Question
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
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
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