Cost/ Crankshaft Calculation On OP 10 (Centre Drilling)

Cost/ Crankshaft Calculation on OP 10 ( Centre Drilling)
Gross Net Scrap

Manpower Electricty Tools Hydroulics/Cutting oil Weight Weight Weight
Per Day Monthly
Salery Hydroulic Requirme
/Average Cost/Pc Spindle motor Motor Cost/unit Cost of Tooling Tool Life Cost/pc nt Rate/Ltr
360 0.24 Toatl M/c Rated 3 Kwh 10 Centre Drill 3000 0.083333
Actual 85 % 2.55
A2/A3 Centre drill cost 250
Edge =2
Cost/Pc 0.16 Cost/Pc 0.08
250
Production/shift Average =1500 Nos
1500
0.24 0.16 0.08 0.00
Total Cost Of Op10 0.48
3 0.85
Cost/ Crankshaft Calculation on OP 20 ( Journal dia Turning )
Gross Net Scrap
Per Day Monthly
360 0.90 Toatl M/c Rated 15 Kwh 10 WNMA 150/edge 0.22 5ltr 140
Actual 85 % 12.75 Kwh VNMA 150/edge 0.5
Grooving 200/Edge 1
TNMG 200/edge 0.20 Cutting Oil
Cost/Pc 2.97 40 ltr 290

WNMA 080408 Cost 200 No of Edge =6
VNMA Cost 300 No of
Production/shift Average =400Nos Edge =4
No of
Grooving Cost 400 Edge =2 32500
No of
400 TNMG 160404 cost 200 Edge =6
0.90 2.97 1.92 0.62

Cost/ Crank calculation on OP 30 ( CAM-DIA Turning )
Gross Net Scrap
Per Day Monthly
360 0.40 Toatl M/c Rated 15 Kwh 10 TNMG 150/edge 0.17 5ltr 140
Actual 85 % 12.75 Kwh
Total tool cost 0.17 0.17 Cutting Oil

Cost/Pc 1.32 30 ltr 290
TNMG 160408 Cost 200 No of Edge =6
Production/shift Average =900Nos
195
900
0.40 1.32 0.17 0.21

Cost/ Crank Calculation on OP 40 ( Journal dia ,centering /Drilling )
Gross Net Scrap
Per Day Monthly
360 0.60 Toatl M/c Rated 15 Kwh 10 TNMG 200/Edge 0.17 10 ltr 140
Actual 85 % 12.75 Kwh TNMG 200/Edge 0.17
Centre drilling 1500/Edge 0.08
Drilling 1500/Edge 0.08 Cutting Oil
Cost/Pc 1.98 60 ltr 290
600
0.60 1.98 0.50 0.31

Cost/ Crank Calculation on OP 50 ( Face Milling )
Gross Net Scrap
Per Day Monthly
360 0.24 Toatl M/c Rated 5 Kwh 10 XOMT 5000/Edge 0.16
Actual 85 % 4Kwh
Cost/Pc 0.25
1500
0.24 0.25 0.16

Cost/ Crankshaft Calculation on OP 60 ( 4 Oil Hole drilling )
Gross Net Scrap
Per Day Monthly
360 0.90 Toatl M/c Rated 5Kwh 10
Actual 85 % 4.25 Kwh Drill with counter 5000 0.24
Cost/Pc 0.99
400
1.80 0.99 0.24 0.00

Cost/ Crankshaft Calculation on OP 70 ( Drilling Dia 7.8 mm )
Gross Net Scrap
Per Day Monthly
360 0.30 Toatl M/c Rated 5 Kwh 10 0.20
Actual 85 % 4.25Kwh
Cost/Pc 0.33
1200
0.60 0.33 0.20

Cost/ Crankshaft Calculation on OP 80 ( Drilling Dia 7.8 mm )
Gross Net Scrap
Per Day Monthly
360 0.30 Toatl M/c Rated 5 Kwh 10 0.20
Actual 85 % 4.25Kwh
Cost/Pc 0.33
1200
0.60 0.33 0.20

Cost/ Crankshaft Calculation on OP 90 ( Drilling 4.0X44 )
Gross Net Scrap
Per Day Monthly
360 0.30 Toatl M/c Rated 5 Kwh 10 Drill 4.0 1500/Drill 0.13
Actual 85 % 4.25 Kwh
Total tool cost 0.13 0.13

Cost/Pc 0.33
1200
0.60 0.33 0.13

Cost/ Crankshaft Calculation on OP 100 ( Drilling 4.0X110 )
Gross Net Scrap
Per Day Monthly
360 0.45 Toatl M/c Rated 5 Kwh 10 Drill 4.0 1500/Drill 0.25
Actual 85 % 4Kwh

Cost/Pc 0.47
800
0.90 0.47 0.25 0.31

Cost/ Crankshaft Calculation on OP 110 ( Drilling 4.0 on CAM )
Gross Net Scrap
Per Day Monthly
360 0.24 Toatl M/c Rated 5Kwh 10 Drill 4.0 1500/Drill 0.13
Actual 85 % 4.25Kwh

Cost/Pc 0.25
1500
0.48 0.25 0.13

Cost/ Crankshaft Calculation on OP 120 ( Slitting 2.0mm on CAM )
Gross Net Scrap
Per Day Monthly
360 0.24 Toatl M/c Rated 5Kwh 10 Slitting Cutter 500 5000/Cutter 0.10
Actual 85 % 4.25Kwh

