Excel Lesson 5 Overview  Watch the Excel Lesson 5 Vid.docx

Excel Lesson 5
Overview
the worksheet using the instructions
below saving it as
“firstName_lastName_L5_Titan_Inventory_Summary”.
“firstName_LastName_L5_Titan_Inventory_Summary” to the
“Lesson 5 Excel
Submission Link”.
Objectives
1. Duplicate spreadsheets.
2. Consolidate data using 3-D referencing.
3. Highlight data using conditional formatting.
Lesson Instructions
Background: You will be completing a Summary Inventory
worksheet for the Titan Off-Campus Shops based

on focused product inventories of individual stores. You will
also be highlighting inventory values that fall
below acceptable amounts. The workbook you will use is the
L5_Titan_Inventory_Summary file. This
workbook contains inventory worksheets for individual stores
(which are complete and you will leave alone),
and a Focused Products Inventory sheet for one of the stores
(which you will use). Open the file and
complete the following instructions. (Note: when no specific
cell reference is given, you are to use your best
judgment based upon how the worksheet is set up for you to
decide what cells are involved or where a result
should be placed.)
1. Re-save the file to either your desktop or other storage device
using the name
“firstName_lastName_L5_Titan_Inventory_Summary”. (Note
firstName and LastName are your own
first and last names).
2. Create three additional “Focused Products” worksheets, one
for the Placentia Store , one for the
Harbor Store, and one to be used as a summary, by making
copies of the “Focused Products –
Chapman” worksheet.

3. Correct the new worksheets subtitles by replacing the words
“Chapman Store”, to “Placentia Store”,
“Harbor Store”, and “Summary” respectively. Also, re-name
the worksheet tabs to “Focused Products
– Placentia”, and “Focused Products – Harbor”, and “Focused
Products-Summary”.
4. Re-order the four “Focused Products” worksheets so that the
Summary is first, followed by Chapman,
then Harbor, and finally Placentia.
5. Replace the inventory quantities on the Focused Products –
Harbor, and Focused Products – Placentia
sheets to the values below.
Lesson 5, P a g e | 2
Harbor Placentia
Sweatshirts - Standard 38 16
Sweatshirts - Premium 3 2
Baseball Hats 14 19

T-Shirts Standard 20 2
T-shirts Premium 31 29
Sweatpants 21 23
Shorts 2 3
Mugs 18 13
6. On the Focused Products – Summary sheet, replace the
quantity for Sweatshirts-Standard (cell C4),
with a 3-D reference function which adds up the quantities of
the three “Focused Products” sheets.
On the Summary sheet, copy this formula down for the column
(through C11). (Be sure not to include
the three additional worksheets which are showing all the
inventory that are also included in this
workbook)
7. Apply conditional formatting to the Quantity column on the
Focused Products – Summary sheet so
that if the inventory levels drop below 10, they will appear with
a red background and a red font color.
Project Complete.

Submission Link.
MFG 240 - Manufacturing Design
Final Project
Scope of Project
You must develop a manufacturing plan to machine the part to
the final dimensions. The company is a small company of about
30 workers currently.
Product Design
You will design 1 tensile test bar using the following diagram
Develop a part print WITH tolerancing for this part
Material Cost
The raw material will be a material you specify. It will come as
1 diameter bar stock at a length you specify
Labor Cost
The labor cost for your plant is $15 per hour for all employees,
except maintenance personnel, which cost $22 per hour.
Volume
Your manufacturing facility must provide 200,000 of the tensile
test specimens
The equipment will be a stand alone cell or line. No other parts
will flow though this area at this time.
Operational Plan

The facility is scheduled to operate 250 days per year and run
two 8 ½ hour shifts per day. The workers must be given 30
minutes for lunch and two 15-minute breaks. The product life
cycle is expected to be 5 years or more.
Reports
Reports must be written using a word processor and spreadsheet
when appropriate. All drawings must be completed using CAD.
1) Title Page
2) Table of Contents
3) Executive Summary
4) A written report detailing the manufacturing plan. The
individual manufacturing deliverables must support all
information presented in the manufacturing plan summary.
i) Part prints (components plus assembly)
ii) Initial investment required and projected cost per part
iii) Conclusions, Recommendations
5) Manufacturing Plan Deliverables including all supporting
data
Manufacturing Plan Deliverables
TAKT Time Calculations - TAKT is a German word for pace.
TAKT time is the rate at which your customer requires the
product. TAKT time defines the manufacturing line speed and
the cycle time for the manufacturing operations. TAKT time is
computed as:

