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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

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

image text in transcribed

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

image text in transcribed

image text in transcribed

Exhibit 6

Selected Data from the Straightening Check Process

image text in transcribed

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

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