PELAJARI TENTANG FACILITY DESIGN

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FACILITY DESIGN

PROJECT II

Arranged by: GROUP I

Gilang Fadhlan Syabanu (004201800077) Jeremy Binsar Gultom (004201800031)

Juan Sihombing (004201700013)

M. Dava Shandy P (004201800055)

Naufaldi Rafif Kusuma (004201800072)

PRESIDENT UNIVERSITY INDUSTRIAL ENGINEERING 2018

Jababeka Education Park, Ki Hajar Dewantara Street, Kota Jababeka, West Cikarang, Bekasi 17550 – Indonesia

Phone (021) 8910 9762-6, Fax (021) 8910 9768

Email: [email protected], http://www.president.ac.id

ACKNOWLEDGEMENT

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The Authors would like to express deepest gratitude to the Almighty God because gives authors a lot of mercy and blessing which make authors can finish this report as well. Authors realized without the other helped, this report cannot be finished well. In this occasion, authors would like to say thanks for some people who already supported authors to complete this report.

● Mrs. Anastasia Lidya Maukar, S.T., M.Sc., M.MT, as a lecture of Facility Design, the one who already guided authors kindly so authors could to make this report.

● Authors’ family which already give author support that make authors can make this report completely.

● Authors’ friends, that support and help authors to do this report.

Authors recognized that this report still far away from perfect. Therefore, with all humility, authors would like to say apologizes for any mistakes in this report. Authors hope that the readers can give a good criticism and suggestion which can make this report better than before. Hopefully this report can help the readers to learn and know more about Facility Design.

Bekasi, January 2021

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CHAPTER I INTRODUCTION

1.1 Background

Facility Layout is the arrangement of everything needed for the production of goods or service delivery. Facilities are entities and facilitate any work, which can be in the form of machine tools, work centers, manufacturing sales, machine shops in departments, warehouses, etc. The layout and design of facilities is an important component of the entire business. Operations, both in terms of maximizing the effectiveness of the production process and meeting the needs of employees. The basic purpose of layout is to ensure a smooth flow of work, materials, and information through a system. The basic meaning of the facility is the space where business activities take place. In order for an organization to have an effective and efficient manufacturing unit, it is important that special attention be given to the layout of the facilities. Facility layout is the arrangement of various aspects of manufacturing in the right way to achieve the desired production results. The facility layout considers the available space, the final product, the user's safety and facilities and the operating comfort. An effective facility layout ensures that there is a smooth and stable flow of production materials, equipment and labor with minimum costs. The facility layout looks at the physical allocation of space for economic activity in the factory. Therefore, the main objective of facility layout planning is to design effective workflows so that equipment and workers are more productive (MSG, 2018).

In this Facility Design report, will be carried out to continue the analysis of the facility design to maximize the efficiency and effectiveness. The data required in this report is in accordance with previous reports, such as detailed information about the bill of material (BOM), the operating process chart for each product, and other product specifications.

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1.2 Objectives

The objectives of this report are:

➢ Understand the process flow of each raw material when making DT and CTT

➢ Determine the efficiency, demand, and processing time of the DT and CTT

➢ Indicate the specific steps for making DT and CTT.

➢ Create and understand MPPC and routing tables.

➢ Find the relationship between the product and each component.

➢ Create an organizational structure and determine the number of personnel or operators required by the company.

1.3 Tools and Equipment

The tools and equipment that being used in this report are:

⮚ Microsoft Word for make a report.

⮚ Microsoft Excel for Calculate MPPC and Routing Sheet.

⮚ Data from REPORT FACILITY DESIGN I.

1.4 Steps

In order to conduct the report, there are several steps that has to be done, which are:

⮚ Collect data needed from previous reports, namely BOM, OPC, and other specifications of each product.

⮚ Define Routing Sheets for each product.

⮚ Summarize the total raw material needed to produce each product.

⮚ Make the MPCC of each product.

⮚ Determine numbers of machine and operator required to produce each product.

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CHAPTER II METHODOLOGY

Methodology is the sciences / methods used to obtain the truth using tracing in a certain way in finding the truth, depending on the reality being studied. (Wikipedia, 2021). The methodology used will impact the methods to be used in an analysis. The methodology used in conducting this report consists of the following steps.

Figure 2.1 Steps

2.1 Problems Identification

Problem identification is the purpose and goal of this report. The purpose is to design and determine the bill of materials, operation flowcharts and assembly drawings of the two products, product requirements, machine efficiency, available working time and understand the relevant routing tables, multi-product), information on the number of machines and operators.

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2.2 Data Collection

The data collection of this report is stated in the facility design module 2020, which states information about dimensions, routes, material costs, material density, etc. To make this report, the information stated in the module is required. For example, making manual engineering drawings requires dimensions, while making process drawings (OPC) requires routes.

2.3 Data Analysis

After obtaining the information required for this report, the content to be analyzed is the routing table, the multi-product flow chart, the number of machines, and the number of operators. This section will explain and explain the analysis and calculations.

2.4 Conclusion

After analysis, a conclusion will be drawn. The conclusion of this report is a summary after analysis. It may also include the author’s suggestions.

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CHAPTER III DATA COLLECTION

3.1 Bill of Material

A bill of materials (BOM) is a centralized source of information used to manufacture a product. It is a list of the items needed to create a product as well as the instructions on how to assemble that product. Manufacturers that build products start the assembly process by creating a BOM. Creating an accurate bill of materials (BOM) is vital because it ensures that parts are available when needed as well as ensuring that the assembly process is as efficient as possible. If the BOM is not accurate, it can cause production to halt, which increases operating costs, as time is needed to locate missing parts, start another production order, or until the correct process of assembly is determined. (Investopedia, 2020). Here, there are three BOM for each product, such as Dump Truck (DT), Crane Truck (CT) and Trailer Truck (TT).

