MANUFACTURING PROPOSAL

GETAFE INDUSTRIAL

Pedro Garca Carreo Arturo Muoz Simn Cristian Prieto Calvo Enrique Redondo Ruiz

1.- PRESENTATION OF GETAFE INDUSTRIAL. __________________________________ 2 2.- MANUFACTURING PROCESS. ___________________________________________________ 2

2.1.- Punching and blanking. ____________________________________________________________ 3 2.2.- Bending 1. _______________________________________________________________________ 4 2.3.- Bending 2. _______________________________________________________________________ 7 2.4.- Deep drawing 1. __________________________________________________________________ 8 2.5.- Deep drawing 2. _________________________________________________________________ 11 2.6.- Steps and process sheet. __________________________________________________________ 13

3.- MACHINES. __________________________________________________________________________ 17 4.- TIMES. _______________________________________________________________________________ 17 5.- QUALITY CONTROL. _______________________________________________________________ 18 6.- MAINTENANCE. ____________________________________________________________________ 20 7.- PACKAGE DESIGN. _________________________________________________________________ 20 8.- LOGISTICS. __________________________________________________________________________ 21 9.- RISK ANALYSIS. ____________________________________________________________________ 24 10.- COSTS. _____________________________________________________________________________ 26 11.- CONCLUSIONS. ____________________________________________________________________ 28

1.- Presentation of Getafe Industrial.

We are a manufacturing company with more than 30 years of experience. We are especially dedicated to forming metals by plastic deformation but we also develop metal forming processes and assembly operations. About 500 people belong to our company and we bet for good continuous formation and experience. Moreover we have the better machines to develop our products. This is the administrative scheme of our company.

We have already worked for GM manufacturing pieces such as structural parts of the chassis of the car. For these and other reasons we are the best option to manufacture this piece, take a look at the special project that we have develop specially for this business.

2.- Manufacturing process.

To meet the specification for this piece we are going to detail the process that from our point of view is the best one. This process starts with the loading of metallic parts on the press. Then these sheets enter into the press by the action of a robot and they are moved through the 4 different steps inside the press by the robots included in the machine. After that a robot takes out the final piece from the press and hangs it to allow the washing to remove lubricants The last phase of the process is the packing into boxes to be delivered to your factories. Notice that the piece will be produced up-side down with respect to the images but we have represented them like this to improve the comprehension. The following points detail the processes inside the press and then you can see the steps sheets that we will use to control the process.

Scheme of the manufacturing cell:

2.1.- Punching and blanking.

The first step in the press consists on punching some holes on the piece that will be used as well to place correctly the piece if needed. At the same time we will blank the piece out of the initial steel sheet. Force required for punching:
F=

R
2

Pe =

45 (420 + 240 + 40)3 = 42412(kg ) 2

Force required for blanking:

F=

R
2

Pe =

45 1500]3 = 253071(kg ) [2(210 + 50 + 84.6 + 30) + 2 2

Total force required for the step:

F = 42412 + 253071(kg ) = 295483(kg ) = 295(T ) = 2900(kN )

The piece after this step will have this shape:

The punch and die required for this step is (bottom view):

2.2.- Bending 1.
For the first bending step, the piece is going to be bended along its length (1,5m).For this purpose we need to calculate all the forces, because along the width of the piece we need to do three bends. After that calculus, the total force developed during the process will be the sum of all forces. Calculating forces:

S=3 mm b=1500 mm =45 Kg/mm2 v= depends on bending side. k=0,75 (between 0,7-0,8)

Force number 1. F1=4104.73 Kg

Force number 2. F2=3674.4 Kg

Force number 3. F3=2680.1 Kg

F= 10459.278 Kg

If we place the flat plate at this step the forces will act as its shown in the scheme:

F1

F2

F3

The final shape of the piece after this bending process is this one:

And the punch and die that we will use for this purpose are the following:

2.3.- Bending 2.
For the second step of bending, as we can see in the main outline there is an angle processed at both sides of the piece. Due to its symmetrical shape we need a step where we can generate 3 grades at both sides along the length and we will measure it from the upper flat floor. We refer to:

For this manufacturing process we calculate the force of the punch as before.