Available work time per day / Daily required demand
(parts/day)
Design Cycle Time Calculations – Design cycle time is the
cycle time at which you design your manufacturing operations
after considering contractual breaks, setup time, planned
maintenance, estimated downtime, reject rates, etc. All of the
items above reduce your actual work time available per day and
reduce the required cycle time. Each team must also consider
the reject produced by the system and increase the required
production to offset the loss. The team must report the
manufacturing cells planned operational availability.
Operational availability is the Planned operating time
/Available work time.
Process Plan Block Diagram – After reviewing the product
prints, develop a process plan block diagram that represents the
product flow through the various machines and processes.
Include equipment, material handling, material flow, quality
checks, repair loops, etc..
Equipment Sequence of Operations and Balance Chart –
Develop a detailed step-by-step sequence of operations for each
process or piece of equipment. Calculate the time required for
each cut or step in the process. This document is required to
determine if the operation can produce parts at the required rate.
Do not forget to include operator load and unload times. When
the sequence-of-operation charts are complete, use a graph to
compare the cycle time of each process against the design cycle
time for the line. The line should be balanced without any
process above or well below the design cycle time of the line.
Tooling – A list of all cutting tools with holders must be
specified. Also include speeds and feeds. Be specific
Fixture – A fixture concept must be specified. This does not
have to be drawn

Machining Equipment Specifications – Select the actual
machines required to produce the parts including manufacture
and model number. Make sure the machines can meet the
required horsepower, federates, and spindle speeds to make the
cuts. Investigate the standard work holding device, turret and
spindle supplied with the machine and make sure the selected
tooling will mate appropriately. Consider the following factors:
tool change time, MCU manufacturer, machine work envelope,
machine footprint, cost, HP, etc…. Also specify the required
chip removal system. Include any sales information you deem
helpful on why you made your choice.
Cost Estimate – Develop a detailed cost estimate of the initial
investment required to purchase and install the manufacturing
cell. Then determine the approximate unit cost of the product
based on your manufacturing cell design. Include the following
items in your calculations:
a) Direct Material Cost – Include the initial purchase price of
each component ($/unit).
b) Direct Labor Cost – Calculate the total labor cost per shift
divided by the number of parts produced per shift ($/unit).
c) Burden Rate – The manufacturing facility has a burden rate
of 250%. The burden rate includes such items as employee
benefits, taxes, insurance, etc… Multiple the direct labor cost
per unit (item b) by the burden rate to determine the burden rate
cost per piece ($/unit).
d) Depreciation Cost – Use straight-line depreciation to
determine the impact of the initial investment. Assume the
usable life of the equipment is 5 years with a salvage value of
15% at the end of the life span. Divide the initial cost minus
the salvage value by five to determine the depreciation cost per
year. Divide the annual depreciation cost by the annual volume

to determine the cost per piece ($/unit)
e) Add all of the above items together to determine the
estimated unit cost of the product.
2
Table of Contents
1. Executive
Summary………………………………………………………………
…….....1
2.
Scope…………………………………………………………………
…………………....1
3.
Deliverables…………………………………………………………
………………….....2
a. TAKT Time
Calculations…………………………………………………………2
b. Design Cycle Time
Calculations………………………………………………….3
c. Process Plan Block
Diagram……………………………………………………...4
d. Equipment Sequence of Operation and Balance
Chart…………………………...4
e.
Fixture…………………………………………………………………
……….....5
f. Machining Equipment
Specifications…………………………………………….6
g. Material Handling, Containerization and Scheduling Plan
……………………...7
h. Quality
Plan…………………………………………………………………...

…9
i. Manufacturing Cell
Layout………………………………………………………10
j. Cost
Estimate………………………………………………………………
…….11
4.
Conclusion……………………………………………………………
………………….11
5.
References……………………………………………………………
………………….12
1.
2. Executive Summary
Tensile bar specimen, also known as “dog bone”, is a
standardized cross-section used to in tensile testing to
determine the tension of the material. The tensile bar has two
shoulders to mate the grips in various machines. Tensile bars
have different shapes, typically round or square.

