 2 150.000 Stage 3

100.000

50.000

0 Machining cost Tool life cost Tool change cost idle time cost Load-unload cost Down-time cost Total cost

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5.000 4.500 4.000 3.500 3.000 2.500 2.000 1.500 1.000 500 0
Stage 1 Stage 2
0

4.540

3.506

Stage 3

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35.000

30.000

25.000

20.000

15.000

10.000

5.000

0 Stage 1 Stage 2 Stage 3

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Tool cost per part trend

0,09 0,08
0,08 0,08

R$

0,07 0,06 0,05 0,04 0,03 0,02 0,01

0,00

0,00 Stage 1 Stage 2 Stage 3

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Productivity and Cost Analysis

Remarks

Attachment

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