3.1.1 Dump Truck (DT)

The Bill of Material of Dump Truck is shown on Table 3.1 below.

Table 3.1 Bill of Material of Dump Truck Bill of Material

Company : - Prepared By : Group 1

Product : Dump Truck Date : January, 31st 2021

Level Part No. Part Name Drawing No. Quantity Make/Buy

0 - Dump Truck DT-1 1

Make

1 - Chassis Assembly DT-2 1

Make

2 TC01 Chassis DT-3 1

Make

2 TC02 Front Bumper DT-3 1

Make

2 TC03 Headlights DT-3 2

Make

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2 -

Sub Assembly

Wheels 1

Make

3 TC04 Axle Blocks DT-3 2

Make

3 TC05 Axles DT-3 2

Make

3 TC06 Wheels DT-3 4

Make 3 TC07 Spacer Washer ¼" DT-3 4

Buy

1 - Cab Assembly DT-4 1

Make

2 C01 Hood DT-5 1

Make

2 C02 Cab DT-5 1

Make

1 - Dump Assembly DT-6 1

Make

2 D01 Dump Bed DT-7 1

Make

2 D02 End Wall DT-7 1

Make

2 D03 Side Walls DT-7 2

Make

2 -

Sub Assembly

Tailgate 1

Make

3 D04 Tailgate DT-7 1

Make

3 D05

Tailgate Hinge

Block DT-7 1

Make

2 D06 Tailgate Pivot Pin DT-7 1

Make

2 D07 Dump Hinge Block DT-7 1

Make 1 D08 Butt Hinge 1" by 2" DT-7 1

Buy

3

Rough Lumber 40"

× 40" × ½" 2

Buy

4

Rough Lumber 40"

× 40" × ½" 2

Buy

3

Rough Lumber 40"

× 40" × ⅚" 1

Buy

4

Rough Lumber 40"

× 40" × ¾" 1

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3

Rough Lumber 40"

× 40" × 1" 1 Buy

3

Rough Lumber 40"

× 40" × 1¼" 1 Buy

3

Rough Lumber 40"

× 40" × ¼" 3 Buy

4

Rough Lumber 40"

× 40" × ¼" 1 Buy

3

Birch Ø½", 20"

long 1 Buy

3 Birch Ø¼", 40" long 1 Buy

Figure 3.1 Product Structure of Dump Truck

As shown on the Bill of Material, there are 4 levels in the making of Dump Truck.

There are one part and 3 assemblies in the first level; chassis assembly, cab assembly, and dump assembly. There is only one subassembly in the second level which is subassembly wheels. Most of the materials are placed in level 3, except for butt hinge in level one, which is used to connect the chassis and the dump assembly. The rough lumber and birch to make subassembly wheels is placed in level 4. The product tree in Figure 3.1 depicts the structure of Dump Truck through the four levels. Higher quality figure is attached in Appendix 2.1.

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CHAPTER III DATA COLLECTION

3.1 Bill of Material

A bill of materials (also known as a BOM or a material bill) is a comprehensive list of the parts, items, assemblies and other materials required for the production of the product, as well as the instructions required for the collection and use of the materials required. The bill of materials can be understood as a supply list and a shopping list for the production of the final product. The material bill explains what, how and where to purchase the correct components, and gives guidance on how to assemble the product from the different parts ordered. Here, there are three BOM for each product, such as Dump Truck (DT), Crane Truck (CT) and Trailer Truck (TT).

3.1.1 Dump Truck (DT)

The Bill of Material of Dump Truck is shown on Table 3.1 below.

Table 3.1 Bill of Material of Dump Truck Bill of Material

Product : Dump Truck Date : January, 31st 2021

0 - Dump Truck DT-1 1

Make

1 - Chassis Assembly DT-2 1

Make

2 TC01 Chassis DT-3 1

Make

2 TC02 Front Bumper DT-3 1

Make

2 TC03 Headlights DT-3 2

Make

2 -

Sub Assembly

Wheels 1

Make

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3 TC04 Axle Blocks DT-3 2

Make

3 TC05 Axles DT-3 2

Make

3 TC06 Wheels DT-3 4

Make 3 TC07 Spacer Washer ¼" DT-3 4

Buy

1 - Cab Assembly DT-4 1

Make

2 C01 Hood DT-5 1

Make

2 C02 Cab DT-5 1

Make

1 - Dump Assembly DT-6 1

Make

2 D01 Dump Bed DT-7 1

Make

2 D02 End Wall DT-7 1

Make

2 D03 Side Walls DT-7 2

Make

2 -

Sub Assembly

Tailgate 1

Make

3 D04 Tailgate DT-7 1

Make

3 D05

Tailgate Hinge

Block DT-7 1

Make

2 D06 Tailgate Pivot Pin DT-7 1

Make

2 D07 Dump Hinge Block DT-7 1

Make 1 D08 Butt Hinge 1" by 2" DT-7 1

Buy

3

Rough Lumber 40"

× 40" × ½" 2

Buy

4

Rough Lumber 40"

× 40" × ½" 2

Buy

3

Rough Lumber 40"

× 40" × ⅚" 1

Buy

4

Rough Lumber 40"

× 40" × ¾" 1

3

Rough Lumber 40"

× 40" × 1" 1 Buy

(12)

3

Rough Lumber 40"

× 40" × 1¼" 1 Buy

3

Rough Lumber 40"

× 40" × ¼" 3 Buy

4

Rough Lumber 40"

× 40" × ¼" 1 Buy

3

Birch Ø½", 20"

long 1 Buy

Figure 3.1 Product Structure of Dump Truck

As shown on the Bill of Material, there are 4 levels in the making of Dump Truck.

