PARTS LIST

Make or Std
PART Part # QTY/Assy
Buy HRS/1
Housing Upper 1 1 Make 0.169
Housing Lower 2 1 Make 0.312
Shank 3 1 Make 0.492
Spindle 4 1 Make 0.408
Intermediate Gear 5 2 Make 0.467
Intermediate Pinion 6 2 Make 0.374
Shank Gear 7 1 Make 0.373
Gear Stud 8 2 Make 0.102
Spindle Bushing 9 1 Make 0.062
Adjustment nut 10 2 Make 0.060
Shank Bushing 12 1 Make 0.028
Spindle Washer 13 1 Buy
Stop Rod 14 1 Buy
Head Set Screw 15 1 Buy
Hex Nut 16 2 Buy
Thrust Bearing 17 1 Buy
Adjustment screw 18 1 Buy
Cork Gasket 19 1 Buy
Radial Seal 20 1 Buy
Pressure Sealing for
21 2 Buy
Nuts and Washers
Pressure Sealing for
22 2 Buy
Screws and Bolts
Breather Plug 23 1 Buy
Square Head Set
24 1 Buy
Screws

STANDARD TIME PER ONE PART PER MACHINE

CONV.
VERT. DRILL HORIZ.
PART AND PART NO. QTY/ASSY VERT. LATHE HOBBING
MILL PRESS MILL
MILL
Housing Lower (2) 1 0.248 0.064
Housing Upper (1) 1 0.169
Intermediate Pinion (6) 2 0.054 0.320
Shank Bushing (12) 1 0.028
Spindle (4) 1 0.088 0.320
Shank Gear (7) 1 0.023 0.350
Adjustment nut (10) 2 0.060
Gear Stud (8) 2 0.102
Intermediate Gear (5) 2 0.117 0.350
Shank (3) 1 0.067 0.425
Spindle Bushing (9) 1 0.024 0.038
TOTAL STD TIME PER PART 0.418 0.067 0.921 0.038 0.064 1.340
TOTAL STD TIME PER/100 41.76 6.7 92.1 3.83 6.4 134
NUMBER OF MACHINES

(assemblies/yr) x (pieces/assembly) x (hrs. to process/piece)

Number of machines =
(utilization) x (no. of hrs. per shift/yr) x (no. of shifts)

Shifts 2 1 NOTE:
No. of hrs. per shift/yr* 4000 2000 * No. of working weeks per year is 50
Utilization 80% 0.8 * No. of working hours per week is 40
Units/yr 24000

No. of CNC Vertical Milling Machines

Hrs. to
Parts Opr. No.
process
Housing Upper 20 0.101
Housing Upper 30 0.068
Housing Lower 20 0.149
Housing Lower 40 0.099
Total time 0.418
Number of machines 6.26 One shift

No. of CNC Horizontal Milling Machines

Hrs. to
Parts Opr. No.
process
Housing Lower 30 0.0640
Total time 0.064
Number of machines 0.96 One shift

No. of Conventional Vertical Milling Machines

Hrs. to
Parts Opr. No.
process
Shank 30 0.067
Total time 0.067
Number of machines 1.01 One shift
0

No. of CNC Lathe Machines

Hrs. to
Parts Opr. No.
process
Intermediate Pinion 20 0.054
Adjustment nut 20 0.060
Gear Stud 20 0.048
Gear Stud 30 0.054
Intermediate Gear 20 0.117
Total time 0.333
Number of machines 2.50
 No. of CNC Lathe Machines
Hrs. to
Parts Opr. No.
process
Spindle 20 0.088
Shank Bushing 20 0.028
Shank Gear 20 0.023
Shank 20 0.220
Shank 40 0.205
Spindle Bushing 20 0.024
Total time 0.588
Number of machines 2.21

No. of Hobbing Machines

Hrs. to
Parts Opr. No.
process
Intermediate Pinion 50 0.320
Intermediate Gear 50 0.350
Total time 0.670
Number of machines 5.02

No. of Hobbing Machines

Hrs. to
Parts Opr. No.
process
Shank Gear 50 0.350
Spindle 50 0.320
Total time 0.670
Number of machines 2.51

No. of Drill Presses

Hrs. to
Parts Opr. No.
process
Spindle Bushing 50 0.038
Total time 0.038
Number of machines 0.575 One shift

Total Number of Each Machine and Std. Time per Part

No. of Total No.of Total Std
Machines
Machines Machines Time
CNC Vertical Milling
6.26 6 0.418
Machines
Horizontal Milling
0.96 1 0.064
Machines
Conventional Vertical
1.01 1 0.067
Milling Machines
CNC Lathe Machines 4.70 5 0.921 NOTE:
Hobbing Machines 7.54 8 1.340 * For each lathe there is a
Drill Presses 0.575 1 0.038 bar feeder, therefore we need
Barr Feeders* 4.70 5 the same amount of bar
TOTAL 21.04 21 2.848 feeders as we do lathes.
ASSEMBLY

No. of Assembly Tables and employees

No. of hrs. per assembly 0.0461
NOTE:
Units/yr 24000 * Number of working weeks per year is 50
Units of units per day* 96 * Number of days per working week is 5
Hours to assamble 96** 4.43 ** Therefore we need one part time employee

NUMBER OF EMPLOYEES

(assemblies/yr) x (pieces/assembly) x (hrs. to process/piece)

Number of operators =
no. of hrs. per shift/yr

No. of hrs. per shift/yr 4000

Units/yr 24000

Total Number of Employees

No. of Total No.of
Machines
employees Employees
CNC Vertical Milling
2.51 3
Machines
CNC Horizontal Milling
0.38 0
Machines
Conventional Vertical
0.40 0
Milling Machines
CNC Lathe Machines 3.53 4
CNC Lathe Machines 4.00 4
Hobbing Machines 4.02 4
Hobbing Machines 8.04 8
Drill Presses 0.23 0
Assembly 1.00 1
Total No. of
Employees 24.11 24

Total Number of Employees

The ratio between shop workers and office workers is 3 to 1
Therefore we need 18 direct and 6 indirect employees.

