(PCA_Otimização_Processo_Sigma_NVCT_OP20)

8/3/2019 (PCA_Otimizao_Processo_Sigma_NVCT_OP20)

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Productivity and Cost Analysis

Productivity and Cost AnalysisProcess Report

Mahle Metal Leve

Eixo Ford I4

Tornear Mancais

10 dezembro 2011


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Customer Production

Customer name Mahle Metal Leve Production type Mass

Location Mogi Guau Parts per year/batch 402000 pcs

Contact person Roberto Cesare Machining hourly rate 50 R$

Contact e-mail

Contact phone Cycle time 0,583 min

Industry segment Automobilistico Load-unload time 0,0833 min

Floor-to-floor time 0,6663 min

Machine

Machine name Torno Romi Objective

Machine type Galaxy

Year of manufacture

Power 15 kW

Power efficiency 85%

Condition Good

Coolant None

Holder 25x25

Operation Overview

Otimizar processo para aumento de produtividade

Max rpm (cont.) 4000

Workpiece

Workpiece name Eixo Ford I4 Solution

Workpiece type

Part no

Operation no 20

Operation desc. Tornear Mancais

Material Fofo Cinzento

Seco material grp. 14

Heat treatment

Surface properties

Hardness Results

Stability

Revisado programa CNC onde foi possivel eliminar 1

ferramenta do processo de usinagem. Isto foi possvel

porque houve uma troca de mquina(torno) da linha com

maior capacidade e rigidez

Com a eliminao foi possivel obter um ganho de 29% em

produtividade.

J t f i i l d d 20% d

6297


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Cost per part Cost per part Cost per part

R$ R$

Total cost Total cost Total cost

R$ R$

Total Cost Savings Total Cost Savings

R$

%

Summary

Operation desc.Mahle Metal LeveCustomer

Eixo Ford I4Workpiece name

Tornear MancaisSeco rep.Guilherme Guizi

52.035

Stage 3Stage 2

20

0,52

207.053


Stage 1

0,64

259.089

259.089

Output per hour Output per hour

114 788 5Output per hour

.

0

52.035

0

Total cost Total Cost Savings


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Machining efficiency 100% Cycle time 0,58 min Total in-cut time 0,58 min

Output per hour 88,5

G50 [rpm] No.of tools 1 Idle time 0,00 min

Operation type Grade Vc Dc n f Ap Ae In-cut time TCF Tool life Comment

[m/min] [mm] [rev/min] [mm/rev] [mm] [mm] [min] [pcs] [min]

- Fechar Porta , Ponto e Placa 0,1 0,00

2 1 1 Turning Desbastar Mancais, Acabar Canal CFIR2525M04 LCMF1604M0-0400 MP TK150 131 27,8 1500 0,15 1,5 66,25 0,283 250 70,75

- 1 Turning Acabar Diam. 29 e chanfro SDJCL2525M11 DCMT11T308 F2 TP2500 320 29 3512 0,1 0,3 32 0,09 600 54,00

- Abrir porta , ponto e placa 0,11 0,00

- 0,00

- 0,00

geo-

metry

Seco PCA Stage 1 - Original method

seq.

#

Tool # POU

#

Operation desc. Holder / Cutter Insert / solid tool

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seq. # - 2 - - - -

Tool # 1

-Fechar Porta ,

Ponto e Placa

Desbastar Mancais,

Acabar Canal

Acabar Diam. 29 e

chanfro

Abrir porta , ponto

e laca

- CFIR2525M04 SDJCL2525M11

-LCMF1604M0-0400-

MPDCMT11T308-F2

Grade - TK150 TP2500

min 0,10 0,28 0,09 0,11

R$ 0,083 0,236 0,075 0,092

R$ 31,59 19,95

-

R$

Machining cost

Tool cost new

Operation desc.

