Equipment Selection and Costing

This document discusses equipment selection and costing in manufacturing processes. It explores the importance of stamping press and its benefits. The document also covers cost calculations and justifications for equipment selection. Additionally, it provides insights into quality control plans and process flow charts and their contribution to manufacturing efficiency.

Assessment

Table of Contents
Introduction......................................................................................................................................3
Equipment selection and costing.....................................................................................................4
Quality Control plans and Process Flow charts...............................................................................6
CONCLUSION................................................................................................................................9
References......................................................................................................................................10

Introduction
Background literature
Quality: It refers to the standard set by production management; it has to be achieved to qualify
the measures and criteria. It also indicates how much variation a finished product have from its
standards; as making product above standards improves the quality but at the same time
increases the cost and on the other hand making product below standards reduces the cost but
also reduces the quality.
Industry revolutions and Industrialization:
The industrial revolution marked a period of progress in the last 50% of the eighteenth century in
which the rural and terrestrial social orders in Europe and America were transformed into
industrial and metropolitan ones.
Previously hand-worked products began to supply large quantities with machines in production
lines, thanks to the introduction of new tools and strategies in materials, ironworking and various
industries.
Inspired by the use of revolutionary steam, the industrial revolution began in Britain and spread
to the rest of the world, including the United States, before the 1930s and 1940s. Modern
antiquities regularly refer to this period as the First Industrial Revolution, to separate it from the
second period of industrialization which took place from the late 19th century to the mid-20th
century and saw rapid advancements in the steel, electrical and automotive industries.
Beginning in the eighteenth century, advances such as air travel, the jenny turntable, the
watercraft, and the force loom made the weaving and turning of yarns and ropes much easier.
Creating clothes turned out to be faster and took less time and much less human activity.
Overview of the proposal
The proposal was to use Aluminium as an alternative of steel due to its more resistivity and
lighter in weight than steel. As it is clear that using Aluminium in place of steel will definitely
increase the cost of manufacturing but at the same time this increased price of the product could

be justify on the ground that it will increase the speed of the car and also mileage will also be
improved due to less weight with same strongness.
This report focuses on providing a collection recommendation that includes the selection of
climbing material and the selection of a collection ring for the backyard. Aluminum material is
chosen as the material for assembly because it is light weight compared to different materials.
Also, bearing in mind that the material collected must satisfy an indirect economy, which means
that the material should be cheaper, should be recycled, and nature should not crush. Aluminum
is one of those materials that achieve the above mentioned points and for this reason the
aluminum material is chosen for the assembly. To make the plan more suitable, FEA inspection
is carried out using a load of 20 kg and movements are carefully monitored. Additionally, the
layout is planned in Fusion 360 programming and an appropriate collection size is selected. A
bike flow card is drawn to bring the entire assembly cycle together from the raw material to the
finished item.
Brief justification of the proposal
The basic explanation behind the choice of aluminum as a collection material is that it has
properties similar to steel buildings. Similarly, in contrast to steel, aluminum is lightweight and
has mechanical properties similar to those of steel buildings. Aluminum, compared to composite
materials, is high in recyclability, lower cost, high clock consumption and henceforth fulfills the
idea of the round economy which is an important goal. What is planned can be achieved using a
step-by-step approach that does not involve any optional route and helps reduce the overall
collection cost.
Equipment selection and costing
Equipment selection and justification
Stamping press has been selected as an equipment selection for manufacturing; because it
doesn’t need any expertise skills for operator and it is cheaper than other equipments. Additional
to this it provides higher precision and accuracy rate. It is best fit for manufacturing simple
designs which are cheap and high in accuracy. As for fender; better quality and perfect structured
equipment requires; which is definitely fulfilled by current selection.

The production of the car involves two costs: the manufacture of the parts and the assembly of
the parts. These costs are estimated using a strategy developed at the MIT Materials Systems
Laboratory called special costs (TCM). A special cost view is a grid-based explanatory tool that
separates assembly cycle costs into basic cyclic steps.2,3 The costs associated with each progress
can be obtained from a combination of design standards and put together exercises. Factors
include plan details, material boundaries (e.g., building design, material costs), boundary
preparation (e.g., gear control limits, space requirements, power consumption), and creation
boundaries (e.g. creation metrics, waste rates, downtime, support time). Additional models
consider the financial opportunity (i.e. the cost of capital associated with owning the gear). The
information sources will be translated into fixed and variable cost estimates for each collection
campaign. Variable costs include energy, materials and direct labor; Fixed costs distribute the
capital hardware needed for the assembly cycle, including equipment, clear machine design,
construction costs, maintenance and overhaul. In the absence of detailed and clear information
on the site, the cost of facilities and equipment can be expected to depend on the decisions of the
object plan using repetitions derived from actual information.
Small parts, which were not practical to go through the cost model, found a standard cost based
on their weight. The largest parts were arranged according to the assembly cycle: advance, throw
or discard. Each of the part dimensions was considered as a contribution to the process-based
cost model (stamping, casting, and extrusion) to assess the cost of creating that part. The cycle
was revised for each part using a large-scale spreadsheet to assess the cost and cost breakdown
(material, machinery, machine cost, labor) in assembling each part. The total costs brought the
total creation costs of Aluminium.
Cost calculations and justifications
Blanking press uses bucket bounce specifically for the part and is important if the table
conditions want it to depend on a part plane or if the build size is valid. Before and after, the
checkered lines work to create over 60 pieces per minute. For very few boards, rectangular,
trapezoidal or slightly curved spaces may have an appropriate shape and can be supplied with
cutting or line tools. Waving peeling is an improvement used for flexibility in clear planning
with a stroke speed greater than 100 per minute. Like these lines, stripping alone and line
blanking can get in the way of some news lines. As invitations take on the general economy, the