The project is to produce round tensile bars that come in round
bar stock in 1 inch diameter x 12 foot length. This project will
focus on the tooling and the machining. It will also include a
part design, a layout design, a cost estimate, a potential failure
mode effect analysis, cycle time calculations, and cost estimate
analysis.
The part is to be produced at the lowest cost possible with high
standards and high quality. Quality plans and techniques will be
used in order to assure that the part will meet the criteria of our
client.
Material handling equipment will be used including storage
racks, fork-lifts, conveyers, horizontal carousels, and waste
containers. These equipment will assure high flow-efficiency.
The project is also to calculate the TAKT time and the design
cycle time. Time standards and time studies are used to
calculate the total cycle time a part takes to be produced from
raw material to a finish product.
3. Scope
The scope of this project includes designing a facility that can
efficiently run three main operation, facing, turning, and
threading the tensile bar specimen. The plant will not have any
tensile bar testing machines. The scope is only machining down
the bar stock to the required material and inspecting the
finished parts. Moreover, we are to design the tensile bar to
demanded dimension, and specify tolerances.
4. Deliverables
a. TAKT Time Calculations
TAKT Time is the first element to be delivered. In order to
calculate the TAKT Time we first need to find the available

time per work day. The available time per is calculated by
multiplying the number of workers available per day by the
operating hours. The annual demand of tensile bars is 200,000
units per year. The available time is calculated as the following:
Available Time= (2 shifts/day) (8.5 hours/shift-1 hour
break/shift) (30 workers per day) = 450 hours/day
Therefore, the amount of available hours per day is 450 hours.
Daily Demand = (200,000 parts/year) / (250 working days/year)
= 800 parts/day
TAKT Time= (450 hours/day) / (800 parts/day) = 0.56
hours/part → 33.75 min/part
b. Design Cycle Time Calculations
The cycle time includes many factors such as the machining
time, setup time, handling time. From previous courses,
Personal, Fatigue and Delay (PFD) are times that reduce the
cycle time used in most manufacturing plants.
Starting with machining time, the part needs three main
operations to be produced. Facing both ends, reducing the
radius, and threading the two ends of the tensile bar specimen.
Using the formula below, the machining times are calculated in
the table following it.
tm= LπD / 12fV
L= Ld + Ls
Operation Time Calculations

Element
Dimension
Depth of Cut
Length of Cut, Ld
Safety Stock, Ls
Length L
Diameter D
Velocity, V, fpm
feed,
f, (ipr)
Minutes, tm
1. Face Ends
1.000
1.000
0.200
1/32
0.231
1.000
120
0.007
0.072

2. Rough turn (Entire Part)
1.000
0.125
7.000
1/32
7.031
1.000
160
0.015
0.767
3. Finish turn (Entire Part)
0.875
0.125
7.000
1/32
7.031
0.875
160
0.007
1.438
4. Rough Turn (Middle)
0.750
0.125
2.000
1/32
2.031
0.750
160
0.015
0.166
5. Finish turn (Middle)
0.625
0.125
2.000
1/32
2.031

0.625
160
0.007
0.297
6. Thread End 1
0.750
0.125
1.500
1/32
1.531
0.750
160
0.007
0.268
7. Thread End 2
0.750
0.125
1.500
1/32
1.531
0.750
160
0.007
0.268
Subtotal of machining times
3.009

· Machining Time: the machining time per part is 3.009.
· Setup and Handling Time: setup and handling time is
estimated to be 3.5 hours/shift → (7 hr/day) / (800 parts/day) =
5.25 min/part
· PFD: Including downtimes of machines, under delays, PFD are
estimated to be 12% of available time = 12% of 450 hours = 54
hours/ day → (54hrs *60 min)/ (200,000 parts/day)= .0162 min/
part
· Maintenance: 40 hours per day = (4 hours * 60 min)/(200,000
parts/day)= .012 min per part
· Quality Check is estimated to take 0.6 min/part
· Packaging : 0.2 min/part
Total Cycle Time per part = 3.009 min + 5.25 min + 0.0162 min
+ 0.012 min + 0.6 min + 0.2 = 9.0872 min per part
c. Process Plan Block Diagram
i.
d. Equipment Sequence of Operation and Balance Chart
i.
ii.
When comparing the actual time to the calculated TAKT time,
we find that the actual time is a lot less than the TAKT time.

