Download - LOGO Working Process analysis - 3 team - 20052411 고견석 20052412 장금혁 20052431 황인성 CapStone Design
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Working Process analysis
- 3 team -20052411 고견석20052412 장금혁20052431 황인성
CapStone Design
Contents
Reason Of Subject Selection
1
Introduction of Company
2
Project Objective3
Project Plan4
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Reason Of Subject Selection
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Company Name : The Pride Address : 258 -4, Song ha
dong, Nam gu, in Kwang Ju Category : KIA automobile
subcontractor Production Iteam : automobile
- Sheet cover Owner : Sun il kim Annual Revenues : 10bilion The number of employees : one hundred twenty
Introduction Of Company
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Project Objective
EconomyAnalysis
Error Process Analysis
Lead Time
Analysis
Process Optimizat
ion
Cost Analysis
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Analysis of Cost & Productivity
Team meeting
Based Data Collection
Visit and process flow
understandingof Process problems
Error Process Analysis
Economic Analysis
Evaluation & Revision
NovOctSep
Project PlanDec
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Contents
Process Flow1
Details Of Process2
Following Plan3
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1. Process Flow
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Material input
원단을 입고하는 공정
Material inspection
원단의 색상 , 폭 , LAMI 상태 ,
Fabric work
Needlework
재단된 형태를 맞대고
Cutting work
Finished product in-
spection
완성품을 품질 기준 및
Waiting for shipping
1. Process Flow
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Put and arrange the materials
which have been stocked from part-nership companies
Material input
2. Details Of Process
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Process that identi-fies a kind and
thickness of materi-als
Material inspec-tion
2. Details Of Process
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Work to spread rolled materials to
cut in fixed size
Fabric work
2. Details Of Process
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Work to cut the ma-terials in the same shape with a paper
pattern by using Cam-machine
Cutting work
2. Details Of Process
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Work to sew the material
Needlework
2. Details Of Process
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Inspection for fin-ished products
Finished prod-uct
inspection
2. Details Of Process
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Stock of finished products com-pleted from final inspection
Waiting for ship-ping
2. Details Of Process
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3. Following Plan
1. Working time analysis at each process line
2. Quantity of equipment at each process line
3. Equipment efficiency analysis
Contents
Error Process Analysis1
Selection Of Alternative
2
Analysis Of Alternative
3
4
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Analysis Direction
3EA23min
3EA15min
60EA1min
10EA0.6min
Process 1
Process 2
Process 1
Overtime Work
Process 2 Overtime Produc-
tion
Week day 08:00~17:00 3 hour 08:00~17
:00 Nothing 7200
Satury day
08:00~12:00
1hour 30minite
08:00~12:00 Nothing 3600
1. Error Process Analysis
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1. Error Process Analysis
0.25% 0.0025 400
1
products good ofNumber
defective ofNumber Ratio efective D
99.75% 0.9975 0.0025 - 1 Ratio Defective - 1 ty Productivi
Components Defective Ratio
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One Process – One machine
Fabric work Cutting work Needlework Finished product
inspection
0
10
2023
15
1
0.600000000000001
Process lead time
Proc...
min
43.04% 23 4
0.6 1 15 23
workplaceofNumber
1EAper work timeTotal )(
EEfficiency
56.06% 0.4304 -1 Efficiency - 1 (D) Rate unbalance
52.4min 39.6 - 23)(4 time-Cycle workplaceofNumber timeIdle
1. Error Process Analysis
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3,125 EA per month
5,625 EA per month
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
Components Finished0
2000400060008000 6750
900
Process Production(per-hour)
Process
Process 1
EA
So we realized that work has to be operated for three more hours to achieve the quantity goal, 900 products,
hour)-3(per3EA750EA machine Cam
1. Error Process Analysis
Process 2
Process 1 Output : 11(hour) X 6750 = 74250 – (74250x 0.0025) = 74064
Process 2 Output : 8(hour) X 900 = 7200
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alternatives : Fabric work and Cutting work alternatives for increasing process efficiency
1. Fabric work will increase workplace2. Fabric work and a CAM plant will increase
Process, the error analysis
Process analysis Fabric work and Cutting work a lot of processing time, delays in operations were supposed to have been analyzed.
