Tool Shelf

Submitted to:
Prof. Dr. Abdalla Wifi (Course Coordinator)
Assoc. Prof. Alaa Elmokadem (Group Instructor)
 Our group

Group No. 7
Subgroup Letter C
Subgroup Leader Mazen Hashem Mohamed Abdelkader (1220019)

1. Aya Abdel Nasser (1220305)

2. Muhammed Elsheshe (1220022)
3. Abdelrahman Ahmed(1220064)
4. Belal Atef (1220041)
5. Haitham Mohamed(1220087)
Subgroup Members 6. Youssef Essam(1220090)
7. Abdelrahman Morsi (1220254)
8. Amr Hassan (1220328)
9. Ibrahim Mohamed Ibrahim ElDesouky(1220114)
10. Abdullah Bekhit (1220183)
11. Mohamed Alaa (1220196)
01. Introduction

04. Manufacturing Process

02. Preliminary Design

05. Cost Analysis

03. Detailed Design

06. Conclusion
 01
Introduction
 Introduction

● In today's increasingly fast-paced

workplaces, accessibility to technologies
and effective organization is essential for
ensuring increased productivity and
safety. As a result, this project aims to
design and build a flexible and useful
tool rack using sheet metal as the main
component.
 02
Preliminary
Design
 Preliminary Design

● These are examples of other designs of the tool

rack which had many flaws that we aimed to
solve in the one we designed.

● Weight to Strength ratio

● Mounted to a wall
● Distinctive Color
 Weight to
Practicality Stability Color Total Score
Strength ratio
Weight 35 Weight 25 Weight 30 Weight 10 Weight 100

Design 1 3 5 3 8 40
Design 2 5 6 5 8 55.5
Our
8 7 9 9 81.5
Design
 03
Detailed
design
 Detailed design

1. A metal sheet of thickness 1mm

Sheet metal comes in thicknesses ranging from

0.5 mm to 6 mm. Any sheet that is thicker than that
is referred to as a metal plate. The thin sheet metal
has made it simple for us to form and of reasonable
weight to strength ratio. These features indicate that
this metal sheet can be suitable to create a tool rack
 Detailed design

2. Choosing the dimensions of metal sheet

Since the metal plate is 2 meters long and 1

meter wide (2x1) m, it was determined that the
piece used in creating the tool rack should be 33
and 25 centimeters in length and width,
respectively. This has the dual purposes of
minimizing material waste and making it simply
divided into an accurate number of identical tool
racks with these dimensions.
 Detailed design

3. Four holes for stabilizing

There are four holes in the design with a diameter

of 0.55 cm. These were made for fixing the tool
rack in the wall using steel screws and S8 wall
plugs.
 Detailed design

4. Ten holes for tools

There are 10 holes for the tools (2 on each side)

which makes the tool shelf carry about 5
screwdrivers at once. The diameter of each hole is
of 1.25 cm and the distance between each two
opposite holes is 4 cm which allows the tool to be
inserted and secured safely in the shelf.
 Detailed design

5.Four wall plugs wall plugs S8 TNP 8*44

mm

To ensure that screws driven into masonry walls

provide a secure fixing, a wall plug is utilized.
They are necessary for screws to grab brickwork
and give enough compressive power to provide a
secure, long-lasting fastening.
 Detailed design

6. Four steel screws

The screws used are M5 counterstruck steel screw.

The screws are chosen of steel to make sure that the
shelf is holding itself firmly to the wall as it has to
carry the weight of the shelf and tools that are on it.
 Detailed design

7. Final Design

Thanks to the design team and the technicians we

were able to manufacture the shelf as imagined and
drawn in 3D CAD software.
 04
Manufacturing
process
 Manufacturing process

1. Firstly, With the worker's assistance, we

marked the required dimensions on the metal
plate using a metal pencil, then we utilized a
manual sheet metal cutting machine to cut the
metal sheet into the pattern we had in design
(33 x 25 cm).