There are one part and 3 assemblies in the first level; chassis assembly, cab assembly, and dump assembly. There is only one subassembly in the second level which is subassembly wheels. Most of the materials are placed in level 3, except for butt hinge in level one, which is used to connect the chassis and the dump assembly. The rough lumber and birch to make subassembly wheels is placed in level 4. The product tree in Figure 3.1 depicts the structure of Dump Truck through the four levels. Higher quality figure is attached in Appendix 2.1.

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3.1.2 Crane Truck (CT) and Trailer Truck (TT)

The Bill of Material of Crane Truck is shown on Table 3.2 below.

Table 3.2 Bill of Material of Crane Truck and Trailer Truck Bill of Material

Product : Crane and Trailer Truck Date : January, 31st 2021

0 -

Crane and Trailer

Truck CTT-1 1 Make

1 - Chassis Assembly CTT-2 1 Make

2 CT01 Chassis CTT-3 1 Make

2 CT02 Front Bumper CTT-4 1 Make

2 CT03 Headlights CTT-4 2 Make

2

Sub Assembly

Wheels 1 Make

3 CT04 Axle Blocks CTT-4 3 Make

3 CT05 Axles CTT-4 3 Make

3 CT06 Wheels CTT-4 6 Make

3 CT07 Spacer Washers CTT-4 6 Buy

2 CT08

Trailer Hook-up

Peg CTT-4 1 Make

1 CT09 Chassis Pivot Disc CTT-4 1 Make

1 - Cab Assembly CTT-4 1 Make

2 CAB01 Hood CTT-5 1 Make

2 CAB02 Cab CTT-5 1 Make

1 -

Crane Housing and Crane Arm

Assembly

CTT-6 1 Make

2 CH01 Floor Panel CTT-7.1 1 Make

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2 -

Sub Assembly

Crane Housing 1 Make

3 CH02 Crane Side Walls CTT-7.1 2 Make

3 CH06 Crank Axle CTT-7.1 1 Make

3 CA02 Boom Pivot Pin CTT-7.1 1 Make

3 CA05 Braided String CTT-7.1 1 Buy

3 CH07 Wind-Up Reel CTT-7.1 1 Make

2 CA01 Boom CTT-7.1 1 Make

2 CA07 Rubber Washers CTT-7.2 2 Buy

2 CA06 Screw Eye CTT-7.2 1 Buy

2 CH03 Crane Pivot Pin CTT-7.1 1 Make

2 CA03 Pick-Up Head CTT-7.1 1 Make

2 CA04 Pick-Up Magnet CTT-7.1 1 Buy

2 CG02 Washers CTT-7.2 8 Buy

2 CG01 Drums CTT-7.2 8 Make

2 CH04 Crank Arm CTT-7.1 1 Make

2 CH05 Crank Handle CTT-7.1 1 Make

1 - Trailer Assembly CTT-8 1 Make

2 TR01 Floor Board CTT-9 1 Make

2 TR06 Side Walls CTT-9 2 Make

2 TR07 End Walls CTT-9 2 Make

2 -

Sub Assembly

Wheels 1 Make

3 TR02 Axle Blocks CTT-9 2 Make

3 TR03 Axles CTT-9 2 Make

3 TR04 Wheels CTT-9 4 Buy

3 TR05 Spacer Washers CTT-9 4 Make

2 TR08 Trailer Hitch CTT-9 1 Make

2 TR09

Flat-Head Wood

Screw CTT-9 1 Buy

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3

Rough Lumber 40"

× 40" × ½" 6 Buy

4

Rough Lumber 40"

× 40" × ½" 3 Buy

3

Rough Lumber 40"

× 40" × ⅚" 2 Buy

4

Rough Lumber 40"

× 40" × ¾" 2 Buy

3

Rough Lumber 40"

× 40" × 1" 1 Buy

3

Rough Lumber 40"

× 40" × 1¼" 1 Buy

3

Rough Lumber 40"

× 40" × ¼" 2 Buy

3

Birch Ø½", 20"

long 1 Buy

3

Birch Ø¼", 40"

long 3 Buy

4

Birch Ø¼", 40"

long 5 Buy

3

Birch Ø⅝", 10"

long 1 Buy

3

Birch Ø¾", 20"

long 1 Buy

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Figure 3.2 Product Structure of Crane and Trailer Truck

As shown on the Bill of Material, there are 4 levels in the making of Crane and Trailer Truck. There are one part and 4 assemblies in the first level; chassis assembly, cab assembly, crane housing and crane arm assembly, and trailer assembly. There are two subassemblies in the second level which is subassembly wheels; each as a component of chassis assembly and trailer assembly. Most of the material are placed in level three except for rough lumber to make chassis pivot disc in level two. The rough lumber and birch to make parts of crane housing and crane arm assembly is placed in level four. The product tree in Figure 3.2 depicts the structure of Crane and Trailer Truck through the four levels. Integrated higher quality figure is attached in Appendix 2.2.

3.2 Assembly Chart

A schematic model that defines how the parts work together, the order of assembly, and the overall structure of the product. This chart is ideal for viewing the bird's eye process for the production of the most assembled products. It lists all major materials and components, subassembly operations, inspection and assembly operations.

3.2.1 Dump Truck (DT) Assembly Chart

The assembly chart of Dump Truck is shown in Appendix 4.1. There are 17 parts needed to make a Dump Truck with two subassemblies, four assemblies, and three inspections. SAD 1 is sub assembly wheels which assembles axle block, axles, wheels, and purchased parts spacer washer. SAD 3 is sub assembly tailgate which assembles tailgate hinge block, and tailgate. The first assembly is AD 1, which is chassis assembly which assembles chassis, front bumper, SAD 1, and headlights together. The second assembly is AD 2, which is cab assembly that only put cab and hood together. The third assembly AD 3 is dump assembly which assemble dump hinge block, dump bed, side walls, end wall, SAD 3, and tailgate pivot pin

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together. Finally, the three assemblies are assembled together with dump and chassis connected with purchased part brass butt hinge.

