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1
2
Given data
Total Production per Day = 400 Parts
Shift Hours = 8 Hrs
Product Weight =30 lb
Product Dimensions = 48” ×60” × 5”
01. Cycle Time
Cycle time =
Time
No of Parts
=
8×60
400
Cycle time = 1.2 Mints/Part
02. Equipment Used In the Facility
A. Pick and Place Robot: Two robots are used in the facility. One of them takes the semi
finished product from the warehouse and places on the conveyor belt. Another one picks
the finished product at the end of conveyer belt places on the industrial truck.
The Motoman CR45 is the first robot on the market to combine environmentally clean
functions with a 45lb handling capability
Brand: Motoman
Model: CR45
3
B. Conveyers
 Rolls: This are used in between the conveyor belts to transfer product from one
conveyor to another conveyor and it works on the principle of gravity
 Belt: A belt conveyor is a system of pulleys with a long loop of fabric or other
material stretched between them. Usually at least one of the pulleys is motorized to
pull the belt along with it. The product flows on the belt in entire facility from initial
part to final product.
Model: TL Heavy duty Horizontal Belt with 52’ width × 120’ length
Brand: Gilmore Kramer
C. Cranes: overhead bridge cranes with 2 ton capacity and 60 ft of span are used to load the
products to the truck at second tier supplier and unload from the truck at first tier
supplier.
Brand: Engineered material handling
Model: ELV 2
D. Industrial Truck: Industrial trucks are used to move materials over variable paths
towards the loading and unloading point.
Brand: Vestil
Model: Electric Power Pallet Truck Ept-2796-45 27x96 Forks
E. Truck: The function of the truck is to transport the product from supplier tier two to
supplier tier one
4
Brand: FORD
Model: F350
03. Cost of the Equipment
Equipment Quantity Actual Cost Total Cost
Rolls 1 $3205 $3205
Belts 3 $3623.07 $10869.21
Pick and Place Robot 2 $3,499.95 $6999.9
Cranes 2 $6000 $12000
Industrial Truck 3 $8,569.00 $25707
Truck 2 $23,995 $47990
04. Employees in the Facility
Position No of Required
Employees
Annual Average
Salary
Total Salary
President 1 $1,98,482 $1,98,482
Vice president HR 1 $1,76,152 $1,76,152
Total Cost of Equipment = $1, 06,771.1
5
Vice president
Manufacturing
1 $1,29,195 $1,29,195
Vice president
Engineering
1 $1,58,818 $1,58,818
Vice President
Marketing
1 $1,38,889 $1,38,889
Production Manager 1 $89,190 $89,190
Assembly Manager 1 $82,260 $82,260
Testing Manager 1 $72,964 $72,964
Project Manager 1 $1,13,963 $1,13,963
Assembly Engineer 4 $68,025 $2,72,100
Mechanical Engineer 4 $80,580 $3,22,320
Electronics Engineer 4 $88,661 $3,54,644
Software Engineer 4 $93,350 $3,73,400
Senior Engineers 4 $1,07,099 $4,28,396
Assistant Engineers 4 $64,008 $2,56,032
Supervisors 8 $52000 $4,16,000
Technicians 15 $54,759 $8,21,385
Workers 25 $43,409 $10,85,225
Total 81 $54, 89,415
6
05. Facility Layout
Fig_01. Layout of the Facility With 10% of Office Area
7
06. Rental Price for the Facility
Location: Denver, Colorado
Average Rate per Sq ft = $9.00
The Facility Area = 75000 Sq Ft
Total Rental Cost Per Year =75000×9
Total Rental Cost of the Facility Per Year = $6, 75,000
8
07. Total Annual Expenses
Total Cost of Equipment = $1, 06,771.1
Interest Rate of Bank loan on Equipment = 6%
Yearly expenses to pay for the bank (including Interest), a =
1,06,771.1
20
+0.06(1, 06,771.1)
(a)= $11,744.82/ year
Utility expenses / Month =$10,000
Utility expenses / Year (b) = $1, 20,000
Annual Employees salaries (c) = $54, 89,415
Annual Rent of the facility (d) =$6, 75,000
Total Annual Expenses = a+b+c+d
=11, 744.82+1, 20,000+54, 89,415+6, 75,000
Total Annual Expenses =$62,96,159.82
Total Expenses for 20 Years = $7, 55, 53, 917.84
9
Fig_02. Cash Flow diagram for 20 Years

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SAMA_RAGAVA REDDY