2. Secondly, in order to run the other

operations, we marked the remaining
measurements on the metal sheet with a metal
pencil. (Such as: Center holes for the drilling,
and bending lines)

F = StL = 345 x 1 x 330 = 113850 N

F = StL = 345 x 1 x 250 = 86250 N
 Manufacturing process

Thirdly, we utilized a manual sheet-folding

machine. It was important to fold the metal
sheet in the right sequence. The 3.5 cm from
the left side had to be bent first, and then the 7
cm from the left had to be folded. The
challenging section then required a little bend
starting from 3.5 cm to the right, followed by a
fold in the center that was 4 cm (As shown in
the figure), and lastly a bend starting from 3.5
cm to the right. To accomplish the final 3.5 cm
bend, a small bend had been made.
Sneak Peek
 Manufacturing process

Fifthly, since some of the edges and drill holes

were still sharp and pointed, they needed to be
finished. To get a decent end result, the edges
were brushed off and smoothed using a steel
file.
Finally, to paint the final product red, we
utilized DUCO paint and a DUCO sprayer.
 05
Cost Analysis
 Cost analysis

The expense of creating the shelf wasn’t

expensive. As shown by the chart and the table the
most expensive operations in making the shelf were
the labor and paint. We are unable to lower labor
costs, but in the future, a less expensive paint will
be used to lower overall shelf costs.

The manufacturer's net profit on this product is

20%. Including the time for painting, the procedure
took around two hours, but with more practice, it
would just take a half-hour, and that means that one
worker can do 16 shelves in a shift (assuming shift
= 8 hours) which makes around 940 pound per
worker per shift.
(Note: All prices are in Egyptian pound.)
 Cost analysis

Cost breakdown:

Item Name Price Per Pack Price Number of items used % of Total Total
Metal sheet 3,200.00 .‫م‬.‫) ج‬Price per KG( 3.20 .‫م‬.‫ج‬ KG 0.5 0.5% 1.60 .‫م‬.‫ج‬
Screws 25.00 .‫م‬.‫) ج‬Price per screw( 6.25 .‫م‬.‫ج‬ 4xScrews 8.6% 25.00 .‫م‬.‫ج‬
Wall plugs 25.00 .‫م‬.‫) ج‬Price per wall plug( 6.25 .‫م‬.‫ج‬ 4xWall Plugs 8.6% 25.00 .‫م‬.‫ج‬
Plastic package 50.00 .‫م‬.‫) ج‬Price per pacakge( 0.50 .‫م‬.‫ج‬ 1xPlastic Package 0.2% 0.50 .‫م‬.‫ج‬
Labour 32.00 .‫م‬.‫) ج‬Price per hour( 32.00 .‫م‬.‫ج‬ 2xHours 21.9% 64.00 .‫م‬.‫ج‬
Machine Depretation 16.00 .‫م‬.‫) ج‬Price per hour( 16.00 .‫م‬.‫ج‬ 2xHours 11.0% 32.00 .‫م‬.‫ج‬
Energy 32.00 .‫م‬.‫) ج‬Price per hour( 32.00 .‫م‬.‫ج‬ 2xHours 21.9% 64.00 .‫م‬.‫ج‬
Finish(Paint) 160.00 .‫م‬.‫) ج‬Price per liter( 160.00 .‫م‬.‫ج‬ L 0.5 27.4% 80.00 .‫م‬.‫ج‬
Total 292.10 .‫م‬.‫ج‬
Sale Price 350.52 .‫م‬.‫ج‬
Conclusion
 Conclusion

Overall, the team believes that this is a normal

product with pros and cons. One of its benefits is that
it is highly sturdy, can bear big weights, has a vivid
red color that is not easily ignored by the eye, has a
very human design, takes up no desk space, and is
simple to set up. On the other side, there are some
issues that must be addressed, such as the painting
type, which must be modified in order to reduce costs
and increase profits.
Thanks!
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