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Cost/ Crankshaft Calculation On OP 10 (Centre Drilling)

This document calculates the costs associated with various machining operations (OP10-OP70) used to produce crankshafts. It includes information on labor costs, electricity costs, tooling costs, production rates, and total costs per operation. The key operations are center drilling (OP10), journal turning (OP20), cam turning (OP30), journal/centering operations (OP40), face milling (OP50), oil hole drilling (OP60), and small diameter drilling (OP70). Costs include labor, electricity for spindles, tooling costs amortized over tool life, and cutting fluids. Total costs per operation range from $0.48 for center drilling to $6.41 for

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166 views16 pages

Cost/ Crankshaft Calculation On OP 10 (Centre Drilling)

This document calculates the costs associated with various machining operations (OP10-OP70) used to produce crankshafts. It includes information on labor costs, electricity costs, tooling costs, production rates, and total costs per operation. The key operations are center drilling (OP10), journal turning (OP20), cam turning (OP30), journal/centering operations (OP40), face milling (OP50), oil hole drilling (OP60), and small diameter drilling (OP70). Costs include labor, electricity for spindles, tooling costs amortized over tool life, and cutting fluids. Total costs per operation range from $0.48 for center drilling to $6.41 for

Uploaded by

azad
Copyright
© © All Rights Reserved
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Available Formats
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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
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 0.90 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

Total Cost Of Op20 6.41


Cost/ Crank calculation on OP 30 ( CAM-DIA Turning )
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 0.40 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

Total Cost Of Op30 2.10


Cost/ Crank Calculation on OP 40 ( Journal dia ,centering /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 0.60 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

Production/shift Average =600 Nos

600

0.60 1.98 0.50 0.31

Total Cost Of Op40 3.40


Cost/ Crank Calculation on OP 50 ( Face Milling )
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 5 Kwh 10 XOMT 5000/Edge 0.16
Actual 85 % 4Kwh

Cost/Pc 0.25

Production/shift Average =1500 Nos

1500

0.24 0.25 0.16

Total Cost Of Op40 0.65


Cost/ Crankshaft Calculation on OP 60 ( 4 Oil Hole 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 0.90 Toatl M/c Rated 5Kwh 10
Actual 85 % 4.25 Kwh Drill with counter 5000 0.24

Cost/Pc 0.99

Production/shift Average =400 Nos

400

1.80 0.99 0.24 0.00

Total Cost Of Op50 3.03


Cost/ Crankshaft Calculation on OP 70 ( Drilling Dia 7.8 mm )
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 0.30 Toatl M/c Rated 5 Kwh 10 0.20
Actual 85 % 4.25Kwh

Cost/Pc 0.33

Production/shift Average =1200 Nos

1200

0.60 0.33 0.20

Total Cost Of Op60 1.13


Cost/ Crankshaft Calculation on OP 80 ( Drilling Dia 7.8 mm )
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 0.30 Toatl M/c Rated 5 Kwh 10 0.20
Actual 85 % 4.25Kwh

Cost/Pc 0.33

Production/shift Average =1200 Nos

1200

0.60 0.33 0.20

Total Cost Of Op60 1.13


Cost/ Crankshaft Calculation on OP 90 ( Drilling 4.0X44 )
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 0.30 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

Production/shift Average =1200 Nos

1200

0.60 0.33 0.13

Total Cost Of Op70 1.06


Cost/ Crankshaft Calculation on OP 100 ( Drilling 4.0X110 )
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 0.45 Toatl M/c Rated 5 Kwh 10 Drill 4.0 1500/Drill 0.25
Actual 85 % 4Kwh

Total tool cost 0.25 0.25


Cost/Pc 0.47

Production/shift Average =800 Nos

800

0.90 0.47 0.25 0.31

Total Cost Of Op80 1.93


Cost/ Crankshaft Calculation on OP 110 ( Drilling 4.0 on CAM )
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 5Kwh 10 Drill 4.0 1500/Drill 0.13
Actual 85 % 4.25Kwh

Total tool cost 0.13 0.13


Cost/Pc 0.25

Production/shift Average =1500 Nos

1500

0.48 0.25 0.13

Total Cost Of Op90 0.86


Cost/ Crankshaft Calculation on OP 120 ( Slitting 2.0mm on CAM )
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 5Kwh 10 Slitting Cutter 500 5000/Cutter 0.10
Actual 85 % 4.25Kwh

Total tool cost 0.10 0.10


Cost/Pc 0.25

Production/shift Average =1500 Nos

1500

0.48 0.25 0.10

Total Cost Of Op100 0.83


Cost/ Crankshaft Calculation on OP 120 ( Slitting 2.0mm on CAM )
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 5Kwh 10 5000/Cutter 0.05
Actual 85 % 4.25Kwh

Total tool cost 0.05 0.05


Cost/Pc 0.25

Production/shift Average =1500 Nos

1500

0.48 0.25 0.05

Total Cost Of Op100 0.78


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

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