  • 1. 1
  • 2. 2 Given data Total Production per Day = 400 Parts Shift Hours = 8 Hrs Product Weight =30 lb Product Dimensions = 48” ×60” × 5” 01. Cycle Time Cycle time = Time No of Parts = 8×60 400 Cycle time = 1.2 Mints/Part 02. Equipment Used In the Facility A. Pick and Place Robot: Two robots are used in the facility. One of them takes the semi finished product from the warehouse and places on the conveyor belt. Another one picks the finished product at the end of conveyer belt places on the industrial truck. The Motoman CR45 is the first robot on the market to combine environmentally clean functions with a 45lb handling capability Brand: Motoman Model: CR45
  • 3. 3 B. Conveyers  Rolls: This are used in between the conveyor belts to transfer product from one conveyor to another conveyor and it works on the principle of gravity  Belt: A belt conveyor is a system of pulleys with a long loop of fabric or other material stretched between them. Usually at least one of the pulleys is motorized to pull the belt along with it. The product flows on the belt in entire facility from initial part to final product. Model: TL Heavy duty Horizontal Belt with 52’ width × 120’ length Brand: Gilmore Kramer C. Cranes: overhead bridge cranes with 2 ton capacity and 60 ft of span are used to load the products to the truck at second tier supplier and unload from the truck at first tier supplier. Brand: Engineered material handling Model: ELV 2 D. Industrial Truck: Industrial trucks are used to move materials over variable paths towards the loading and unloading point. Brand: Vestil Model: Electric Power Pallet Truck Ept-2796-45 27x96 Forks E. Truck: The function of the truck is to transport the product from supplier tier two to supplier tier one
  • 4. 4 Brand: FORD Model: F350 03. Cost of the Equipment Equipment Quantity Actual Cost Total Cost Rolls 1 $3205 $3205 Belts 3 $3623.07 $10869.21 Pick and Place Robot 2 $3,499.95 $6999.9 Cranes 2 $6000 $12000 Industrial Truck 3 $8,569.00 $25707 Truck 2 $23,995 $47990 04. Employees in the Facility Position No of Required Employees Annual Average Salary Total Salary President 1 $1,98,482 $1,98,482 Vice president HR 1 $1,76,152 $1,76,152 Total Cost of Equipment = $1, 06,771.1
  • 5. 5 Vice president Manufacturing 1 $1,29,195 $1,29,195 Vice president Engineering 1 $1,58,818 $1,58,818 Vice President Marketing 1 $1,38,889 $1,38,889 Production Manager 1 $89,190 $89,190 Assembly Manager 1 $82,260 $82,260 Testing Manager 1 $72,964 $72,964 Project Manager 1 $1,13,963 $1,13,963 Assembly Engineer 4 $68,025 $2,72,100 Mechanical Engineer 4 $80,580 $3,22,320 Electronics Engineer 4 $88,661 $3,54,644 Software Engineer 4 $93,350 $3,73,400 Senior Engineers 4 $1,07,099 $4,28,396 Assistant Engineers 4 $64,008 $2,56,032 Supervisors 8 $52000 $4,16,000 Technicians 15 $54,759 $8,21,385 Workers 25 $43,409 $10,85,225 Total 81 $54, 89,415
  • 6. 6 05. Facility Layout Fig_01. Layout of the Facility With 10% of Office Area
  • 7. 7 06. Rental Price for the Facility Location: Denver, Colorado Average Rate per Sq ft = $9.00 The Facility Area = 75000 Sq Ft Total Rental Cost Per Year =75000×9 Total Rental Cost of the Facility Per Year = $6, 75,000
  • 8. 8 07. Total Annual Expenses Total Cost of Equipment = $1, 06,771.1 Interest Rate of Bank loan on Equipment = 6% Yearly expenses to pay for the bank (including Interest), a = 1,06,771.1 20 +0.06(1, 06,771.1) (a)= $11,744.82/ year Utility expenses / Month =$10,000 Utility expenses / Year (b) = $1, 20,000 Annual Employees salaries (c) = $54, 89,415 Annual Rent of the facility (d) =$6, 75,000 Total Annual Expenses = a+b+c+d =11, 744.82+1, 20,000+54, 89,415+6, 75,000 Total Annual Expenses =$62,96,159.82 Total Expenses for 20 Years = $7, 55, 53, 917.84
  • 9. 9 Fig_02. Cash Flow diagram for 20 Years