I was recently hired as a production engineer for a factory which desi 1

[nilsht]

I was recently hired as a production engineer for a factory which design and produce office and shop furniture, mainly made of steel.
There is per today no procedures for calculation of direct cost in the production. One of my duties will be to create and implement a system for calculation of the cost of each component in the production. By breaking down each finnished product to simple componets. I will then try to see how much each operation (such as welding, drilling, bending, shearing etc.)will cost for each component.

My question is: Is there any standard system for calculating the cost of operations such as cost per mm TIG welding on a given type of profile? If there is, does this standards differ between industrial work and fine finnish?

Can anyone give me a tip or atleast give me an idea about litterature about the subject? [sig][/sig]

 

[don01]

hi
Don't know much about making office furniture but our prod engs aproach some of these hard to calculate issues by:-
1) count the number of actions or distance welded and divide that into consumables.
2) annoy the s**t out of your machine service / suppliers and your consumables sales office. The may even have a savings suggestion or two.

I have seen statements in machine manuals for approximate usage but never taken a lot of notice because I'm too busy getting it going.

Best of luck
Don

 

[gato]

Nilsht:

First, I suggest you to read about Drum Buffer Rope DBR

IVAN

 

[drjorde]

I have been in manufacturing for 36 years. There are no ideal solutions/programs for performing estimating. As a former estimator, I can say, use your favorite spreadsheet program and break down each completed assembly into individual operations. You can establish material cost, handling and cutting cost, any special operations, machining, welding (time per inch), Out side processing, inspection. Don't forget set-up and clean up. Amortise this over all that is done during that operation.
Each of these discipline have a burdon rate; Take that times the time per operation and that will cover the labor cost.
After a while, you will have a database of information you can put into a format that makes this easy.
The most important thing you must do is; go to the floor and talk to the people. You will find a lot of truth and experience there.
Use the power of the spreadsheet to write macros and lookup tables for rates.
I hope this helps.
DrJorde |-0

 

[uWaveFDL]

You would be better off generating "true cost" numbers rather than a "generalized standard".
Create a MFG. Flow Chart for each product.
drjorde's suggestions are correct. The only thing I would add would be the number of scrapouts/reworks per operation.

 

[CC9513493]

You can consulting "the procedure hanbook of arc welding " the lincoln electric, section 12.1 Estimating welding costs or Welding hanbook volume 5 Seventh edition of AWS section 3 Economics and costs estimating.

I hope you can found a answer to your Quetion.
Very lucky.
Regards

Jorge.
jorge@tecnicontrol.com.co