Where the value v is now calculated as the distance between the two points of the figure:

Front view of the piece

V= 600 mm

The length b will be the width of the piece on this point. b= 5 cm 7

The value for the force of the punch will be: F= 25.31 Kg Since the piece is symmetrical the total force applied in the same step will be the double: F= 50.62 Kg

The final shape and the punch and die configuration used are the following:

2.4.- Deep drawing 1.

In this step the central part of the piece will be shaped as desired. In the next two figures we can see how the material enters and exits this step, respectively:

This deformation of the material is produced by a deep drawing, applied on the central part of the piece. Following are the calculations of the power required to perform this operation.

The die should be able to contain piece, while the punch dimensions should be those of the central part flat zone, which measures 50x100 mm.

Since the shape is rectangular, an equivalent diameter has been calculated, using the following criteria: = 4

being A the area of the rectangular shape, and P its perimeter Diameter of the blank: = Diameter of the punch: = 4 0,05 0,1 = 66,67 2(0,05 + 0,1) 4 0,05 0,42 = 89,36 2(0,05 + 0,42)

 coefficient: = 1,34

Thus, since is lower than the maximum for our material, which is a bit over 2, we can do this process in a single step. n coefficient: = (1,15 0,001 ) 1,2( 1) = 1,2(1,34 1) = 0,3618 66,67 (1,15 0,001 3 )

where s the thickness of our blank, which is 3 mm.

Punch force: = = 0,3618 66,67 3 45 = 10230,17

where B the ultimate tensile strength of our material, which is 45 kg/mm2. Punch and die configuration:

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2.5.- Deep drawing 2.

In this step the flanges are formed. They are located on the lateral flat zones of our piece, as illustrated in the figures:

Deep drawing is the process that fits best to what we need. To calculate the force needed to be applied, we have considered all the flanges equals in shape and forty (40) of them present alongside the piece. As in the previous deep drawing, the punch and the piece are rectangular shaped, forcing us to calculate an equivalent diameter first. The punch dimensions are 30x30 mm, while for the blank we have consider a clearance of 15mm to each size. Diameter of the blank: = Diameter of the punch: = 4 0,03 0,03 = 30 2(0,03 + 0,03) 11 4 0,03 0,06 = 40 2(0,03 + 0,06)

 coefficient: = 1,33

Thus, since is lower than the maximum for our material, which is a bit over 2, we can do this process in a single step. n coefficient: = (1,15 0,001 ) 1,2( 1) = 1,2(1,33 1) = 0,347 30 (1,15 0,001 3 )

being s the thickness of our blank, which is 3 mm.

Punch force: = = 0,347 30 3 45 = 4415,04

being B the ultimate tensile strength of our material, which is 45 kg/mm2.

That is the force required for a single flange. For the 40 of them present in the whole piece, we will need a force of: = 40 = 176601,6

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2.6.- Steps and process sheet.

Times included in steps sheets refer only to the formation process but as all of them are done in the same press the time for each punch will be the biggest and we need to add some time for the punch to go up and down. STEP SHEET Piece: Verst. Boden Tunnel vorn aussen Reference n:24 466 392 / 94 Material: Low carbon steel ASTM A572 gr50 Step n:1 Step:PUNCHING + BLANKING Description: MAKE THE HOLES AND BLANK THE PIECE Execution time:0.24s Machine: Coolant: NONE Previous step: NONE Next step: 2 Tool Tool Bottom view of the punch number 1 Punch and die

Final piece apearance

Engineer: Pepe Jimenez Fernandez Review number:3 Development date(dd/mm/yyyy):01/05/2013

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STEP SHEET Piece: Verst. Boden Tunnel vorn aussen Reference n:24 466 392 / 94 Material: Low carbon steel ASTM A572 gr50 Step n:2 Step: BENDING 1 Description: BEND THE PIECE. Execution time:16s Machine: Coolant: NONE Previous step: 1 Next step: 3 Tool Tool Side view number 1 Punch and V die

