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    The Capacity Can Be Increased in The Following Manner

    Uploaded by

    sagar
    The document summarizes production capacity and proposals to increase capacity of gear box manufacturing. It shows current daily and monthly production of gears, shafts and assemblies from heat treatment across morning, evening and night shifts. Total gear boxes produced is 63 with an efficiency-adjusted amount of 53.55. Capacity can be increased by converting machines after every 4-5 shifts to gear hobbing and shaving as the number of gear sets is less than shafts, and using extra shafts produced with extra gears manufactured.

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    The Capacity Can Be Increased in The Following Manner

    Uploaded by

    sagar
    24 views8 pages
    The document summarizes production capacity and proposals to increase capacity of gear box manufacturing. It shows current daily and monthly production of gears, shafts and assemblies from heat treatment across morning, evening and night shifts. Total gear boxes produced is 63 with an efficiency-adjusted amount of 53.55. Capacity can be increased by converting machines after every 4-5 shifts to gear hobbing and shaving as the number of gear sets is less than shafts, and using extra shafts produced with extra gears manufactured.

    Original Title

    Vikramaditya 14P178

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    The document summarizes production capacity and proposals to increase capacity of gear box manufacturing. It shows current daily and monthly production of gears, shafts and assemblies from heat treatment across morning, evening and night shifts. Total gear boxes produced is 63 with an efficiency-adjusted amount of 53.55. Capacity can be increased by converting machines after every 4-5 shifts to gear hobbing and shaving as the number of gear sets is less than shafts, and using extra shafts produced with extra gears manufactured.

    Copyright:

    © All Rights Reserved
    Download as XLSX, PDF, TXT or read online from Scribd
    Download as xlsx, pdf, or txt
    24 views8 pages

    The Capacity Can Be Increased in The Following Manner

    Uploaded by

    sagar
    The document summarizes production capacity and proposals to increase capacity of gear box manufacturing. It shows current daily and monthly production of gears, shafts and assemblies from heat treatment across morning, evening and night shifts. Total gear boxes produced is 63 with an efficiency-adjusted amount of 53.55. Capacity can be increased by converting machines after every 4-5 shifts to gear hobbing and shaving as the number of gear sets is less than shafts, and using extra shafts produced with extra gears manufactured.

    Copyright:

    © All Rights Reserved
    Download as XLSX, PDF, TXT or read online from Scribd
    Download as xlsx, pdf, or txt
    of 8

    Q.

    No.of Gears machined ( ready to be put in heat treatment)


    No.of Shafts machined ( ready to be put in heat treatment)
    No. Of Assemblies (these are from the heat treatment which have been loaded 2 shifts bef

    Total Gear Boxes


    Total Gear Boxes With 85% efficiency taken into account

    The capacity can be increased in the following manner

    1. Number of gear sets < Number of shafts, so converting to H2 and S2 to gear hobbing an
    shaving machines can be done for every 4-5 shifts
    2. The extra shafts that have been produced can be used
    with extra gears manufactured by the shifts in step 1

    Morning Shifts Evening Shift Night shift Total


    90
    90
    78
    258
    56
    56
    48
    160
    22
    19
    22
    63

    63
    53.55 53(approx)

    Gear Box Manufacturing Cost

    S.No

    Item
    1 Gear Blanks
    2 Cost of Gear Shaft blanks
    3 Grear Housing
    4 Gear Box Assembly Kit
    5 Other Tools and consumables
    6 packaging material
    Total Cost Price of Gear Box
    Selling Price of the Gear Box
    Units Sold in 2013-14
    Closing Stock of year
    Total Units manufactured in 2013-14
    Total Units to be manufactured in 2014-15
    Total Cost of Manufacturing

    Working hours per day = (450+450+390)*.85


    1 gear box = 4 gears + 2 gear shafts
    Monthly Capactiy of H1 = (1096/(5*4))*25
    Monthly Capacity of H2 = (1096/(8*2))*25
    Monthly Capacity of S1 = (1096/(3*4))*25
    Monthly Capacity of S2 = (1096/(5*2))*25
    Monthly Capacity of FG1 and FG2
    =(1096/(2*4))*25
    Monthly Capacity of FG1 and FG2 =
    (1096/(6*2))*25
    Monthly Capacity of Heat Treatment
    Monthly Capacity of Heat Treatment
    Assembly Capacity monthly for a complete gear Box

    Annual Capacity of the Plant = 1370*12


    Total Units to be manufactured in 2014-15
    therefore units to be manufactured per month

    Cost

    S.No
    2400
    2800
    6000
    800
    340
    160
    12500

    1
    2a
    b
    c
    d
    3
    a
    b
    4
    5
    6
    7
    8
    9
    10
    11

    20000
    11700
    1125
    12825
    14580
    160312500

    1096

    1350 GBE
    1700 GBE
    2275 GBE
    2725 GBE

    for gear
    for shaft
    for gear
    for shaft

    3425 GBE

    for gear

    2275 GBE
    2130 GBE
    1710 GBE
    6075 GBE

    for
    for
    for
    for

    shaft
    gears
    shafts
    gear box

    (capacity) Capacity-(Units
    Units manf
    16200 manf)
    -closing stock
    14580
    1620
    495
    1215

    Capacity for
    entire plant

    Factor
    Sales Realization
    Raw Material Cost
    Bougt out items
    Rejections
    packing material costs
    Manpower
    Direct
    Indirect
    Other cost tools and consumables
    Plant O H and Power etc.
    Repairs and Maintenance
    Depreciation
    Interest
    Administrative and selling costs
    welfare costs
    [1-(2 to 10)] PBT
    Profitability

    After Changes(for 25%


    Current
    increase in profitability
    256500000
    291600000
    66690000
    75816000
    87210000
    99144000
    1333800
    1516320
    2052000
    2332800
    11760000
    0
    4360500
    21600000
    5130000
    7480000
    7200000
    5130000
    1000000
    35553700
    Target PBT
    13.861091618
    PBT growth

    11760000
    0
    4957200
    21600000
    5832000
    7480000
    7200000
    5832000
    1000000
    47129680
    44442125
    16.162441701
    32.5591429303

    Q.1 (Part 1)

    No.of Gears machined ( ready to be put in heat treatment)


    No.of Shafts machined ( ready to be put in heat treatment)
    No. Of Assemblies (these are from the heat treatment which have been loaded 2 shifts bef

    Total Gear Boxes


    Total Gear Boxes With 85% efficiency taken into account

    Part 2
    The capacity can be increased in the following manner
    1. The number of gear sets of gear box is less compared to the shafts needed for a gear bo
    2. the shafts extra that have been produced can be used along the extra gears that we have

    Morning SEvening Sh
    Night shift
    90
    90
    78
    56
    56
    48
    22
    19
    22

    63
    53.55

    box, so we can choose after every 4-5 shifts to convert H2 and S2 to geart hobbing and shaving ma
    ve manf. in this shift

    bing and shaving machines

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