I need help in Project for Manufacturing design. I will provid an example file of the project to help understanding but making sure “NO Plagarism”. Also, I will proviod another file that has the instructions of the project. The instructions has to be followed cearfully.

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. 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.

2. 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.

3. 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, reducingthe 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

4. 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.

5. 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.