Assigment Chapter 17

Problem 17.2

QUESTION:

Many consumers item today are designed in the United State and manufactured over-seas where labor cost is much lower. A middle range athletic shoe from a name brand manufacturer sells for $70 in the U.S. The shoe company buys the shoe from an off-shore supplier for $20 and sells to the retailer for $36. The profit margin for each unit in the chain is: supplier-9%, shoe company-17%, retailer-13%. Estimate major categories of cost breakdown for each unit of chain. Do this as a team problem and compare the results for the entire class.

No	Major Catogories	Detail Items	Cost (USD)
1.	Athletic Shoe Company	Materials	7.00
		Supplier’s operating profit	2.00
		Production Labor	3.00
		Rent, equipment	2.50
		Duties	4.00
		Shipping	1.00
		Total Cost	19.50
2.	Retailer	Sales, Distribution, admin	5.00
		Promotion and adverstising	4.00
		Company’s operating profit	7.00
		Research and development	30.00
		Total Cost	46.00
3.	Consumer	Personnel	16.00
		Retailer’s rent	19.00
		Retailer’s operating profit	20.00
		Others	16.00
		Total Cost	66.00

ASSIGNMENT 17.1

QUESTION:

In an environmental upgrade of a minimill making steel bar, it is found that a purchase must be made for a large cyclone dust collector. It is the time of the year for capital budget submissions, so there is no time for quotations from suppliers. The last unit of that type was purchased in 1985 for $35,000. It had a 100ft³/min capacity. The new installation in 2012 will require 1000ft³/min capacity. The cost escalation for this kind of equipment has been about 5 percent per year. For budget purposes, estimate what it will cost to purchase the dust collector.

Answer:

To answer this question, equation below is provided:

C₁ = C₀ (L₁/L₀)^x    (Cost-Size Relationship ~page799)

• C₀= $35,000    
• L₀= 100ft³/min
• L₁= 1000ft³/min         
• C₁= ?

Based on Table 17.4 in the text book, x for dust collector= 0.61. Because of economies of scale, the new unit has 10 times the capacity as the unit purchased in 1985 will not cost 10 times more. However, the purchase cost will have increased because of inflation in the 27 years since it was purchased in 1985. Assuming cost inflation in of 5% per year, the original cost of $35,000 is now equivalent to:
P= F(1+i)n
P=35000(1+0.05)²⁷ 
 = 35000(2.92526) 
 = $130 671.00

Thus, the cost estimation can be calculated as:

C₁ = C₀ (L₁/L₀)^x 
       =130 671.00(1000/100)^0.61 
     = $ 532 327.00

ASSIGNMENT 13.1 SHAPE-REPLICATION AND SHAPE-GENERATIVE

ASSIGNMENT 13.1  

QUESTION :

Classify the following manufacturing processes as to whether they are shape-replication or shape-generative:

(a)Honing the bore of a cylinder,

(b)Powder metallurgy gear,

(c)Rough turning a cast roll,

(d)Extrusion of vinyl house siding.

ANSWER:

 Shape replication is an example of process under mass conserving which the part replicates the information stored in the tooling by being forced to assume the shape of the surface of the tool cavity. The examples of shape-replication process can be define by the process of casting, injection molding, and closed-die forging. In addition, during mass reducing processes or shape-generation processes, the starting material is greater than the mass of the final part. This is because the part shape is produced by the relative motion between the tool and the workpiece. The examples manufacturing processes that undergo through this process is milling and drilling.

The manufacturing processes are classified as follow: 

(a)    Honing the bore of a cylinder      

     *Shape-generation
     

(b)   Powder metallurgy gear               

     *Shape- replication
      

(c)    Rough turning a cast roll               

     *Shape-generation
     

(d)   Extrusion of vinyl house siding 

     *Shape-replication
     

 

ASSIGNMENT 11.3

QUESTION:

Which material property would you select as a guide in material selection if the chief performance characteristic of the component was:

Answer :

PERFORMANCE CHARACTERISTIC	MATERIAL PROPERTY
a)	The ability of a sheet material to be stretched into a complex curvature	Ductility
b)	Resistance to twisting	Toughness
c)	Strength in bending	Tensile strength
d)	Ability to resist fracture from cracks at low temperatures	Malleability
e)	Ability to resist shattering if dropped on floor	Hardness

ASSIGNMENT 9

9.1 Examine the detail drawings for a product designed by a nearby manufacturing company. Be sure you can identify the actual shape, dimensions, and tolerances. What other information is contained in the drawing?

Assembly the design part by using  Catia software

Dimension of Structure

Label of Structure Diagram and Bill of Material

ASIGNMENT 8

Assignment 8.1

Look your design to find some common consumer product. Identify which are primary modular, integral, or mixed product architecture.

______________________________________________________________________

Modular product

Modular products may be defined as machines, assemblies or components that accomplish an overall function through combination of distinct building blocks or modules. A modular product development is one in which the input and output relationships between components, that is, the component interfaces, in a product have been fully specified and standardized.

To exploit the benefits of modular product development, it is crucial to have modularization in mind from the start of the design process, and not only as an afterthought when all components are developed.

Integral product architecture

Integral product may be defined as functional elements are implemented by multiple chunks, or a chunk may implement many functions and interaction between chunks is poorly defined. Besides, integral architecture generally increase performance and reduces costs for any specific product model.

Existing Cloth Dryer In The Market.

Proposed Cloth Dryer

1st Draft of Design

ASSIGNMENT 7

QUESTION

In the search for more environmentally friendly design, paper cups have replaced Styrofoam cups in most fast-food restaurants. These cups are less effective insulators and the paper cups often too hot for the hand. A design team is in search of a better disposable coffee cup. The designs to be evaluated are: (a) a standard Styrofoam cup, (b) a rigid injection-molded cup with a handle, (c) a paper cup with a cardboard sleeve, (d) a paper cup with a pull-out handle, and (e) a paper cup with a cellular wall. These design concepts are to be evaluated with the Styrofoam cup as the datum. 

The engineering characteristics on which the cups are evaluated are:

1. Temperature in the hand
2. Temperature of the outside of the cup
3. Material environmental impact
4. Indenting force of cup wall
5. Porosity of cup wall
6. Manufacturing complexity
7. Ease of stacking the cups
8. Ease of use by customer
9. Temperature loss of coffee over time
10. Estimated cost for manufacturing the cup in large quantities

Using your knowledge of fast-food coffee cups, use the Pugh concept selection method to select the most promising design.

ANSWER

Pugh Concept Chart 1

Pugh Concept Chart 2

From the result, we can conclude that concept C has the highest number of positive and lowest number of negative compared to other design concepts. So, we choose design concept C which is paper cup with cardboard sleeve to replace the Styrofoam cup.