COSTO DE MANUFACTURA

COSTO MANUFACTURA =
COSTO MATERIAL
COSTO PROCESO
COSTO HERRAMENTAL

PRODUCTION METRICS

Production Capacity

Production capacity is defined as the maximum rate of output that a production facility

(a production line, a work center, or a group of work centers)is able to produce under a

given set of assumed operation conditions.

The production capacity is measured in periods such as: Week, Month and year, but

the number of pieces per week is a critical issue in defining plant, then:

𝑃𝐶 = 𝑛 ∗ 𝑆 ∗ 𝐻 ∗ 𝑅𝑝

𝑃𝐶 = 𝑛 ∗ 𝑆 ∗ 𝐻

𝐴𝑇 = 𝑆 ∗ 𝐻

 Where

 n : number of work center

 S : number of shift per period (shift/week)

 H: number of hour per shift (8 hour/shift)

Work In Process

WIP is the quantity of parts or products currently located in the factory that either are

being processed or are between processing operations. WIP Is inventory that is being

transformed from raw material to finished product.

 Work-in-process represents an investment by the firm, but one that cannot be turned

into revenue until all processing has been completed. Many manufacturing companies

sustain major costs because work remains in-process in the factory too long.

𝐴𝑈(𝑃𝐶)(𝑀𝐿𝑇)
𝑊𝐼𝑃 =
𝑆𝐻

Where WIP is expressed in [𝑝𝑐]

WORKLOAD

Workload is defined as the total hours required to complete a given amount of work or

to produce a given number of work units scheduled during the period

𝑊𝐿 = 𝑄 ∗ 𝑇𝑐

With multiple parts

𝑊𝐿 = ∑(𝑄𝑗 ∗ 𝑇𝑐𝑗)
𝑗

𝑊𝐿
𝑛 =
𝐴𝑇

CORRECTION FACTORS

• Setup time in batch production.

• Availability.
• Utilization.
• Defect rate.
• Setup Time

In batch production occurs between batches because the tooling and fixturing must be
changed over from the current part style to the next part style, and the equipment
controller must be reprogrammed.
During setup, the workstation is not producing.

Tb = Tsu + Tc. Q
Tb
Tc ∗ = Q = Tp
WL = Q. Tc ∗

Sheet Metal Stamping Dies & Processes

https://www.youtube.com/watch?v=5CuJjSk4U38

Stamping mold mounting die punch machine from Krrass

https://www.youtube.com/watch?v=ab1jLPVQNXM
Quick, easy and safe die change
https://www.youtube.com/watch?v=cwLR76KEthk
• Availability.
Availability is a common measure to reliability for equipment.

𝑀𝑓– 𝑀𝑟
𝐴=
𝑀𝑓

Where

A: Availability (typically expressed as a percentage)

Mf: Mean time between failures (hr)

Mr: Mean time to repair (hr)

• Utilization.
Refers to the amount of output of a production facility relative to its capacity.

Workstations may not be fully utilized due to scheduling problems, lack of work for a

given machine type, workload imbalance among workstations, and other reasons.

𝑄
𝑈=
𝑃𝐶

Where

U: Utilization of the facility

Q: Actual quantity produced by the facility during a given time period

PC: Production capacity for the same period (pc/wk)

Worker efficiency is defined as the number of work units actually completed by the
worker in a given time period divided by the number of units that would be produced at
standard performance.

Amazing Workers Compilation

https://www.youtube.com/watch?v=SMxGF8-xmAg

• Defect rate. The output of the manufacturing system may not be 100% good quality.
Defective units are produced at a certain fraction defect rate. This must be accounted
for by increasing the total number of units processed.

CAPACITY INCREASE

Is defined as the maximum rate of output that a production facility (or production line,

work center, or group of work centers) is able to produce under a given set 01 assumed

operating conditions.

Changes can be made to increase or decrease plant capacity, this may happens under:

Short terms

 Increase H (Hours worked per Shift).

 Increase S (Shifts per Week).

Longer terms

 Increases n (number of work centers).

 Increase Rp (production rate).

  Reduce no (number of operation).

DIAGRAMAS DE FLUJO

Process scheme

20 30
10
stampi paintin .... i
cutting
ng g

Figure 1.Process Scheme

Processes required to make a part are numbered from 1 to i
 GRÁFICA DE ENSAMBLE (O GOZINTO)

PRODUCT STRUCTURE

Figure 2.Product Structure for product P1

Parts (subassemblies or components) required to assembly a product are numbered

from 1 to j
MANUFACTURING LEAD TIME

Setup Time

Time required preparing the machine for a specific operation, example: charge drill

tools, charge mill tools or charge molds.

Tsui = (min)

Example:

Table 1 Tsu, Task Tool

𝑇𝑠𝑢10 𝑇𝑠𝑢20 𝑇𝑠𝑢30 …. 𝑇𝑠𝑢𝑖

Task: Tool

Charge Task: Tool Charge Task: Tool Charge Task: …

Tool: Center Tool: Drilling Tool: Taper Tool: ….

Drill

Cycle Time

The operation cycle time Tc is defined as the time that one work unit spends being

processed or assembled.