2. Selection Of Alternative
Fabric work Cutting work
Needlework Finished product
inspection
0
10
20 1815
1
0.600000000000
001
Process lead time
Process
min
48.1% 18 4
0.6 1 15 18
workplaceofNumber
1EAper work timeTotal )(
EEfficiency
51.9% 0.481 -1 Efficiency - 1 (D) Rate unbalance
37.4min 34.6 - 18)(4 time-Cycle workplaceofNumber timeIdle
3. Analysis Of Alternative
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3,125 EA per month
5,625 EA per month
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
Components Finished0
5000
10000 7875
900
Process Production
Process
Process 1
EA
We can see that work hour is decreased about 1hour and half because of increasing the quantity of production of components in first process line.
hour)-3.5(per3EA750EA machine Cam
3. Analysis Of Alternative
Process 2
Process 1 Output : 9.5(hour) X 7875 = 74813 –(74813)x 0.0025 = 74625
Process 2 Output : 8(hour) X 900 = 7200
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Fabric work Cutting work
Needlework Finished product
inspection
05
101520 17
11
1
0.600000000000
001
Process lead time
Process
min
43.5% 17 4
0.61 11 17
workplaceofNumber
1EAper work timeTotal )(
EEfficiency
56.5% 0.435 -1 Efficiency - 1 (D) Rate unbalance
38.4min 29.6 - 17)(4 time-Cycle workplaceofNumber timeIdle
3. Analysis Of Alternative
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3,125 EA per month
5,625 EA per month
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
Components Finished0
5000
10000 9000
900
Process Production
Process
Process 1
EA
Inventory for the extra 30 minutes at a 1process must be no overtime.
hour)-3(per4EA750EA machine Cam
3. Analysis Of Alternative
Process2
Process 1 Output : 8(hour) X 9000 = 72000 – (72000x0.0025) = 71820
Process 2 Output : 8(hour) X 900 = 7200
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4. Analysis Of Direction
Follwing Plan
1. Of each alternative over time, labor costs, overtime
2. Equipment costs by improving facilities.
3. Labor costs due to hiring personnel.
4. Labor costs for each alternative for the next ten
years, depreciation, taxes, Inflation ,electricity, and
cash flow statement written in.
5. Due to production targets due to the cost of each
alternative analysis of the economics.
Contents
Condition Of Analysis
1
Method of Economical Analyze
2
Analysis Of Each Alternative
3
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Economical Analyze4
Conclusion5
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1. Condition Of Analysis
Objective : Figure out the equipment costs and the labor costs with effective productivity and select the most reasonable alternative
Alternative A : Existing Process
Alternative B : 3 worktable and 3 workers in-crement
Alternative C : 1 Equipment and 4 workers in-crement
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3EA23min
3EA15min
60EA1min
10EA0.6mi
n
Process 1
Process 2
Process 1 is need to improve
for efficient work
31
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terms
We analysised each project whether it is economically proper or not.
We excluded the matter that occurred in other process because we only made the error process better
Apply equally to all employees on wages were computed for 10 years average inflation rate last year was applied.
Calculate wage the employee the same salary was 5,000 won per hour. (Overtime hours only 7,500 won).
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1. Condition Of Analysis
32
2. Method of Economical Analyze
Depreciation(Decline-balance method) 1 1
N 10Depreciation factor ( ) = 1-(0.05) = 1-(0.05) 0.2588
N D-fac-tor
Dn Bn
0 0 0 50,000,000
1 0.2588 Bn x factor = 12,940,000
Bn – Dn1 = 37,060,000
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
2,502,212(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
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N Year Average Inflation Rate
0 2011 -
1 2012 7.48%
2 2013 7.48%
3 2014 7.48%
4 2015 7.48%
5 2016 7.48%
6 2017 7.48%
7 2018 7.48%
8 2019 7.48%
9 2020 7.48%
10 2021 7.48%
7.48% 0.0747 1 )2100
4320( : RateInflation Average 10/1
To 2011 from 2001 for ten years of the average inflation rate.
