CHAPTER IV DATA ANALYSIS
4.1 Routing Sheet
4.1.1 Routing Sheet of Dump Truck (DT)
Table 4.1 Chasis Operation
No.
Process Name Machine Time (min)
Capacity Scrap (%)
Production Requirement Number of M/C
Theoritical Actual In Out
1
Plane flat surface
top 1/2" Thickness Planner 0,6 4000 3600 1,5% 473,1696865 466,0721 0,131436 1 2 Cut to the width Jointer 0,45 5333,333 4800 1,5% 466,0721412 459,0811 0,097098 1 3 Cut to the length Circle Saw 0,36 6666,667 6000 1,5% 459,0810591 452,1948 0,076514 1 4
Sand with Sand
paper Disc Sand 0,8 3000 2700 1,5% 452,1948432 445,4119 0,16748 1
5 Coat Spray gun 0,75 3200 2880 1,5% 445,4119206 438,7307 0,154657 1
Table 4.2 Front Bumper Operation
No.
Process Name Machine Time (min)
Capacity Scrap (%)
Production Requirement Number of
Theoritical Actual In Out M/C
6 Plane flat surface Planner 0,72 3333,333 3000 1,5% 480,3753163 473,1697 0,160125 1 7 Cut to the width Jointer 0,6 4000 3600 1,5% 473,1696865 466,0721 0,131436 1 8 Cut to the length Circle saw 0,54 4444,444 4000 1,5% 466,0721412 459,0811 0,116518 1 9 Drill two holes Drill Press 1,1 2181,818 1963,636 1,5% 459,0810591 452,1948 0,233791 1 10 Sand with sand
paper Disc Sand 0,7 3428,571 3085,714 1,5% 452,1948432 445,4119 0,146545 1
11 Coat Spray Gun 0,6 4000 3600 1,5% 445,4119206 438,7307 0,123726 1
Table 4.3 Headlights Operation
No.
Process Name Machine Time (min)
Capacity Scrap (%)
Production Requirement Number of
Theoritical Actual In Out M/C
30 Cut to the length Circle saw 0,5 4800 4320 0,015 932,1442824 918,1621 0,215774 1 31 Drill the hole Drill press 0,4 6000 5400 0,015 918,1621182 904,3897 0,17003 1 32
Sand with sand
Paper Disc Sand 0,55 4363,636 3927,273 0,015 904,3896864 890,8238
0,230284 1 33 Coat Spray gun 0,45 5333,333 4800 0,015 890,8238411 877,4615 0,185588 1
Table 4.4 Axle Blocks Operation
No.
Process Name Machine Time (min)
Capacity Scrap (%)
Production Requirement Number of
Theoritical Actual In Out M/C
12 Plane Flat surface
to 3/4" Thickness Planner 0,72 3333,333 3000 0,015 975,3813528 960,7506 0,325127 1 13 Cut to the width Jointer 0,5 4800 4320 0,015 960,7506325 946,3394 0,222396 1 14 Cut to the length Circle saw 0,42 5714,286 5142,857 0,015 946,339373 932,1443 0,18401 1 15 Drill the hole Drill press 0,9 2666,667 2400 0,015 932,1442824 918,1621 0,388393 1 16 Sand with sand
Paper Disc sand 0,7 3428,571 3085,714 0,015 918,1621182 904,3897 0,297553 1
17 Coat Spray Gun 0,6 4000 3600 0,015 904,3896864 890,8238 0,251219 1
Table 4.5 Axle Operation
No.
Process Name Machine Time (min)
Capacity Scrap (%)
Production Requirement Number of
Theoritical Actual In Out M/C
18 Cut to length Hand Paper 0,4 6000 5400 0,015 932,1442824 918,1621 5,881314 6 19 Sand with sand
paper Disc Sand 0,6 4000 3600 0,015 918,1621182 904,3897 3,980585 4
20 Coat Spray gun 0,5 4800 4320 0,015 904,3896864 890,8238 4,849444 5
Table 4.6 Wheels Operation
No.