Holder / Cutter

Insert / solid tool

In-cut time

Cost per regrind

Number of regrinds

Seco PCA Stage 1 - Original Method - Cost Calculation

R$ 31,59 19,95

- 2,00 2,00

- 1,00 1,00

R$ 15,80 9,98

pcs 250,00 600,00

R$ 0,063 0,017

402.000 402.000 402.000 402.000 402.000 402.000

pcs 250,00 600,00

1608 670

min 2 2

h 53,60 22,33

R$ 0,007 0,003

R$ 0,08 0,31 0,09 0,09

0,64

88,5

Parts per year/batch

Tool changes per year

Total time for tool changing

No of cutting edges

Total tool cost

Tool life cost

Tool change frequency

Machine load cost

No. of inserts in cutter/holder

Tool change cost

Tool change allowance


Output per hour

Total cost per part

Sub cost

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Machining efficiency 100% Cycle time 0,43 min Total in-cut time 0,43 min min

Output per hour 114,7

G50 [rpm] No.of tools 1 Idle time 0,00 min Reason for process mod

Operation type Grade Vc Dc n f Ap Ae In-cut time TCF Tool life Comment

[m/min] [mm] [rev/min] [mm/rev] [mm] [mm] [min] [pcs] [min] or Investment Cost

- Fechar Porta, Placa e Ponto 0,10 0,00

2 1 1 Turning Acabar Mancais e Canal CFIR2525M04 LCMF1604M0-0400 MP TK150 163 27,8 1866 0,16 1,5 66,25 0,22 200,0 44,00

- Abrir Porta, Ponto e Placa 0,11 0,00

- 0,00 0,00

- 0,00 0,00

- 0,00 0,00

Seco PCA Stage 2 - Proposed method 1

geo-

metry

Process modification time

Operation desc. Holder / Cutter Insert / solid toolPOU

#

Tool #seq.

#

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seq. # - 2 - - - -

Tool # 1

-Fechar Porta, Placa

e Ponto

Acabar Mancais e

Canal

Abrir Porta, Ponto e

Placa

- CFIR2525M04

- LCMF1604M0-0400-MP

Grade - TK150

min 0,10 0,22 0,11

R$ 0,083 0,183 0,092

R$ 31,59

-

In-cut time

Machining cost

Tool cost new

Operation desc.

Holder / Cutter

Insert / solid tool

Seco PCA Stage 2 - Proposed method 1 - Cost Calculation

-

R$

R$ 31,59

- 2,00

- 1,00R$ 15,80

pcs 200,00

R$ 0,079

402.000 402.000 402.000 402.000 402.000 402.000

pcs 200,00

2010

min 2

h 67,00

R$ 0,008

R$ 0,08 0,27 0,09

0,52

114,7

Tool change cost

Sub cost

Total cost per part

Output per hour


Tool changes per year

Tool change allowance

Total time for tool changing

Machine load cost


Tool life cost

Parts per year/batch

Cost per regrind

Total tool cost

No of cutting edges

No. of inserts in cutter/holder

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0,50

0,60

0,70

Stage 1

R$Cost per part

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0,00

0,10

0,20

0,30

,

Machining cost Tool life cost Tool change cost idle time cost Load-unload cost Down-time cost Total cost

Stage 3

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200.000

250.000

300.000

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0

50.000

100.000

150.000

Machining cost Tool life cost Tool change cost idle time cost Load-unload cost Down-time cost Total cost

Stage 2

Stage 3

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4.540

3.506

3.000

3.500

4.000

4.500

5.000

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00

500

1.000

1.500

2.000

2.500

Stage 1 Stage 2 Stage 3

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25.000

30.000

35.000

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0

5.000

10.000

15.000

20.000


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0,08 0,08

0,06

0,07

0,08

0,09

Tool cost per part trend R$

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0,00

0,00

0,01

0,02

0,03

0,04

0,05


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Remarks

Attachment

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Documents

(PCA_Otimização_Processo_Sigma_NVCT_OP20)