2. Method of Economical Analyze
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Alternative A : Analysis Of Existing Process
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Analysis List
1. Labor Costs : 5000won/per-hour2. Overtime wage : time and a half3. Overtime : 20hour 30minutes/
per-week4. Total Woker : 12 people
Classifica-tion Wage EA/People/
Hour Total Costs
Labor costs5000won
/per-hour
12 people X 8hour 480,000won
Per - day
Overtime wage
7500won/
per-hour
12 people X 3hour 27,0000won
3. Analysis Of Each Alternative
Costs Calculation
Weekday(12 worker) : 480,000(8h) + 270000(3h ) = 750,000
750,000 x 22(day) = 16,500,000(month)
Weekend(12worker) : 75,00 x (5.5h) x12(worker) = 495,000
495,000 x 4(day) = 1,980,000(month)
1year = 18,480,000 x 12(month) = 221,760,000
1month = 16,500,000+1,980,000 = 18,480,000
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3. Analysis Of Each Alternative
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Alternative B : 3 worktable and 3 workers increment
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Analysis List
1. Addition of three worktable2. Addition of three workers3. Labor Costs : 5000won/per-hour4. Overtime Wage : time and a half5. Overtime : 12hour /per-week6. Total Worker : 15 people
Classifica-tion
Wage & Costs
EA/People/Hour
Total Costs
Worktable 300,000-won 3EA 900,000-
won
Per - day
Labor Costs
5000won/per-hour
15 people X 8hour
600,000-won
Overtime Wage
7500won/per-hour
15 people X 1.5 hour
168750won
3. Analysis Of Each Alternative
Costs calculation
Weekday(15 worker) : 600,000(8h) + 168750(1.5h) = 768,750
768,750 x 22(day) = 16,912,500(month) Weekend(15 worker) : 75,00 x (4.5h) x
15(worker) = 506,250 506250 x 4(day) = 2,025,000(month)
1year = 18,937,500 x 12(month) = 227,250,000
1month = 16,912,500+2,025000 = 18,937,500
Worktable= 300,000 x 3EA = 900,000
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3. Analysis Of Each Alternative
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Alternative C : 1 Equipment and 4 workers increment
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Analysis List1. Addition of one cam equip-
ment2. Addition of one worktable3. Addition of four workers4. Overtime : 30 minutes/per-
week5. Total worker : 16 people
Classifica-tion
Wage & Costs
EA/People/Hour
Total Costs
Cam Equip-ment
50,000,000won 1 50,000,000
won
Worktable 300,000won 1 300,000-won
Labor Costs 5000won/per-hour
16 people X 8hour
640,000-won Per-
dayOvertime wage
7500won/per-hour
16 people X 0.5hour 60,000won
Analysis Of Each Alternative
Costs calculation
Weekday(16 worker) : 80,000(8h) = 640,000640,000x 22(day/month) = 14,080,000
Weekend(16worker) : 75,00 x (4h) x16(worker) = 480,000
480,000 x 4(day/month) = 1,920,000
1year = 16,000,000 x 12(month) = 192,000,000
1month = 14,080,000+1,920,000 = 16,000,000
Worktable = 300,000 x 1EA = 300,000
Cam machine = 500,00,000 x 1EA = 500,000,000
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3. Analysis Of Each Alternative
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N YearAverage Inflation
RateLabor Costs
0 2011 - ₩221,760,000
1 2012 7.48% ₩238,347,648
2 2013 7.48% ₩256,176,052
3 2014 7.48% ₩275,338,021
4 2015 7.48% ₩295,933,305
5 2016 7.48% ₩318,069,116
6 2017 7.48% ₩341,860,686
7 2018 7.48% ₩367,431,865
8 2019 7.48% ₩394,915,769
9 2020 7.48% ₩424,455,468
10 2021 7.48% ₩456,204,737
Total Costs ₩3,590,492,666
4. Economical Analyze
Alternative A
N YearAverage Inflation
RateLabor Costs
0 2011 - ₩227,250,000
1 2012 7.48% ₩244,248,300
2 2013 7.48% ₩262,518,073
3 2014 7.48% ₩282,154,425
4 2015 7.48% ₩303,259,576
5 2016 7.48% ₩325,943,392
6 2017 7.48% ₩350,323,958
7 2018 7.48% ₩376,528,190
8 2019 7.48% ₩404,692,498
9 2020 7.48% ₩434,963,497
10 2021 7.48% ₩467,498,767
Total Costs ₩3,679,380,674
Alternative B
Total Costs Of Alternative A : 3,590,492,666
Total Costs Of Alternative B3,679,380,674 + 900,000 = 3,680,280,674
Total labor costs : 3,679,380,674 Worktable : 900,000
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N YearAverage Inflation
Rate Labor Costs D-Factor Dn Bn