𝑇𝑐𝑖 = 𝑇𝑜 + 𝑇ℎ + 𝑇𝑡 (min/pc)

Figure 3.Maquina with Cycle Time

Where:

𝑇𝑐 = 𝐶𝑦𝑐𝑙𝑒 𝑡𝑖𝑚𝑒.

𝑇𝑜 = 𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑡𝑖𝑚𝑒.
𝑇ℎ = 𝐻𝑎𝑛𝑑𝑙𝑖𝑛𝑔 𝑡𝑖𝑚𝑒.

𝑇𝑡ℎ = 𝑇𝑜𝑜𝑙 𝐻𝑎𝑛𝑑𝑙𝑖𝑛𝑔 𝑡𝑖𝑚𝑒.

CNC minimizes tool change time.

Task1 Task2 Task3 Task4 Task5

𝑇ℎ1 𝑇𝑡ℎ2 𝑇𝑜2 𝑇𝑡ℎ3 𝑇𝑜3 𝑇𝑡ℎ4 𝑇𝑜4 𝑇ℎ5

Tool
Tool Opera
Chan Tool
Charge Change Oper tion Opera Discharge
ge Change
Part Center ation Drillin tion Part
Drilli Taper
Drill g
ng

Example:

Table 2 M10 tapping in a plate

Batch Time

The batch time for process i is:

𝑇𝑏𝑖 = 𝑇𝑠𝑢𝑖 + 𝑄𝑏𝑗 ∗ 𝑇𝑐𝑖 (min)

Figure 4. Batch time

Where:

𝑄𝑏𝑗 = 𝑏𝑎𝑡𝑐ℎ 𝑞𝑢𝑎𝑛𝑡𝑖𝑡𝑦 𝑓𝑜𝑟 𝑝𝑎𝑟𝑡 𝑗 (𝑝𝑐)

Manufacturing Lead Time

MLT is the total time required to process a given part or product through the plant.

Including:

 Lost Time Due To Delays

 Time Spent In Storage

 Reliability Problems Categories Of Activities:

 Operation: In Machine

 Nonoperation: Material Handling, storage, inspection.

Considering the following process:

Figure 5.Manufacturing Lead Time

If we write the batch time for each process, we have:

𝑇𝑏1 = 𝑇𝑠𝑢1 + 𝑄𝑏𝑗 ∗ 𝑇𝑐1

𝑇𝑏2 = 𝑇𝑠𝑢2 + 𝑄𝑏𝑗 ∗ 𝑇𝑐2

𝑇𝑏𝑖 = 𝑇𝑠𝑢𝑖 + 𝑄𝑏𝑗 ∗ 𝑇𝑐𝑖

Then, Manufacturing Lead time for part j is writed as:

𝑛

𝑀𝐿𝑇𝑗 = ∑(𝑇𝑏𝑖)
𝑖=1

When we include non-operating time, then for part j

 𝑛

𝑀𝐿𝑇𝑗 = ∑(𝑇𝑏𝑖 + 𝑇𝑛𝑜𝑖)

𝑖=1

Production Rate

The production rate for an individual processing or assembly operation is usually

expressed as an hourly rate, that is, parts or products per hour.

a. Average Production Time

𝑇𝑏𝑗
𝑇𝑝𝑗 = [𝑚𝑖𝑛/𝑝𝑐]
𝑄𝑏𝑗

b. Production Rate

60
𝑅𝑝𝑗 = [𝑝𝑐/ℎ𝑟]
𝑇𝑝𝑗

Examples:

If:

𝑄𝑏 = 1000 [𝑢]

𝑇𝑐 = 1 [𝑚𝑖𝑛]

𝑇𝑠𝑢 = 30 [𝑚𝑖𝑛]

Tb = 1030 [pc]

1030
𝑇𝑝𝑗 = = 1.03 [𝑚𝑖𝑛/𝑝𝑐]
1000

1 1 𝑝𝑐 𝑝𝑐
𝑅𝑝𝑗 = = = 0.97 [ ] = 58.25 [ ]
𝑇𝑝𝑗 1.03 𝑚𝑖𝑛 ℎ𝑟
 c. Job shop and mass production

 Sometimes we can find processes which need to be produced in series, otherwise

we might be wasting time. Then, let us compare job shop production (Qb=1) and mass

production (Qb= very large):

 Job shop Q = 1

 𝑇𝑐 = 1 [𝑚𝑖𝑛]

 𝑇𝑠𝑢 = 30 [𝑚𝑖𝑛]

 𝑇𝑏 = 30 + 1𝑥1 = 31 [𝑚𝑖𝑛]

1 (𝑝𝑐) 𝑚𝑖𝑛 𝑝𝑐
 𝑅𝑝 = 31 (min) 60 ( ℎ𝑟 ) = 1.94 (ℎ𝑟)

 Mass production Q2 = 1000

 𝑇𝑐 = 1 [𝑚𝑖𝑛]

 𝑇𝑠𝑢 = 30 [𝑚𝑖𝑛]

 𝑇𝑏 = 30 + 1000𝑥1 = 1030 [𝑚𝑖𝑛]

1000 (pc) 𝑚𝑖𝑛 𝑝𝑐

 𝑇𝑝 = 1030 (min) 60 ( ℎ𝑟 ) = 58.25 (ℎ𝑟)