3.2.2 Crane Truck (CT) and Trailer Truck (TT) Assembly Chart

The assembly chart of Crane and Trailer Truck is shown in Appendix 4.1. There are 36 parts needed to make a Crane and Trailer Truck with three subassemblies, five assemblies, and three inspection. SAC2 is sub assembly wheels which assembles axle block, axles, wheels, and purchased parts spacer washer. SAC1 is sub assembly crane housing which assembles crane side walls, crank axle, boom pivot pin, wind-up reel, and purchased part, braided string. The first assembly is AC3, which is chassis assembly which assembles chassis, front bumper, SAC2, headlights, and trailer hook-up peg together. The second assembly is AC2, which is cab assembly that only put cab and hood together. The third assembly AC1 is crane housing and crane arm assembly which assemble floor panel, SAC1, boom, purchased parts screw eye washers, magnet, crane pivot pin, pickup head, crank arm, crank handle, drums, together. Next is trailer assembly which assembles floor board, SAC2, side walls, end walls, trailer hitch and flat wood screw. Finally, the three assemblies are assembled together with the chassis pivot disc put between the chassis and crane housing.

3.3 Operation Process Chart

A diagram showing the manufacturing processes of a given product or the delivery of a particular service.

3.3.2 Dump Truck (DT) OPC

The operation process chart of Dump Truck is shown in Appendix 3.1. The OPC started from the purchased materials of fifteen parts; chassis, front bumper, headlights, axle blocks, axles, wheels, hood, cab, dump bed, end wall, side walls, tailgate, tailgate hinge block, tailgate pivot pin, dump hinge block. All previously mentioned parts are either processed from rough lumber or birch, both have different specification for each part. In total, there are 93 operation and 3 inspection

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processes with one process combining operation and inspection at the same time.

The time needed to finish each component is summarized in the table below.

Table 3.3 Dump Truck OPC Summarized

Components Operation Inspection

No. Of Process Time No. of Process Time

Chassis 5 2.96 0 -

Front

bumper 6 4.26 0 -

Headlights 4 1.9 0 -

Axle blocks 6 3.84 0 -

Axles 3 1.5 0 -

Wheels 5 3.45 0 -

Hood 6 4.95 0 -

Cab 8 5.49 0 -

Dump bed 6 4.07 0 -

End wall 6 3.08 0 -

Side walls 6 3.82 0 -

Tailgate 5 2.72 0 -

Tailgate

hinge block 6 3.65 0 -

Tailgate

pivot pin 2 0.72 0 -

Dump hinge

block 5 1.97 0 -

Sub Assembly Sub

assembly

wheels 3 3.5 0 -

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Sub assembly

tailgate 1 0.85 0 -

Assembly Truck

chassis

assembly 2 3.2 0 -

Cab

assembly 1 0.72 1

Dump

assembly 3 4.9 2 0.75

Final

assembly 3 3.25 1.8

Total 92* 64.8 3 2.55

Total Time 67.35

*There are 93 operations, and 3 inspection. One process is done together

3.3.2 Crane Truck (DT) and Trailer Truck (TT) OPC

The operation process chart of Dump Truck is shown in Appendix 3.2. The OPC started from the purchased materials twenty-eight parts. All parts are either processed from rough lumber or birch, both have different specification for each part. In total, there are 161 operations and 3 inspection processes needed to make Crane and Trailer Truck. The total time needed is for operations is 94.01 minutes and 2.64 minutes for inspection, totaling 96.65 minutes. The time needed to finish each component is summarized in the table below.

Table 3.4 Crane and Trailer Truck OPC Summarized

Components

Operation Inspection

No of

Process Time

No of Process Time

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Chassis 5 2.96 0 -

Front bumper 6 4.26 0 -

Headlights 4 1.9 0 -

Axles 3 1.5 0 -

Wheels 5 3.45 0 -

Trailer hookup 2 0.7 0 -

Chassis pivot

pin 5 2.36 0 -

Hood 6 4.95 0 -

Cab 8 5.49 0 -

Floor panel 7 3.68 0 -

Crane side

walls 8 4.56 0 -

Crane pivot pin 1 0.36 0 -

Crank arm 6 3.52 0 -

Crank handle 2 0.55 0 -

Crank axle 2 0.55 0 -

Windup reel 2 0.56 0 -

Boom 8 5.54 0 -

Boom pivot

pin 1 0.24 0 -

Pickup head 1 0.24 0 -

Floor board 6 3.34 0 -

Axles 3 1.5 0 -

Wheels 5 3.45 0 -

Side walls 7 4.22 0 -

End wall 8 3.85 0 -

Trailer hitch 6 2.74 0 -

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Drums 3 0.91 0 - Sub Assembly

Sub assembly

crane housing 3 1.66 0 -

Sub assembly

wheels 3 3.5 0 -

Assembly Crane housing

and Crane arm

assembly 10 3.46 2 1.84

Cab assembly 1 0.72 0 -

Trailer

assembly 4 3.83 0 -

Chassis

assembly 3 3.38 0 -

Final assembly 5 2.4 1 0.8

Total 161 94.01 3 2.64

Total Time 96.65

3.4 Material Specification

One of the factors that determine the success of creating the best product is determining and following the precise specification of the material and product. The material specification has a purpose to acknowledge the types and amount of raw material that will be needed in each part of the product and differentiate the specification of material from each part.

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Table 3.5 Material Specification for Dump Truck

Material Name Specification Number of

Parts per Production Thickness

(inches)

Length (inches)

Width (inches)

Rough Lumber 1/2 40 40 1

Birch ⌀ 1/2 20 2

Birch ⌀ 1/4 40 2

Stell ¼ 4

Rough Lumber 1 40 40 1

Rough Lumber 1 ¼ 40 40 1

Rough Lumber ¼ 40 40 1

Rough Lumber ½ 40 40 1

Birch ⌀ 1/4 40 1

Brass 1 1 1

Table 3.5 shows us the detailed information of material specifications, including material name, material length, width and thickness, and other specifications, as well as the quantity of each part required for each production in dump truck production.