0 2011 - ₩192,000,000 0 ₩0 ₩50,000,00
0
1 2012 7.48% ₩206,361,600 0.2588₩12,940,00
0 ₩37,060,00
0
2 2013 7.48% ₩221,797,448 0.2588 ₩9,591,128 ₩27,468,87
2
3 2014 7.48% ₩238,387,897 0.2588 ₩7,108,944 ₩20,359,92
8
4 2015 7.48% ₩256,219,311 0.2588 ₩5,269,149 ₩15,090,77
9
5 2016 7.48% ₩275,384,516 0.2588 ₩3,905,493 ₩11,185,28
56 2017 7.48% ₩295,983,278 0.2588 ₩2,894,752 ₩8,290,533
7 2018 7.48% ₩318,122,827 0.2588 ₩2,145,590 ₩6,144,943
8 2019 7.48% ₩341,918,414 0.2588 ₩1,590,311 ₩4,554,632
9 2020 7.48% ₩367,493,912 0.2588 ₩1,178,739 ₩3,375,893
10 2021 7.48% ₩394,982,456 0.2588 ₩873,681 ₩2,502,212
Total Costs ₩3,108,651,659 ₩47,497,78
8
4. Economical Analyze Alternative C : 1 Equipment and 4
workers increment
Salvage Value :
2,502,212/50,000,000
= 0.05 = 5% Total Costs Of Alternative B3,108,651,659 +300,000 +47,497,788 = 3,156,449,447
Total labor costs : 3,108,651,659 Worktable : 300,000 Depreciation Costs : 47,497,788
0.2588 (0.05)-1 Rateon Depreciati 10
1
Alternative A (Operation like present)For worker wages during 10 years the future 3,590,492,666 won occurrence
Alternative B ( 3 worktable and 3 workers increment)
As equipment investment expense, worker wages and warehouse investment expense during 10 years the future 3,680,280,674 won occurrence
Therefore, it is reasonable that select alternative C
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5. Conclusion
Alternative C (1 Equipment and 4 workers increment)
As equipment investment expense, worker wages and warehouse investment expense during 10 years the future 3,156,449,447 won occurrence
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6. Simulation analysis
Entire Simulation Module of The Pride
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6. Simulation analysis
Failure Factor 1
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6. Simulation analysis
Failure Factor 2
A B
C
H
K
D
I
L
E
J
M
F GINPUT
1
1
1
23
18
17
15
15
11
1
1
1
0.60 0
1 1
1 6
1 10
24 24
19 24
18 28
39 39
34 39
29 39
40.6 40.640 40
Fabric work
Cut-ting work
Nee-dle
workFin-
ished productinspec-
tion
Wait-ing for ship-ping
7. Pert/CPM analysis
※Figure out surplus time, S(TL-TE).Calculate surplus time, S by using TL and TE1.Positive slack : TL-TE>0 = S>0 (Excessive time resource) 2.Zero slack : TL-TE=0 = S=0 (Proper time resource)3.Negative slack : TL-TE<0 = S<0 (Insufficient time resource)
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A B
C
H
K
D
I
L
E
J
M
F GINPUT
1
1
1
23
18
17
15
15
11
1
1
1
0.60 0
1 1
1 6
1 10
24 24
19 24
18 28
39 39
34 39
29 39
40.6 40.640 40
7. Pert/CPM analysis
Process blueprint
Alternative B: A→B → H → I →J →F →G :TL-TE=6-1=5>0Alternative C: A →B →K →L →M →F →G : TL-TE=10-1=9>0
CP(Critical Path) : A →B →C →D →E →F →G
Conclusion :Alternative C whose surplus time is 9 is the most efficient way
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8. Simulation Module
Alternative A
8. Simulation Module
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Alternative A
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8. Simulation Module
Alternative B (1/10)
8. Simulation Module
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Alternative B (1/10)
We’ve decided to reduce the entities with regular ratio
8. Simulation Module
Alternative B (1/100)
8. Simulation Module
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Alternative C (1/100)
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8. Simulation Module
FABRIC WORK CAM WORK
Alternative A 23Min(Per 750EA) 15Min(Per 750EA)
Alternative B 18 15
Alternative C 17 11
FABRIC WORK CAM WORK
Alternative A 0.03 0.02
Alternative B 0.024 0.02
Alternative C 0.022 0.01
1/10 1/100
712 69
X 87
X 93
Variables(into simulation)
Result
Real output per time
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8. Simulation Module
1/10 1/00
Alternative A 712 69
Alternative B X 87
Alternative C X 93
1 1/10 1/00
7200 712 69
9000 890 87
9600 950 93
Result Exchange result(Output)
∴When Alternative C is cosidered, The Pride can produce 9,600 of car-seat per day.
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