Engineer: Pepe Jimenez Fernandez Review number: 2

Development date(dd/mm/yyyy):01/05/2013

STEP SHEET Piece: Verst. Boden Tunnel vorn aussen Reference n:24 466 392 / 94 Material: Low carbon steel ASTM A572 gr50 Step n:3 Step:BENDING (2) Description: BEND THE PIECE.PUNCHE WILL BE PLACE AT MIDDLE POINT OF THE FLAT SURFACE TO GET THE SYMMETRIC ANGLE. Execution time:0.24s Machine: Coolant: NONE Previous step: 2 Next step: 4 Tool number Tool 1 Punch and V die

Engineer: Pepe Jimenez Fernandez Review number:3 Development date(dd/mm/yyyy):01/05/2013

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STEP SHEET Piece: Verst. Boden Tunnel vorn aussen Reference n:24 466 392 / 94 Material: Low carbon steel ASTM A572 gr50 Step n: 4 Step: DEEP DRAWING (1) Description: DEEP DRAWING OF THE CENTRAL PART TO OBTAIN THE DESIRED SHAPE Execution time: 8s Machine: Coolant: NONE Previous step: 3 Next step: 5 Tool Tool number 1 Punch and die

Engineer: Pepe Jimenez Fernandez Review number: Development date(dd/mm/yyyy):01/05/2013

STEP SHEET Piece: Verst. Boden Tunnel vorn aussen Reference n:24 466 392 / 94 Material: Low carbon steel ASTM A572 gr50 Step n: 5 Step: DEEP DRAWING (2) Description: CREATION OF FLANGES Execution time: 0.8s Machine: Coolant: NONE Previous step: 4 Next step: WASHING Tool Tool number 1 Punch and die

Engineer: Pepe Jimenez Fernandez Review number: Development date(dd/mm/yyyy):01/05/2013 15

STEP SHEET Piece: Verst. Boden Tunnel vorn aussen Reference n:24 466 392 / 94 Material: Low carbon steel ASTM A572 gr50 Step n: 6 Step: WASHING Description: CLEANING OF THE PIECE + DRYING Execution time: 15s Machine: Coolant: WATER Previous step: 5 Next step: NONE Tool Tool number 1 Hose 2 Dryer

Engineer: Pepe Jimenez Fernandez Review number:

Development date(dd/mm/yyyy):01/05/2013

PRODUCTION SHEET Piece: Verst. Boden Tunnel vorn aussen Material: Low carbon steel ASTM A572 gr50 Operation Brief description number 1 Punching and Blanking 2 Bending 1 3 Bending 2 4 Deepdrawing 1 5 Deepdrawing 2 6 Washing+drying Overview:

Reference n:24 466 392 / 94 Machine Execution time: 1 1 1 1 1 2 0.24s 16s 0.24s 8s 0.8s 15s

Engineer: Pepe Jimenez Fernandez Review number: 4

Development date:06/05/2013

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3.- Machines.
From the previous calculus we realized that we 5000 kN to develop the process, so we have chosen a 6300 kN Schuler press. We have also made sure that the press is big enough to allow this big piece to flow inside. The model is SH-630. It has 1.6m width and 2.5 length. You can have a look at the end of this document where we have attached the catalogue of presses.

4.- Times.
This is the analysis of the times required to manufacture each piece.

Maximum working velocity: 0,75 m/min Maximum velocity: 20 m/min Operation times Punching = = 3 = 0,24 0,75 /

Bending

Deep Drawing 1

0,2 60 / = 16 0,75 / = = 0,1 = 8 0,75 / 0,01 = 0,8 0,75 /

Deep Drawing 2

Other times:

Up and down = 2 0,3 = 1,8 20 /

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Change of piece = 2 Total time = 16 + 2 + 1,8 = 19,8

Assuming an effectiveness of 80% of the time, to make the 3200 pieces a day, we will use the press each day a total time of:

= 19,8

1 3200 = 22 0,8

5.- Quality control.

For this piece we will do a sampling quality control. For each production shift we will check 3 pieces, one at the beginning, one at the middle and one at the end. If any one of these pieces does not fulfill the requirements we will check 10 pieces of the batch and if one of them is wrong we will reject the full batch. The control will consist on a control gage in which we will check the following dimensions.

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That will be enough to check the shape of the piece but we want to check also the material properties. As we rely on our raw material supplier we will only analyze one finished part per batch of raw material by liquid penetration inspection.