Table 3.6 Material Specification for Crane Trailer and Truck

Material Name Specification Number of

Parts per Production Thickness

(inches)

Length (inches)

Width (inches)

(24)

Birch ⌀ ½ 20 2

Rough Lumber ¾ 40 40 3

Birch ⌀ ¼ 40 3

Steel ¼ 6

Birch ⌀ ¼ 40 1

Rough Lumber 1 40 40 1

Rough Lumber 1 ¼ 40 40 1

Birch ⌀ ¼ 40 1

Birch ⌀ 5/8 10 1

Magnet ¼ ⌀ ½ 1

Nylon 12 1

Steel 1

Rubber ¼ 2

Rough Lumber ¾ 40 40 2

Birch ⌀ ¼ 40 2

Steel ¼ 4

(25)

Brass ¼ 1

Birch ⌀ ¾ 20 8

Steel ⌀ 5/8 8

Table 3.6 shows us the detailed information of material specifications, including material name, material length, width and thickness, and other specifications, as well as the quantity of each part required for each production in dump truck production.

3.5 Part Specification

The Part Specification will show the data of each part in detail for Dump Truck and CTT (Crane and Trailer Truck).

Table 3.7 Part Specification of Dump Truck and CTT (Crane Trailer Truck)

Part No. Part Name Specification Raw Material

Thickness Length Width Dump Truck

1 Chassis ½ 2 1/8 6 1/8

Rough lumber (40" x 40" x

1/2")

2 Front Bumper ⅚ 2 7/8 ⅚

5/6")

3 Headlights ɸ5/16, 3/4 long

4 Axle Blocks ¾ ⅝ 2 1/8 Rough lumber

(40" x 40"x 3/4")

5 Axles ɸ1/4, 3 3/8 long

6 Wheels ɸ1 5/6, 1/2 thick

(26)

7 Spacer Washer - ¼ - Steel (buy)

8 Hood 1 1 7/8 1 3/4 Rough lumber

(40" x 40" x 1")

9 Cab 1 ¼ 2 1/8 2

Rough lumber (40" x 40" x 1

1/4")

10 Dump Bed ¼ 2 3/8 3 5/8

1/4")

11 End Wall ¼ 2 1/8 2 3/8

1/4")

12 Side Walls ¼ 2 1/8 3 3/4

1/4")

13 Tailgate ¼ 2 1/8 1

13/16

1/4") 14 Tailgate Hinge

Block ½ ¾ 2 1/8

1/2") 15 Tailgate Pivot

Pin ɸ1/4, 2 3/4 long

16 Dump Hinge

Block ½ 9/16 2 1/8

1/2") 17 Butt Hinge 1 "by 2"

Crane and Trailer Truck

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18 Chassis ½ 2 1/8 6 1/8

1/2")

19 Front Bumper ⅚ 2 7/8

11/16

5/6")

20 Headlights ɸ5/16, 3/4 long

21 Axle Blocks ¾ ⅝ 2 1/8

3/4")

22 Axles ɸ1/4, 3 3/8 long

25 Trailer hook-up

peg ɸ1/4, dowel by 3/4 in long 26 Chassis pivot

disc ɸ1 1/2, 7/16 thick

27 Hood 1 1 7/8 1 3/4 Rough lumber

(40" x 40" x 1")

28 Cab 1 ¼ 2 1/8 2

Rough lumber (40" x 40" x 1

1/4")

29 Floor Panel ½ 2 1/2 7/8

1/2")

30 Crane Side

Walls ½ 2 1/2 1 3/4

1/2") 31 Crane Pivot Pin ɸ¼, 1 1/8 long, with ɸ head ⅝

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32 Crank Arm ¼ 1 3/4 ¾

1/4") 33 Crank Handle ɸ¼, dowel by 1 1/8 in long

34 Crank Axle ɸ¼, dowel by 1 3/4 in long 35 Wind-up Reel ɸ¼, dowel by 5/8 in long

36 Boom ½ 5 3/8 ¾

1/2") 37 Boom Pivot Pin ɸ¼, dowel by 1½ in long

38 Pick-up head ɸ⅝, dowel by ¾ in long 39 Pick-up magnet ɸ½ by ¼ in thick

40 Braided String - 12 - Nylon (buy)

41 Screw Eye Mini (smallest size)

42 Washers - ¼ - Rubber (buy)

43 Floor Board ¼ 3 3/8 1 3/4

1/4")

44 Axle Blocks ¾ 2 1/8 ⅝

3/4") 45 Axles ɸ¼, dowel by 3 3/8 in long

48 Side Walls ¼ 3 3/8 1 1/4

1/4")

49 End Walls ¼ 2 3/16 1 1/4

1/4")

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50 Trailer Hitch ¼ 2 5/8 ⅝

1/4") 51 Flat-head wood

screw - ¼ - Brass

52 Drums ɸ¾, dowel by 1 3/8 in long

53 Washers - ɸ⅝ - Steel (buy)

3.6 Demands, Efficiency and Parts Specification

Below are shown the demand, efficiency, and working hours available used on the next chapter – Data Analysis.

Table 3.8 Demands, Efficiency and Parts Specification

Product Deemand (Units per Week) Efficiency Working Hours Available

Dump Truck 480 90% 8*60 = 480

minutes/day Crane and

Trailer Truck

360

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CHAPTER IV DATA ANALYSIS

4.1 Routing Sheet

A route sheet is used to note a number of things to track a particular set of steps or a sequence in the manufacturing process. Route sheets define a work order and number it, and usually include a symbol or other specific way of defining a component. Route sheet will be useful to make MPPC (Multiple Product Process Chart). The routing sheet of DT (Dump Truck) and CTT (Crane and Trailer Truck) are show below.

