Chapter5: Production Design Innovation

Operational Plan

Product: Bipedal Walking Assist

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1.1 Flow of operation

Step1: Material preparation

1. Cutting the Flat steel bar to desired dimensions, and grinding out the uneven
surface
2. Grind out the sharp edges of the Flat steel bar
3. Drill out all the holes in the Flat steel bar according to the drawings
4. Cutting out the Steel sheet into desired shape and dimension according to
drawings
5. Cutting out the hard fabric into desired shape and dimension according to
drawings
6. Cutting out the sponge sheet into desired shape and dimension according to
drawings

Step2: Primary Assembly

1. Start by assemble the steel bar together according to drawings with bolt, nut and
the amount of washer stated on drawings
2. Assemble the feet piece according to drawings
3. Assemble the strap component together using steel sheet, sponge and belts. Three
components stated are then wrap around by hard fabric to hold them together

Step3: Final Assembly Process

1. Start by assemble the feet piece to the main structure frame using bolt, but and
the amount of washer stated on drawings
2. Attach the grade 30N gas spring to the feet piece and the lower main frame (leg
section)
3. Attach the grade 50N gas spring to the upper main frame(thigh section) and
lower main frame (leg section)
4. Attach all the strap component to the main frame according to drawings
5. Finally with the completed structure, it is then attach together with the harness
6. Package and shipment and distribution.

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 1.2 Operation layout plan

Stations

Station 1: Prep Station

Raw Material preparation
1. Cutting the Flat steel bar to desired dimensions, and grinding
out the uneven surface
2. Grind out the sharp edges of the Flat steel bar
3. Drill out all the holes in the Flat steel bar according to the
drawings
4. Cutting out the Steel sheet into desired shape and dimension
according to drawings
5. Cutting out the hard fabric into desired shape and dimension
according to drawings
6. Cutting out the sponge sheet into desired shape and
dimension according to drawings
1.

Station 2: Pre-assembly Station

Pre-Assembly of Parts
2. Start by assemble the steel bar together according to
drawings with bolt, nut and the amount of washer stated on
drawings
3. Assemble the feet piece according to drawings
4. Assemble the strap component together using steel sheet,
sponge and belts. Three components stated are then wrap
around by hard fabric to hold them together

Station 3: Final Assembly

Final assembly of all parts
1. Start by assemble the feet piece to the main structure frame
using bolt, but and the amount of washer stated on drawings
2. Attach the grade 30N gas spring to the feet piece and the
lower main frame (leg section)
3. Attach the grade 50N gas spring to the upper main
frame(thigh section) and lower main frame (leg section)
4. Attach all the strap component to the main frame according
to drawings
5. Finally with the completed structure, it is then attach
together with the harness
6. Package and shipment and distribution.

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1.3 Production Schdule/Planning

Production Plan
Production Rate 2019 2020 2021
Per year 20000 25000 25000
Per month 1667 2083 2083
Per day(work days) 75 94 94
Per hr (8hr) 10 11 11

1.4 Materials need (Per month)

Material Total quantity Unit price Total Price Company

Supplier
Flat Steel Bar 2.2 Tons RM1476/Ton RM3247.20 TianJinZhenXi
ang Strip
Processing Co.
Ltd.
Gas Spring 6250Units RM5/Unit RM31250 Hangzhou
30N/50N Fuyang Tainli
Machine Co.
Ltd.
Steel Sheet 0.29tons RM4057/Ton RM1176.53 Shanghai
Bozhong
Metal Group
Co. Ltd.
Sponge Sheet 0.2kg RM24.6/kg RM4.92 Sansd (Fujian )
Plastic Co.
Ltd.
Harness 1250Units RM41/Unit RM51250 Hangzhou Yale
Industries Co.
Ltd.
Canvas 0.2Tons RM12/Ton RM2.4 Qingdao
Taimei
Products Co.
Ltd.
Sets of Nuts 31250Units RM0.05/Piece RM1562.5 Beijing ZLRC
and bolts Environmental
Protection
Equipment Co.
Ltd.
Straps/Belts 11250 RM0.41/Unit RM4612.5 Zhongshan
Hoanan
Handicraft
Manufacturer
Packaging 1250 RM0.8/nos 1000 PackagingMart
Supplies

Total Cost (per month) =RM 93106.5

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Cost per unit= RM 74.50

1.5Operation Work Schedule

Day/Time 9:00- 10:00- 11:00- 12:00- 13:00- 12:00-

10:00 11:00 12:00 13:00 14:00 13:00
Monday Op. Op. Start work Lunch Lunch work
P.Start
Tuesday Op. Op. Start work Lunch Lunch work
P.Start
Wednesda Op. Op. Start work Lunch Lunch work
y P.Start
Thursday Op. Op. Start work Lunch Lunch work
P.Start
Friday Op. Op. Start work Lunch Lunch work
P.Start
Saturday Op. Op. Start work Lunch Lunch work
P.Start
Sunday OFF DAY OFF DAY OFF DAY OFF OFF OFF
DAY DAY DAY
Day/Time 13:00- 14:00- 15:00- 16:00- 17:00- 18:00-
14:00 15:00 16:00 17:00 18:00 19:00
Monday work work work Op. Stop - -
Tuesday work work work Op. Stop - -
Wednesda work work work Op. Stop - -
y
Thursday work work work Op. Stop - -
Friday work work work Op. Stop - -
Saturday work work work Op. Stop - -
Sunday OFF DAY OFF DAY OFF DAY OFF - -
DAY

Legend: Op. P.start- Operation Pre-Start (Start of the day)

Op. Start - Operation Start
Op.Stop - Operation Stop (End of the day)

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1.6 List of Machinery

Machimery Total Unit price Total Price Maintenanc Company

quantity e cost (per Supplier
month)
Conveyor 10 nos 1592/nos RM159200 RM5000 Hairise
belt
machine
Fork Lift 1 nos RM53000/n Rm53000 RM200 Toyota
os Industrial
Equipment
Assembly 20nos RM500/nos RM10000 RM100 Pelican
and work
tools

Description:

Conveyor belt machine: To keep the assembly line moving and minimize any delay
in the line.

Fork lift: To assist packaging and loading of the product

Assembly and work tools: Tools to assembe the parts