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6.- Maintenance.
This product will take advantage of the Total Productive Maintenance system that we set in our factory several years ago. It has got 4 main characteristics. - Corrective maintenance: A group of 5 people per shift are in charge of solving problems as soon as possible and with a quality assurance. They are all well experienced and well formed. - Preventative maintenance: The same group of people prepares and develops regular schedule for checking and repair before break the machines and systems of the factory. - Predictive maintenance: All our machines are equipped with sensors that help us to monitor the operation of every single machine. - Well-formed workers: Each of our workers is able to maintenance his machine because he is the best person to detect a wrong operation. With this method we have reduced a lot the break down time of our production chain ensuring that we fulfill the orders on time.

7.- Package design.

First of all we need to specify in order to safe costs that we are going to use a reusable package to carry the pieces to the container and to deliver them to our costumer. For this purpose we are using metal boxes. The dimensions for these boxes are going to be 1600x500x400 with a weight capacity of 1000 Kg and its own weight is 70 Kg. The dimensions of the piece are 1500x200x200. But because of the type of geometry of the pieces we can stack them up occupying less space. When we stack the pieces we make sure there is a protective paper between each piece so there is no friction between pieces that can cause some imperfections. And for stacking them up we need to consider that the lowest piece in the box doesnt support much weight from the upper ones, and as the weight of each piece is 13.3 Kg we are going to stack just 10 pieces. And also because the boxes are 500 mm we can have two rows of pieces in each box, so every box is coming with a separator wall to separate the two rows. Having in account that each of the rows we have stacked 15 pieces so at the end in each box we can have 30 pieces. Knowing that we have 30 pieces o 13.3 Kg we have a weight of 399 Kg so we are not having problems with weights box capacity because is of 1000 Kg. 20

At the end the weight of the box full of pieces is going to be 469 kg. So with a truck elevator of 4000 Kg we are going to be able to carry 8 boxes at a time. The price of the metal boxes with separator is of 70 each, but if we buy a big number (of 100) more or less, we can get prices of 50 each that is much cheaper.

8.- Logistics.
In order to send the pieces to each destination we need to set the number of trucks and how often they will do a travel. Our company produces the next set of pieces: -To Zaragoza: 2000 pieces/day -To Bochum: 1200 pieces/day We can do it by two ways: -Sending the pieces that factories need for each day. These will lead to a high investment and cost in transportation. -Stock a limited number of pieces in our factor, and send a large number of pieces to each destination, such that each one will have enough number of pieces for more days. The dimensions of the truck rented are: Renault Magnum 480dxi Renault Magnum 480dxi

Measures of rigid interior : 7300x2400x3000 measures of the interior trailer 3 central axis :8000x2400x3000

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Since each container has 1600x500x400, then we can transport 164 containers (4920 pieces) inside each truck. These leads to know what we need for:

To Zaragoza To Bochum

1 truck 1 truck

(2000 pieces) (1200 pieces)

The cost of each travel is displayed in the next page. Since we need the container get back, we will do the calculations thinking about nothing will come back on that trucks in the Bochum - Getafe and Zaragoza - Getafe travels. But, we may consider that trucks could be useful to do another transport of another pieces or something else. All prices and taxes are established with the next value: 0,95/km ( salary and fuel consumption are included) GETAFE ZARAGOZA (327 Km) Time:4 hours Total cost=310.65 x2=621.3 euros Percentage of use=67.75 %

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GETAFE -BOCHUM (1835 Km).Time: 20 hours aprox. 1743.25 euros Toll tax= 250 euros Total cost=1993.25x2=3986.5 euros

Finally, our company will send the pieces two days per week (Tuesday afternoon and Friday morning) for the case of Bochum and it goes full, but the Zaragoza trip must do a trip each two days (three travels per week), and the drivers can must exchange their destination once they finish the travel. So in terms of transport each week we will spend the next amount of money: CT=(621.3)*3 trips*0.6775* 1*truck +3986.5*2 trips*1 truck=9235.8 euros/ week

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9.- Risk analysis.

Here we can see the risk analysis for this project.