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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.

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

(32)

11 Coat Spray Gun 0,6 4000 3600 1,5% 445,4119206 438,7307 0,123726 1

Table 4.3 Headlights Operation

No.

Capacity Scrap (%)

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.

Capacity Scrap (%)

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

(33)

Table 4.5 Axle Operation

No.

Capacity Scrap (%)

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.

Capacity Scrap (%)

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

(34)

Table 4.7 Hood Operation

No.

Capacity Scrap (%)

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.

Capacity Scrap (%)

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

(35)

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.

Capacity Scrap (%)

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

(36)

Table 4.10 End Wall Operation

No.

Capacity Scrap (%)

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.

Capacity Scrap (%)

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

(37)

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.

Capacity Scrap (%)

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.

Capacity Scrap (%)

to 1/2" thickness Planner 0,65 3692,308 3323,077 0,015 485,2275922 477,9492 0,146018 1

(38)

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.

Capacity Scrap (%)

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.

Capacity Scrap (%)

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

(39)

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.

Capacity Scrap (%)

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

(40)

Table 4.17 Sub Assembly Bumper Operation

No.

Capacity Scrap (%)

Assembly the headlights and front bumper

1,5 1600 1440 438,7307418 438,7307 0,304674 1

Table 4.18 Truck Chasis Operation

No.

Capacity Scrap (%)

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

(41)

Table 4.19 Cab Assembly Operation

No.

Capacity Scrap (%)

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.

Capacity Scrap (%)

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.

Capacity Scrap (%)

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

(42)

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.

Capacity Scrap (%)

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

(43)

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.

Capacity Scrap (%)

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

(44)

4.1.2 Routing Sheet of Crane Truck (CT) and Trailer Truck (TT)

Table 4.23 Routing Sheet of Chasis (CT 01) Operation

No.

Capacity Scrap (%)

Plane flat surface to ½" thickness

Planner 0,6 4000,00 3600 1,50% 326,82 321,91 0,09

1 Cut to the width Jointer 0,45 5333,33 4800 1,50% 321,91 317,09 0,07 1 Cut to the length Circle saw 0,36 6666,67 6000 1,50% 317,09 312,33 0,05 1 Sand with sand

paper

Disc sand 0,8 3000,00 2700 1,50% 312,33 307,64 0,12

1

Coat Spray gun 0,75 3200,00 2880 1,50% 307,64 303,03 0,11 1

Table 4.24 Routing Sheet of Front Bumper (CT 02) Operation

No.

Capacity Scrap

(%)

Production Requirement

Number of M/C

6 Plane flat surface Planner 0,72 3333,33 3000 1,50% 331,79 326,82 0,11 1

7 Cut to the width Jointer 0,6 4000,00 3600 1,50% 326,82 321,91 0,09 1

8 Cut to the length Circle saw 0,54 4444,44 4000 1,50% 321,91 317,09 0,08 1 9 Drill 2 holes Drill press 1,1 2181,82 1963,636364 1,50% 317,09 312,33 0,16 1

(45)

10 Sand with sand paper

Disc sand 0,7 3428,57 3085,714286 1,50% 312,33 307,64 0,10

1

11 Coat Spray gun 0,6 4000,00 3600 1,50% 307,64 303,03 0,09 1

Table 4.25 Routing Sheet of Headlights (CT 03) Operation

No.

Capacity Scrap

(%)

Number of M/C

33 Cut to the length Circle saw 0,5 4800,00 4320,00 1,50% 643,83 634,17 0,15 1 34 Drill the hole Drill press 0,4 6000,00 5400,00 1,50% 634,17 624,66 0,12 1 35 Sand with sand

paper

Disc sand 0,55 4363,64 3927,27 1,50% 624,66 615,29 0,16

1

36 Coat Spray gun 0,45 5333,33 4800,00 1,50% 615,29 606,06 0,13 1

Table 4.26 Routing Sheet of Axle Blocks (CT 04) Operation

No.

Capacity Scrap

(%)

Number of M/C

12 Plane flat surface to ¾'" thickness

Planner 0,72 3333,33 3000,00 1,50% 9953,82 9804,52 3,32

1 13 Cut to the width Jointer 0,5 1200,00 1080,00 1,50% 9804,52 9657,45 9,08 1 14 Cut to the length Circle saw 0,42 1008,00 907,20 1,50% 9657,45 9512,59 10,65 1

(46)

15 Drill the hole Drill press 0,9 2160,00 1944,00 1,50% 9512,59 9369,90 4,89 1 16 Sand with sand

paper

Disc sand 0,7 1680,00 1512,00 1,50% 9369,90 9229,35 6,20

1

17 Coat Spray gun 0,6 1440,00 1296,00 1,50% 9229,35 9090,91 7,12 1

Table 4.27 Routing Sheet of Axle (CT 05) Operation

No.

Capacity Scrap

(%)

Number of M/C

18 Cut to the length Hand saw 0,4 6000 5400 1,50% 9512,59 9369,90 1,76 1

Disc sand 0,6 4000 3600 1,50% 9369,90 9229,35 2,60

1

20 Coat Spray gun 0,5 4800 4320 1,50% 9229,35 9090,91 2,14 1

Table 4.27 Routing Sheet of Wheels (CT 06) Operation

No.

Capacity Scrap

(%)

Number of M/C

23 Plane flat surface Planner 1,2 2000,00 1800,00 1,50% 19609,03 19314,90 10,89 1 24 Cut to the wheel Hole saw 0,8 3000,00 2700,00 1,50% 19314,90 19025,17 7,15 1 25 Drill the center Drill press 0,4 6000,00 5400,00 1,50% 19025,17 18739,80 3,52 1

(47)

Disc sand 0,5 4800,00 4320,00 1,50% 18739,80 18458,70 4,34

1

27 Coat Spray gun 0,55 4363,64 3927,27 1,50% 18458,70 18181,82 4,70 1

Table 4.28 Routing Sheet of Trailer Hool-up Peg (CT 08) Operation

No.

