logo working process analysis - 3 team - 20052411 고견석 20052412 장금혁 20052431 황인성...

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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

www.themegallery.com Company Logo

Reason Of Subject Selection


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


Project Objective

EconomyAnalysis

Error Process Analysis

Lead Time

Analysis

Process Optimizat

ion

Cost Analysis


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


Contents

Process Flow1

Details Of Process2

Following Plan3


1. Process Flow


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


Put and arrange the materials

which have been stocked from part-nership companies

Material input

2. Details Of Process


Process that identi-fies a kind and

thickness of materi-als

Material inspec-tion



Work to spread rolled materials to

cut in fixed size

Fabric work



Work to cut the ma-terials in the same shape with a paper

pattern by using Cam-machine

Cutting work



Work to sew the material

Needlework



Inspection for fin-ished products

Finished prod-uct

inspection



Stock of finished products com-pleted from final inspection

Waiting for ship-ping



Company Logowww.themegallery.com

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


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



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


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



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


Process 2

Process 1 Output : 11(hour) X 6750 = 74250 – (74250x 0.0025) = 74064

Process 2 Output : 8(hour) X 900 = 7200



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


EEfficiency



3. Analysis Of Alternative


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


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


Process 2

Process 1 Output : 9.5(hour) X 7875 = 74813 –(74813)x 0.0025 = 74625



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


EEfficiency





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


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


Process2

Process 1 Output : 8(hour) X 9000 = 72000 – (72000x0.0025) = 71820




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


Economical Analyze4

Conclusion5

Company Logo

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

www.themegallery.com

3EA23min

3EA15min

60EA1min

10EA0.6mi

n

Process 1

Process 2

Process 1 is need to improve

for efficient work

31

Company Logo

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).


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



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

Company Logo

Alternative A : Analysis Of Existing Process


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



Company Logo

Alternative B : 3 worktable and 3 workers increment


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


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



Company Logo

Alternative C : 1 Equipment and 4 workers increment


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




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


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



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


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


6. Simulation analysis

Entire Simulation Module of The Pride



Failure Factor 1



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)


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


8. Simulation Module

Alternative A



Alternative A



Alternative B (1/10)




We’ve decided to reduce the entities with regular ratio



Alternative C (1/100)



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



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.

logo working process analysis - 3 team - 20052411 고견석 20052412 장금혁 20052431 황인성...

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