NOTE:
Actual calculated number of employees is 24
However, number of employees required is 14
due to the fact that we only need 1 worker
for 3 separate machines.
 Rank Order Clustering Technique

Housing Housing Interm. Interm. Shank Gear Spindle Adjust. Shank

Shank Spindle
Lower Upper Gear Pinion Gear Stud Bush nut Bush
CNC Vertical Mill 1 1 1536
Horizontal Mill 1 1024
Con Vertical Mill 1 256
CNC Lathe 1 1 1 1 1 1 1 1 1 511
Hobbing Machines 1 1 1 1 240
Drill Presses 1 4

Housing Housing Interm. Interm. Shank Gear Spindle Adjust. Shank

Shank Spindle
Lower Upper Gear Pinion Gear Stud Bush nut Bush
CNC Vertical Mill 1 1 1536
Horizontal Mill 1 1024
CNC Lathe 1 1 1 1 1 1 1 1 1 511
Con Vertical Mill 1 256
Hobbing Machines 1 1 1 1 240
Drill Presses 1 4
48 32 12 10 10 10 10 8 10 8 8
1 2 3 4 5 6 7 9 8 10 11

Housing Housing Interm. Interm. Shank Spindle Gear Adjust. Shank

Shank Spindle
Lower Upper Gear Pinion Gear Bush Stud nut Bush

CNC Vertical Mill 1 1

Horizontal Mill 1
CNC Lathe 1 1 1 1 1 1 1 1 1
Con Vertical Mill 1
Hobbing Machines 1 1 1 1
Drill Presses 1
48 32 12 10 10 10 10 10 8 8 8
1 2 3 4 5 6 7 8 9 10 11
k Order Clustering Technique

1
2
4
3
5
6

1
2
3
4
5
6
Number of Bars Required

NOTE:
* For each bar there is scrap material of 1/16"x2 for facing the ends, 1/8" for partoff and
aproximately 2.5"* of material is left in the chuck.
** Each bar is 72" long
*** All bar rounds were round up or round down as necessary

Bar length 72
Chuck Scrap 2.5
Scrap (facing & partoff) 0.25

Peaces No. of
Part # Part Length Round No. Round No.
per Bar Bars/day
C 1018
Shank 3 9.25 7.32 7 13.71 14
Gear Stud 8 3.687 17.65 17 11.29 12
Adjustment nut 10 0.25 139.00 139 1.38 2
Total No. of bars/day 26.39 27

AISI 8620
Spindle 4 3.5 18.53 18 5.33 6
Intermediate Gear 5 0.75 69.50 69 2.78 3
Intermediate Pinion 6 1.937 31.78 31 6.19 7
Shank Gear 7 0.75 69.50 69 1.39 2
Total No. of bars/day 15.70 16

510 PH. BRONZE

Spindle Bushing 9 1.625 37.07 37 2.59 3
Shank Bushing 12 1.875 32.71 32 3.00 3
Total No. of bars/day 5.59 6
 NUMBER OF REQUIRED PARTS PER WEEK
AND WORK IN PROGRESS (WIP)

QTY per No. of No. of

PART Part # Material WIP
Assy parts/day parts/wk
Housing Upper 1 1 96 480 6
Housing Lower 2 1 96 480 6
Spindle Washer 13 1 96 480 6
Stop Rod 14 1 96 480 6
Head Set Screw 15 1 96 480 6
Hex Nut 16 2 192 960 12
Thrust Bearing 17 1 96 480 6
Adjustment Nuts 18 1 96 480 6
Cork Gasket 19 1 96 480 6
Radial Seal 20 1 96 480 6
Pressure Sealing for Nuts
21 2 192 960 12
and Washers
Pressure Sealing for
22 1 96 480 6
Screws and Bolts
Breather Plug 23 2 192 960 12
Square Head Set Screws 24 1 96 480 6

No. of
Bars/wk
Shank 3 C 1018 (Ø1 1/8"x6") 1 96 70 6
Spindle 4 AISI 8620 (Ø1 1/2"x6") 1 96 30 6
Intermediate Gear 5 AISI 8620 (Ø2 3/8"x6") 2 192 15 12
Intermediate Pinion 6 AISI 8620 (Ø1 1/2"x6") 2 192 35 12
Shank Gear 7 AISI 8620 (Ø2 1/2"x6") 1 96 10 6
Gear Stud 8 C 1018 (Ø7/8"x6") 2 192 60 12
Spindle Bushing 9 510 PH Bronze (Ø1 1/2"x6") 1 96 15 6
Adjustment nut 10 C 1018 (Ø1 3/4"x6") 2 192 10 12
Shank Bushing 12 510 PH Bronze (Ø3/4"x6") 1 96 15 6

Units/yr 24000
Number of units per day 96
No. of hours per shift 8