This means that at the current production rate with this
available time, the plant will be able to produce 200,000 tensile
bar specimens annually.
In the graph i, the total calculated TAKT time is divided by the
number of elements and compared to each actual element. Graph
ii shows the total actual time compared to the total TAKT time.
e. Fixture
i. The fixture used to produce the tensile bar specimens is a
turning fixture. The reason this type of fixture is selected is
because the tensile bar is a round one. All operation can be done
using the turning fixture including facing, turning, and
threading. An adjustable fixture is to be used in order to
accommodate the dimensions of the tensile bar specimen.
f. Machining Equipment Specifications
In order to calculate the horsepower required to perform the
proper machining operations, the following equation is to be
used:
Using this equation, the following table demonstrates the hp
required for each machine.
No.
Operation
Ft (lbf)
V (ft/min)
HP
1
Facing
115
120
0.42
2

Rough Turn
65
160
0.32
3
Finish Turn
65
160
0.32
4
Rough Turn
65
160
0.32
5
Finish Turn
65
160
0.32
6
Threading End 1
65
160
0.32
7
Threading End 2
65
160
0.32
The equipment to be used is a lathe machine from Alibaba with
a HP of 2.
Height of center
8"

Distance between centers
40"
Spindle bore
2"
Spindle nose
D1-5
Spindle drive motor
2 hp
overall pkg
760/840 kg
Model Number
CQ6240
g. Material Handling, Containerization and Scheduling Plan
The plant will have four main material handling equipment in
order to ensure the highest efficiency and material flow.
1.
Stacking racks: to be used for storing bar stock once the raw
material arrives at the manufacturing plant in the receiving/
storage department.
2.
Conveyer belts: this material handling equipment is very
efficient in delivering materials from one station to another. For
our particular plant design and requirements, the conveyer belts
are designed to have dividers and edges in order to prevent the
round material from falling off the belt as it is moving.
3.
Defects and scrap container: this material handling equipment is
needed at every station to contain the waste chips produced
from machining every tensile bar. Such container will also be at
the inspection department in order to dispose the defective
parts. The container will have wheels to be easily moved
outside of the manufacturing plant and properly dispose the
material.

4.
Horizontal carousel: this equipment is a storage equipment. For
our plant, the carousels will be placed in the shipping
department. Their design will consist of movable racks that can
carry the packaged boxes of the finished and inspected parts
that are ready to be shipped.
5.
Fork-lift: Fork-lifts will be present at the receiving and
shipping departments. Their duty is to transport material
between the delivery trucks and the plant area.
h. Quality Plan
Tools:
1. GO/NO-GO gauge in a form of a nut to assure that the
dimensions of the threads meet the criteria
2. Venier Calipers to measure the overall length and the length
of the threaded part of the tensile bar specimen
3. Brinell hardness testing machine to measure the hardness of
the material before it leaves the manufacturing plant
i. Manufacturing Cell Layout

j. Cost Estimate
Total Cost Per Part
$45.83
5. Conclusion
In conclusion, the determined cost is $45.83 per tensile bar
specimen. The layout of the plant is designed in a U-shape with
a conveyer that goes through each department from receiving to
shipping. Material handling equipment are used to assure flow
efficiency and time saving. TAKT time is calculated to 33.75
min/part which is less than the design cycle time, 9.1 min/part.
The process plan is simply (receiving/storage, loading, facing,
turning reduced section, turning shoulders, threading,
inspection, packaging, and finally packaging/storage). The
machines are selected based on the horsepower required. Tools
along with feeds and speeds where also selected, they were also
used in determining the design cycle time.

