Automatic Welding Lathe Capacity Utilization Calculation

Operative Step

Output/8 hour shift

Bottom Bracket/Seat Tube

Head Tube/Down Tube
Seat Tube/Top Tube
Bottom Bracket/Down Tube
Head Tube/Top Tube
Cycle Time
Units/Day Without Setup Time
Output per Month
Marketing Department Demand
Units per day according to demand
Difference
Capacity Utilization @ Auto Welding Lathe

360
360
360
315
315
7.0456852792
68
1635
4000
167
99
41%

Automated Welding Lathe Overtime Cost Calculation

Monthly Overtime/Welding Station

Days Overtime Done
Employee Salary
Employee Salary per day
Employee Salary in case of Overtime
Overtime Cost

75
9.375
1700
70.8333333333
106.25
996.09375

Calculation
Units per
hour
45
45
45
39.4
39.4

Cycle Time
1.3333333333
1.3333333333
1.3333333333
1.5228426396
1.5228426396

Maintaining 60-40 ratio

Description
Plastic
Steel

Employees

Production/D
ay
2
70
3
19

taining 60-40 ratio

No. of Cycles
actually produced

Production as per
60-40 ratio@
1200/24
35
30
9.5
20

Mitreing
Operations

Number of Operations
in 8 hour Shift
630
630
1260
1260
1260
840

Top Tube (both end)

Down Tube (both end)
Seat Tube
Backstay (left)
Backstay (right)
Handle Cross Brace
Total Cycle Time
Total Time Per Shift in minutes
Capacity per shift
Capacity per month (units)

Cycle Time
1.3125
1.3125
2.625
2.625
2.625
1.75
12.25
480
39.1836734694
1018.7755102041

Welding Station 2
Operations

Number of Operations
in 8 hour Shift

Chainstay/Backstay/Endplate Welding
Left Side
Right Side
Total Cycle Time
Total Time per shift in minutes
Capacity per shift
Capacity per month (units)

420
420

Cycle Time

1.1428571429
1.1428571429

2.2857142857
480
210
2730
Welding Station 3

Operations

Number of Operations
in 8 hour Shift

Front triangle/Chainstay/Backstay
assembly and welding
Frame Complete

96

Total Cycle Time

Total Time per shift in minutes
Capacity per shift
Capacity per month (units)

5
480
96
2496
Welding Station 4

Cycle Time

Operations

Number of Operations
in 8 hour Shift
230
185

Handle Bar/Brace Welding

Handle Stem

Total Cycle Time

Total Time per shift in minutes
Capacity per shift
Capacity per month (units)

Cycle Time
2.0869565217
2.5945945946

4.6815511163
480
102.5301204819
2665.7831325301
Welding Station 5

Operations
Front Fork Blades L/R and Steering Welding
Front Fork Blades/Endplate Welding

Total Cycle Time

Total Time per shift in minutes
Capacity per shift
Capacity per month (units)

Number of Operations
in 8 hour Shift
210
230

4.3726708075
480
109.7727272727
2854.0909090909

Cycle Time
2.2857142857
2.0869565217