Cost/Pc 0.25
1500
0.48 0.25 0.10

Cost/ Crankshaft Calculation on OP 120 ( Slitting 2.0mm on CAM )
Gross Net Scrap
Per Day Monthly
360 0.24 Toatl M/c Rated 5Kwh 10 5000/Cutter 0.05
Actual 85 % 4.25Kwh

Cost/Pc 0.25
1500
0.48 0.25 0.05

SUMMARY
S.No Opearation Manpower Electricty Tools Hydroulics/Cutting oil Total operation cost
1 Centre Driiling 0.24 0.16 0.08 0.00 0.48
2 Journal Dia 0.90 2.97 1.92 0.62 6.41
3 Cam Dia 0.40 1.32 0.17 0.21 2.10
4 Journal /Centering 0.60 1.98 0.50 0.31 3.40
5 Face Milling 0.24 0.25 0.16 0.00 0.65
6 4 oil hole Drilling 1.80 0.99 0.24 0.00 3.03
7 Drilling dia7.8 0.60 0.33 0.20 0 1.13
8 Reaming 8.0mm 0.60 0.33 0.20 0 1.13
9 Drilling dia 4.0X44 0.60 0.33 0.13 0 1.06
10 Drilling dia 4.0X110 0.90 0.47 0.25 0.31 1.93
11 Drilling 4.0 on CAM 0.48 0.25 0.13 0.31 1.18

Slitting 2.0 mm on
12 CAM 0.48 0.25 0.10 0 0.83
Deburring,
13 Chamfering 0.48 0.25 0.05 0 0.78
COST OF PRODUCTION
24.10
CRANKSHAFT CYCLE-TIME ESTIMATION
CYCLE TIME in
S.NO OPERATION DETAIL M/C NAME MANPOWER sec.
1 Centre Drilling Drilling SPM 20
2 Journal dia Turning CNC 90
3 Cam-Dia Turning CNC 40
Journal dia
4 CNC 60
Turning,cenreing/Drilling
5 Face Milling CNC 20
5 4 Oil hole drilling with counter SPM-DRILLING 90
6 Drilling Dia 7.8 SPM-DRILLING 30
6 Reaming Dia 8.0 SPM-DRILLING 30
7 Drilling dia 4.0X44 SPM-DRILLING 30
8 Drilling dia 4.0X110 VMC 45
9 Drlling dia 4.0 On cam SPM-DRILLING 20
10 Sliting 2mm on cam Milling 20

N
Prod Target/Shift
1782
396
891
594
1782
396
1188
1188
1188
792
1782
1782

Cost/ Crankshaft Calculation On OP 10 (Centre Drilling)

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Cost/ Crankshaft Calculation on OP 10 ( Centre Drilling)

Gross Net Scrap

0.24 0.16 0.08 0.00

Total Cost Of Op10 0.48

Cost/Pc 2.97 40 ltr 290

0.90 2.97 1.92 0.62

Total Cost Of Op20 6.41

Total tool cost 0.17 0.17 Cutting Oil

0.40 1.32 0.17 0.21

Total Cost Of Op30 2.10

Production/shift Average =600 Nos

0.60 1.98 0.50 0.31

Total Cost Of Op40 3.40

Production/shift Average =1500 Nos

0.24 0.25 0.16

Total Cost Of Op40 0.65

Production/shift Average =400 Nos

1.80 0.99 0.24 0.00

Total Cost Of Op50 3.03

Production/shift Average =1200 Nos

0.60 0.33 0.20

Total Cost Of Op60 1.13

Production/shift Average =1200 Nos

0.60 0.33 0.20

Total Cost Of Op60 1.13

Total tool cost 0.13 0.13

Production/shift Average =1200 Nos

0.60 0.33 0.13

Total Cost Of Op70 1.06

Total tool cost 0.25 0.25

Production/shift Average =800 Nos

0.90 0.47 0.25 0.31

Total Cost Of Op80 1.93

Total tool cost 0.13 0.13

Production/shift Average =1500 Nos

0.48 0.25 0.13

Total Cost Of Op90 0.86

Total tool cost 0.10 0.10

Production/shift Average =1500 Nos

0.48 0.25 0.10

Total Cost Of Op100 0.83

Total tool cost 0.05 0.05

Production/shift Average =1500 Nos

0.48 0.25 0.05

Total Cost Of Op100 0.78

1 Centre Driiling 0.24 0.16 0.08 0.00 0.48

2 Journal Dia 0.90 2.97 1.92 0.62 6.41

3 Cam Dia 0.40 1.32 0.17 0.21 2.10

4 Journal /Centering 0.60 1.98 0.50 0.31 3.40

5 Face Milling 0.24 0.25 0.16 0.00 0.65

6 4 oil hole Drilling 1.80 0.99 0.24 0.00 3.03

7 Drilling dia7.8 0.60 0.33 0.20 0 1.13

8 Reaming 8.0mm 0.60 0.33 0.20 0 1.13

9 Drilling dia 4.0X44 0.60 0.33 0.13 0 1.06

10 Drilling dia 4.0X110 0.90 0.47 0.25 0.31 1.93

11 Drilling 4.0 on CAM 0.48 0.25 0.13 0.31 1.18

1 Centre Drilling Drilling SPM 20

2 Journal dia Turning CNC 90