Capacity Scrap

(%)

Number of M/C

30 Cut to length Hand saw 0,4 6000 5400 1,50% 312,33 307,64 0,06 1

Disc sand 0,3 8000 7200 1,50% 307,64 303,03 0,04

1

Table 4.28 Routing Sheet of Pivot Disc (CT 09) Operation

No.

Capacity Scrap

(%)

Number of M/C

54 Plane flat surface to ¼" thickness

Planner 0,42 5714,29 5142,86 1,50% 321,91 317,09 0,06

1 55 Mark to the

diameter

0,3 8000,00 7200,00 317,09 317,09 0,04

1 56 Cut to the

diameter

Router 0,56 4285,71 3857,14 1,50% 317,09 312,33 0,08

1

(48)

Disc sand 0,6 4000,00 3600,00 1,50% 312,33 307,64 0,09

1

58 Coat Spray gun 0,48 5000,00 4500,00 1,50% 307,64 303,03 0,07 1

Table 4.29 Routing Sheet of Hood (CT 10) Operation

No.

Capacity Scrap

(%)

Number of M/C

54 Plane flat surface to ¼" thickness

Planner 0,42 5714,29 5142,86 1,50% 321,91 317,09 0,06

1 55 Mark to the

diameter

0,3 8000,00 7200,00 317,09 317,09 0,04

1 56 Cut to the

diameter

Router 0,56 4285,71 3857,14 1,50% 317,09 312,33 0,08

1 57 Sand with sand

paper

Disc sand 0,6 4000,00 3600,00 1,50% 312,33 307,64 0,09

1

58 Coat Spray gun 0,48 5000,00 4500,00 1,50% 307,64 303,03 0,07 1

(49)

Table 4.30 Routing Sheet of Hood (CAB 01) Operation

No.

Capacity Scrap

(%)

Number of M/C

46 Plane flat surface to 1" thickness

Planner 0,75 3200,00 2880,00 1,50% 331,79 326,82 0,12

1 47 Cut to the width Jointer 0,6 4000,00 3600,00 1,50% 326,82 321,91 0,09 1 48 Cut to the length Circle saw 0,6 4000,00 3600,00 1,50% 321,91 317,09 0,09 1 49 Cut the sides at

17° using angle- cutting jig

Circle saw 1,8 1333,33 1200,00 1,50% 317,09 312,33 0,26

1 50 Sand with sand

paper

Disc sand 0,6 4000,00 3600,00 1,50% 312,33 307,64 0,09

1

51 Coat Spray gun 0,6 4000,00 3600,00 1,50% 307,64 303,03 0,09 1

Table 4.31 Routing Sheet of Cab (CAB 02) Operation

No.

Capacity Scrap

(%)

38 Plane flat surface to 1¼"

thickness

Planner 0,75 3200,00 2880,00 1,50% 336,846816 331,79 0,12 1 39 Cut to the width Jointer 0,6 4000,00 3600,00 1,50% 331,7941138 326,817202 0,09 1

(50)

40 Cut to the length

Circle saw 0,6 4000,00 3600,00 1,50% 326,8172021 321,91 0,09 1 41 Lay out the

window

0,5 4800,00 4320,00 321,9149441 321,914944 0,07

1 42 Drill the

window

Drill press 0,98 2448,98 2204,08 1,50% 321,9149441 317,09 0,15 1 43 Cut the front of

the cab at 30°

using tenoning jig

Circle saw 0,86 2790,70 2511,63 1,50% 317,0862199 312,329927 0,13 1

Disc sand 0,6 4000,00 3600,00 1,50% 312,3299266 307,64 0,09 1

45 Coat Spray gun 0,6 4000,00 3600,00 1,50% 307,6449777 303,03 0,09 1

Table 4.32 Routing Sheet of Floor Panel (CH 01) Operation

No.

Capacity Scrap

(%)

thickness

Planner 0,6 4000,00 3600,00 1,50% 343,6861708 338,53 0,10 1 77 Cut to the width Jointer 0,42 5714,29 5142,86 1,50% 338,5308783 333,452915 0,07 1

(51)

Circle saw 0,32 7500,00 6750,00 1,50% 333,4529151 328,45 0,05 1 79 Trim the back

edge at 17°

Router 0,28 8571,43 7714,29 1,50% 328,4511214 323,524355 0,04 1 80 Drill for the

crane pivot

Drill press 0,68 3529,41 3176,47 1,50% 323,5243545 318,67 0,10 1 81 Sand with sand

paper

Disc sand 0,72 3333,33 3000,00 1,50% 318,6714892 313,891417 0,11 1

82 Coat Spray gun 0,66 3636,36 3272,73 1,50% 313,8914169 309,18 0,10 1

Table 4.33 Routing Sheet of Walls (CH 02) Operation

No.

Capacity Scrap

(%)

thickness

Planner 0,78 3076,92 2769,23 1,50% 683,952926 673,69 0,25 1 61 Cut to the width Jointer 0,48 5000,00 4500,00 1,50% 673,6936321 663,588228 0,15 1 62 Cut to the

length

Circle saw 0,4 6000,00 5400,00 1,50% 663,5882276 653,63 0,12 1 63 Drill Drill press 0,48 5000,00 4500,00 1,50% 653,6344042 643,829888 0,15 1 64 Rabbet along

the inside

Jointer 0,36 6666,67 6000,00 1,50% 643,8298881 634,17 0,11 1

(52)

bottom edges (equiped with Chisel) 65 Cut the boom

end of the side wall at 17°

Router 0,56 4285,71 3857,14 1,50% 634,1724398 624,659853 0,16 1 66 Sand with sand

paper

Disc sand 0,8 3000,00 2700,00 1,50% 624,6598532 615,29 0,23 1

67 Coat Spray gun 0,7 3428,57 3085,71 1,50% 615,2899554 606,06 0,20 1

Table 4.34 Routing Sheet of Pivot Pin (CH 03) Operation

No.