6. Refrences
a. Tompkins, James A., and John A. White. Facilities Planning.
New York: Wiley, 1984. Print.
b. Ostwald, Fillip F., and Timothy S. McLaren, PhD. Cost
Analysis and Estimating for Engineering and Management. N.p.:
Prentice Hall, 2003. Print.
Balance Chart
Actual Time Setup and Handling Face EndsRough Turn
(Entire Part) Finish Turn (Entire Part) Rough Turn (Middle)
Finish Turn (Middle) Thread End 1 Thread End 2
Maintenance PFD Quality Check Packaging5.25
7.1999999999999995E-2 0.76700000000000002
1.4379999999999999 0.16600000000000001
0.29699999999999999 0.26800000000000002
0.26800000000000002 1.2E-2
1.6199999999999999E-2 0.6 0.2 TAKT Time Setup
and Handling Face EndsRough Turn (Entire Part) Finish Turn
(Entire Part) Rough Turn (Middle) Finish Turn (Middle)
Thread End 1 Thread End 2 Maintenance PFD Quality
Check Packaging2.8125 2.8125 2.8125 2.8125
2.8125 2.8125 2.8125 2.8125 2.8125 2.8125
2.8125 2.8125
Element
Time (Min)
Total Actual Time TAKT Time 9.3542000000000005

33.75
Focused Products-ChapmanTitan Off-Campus ShopsFocused
Products Inventory - Chapman
StoreCategoryDescriptionQuantityCostRetail PriceTotal Retail
Value1001-SSSweatshirts - Standard42$ 12.00$ 32.00$
1,344.001002-SPSweatshirts -
Premium1818.0054.00972.001003-HABaseball
Hats214.0016.00336.001004-TST-Shirts
Standard137.0018.00234.001005-TPT-shirts
Premium4112.0028.001,148.001006-
SPSweatpants1914.0032.00608.001007-
SHShorts39.0022.0066.001008-
MUMugs12.0012.0012.00Total158$ 4,720.00
Inventory - ChapmanTitan Off-Campus ShopsProduct Inventory:
Chapman StoreCategoryDescriptionQuantityCostRetail
PriceTotal Retail Value1001-SSSweatshirts - Standard42$
12.00$ 32.00$ 1,344.001002-SPSweatshirts -
Hats214.0016.00336.001004-TST-Shirts
Premium4112.0028.001,148.001006-
SPSweatpants1914.0032.00608.001007-
SHShorts39.0022.0066.001008-MUMugs12.0012.0012.001009-
GLGlasses322.0012.00384.001010-PSPens -
Standard540.251.99107.461011-PDPens -
Delux137.0025.00325.001012-PEPencils750.101.0075.001013-
SAStuffed Animals73.0015.00105.001014-
BPBackpacks49.0025.00100.001015-
FOFolders430.252.0086.001016-BSBinders -
Standard411.004.00164.001017-BDBinders -
Delux241.506.00144.001018-
PWPaperweight141.5010.00140.001019-TCTie

clips131.5015.00195.001020-TITies93.0020.00180.001021-
KCKeychains440.751.9585.80Total531$ 6,811.26
Inventory - HarborTitan Off-Campus ShopsProduct Inventory:
Harbor StoreCategoryDescriptionQuantityCostRetail PriceTotal
Retail Value1001-SSSweatshirts - Standard38$ 12.00$
32.00$ 1,216.001002-SPSweatshirts -
Hats144.0016.00224.001004-TST-Shirts
Premium3112.0028.00868.001006-
SPSweatpants2114.0032.00672.001007-
SHShorts29.0022.0044.001008-
MUMugs182.0012.00216.001009-
Standard480.251.9995.521011-PDPens -
Delux147.0025.00350.001012-PEPencils700.101.0070.001013-
BPBackpacks29.0025.0050.001015-
Delux281.506.00168.001018-
clips121.5015.00180.001020-TITies93.0020.00180.001021-
Inventory - PlacentiaTitan Off-Campus ShopsProduct Inventory:
Placentia StoreCategoryDescriptionQuantityCostRetail
PriceTotal Retail Value1001-SSSweatshirts - Standard16$
12.00$ 32.00$ 512.001002-SPSweatshirts -
Hats194.0016.00304.001004-TST-Shirts
Premium2912.0028.00812.001006-
SPSweatpants2314.0032.00736.001007-
SHShorts39.0022.0066.001008-
MUMugs132.0012.00156.001009-

Standard500.251.9999.501011-PDPens -
Delux107.0025.00250.001012-PEPencils650.101.0065.001013-
BPBackpacks19.0025.0025.001015-
Delux261.506.00156.001018-
clips211.5015.00315.001020-TITies173.0020.00340.001021-

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