blanking line includes ring handles, unwinder, leveler / leveler, feeder, blanking press and
stacker for places.
Dedicated welding gaps for complex boards are established through various splice steps - laser
welding, spot welding or seam welding resulting in tons of material savings and superior quality.
At least two pieces of the same material and different materials or studies are welded into a clear
solitaire before climbing. The use of more expensive materials, for example, thicker stock, with
more ground or cover can be restricted to exactly where it is needed. Individual molds of more
expensive material and then welded them may have different steps, different functions, assembly
and inspection of centers. Thick or thick mixtures or of different quality also cause weight
reduction. In one step of an engine ration rail, the first solution was to extract a 2mm thick stock
over the entire length. After examining the confined parts, it was decided to use two 0.8 mm
spots for the front of the line and 2 mm dry for the rest. This resulted in a net weight saving of
3.4 kg. in purchased steel and 1.3 kg. vehicle weight savings without loss of stiffness or
expectations for well-being. Similarly, separating the turned table into more than one piece can
promote settling and heavier output from the blank. In fact, even with the expansion of two-part
laser welding prior to the switchover, the savings could be in the millions for a full delivery
board for a car manufacturer. In inner heels, 0.81mm and 1.83mm thick lifting pieces eliminated
the requirement for pin and mirror fasteners and provided spot welding.
The Michigan die-maker showed that the cost charged to the customer for the sink design alone
was USD 0.45 / lb (USD 0.99 / kg) (preventing any planning, design or processing costs). Using
this "spill cost", the part of the total kick of the bucket cost that can only be attributed to the
project cycle was added to Figure 16. It shows that the project cycle produces less than 35% of
the overhead. It appears that the cost of a project could be relatively higher for larger dust mite
bites. This may be because the design and engineering costs do not directly increase by biting the
size of the powder, unlike the cost of a project.
Quality Control plans and Process Flow charts
Quality control:
The engineering quality of manufacturing process always reflects in its quality of work. Quality
control assures to minimize the standard deviation of outputs from different processes. For doing

this; first step includes identification of particular manufacturing point which has more number
of defects. After that reason for particular defects is identifies and proper rectification is to be
applied. Some of the factors of quality processes include operator (man), machine and equipment
(machine), raw materials (material), process (processing), detecting methods (method) and
environment (milieu).
The rear quarter panel is curved in shape and can be made with a stamping press process the
quarter panel is less in thickness and can be made with aluminium. Stamping press is suitable for
the components output in desired shape. Two moulds are placed up and down and are fixed to
the machinery. After placing the sheet metal over the bottom mould, we can give access to the
machinery to stamp press it to get into required shape. Aluminium’s are good to manufacture
with open die forging, closed die forging and stamping press. In this process we are selecting
stamping press because the given part has curves which can be obtained by stamping press only.
Open die forging and closed die forging needs a bulk material that needs to be placed in between
the mould and needs to press against it. For open die forging we can cut the excess material of
the component and for closed die we will get the shape of the mould. So,I am choosing stamping

press as the best option. For fixtures we can cut holes through laser cutting or through hole punch
machine.
In general moulds for stamping press are made with steel materials such as carbon tool steel, low
alloy steel, high carbon steel, medium carbon alloy steel, high speed steel and steel cemented
carbide etc. in addition to that we should also consider thickness, shape and size of the workpiece
for the mould materials consideration and balance should be achieved cost and life time of the
material.
Many developments are seen in steel and we are using high structed steel as the mould tool
material. This material has great strength when compared with weight ratio which explains it’s
high strength per mass. As the experiment needs a lower volume of tools aluminium is best as a
cost-effective choice and it is low in price. Tools can be generated faster with aluminum when
compared with other materials. So we are choosing aluminum as the mould/tool material for the
process.
We have generated mould structure from the given part with the help of project option in fusion
360. After getting the profile we extruded the profile and got a body which is divided into two
parts with the help of combine option.
The mould can be manufactured with help of fusion 360. After getting the body we can create a
tool path with the help of manufacture option in fusion 360. The generated tool path can be used
to make a new mould in the CNC machine with milling operations. For this operation I have
used 3D adaptive clearing, slot operation and scallop operations. In this operation the body is
curve in structure, and it can be generated with ball end mill in milling operations. I have
selected 10 mm diameter ball end mill for this operation, and it can be finished easily.
PROCESS FLOW CHART
Research on Materials Selection of materials

CONCLUSION
The given component is analyzed and research is done in selecting the material and process
selection for the component. Circular economy is met which satisfies eliminating waste material,
Tool selection
Product design
Process selection Mould design
Manufacturing actual component Manufacturing prototype
Assembling Delivering to customer

recycling products and controlling resources. Also, FEA analysis was done on the component for
better understanding of the design and its need.
In the current generation, additive manufacturing is booming in advance manufacturing
technologies which mainly aim in producing mass/bulk production. If cost structure is controlled,
additive manufacturing can be used to for the manufacturing and composite materials can be
used as materials for better optimization.

References
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using ashby charts," International journel of mater engineering , vol. 8, pp. 40-54, 2018.
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[Accessed: 14- Sep- 2020].
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Manufacturing Processes, and Light Duty Vehicle Propulsion," Ann Arbor, MI: Center for
Automotive Research., 2017.
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Performance in 2017," Car Manufacturers’ Performance in 2017, 2018.