Capacity Scrap

(%)

Hand saw 0,36 6666,67 6000,00 1,50% 310,7525027 306,09 0,05 1

Table 4.35 Routing Sheet of Pivot Pin (CH 03) Operation

No.

Capacity Scrap

(%)

Hand saw 0,36 6666,67 6000,00 1,50% 310,7525027 306,09 0,05 1

(53)

Table 4.36 Routing Sheet of Crank Arm (CH 04) Operation

No.

Capacity Scrap

(%)

thickness

Planner 0,78 3076,923077 2769,230769 1,50% 335,1455695 330,12 0,12 1 106 Cut to the

width

Jointer 0,48 5000 4500 1,50% 330,1183859 325,16661 0,07 1 107 Cut to the

length

Circle saw 0,4 6000 5400 1,50% 325,1666102 320,29 0,06 1 108 Drill for the

crank handle

Drill press 0,38 6315,789474 5684,210526 1,50% 320,289111 315,484774 0,06 1 109 Sand with sand

paper

Disc sand 0,86 2790,697674 2511,627907 1,50% 315,4847743 310,75 0,13 1 110 Coat Spray gun 0,62 3870,967742 3483,870968 1,50% 310,7525027 306,091215 0,09 1

Table 4.37 Routing Sheet of Crank Handle (CH 05) Operation

No.

Capacity Scrap

(%)

Hand saw 0,25 9600 8640 1,50% 315,4847743 310,75 0,04

1

(54)

112 Drill the hole through the length

Drill press 0,3 8000 7200 1,50% 310,7525027 306,091215 0,04 1

Table 4.38 Routing Sheet of Crank Axle (CH 06) Operation

No.

Capacity Scrap

(%)

Hand saw 0,25 9600 8640 1,50% 312,3299266 307,64 0,04

1 69 Drill the hole

through the length

Drill press 0,3 8000 7200 1,50% 307,6449777 303,03 0,04 1

Table 4.39 Routing Sheet of Wind-up Reel (CH 07) Operation

No.

Capacity Scrap

(%)

Hand saw 0,34 7058,82 6352,94 1,50% 312,33 307,64 0,05 1

73 Coat Spray gun 0,22 10909,09 9818,18 1,50% 307,64 303,03 0,03 1

(55)

Table 4.40 Routing Sheet of Wind-up Reel (CA 01) Operation

No.

Capacity Scrap

(%)

85 Plane flat surface to ¼"

thickness

Planner 0,78 3076,92 2769,23 1,50% 348,92 343,686171 0,13 1 86 Cut to the

width

Jointer 0,48 5000,00 4500,00 1,50% 343,69 338,530878 0,08 1 87 Cut to the

length

Circle saw 0,4 6000,00 5400,00 1,50% 338,53 333,452915 0,06 1 88 Drill the seven,

evenly spaced holes in the boom using spacer block techniques

Drill press 1,5 1600,00 1440,00 1,50% 333,45 328,451121 0,23

1

89 Drill the pivot pin hole at the end of the boom

Drill press 0,7 3428,57 3085,71 1,50% 328,45 323,524355 0,11 1

90 Drill the end of mini screw

Drill press 0,2 12000,00 10800,00 1,50% 323,52 318,67 0,03 1

(56)

Disc sand 0,86 2790,70 2511,63 1,50% 318,67 313,891417 0,13 1

92 Coat Spray gun 0,62 3870,97 3483,87 1,50% 313,89 309,18 0,09 1

Table 4.41 Routing Sheet of Boom Pivot Pin (CA 02) Operation

No.

Capacity Scrap

(%)

Hand Saw 0,24 10000 9000 1,50% 307,6449777 303,03 0,03 1

Table 4.42 Routing Sheet of Pick-up Head (CA 03) Operation

No.

Capacity Scrap

(%)

Hand Saw 0,24 10000 9000 1,50% 310,7525027 306,09 0,03 1

Table 4.43 Routing Sheet of Floor Board (TR 01) Operation

No.

Capacity Scrap

(%)

115 Plan flat surface to 3/4 inch thickness

Planner 0,6 4000 3600 1,50% 331,79 326,82 0,09

1

(57)

116 Cut to the width

Jointer 0,52 4615,384615 4153,846154 1,50% 326,82 321,91 0,08 1 117 Cut to the

length

Circle Saw 0,42 5714,285714 5142,857143 1,50% 321,91 317,09 0,06 1

118 Drill the hole Drill Press 0,5 4800 4320 1,50% 317,09 312,33 0,07 1

Disc Sand 0,7 3428,571429 3085,714286 1,50% 312,33 307,64 0,10 1

120 Coat Spray Gun 0,6 4000 3600 1,50% 307,64 303,030303 0,09 1

Table 4.44 Routing Sheet of Axle Blocks (TR 02) Operation

No.

Capacity Scrap

(%)

136 Plan flat surface to 3/4 inch thickness

Planner 0,7 3428,571429 3085,714286 1,50% 6.635,88 6.536,34 2,15 1 137 Cut to the

width

Jointer 0,5 4800 4320 1,50% 6.536,34 6438,29888 1,51

1 138 Cut to the

length

Circle Saw 0,42 5714,285714 5142,857143 1,50% 6.438,30 6341,7244 1,25 1 139 Drill the hole Drill Press 0,9 2666,666667 2400 1,50% 6.341,72 6.246,60 2,64 1 140 Sand with sand

paper

Disc Sand 0,7 3428,571429 3085,714286 1,50% 6.246,60 6.152,90 2,02 1