Process Name Machine Time (min)
Capacity Scrap (%)
Production Requirement Number of
Theoritical Actual In Out M/C
23 Plane flat surface Planner 1,2 2000 1800 0,015 1892,678746 1864,289 1,035716 2 24 Cut the wheel f
15/6 Hole saw 0,8 3000 2700 0,015 1864,288565 1836,324 0,68012 1
25 Drill the center Drill Press 0,4 6000 5400 0,015 1836,324236 1808,779 0,334959 1 26 Sand with sand
paper Disc Sand 0,5 4800 4320 0,015 1808,779373 1781,648 0,412418 1 27 Coat Spray gun 0,55 4363,636 3927,273 0,015 1781,647682 1754,923 0,446855 1
Table 4.7 Hood Operation
No.
Process Name Machine Time (min)
Capacity Scrap (%)
Production Requirement Number of
Theoritical Actual In Out M/C
43 Plane flat surface
to1" Thickness Planner 0,75 3200 2880 0,015 480,3753163 473,1697 0,164295 1 44 Cut to the width jointer 0,6 4000 3600 0,015 473,1696865 466,0721 0,129464 1 45 Cut to the length Cricle Saw 0,6 4000 3600 0,015 466,0721412 459,0811 0,127523 1 46
Cut the sides at 17° Using angle- Cutting Jig
Circle saw 1,8 1333,333 1200 0,015 459,0810591 452,1948 0,376829 1
47 Sand with sand
paper Disc sand 0,6 4000 3600 0,015 452,1948432 445,4119 0,123726 1
48 Coat spray gun 0,6 4000 3600 0,015 445,4119206 438,7307 0,12187 1
Table 4.8 Cab Operation
No.
Process Name Machine Time (min)
Capacity Scrap (%)
Production Requirement Number of
Theoritical Actual In Out M/C
35 Plane flar surface
to 1 1/4" thickness Planner 0,75 3200 2880 0,015 495,117438 487,6907 0,169337 1 36 Cut to the width Jointer 0,6 4000 3600 0,015 487,6906764 480,3753 0,133438 1 37 Cut to the length Circle Saw 0,6 4000 3600 0,015 480,3753163 473,1697 0,131436 1
38 Lay out the
window 0,5 4800 4320 0,015 473,1696865 466,0721 0,107887 1
39 Drill the window Drill Press 0,98 2448,98 2204,082 0,015 466,0721412 459,0811 0,208287 1 40
Cut the front of the cab at 30° Using tenoning jig
Circle Saw 0,86 2790,698 2511,628 0,015 459,0810591 452,1948 0,180041 1 41 Sand with Sand Disc sand 0,6 4000 3600 0,015 452,1948432 445,4119 0,123726 1
42 Coat Spray gun 0,6 4000 3600 0,015 445,4119206 438,7307 0,12187 1
Table 4.9 Dump Bed Operation
No.
Process Name Machine Time (min)
Capacity Scrap (%)
Production Requirement Number of
Theoritical Actual In Out M/C
56 Plane flat surface
to 1/4" thickness Planner 0,8 3000 2700 0,015 485,2275922 477,9492 0,177018 1 57 Cut to the width Jointer 0,45 5333,333 4800 0,015 477,9491783 470,7799 0,098079 1 58 Cut to the length Circle Saw 0,4 6000 5400 0,015 470,7799406 463,7182 0,085874 1 59
Form the along the bottom inside edges
Bending 0,82 2926,829 2634,146 0,015 463,7182415 456,7625 0,173401 1
60 sabd with sand
paper Disc snad 0,9 2666,667 2400 0,015 456,7624679 449,911 0,187463 1 61 Coat Spray gun 0,7 3428,571 3085,714 0,015 449,9110309 443,1624 0,143617 1
Table 4.10 End Wall Operation
No.
Process Name Machine Time (min)
Capacity Scrap (%)
Production Requirement Number of
Theoritical Actual In Out M/C
68 Plane flat surface
to 1/4" thickness Planner 0,5 4800 4320 0,015 485,2275922 477,9492 0,112321 1 69 Cut to the width Jointer 0,3 8000 7200 0,015 477,9491783 470,7799 0,066382 1 70 Cut to the length Circle Saw 0,36 6666,667 6000 0,015 470,7799406 463,7182 0,078463 1 71
Forming the along the bottom inside edges
Bending 0,58 4137,931 3724,138 0,015 463,7182415 456,7625 0,124517 1
72 Sanding with sand
paper Disc sand 0,72 3333,333 3000 0,015 456,7624679 449,911 0,152254 1 73 Coat Spray gun 0,62 3870,968 3483,871 0,015 449,9110309 443,1624 0,129141 1
Table 4.11 Side Walls Operation
No.