Failure Mode

Effects Delay on production/Repairs costs

Causes Misuse of the press/bad maintenance

Detection method S

RPN

Press breakdown Strike

Saw by worker Usually previously scheduled

9 7

4 5

1 1

36 35

Delay on production Bad labor conditions Delay on production/Repairs costs

Truck accident Inefficient employee Raw material delay Bad quality of raw material Power outage Orders with higher priority

Bad driver/luck Not enough supervision or Delay on production rewards Delay on production Bad provider Bad quality of pieces Bad provider Delay on production Maintenance failure Delay on production Bad management

Low production rate Test on pieces MPS

144

5 8 4 8 7

7 3 3 2 3

7 1 6 1 5

245 24 72 16 105

High rate of production/low Upkeep costs frequency of trucks Too much stock Misuse of the robot/bad Robot Delay on production maintenance breakdown Delay on production/bad image

Warehouse full

60

Saw by worker

20

Accidents Employee not attending Wear of punch or die

Bad safety conditions Worker wounded Test on pieces

9 3 6

4 5 6

1 4 8

36 60 288

Luck/not enough Delay on production rewards Bad quality of pieces Bad maintenance

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These are the actions we have taken to reduce the risks.

Failure Mode Action Taken Total Productive Maintenance Better labor conditions Improve route Warning and rewards (Kaizen)

O D

RPN

Press breakdown Strike Truck accident

9 5 8

2 4 2

1 1 6

18 20 96

Inefficient employee

140

Raw material Hire a better supplier delay Bad quality of raw material Hire a better supplier

16

48

Have a secondary Power outage generator Orders with higher priority Too much stock

MPS Kanban Total Productive Maintenance

7 5

1 2

3 3

21 30

Robot breakdown Accidents

2 9

4 1

2 1

16 9

Better safety conditions Make them attend before Employee not the previous turn finish attending Total Productive Wear of punch or die Maintenance

2 5

5 4

3 8

30 160

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10.- Costs.
Production rate: It depends on the time spent in the manufacturing process of the piece. Each piece takes 19.6 seconds to be manufactured completely.

Amortization of the press: Time to be used: 20 years

E=175000 i=5% n=20 years HA=246*22=5412 h/( handworker*year) NT=3 shifts Ai=1.429 /h 19.6 s/piece 7.78*10-3 /piece

Amortization of the containers We have a total amount of containers: 600 containers The containers are brought to each factory, but we need to leave the boxes in the factory ( the truck back home empty. In conclusion we need the number of containers twice. Also we have added some boxes for losing, broken ones

E=30000 N=3 years E/N(per year)=10000 Cac=0.0127 /piece Total cost of amortization=0.02048 /piece

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Also we could include other services for press use, so the final cost for us in order to calculate the price of each piece will be lower.

Workers in our factory:

Since we distinct three areas in the production of the piece, we have assigned two workers in the total area. Manufacturing area: the operator will control, advertise and repair if any problem takes place. Washing area: the same operator of manufacturing area will be controlling at the same time. We think by this way we could reach high cost efficient tasks. Logistic area: in this area we have set an operator to carry out with the elevator truck, such that the pieces are placed into the container and, after that in the truck.

Salary of each worker (in the factory): Salary=13200 / year taxes included

Other cost associated with workers: Meals and hotels= -To Bochum=160 /per travel -To Zaragoza=15 /per travel C=18500 / year Total cost associated with labor turns+9215+480261.2=587176 /year ( per year)=18500+13200*2*workers*3

Total pieces produced in a hole year:3200*246=787200 pieces /year Total cost associated with labor ( per piece)=0.745 /piece

Cost of material (steel carbon): Carbon steel price=644 /ton Weight of the piece=13.3 Kg 27

Cost=8.565 /piece

Total cost accumulated for the piece: C=0.745 /piece+0.02048 /piece+8.565 /piece=9.33 /piece Cost associated with other operations (electricity, water, lubricants and administration) = 30 % C=9.33*1.3=12.13 /piece

Benefit estimated: Market price=12.505 /piece We obtain 3% of benefits from this piece.

11.- Conclusions.
With this project we offer an economical manufacturing process for your piece. We also have a good quality control and a maintenance system that will make your investment a good fact. We have thought also on other systems as logistics or possible risk to develop the project in the most efficient way. We hope to work with you because everybody will be satisfied.

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