Komtek Case

Compute the cost of scrap for the Zimmer order using the table and information below.

Komtek Cost of Scrap Estimate
Team Names:
			Work Order - 811073 (1025 pieces)
Opr.	Description	Std. Total Cost ($/pc)	Labor Cost ($/pc)	OH Cost ($/pc)	Outside Cost ($/pc)	Total Cost ($/pc)	1	2	3	4
1	Kitup + Die + Material	62.27				62.27
10	Abrasive Cutting	1.16	0.32	0.83		1.15
15	Grind Slugs	0.97	0.29	0.70		0.99
20	Wheelabrate	0.21	0.22			0.22
30	Coat Slugs	0.59	0.17	0.42		0.59
40	Extrude	7.07	0.91	7.13		8.05
50	Wheelabrate	0.21	0.21			0.21
60	Forge	13.59	1.05	13.74		14.79
65	Helper	2.55	1.07	2.38		3.45
80	Alox 90	1.43	0.46	1.38		1.83
90	Staging for Inspection	0.42		0.44		0.44
100	Visual	0.97	0.33	0.90		1.24
103	Parting line sample	1.18	0.28	0.72		1.01
105	Deburr	4.83	1.16	3.09		4.25
110	Hot Coin	0.72	0.93			0.93
111	Tensile Testing
115	Straighten	2.38	1.14	3.40		4.54
120	Chem Polish	7.00			7.00	7.00
130	Cleaning	1.00			1.00	1.00
140	NDT Facility	4.96	2.72	7.01		9.73
150	Quality Control	1.19	0.49	0.92		1.41
160	Final Prep	0.58	0.14	0.34		0.48
	Subtotal Costs	115.27	11.89	43.42	8.00	125.57				.

Exhibit 1

Hip Prosthetic

Exhibit 2

The Process

Operation No.	Description	Comments	Setup Time (mins)	Run Time (mins)
1	Kitup	Release work order to floor		0.3
10	Abrasive Cutting	Cut bars to length	18	1.002
15	Grind Slugs	Grind off sharp edge of bar		1.002
20	Wheelabrate	Clean bars before coating		0.402
30	Coat Slugs	Coat slugs for extrusion		0.6
40	Extrude	Extrude	120	1.5
50	Wheelabrate	Clean before forging		0.402
60	Forge	Forge in tolerance per print	150	1.5
65	Helper	Help hammerman in lubrication, flash removal	150	3
80	Alox 90	Cleaning process		1.5
90	Staging for Inspection	Parts waiting for inspection		0.3
100	Visual	100% inspection		1.002
103	Parting line sample	Grind sample (10%) of parts for line cracks	120
105	Deburr	Rework marked indications		4.998
110	Hot Coin	HC parts into tol. per print	120	1.5
111	Tensile testing	Test 2 pieces per heat for tensile
115	Straighten	Check straightness per print, 100%		2.4
120	Chem Polish	Outside service
130	Cleaning	Outside service
140	NDT Facility	Non destructive testing 100%		4.998
150	Quality Control	Acceptable Quality Level (AQL)	120
160	Final Prep	Package and Ship		0.6

Exhibit 3

Work Order Review (for week ending 8/29/97)

Exhibit 4

Material Review

Exhibit 5

Standard Costs and Zimmer Order Costs

Exhibit 6

Selected Data from the Straightening Check Process

KomTek (C) BAB094 Exhibit 1 Hip Prosthetic PAGE 1 0F1 COBALT TTL.TES 24 72 S 4S-01lSURPACE) 00-7853-716-0O FORGING CASTING [0PERATIONSM Vusut HER 020 i .010 ON 31STAL TIP) AREA, Z0NE IINTH SPACINC NOTES/SPECIAL INSTRUCTIONS: CENTER LINE 407 457 DISTAL BR 157 330 CTSS 0.25t0.01 PATTERN 3256 0.02 DIMPLES DATE: DRABK BY REVIEIED BY (P-PINAL PREP 129 19 7 KomTek (C) BAB094 Exhibit 1 Hip Prosthetic PAGE 1 0F1 COBALT TTL.TES 24 72 S 4S-01lSURPACE) 00-7853-716-0O FORGING CASTING [0PERATIONSM Vusut HER 020 i .010 ON 31STAL TIP) AREA, Z0NE IINTH SPACINC NOTES/SPECIAL INSTRUCTIONS: CENTER LINE 407 457 DISTAL BR 157 330 CTSS 0.25t0.01 PATTERN 3256 0.02 DIMPLES DATE: DRABK BY REVIEIED BY (P-PINAL PREP 129 19 7