Process Name Machine Time (min)
Capacity Scrap (%)
Production Requirement Number of
Theoritical Actual In Out M/C
62 Plane flat surface
to 1/4" thickness Planner 0,78 3076,923 2769,231 0,015 485,2275922 477,9492 0,175221 1 63 Cut to the width Jointer 0,48 5000 4500 0,015 477,9491783 470,7799 0,106211 1 64 Cut to the length Circle saw 0,4 6000 5400 0,015 470,7799406 463,7182 0,087181 1
65 Form along the
front inside edge Bending 0,66 3636,364 3272,727 0,015 463,7182415 456,7625 0,141692 1 66 Sanding with sand
paper Disc Sand 0,8 3000 2700 0,015 456,7624679 449,911 0,169171 1
67 Coat Spray gun 0,7 3428,571 3085,714 0,015 449,9110309 443,1624 0,145805 1
Table 4.12 Tailgate Operation
No.
Process Name Machine Time (min)
Capacity Scrap (%)
Production Requirement Number of M/C
Theoritical Actual In Out
81 Plane flat surface
to 1/4" thickness Planner 0,72 3333,333 3000 0,015 477,9491783 470,7799 0,159316 1 82 Cut to the width jointer 0,46 5217,391 4695,652 0,015 470,7799406 463,7182 0,100259 1 83 Cut to the length circle saw 0,4 6000 5400 0,015 463,7182415 456,7625 0,085874 1 84 Sand with sand
paper Disc sand 0,64 3750 3375 0,015 456,7624679 449,911 0,135337 1
85 Coat Spray gun 0,5 4800 4320 0,015 449,9110309 443,1624 0,104146 1
Table 4.13 Tailgate Hinge Block Operation
No.
Process Name Machine Time (min)
Capacity Scrap (%)
Production Requirement Number of
Theoritical Actual In Out M/C
75 Plane flat surface
to 1/2" thickness Planner 0,65 3692,308 3323,077 0,015 485,2275922 477,9492 0,146018 1
76 Cut to the width jointer 0,6 4000 3600 0,015 477,9491783 470,7799 0,132764 1 77 Cut to the length circle saw 0,56 4285,714 3857,143 0,015 470,7799406 463,7182 0,122054 1 78 Drill holes drill press 0,96 2500 2250 0,015 463,7182415 456,7625 0,206097 1 79 Sand with sand
paper Disc Sand 0,48 5000 4500 0,015 456,7624679 449,911 0,101503 1
80 Coat Spray Gun 0,4 6000 5400 0,015 449,9110309 443,1624 0,083317 1
Table 4.14 Tailgate Pivot Pin Operation
No.
Process Name Machine Time (min)
Capacity Scrap (%)
Production Requirement Number of
Theoritical Actual In Out M/C
87 Cut to the length Circle saw 0,32 7500 6750 0,015 456,7624679 449,911 0,067669 1 88 Sand with sand
paper Disc sand 0,4 6000 5400 0,015 449,9110309 443,1624 0,083317 1
Table 4.15 Dump Hinge Block Operation
No.
Process Name Machine Time (min)
Capacity Scrap (%)
Production Requirement Number of
Theoritical Actual In Out M/C
51 Plane flat surface
to 1/2" Thickness Planner 0,56 4285,714 3857,143 0,015 477,9491783 470,7799 0,123913 1 52 Cut to the width Jointer 0,2 12000 10800 0,015 470,7799406 463,7182 0,043591 1 53 Cut to the length Circle saw 0,25 9600 8640 0,015 463,7182415 456,7625 0,053671 1
54 Sand with sand
paper Disc sand 0,6 4000 3600 0,015 456,7624679 449,911 0,126878 1
55 Coat Spray gun 0,36 6666,667 6000 0,015 449,9110309 443,1624 0,074985 1
Table 4.16 Sub Assembly Wheels Operation
No.
Process Name Machine Time (min)
Capacity Scrap (%)
Production Requirement Number of
Theoritical Actual In Out M/C
21
Put the axle into axle blocks and trim to the correct axle length
Cricle saw 1,5 1600 1440 0,015 445,4119206 438,7307 0,309314 1
22 Assemble the axle
and axle blocks 0,6 4000 3600 438,7307418 438,7307 0,12187 1
28
Assemble the axle, space washer and wheels using glue
1,4 1714,286 1542,857 438,7307418 438,7307 0,284363 1
Table 4.17 Sub Assembly Bumper Operation
No.
Process Name Machine Time (min)
Capacity Scrap (%)
Production Requirement Number of
Theoritical Actual In Out M/C
Assembly the headlights and front bumper
1,5 1600 1440 438,7307418 438,7307 0,304674 1
Table 4.18 Truck Chasis Operation
No.
Process Name Machine Time (min)
Capacity Scrap (%)
Production Requirement Number of M/C
Theoritical Actual In Out
29
Assembly the bumper. The wheels to the chassis using glue
2,5 960 864 438,7307418 438,7307 0,50779 1
34
install the headlight using glue
0,7 3428,571 3085,714 438,7307418 438,7307 0,142181 1
Table 4.19 Cab Assembly Operation
No.
Process Name Machine Time (min)
Capacity Scrap (%)
Production Requirement Number of
Theoritical Actual In Out M/C
49
Assembly the hood and the cab using glue
0,72 3333,333 3000 438,7307418 438,7307 0,146244 1
Table 4.20 Sub Assembly Tailgate Operation
No.
Process Name Machine Time (min)
Capacity Scrap (%)
Production Requirement Number of M/C
Theoritical Actual In Out
86
Assemble the tailgate and tailgate hinge block
0,85 2823,529 2541,176 443,1623654 443,1624 0,174393 1
Table 4.21 Dump Assembly Operation
No.
Process Name Machine Time (min)
Capacity Scrap (%)
Production Requirement Number of
Theoritical Actual In Out M/C
74
Assemble the end wall and side walls to the dump bed
2,2 1090,909 981,8182 443,1623654 443,1624 0,451369 1
89
Align the tailgate hinge block
between side walls and glue in tailgate pivot pin
1,8 1333,333 1200 443,1623654 443,1624 0,369302 1
90
Fasteb tha dump assemble to the dump hinge block using glue
0,9 2666,667 2400 443,1623654 443,1624 0,184651 1
I-1 Inspection 0,75 3200 2880 0,01 443,1623654 438,7307 0,153876 1
Table 4.21 Dump Assembly Operation
No.
Process Name Machine Time (min)
Capacity Scrap (%)
Production Requirement Number of
Theoritical Actual In Out M/C
74
Assemble the end wall and side walls to the dump bed
2,2 1090,909 981,8182 443,1623654 443,1624 0,451369 1
89
Align the tailgate hinge block
between side walls and glue in tailgate pivot pin
1,8 1333,333 1200 443,1623654 443,1624 0,369302 1
90
Fasteb tha dump assemble to the dump hinge block using glue
0,9 2666,667 2400 443,1623654 443,1624 0,184651 1
I-1 Inspection 0,75 3200 2880 0,01 443,1623654 438,7307 0,153876 1
Table 4.22 Final Assembly Operation
No.
Process Name Machine Time (min)
Capacity Scrap (%)
Production Requirement Number of
Theoritical Actual In Out M/C
50
Assemble the Cab to the chassis using glue
0,8 3000 2700 438,7307418 438,7307 0,162493 1
91
Connect the dump assembly to the chassis with brass butt hinge
1,5 1600 1440 438,7307418 438,7307 0,304674 1
I-2 Inspection 0,7 3428,571 3085,714 0,01 438,7307418 434,3434 0,140759 1 92 final Coating 0,95 2526,316 2273,684 434,3434343 434,3434 0,191031 1 I-3; 93
Final inspection
and packaging 1,1 2181,818 1963,636 0,01 434,3434343 430 0,218981 1