`

PART NO. Front Axle Bracket ( 4 WD)

DRG NO. 10070752 AC
LOT SIZE 150 Nos.
No. Of Mach. time
Cutting
Feed Feed RPM DIA LOC passes/
Operation speed
Machin Usage stroke TH PR
S. No. Tool used
Description e Used /tips

Met/min mm / rev mm/min mm mm Nos' min min

1 Rough Milling Makino Cutter 6 180 0.7 501.3 716 80 2000 4.00 15.96

2 Drilling Makino Drill 2 60 0.2 224.7 1123 17 50 4 0.89

3 Drilling Makino Drill 2 60 0.2 272.8 1364 14 50 18 3.299

5 Drilling Makino Drill 2 60 0.2 238.7 1194 16 50 2 0.419

5 Drilling Makino Drill 2 60 0.2 246.4 1232 15.5 50 2 0.406

6 Drilling Makino Drill 2 50 0.15 353.6 2358 6.75 50 1 0.141

7 Chamfer Makino Counter 4 20 0.3 76.38 255 25 3 30 1.178

8 Tapping Makino Tap 7 1.25 348.1 278 8 80 1 0.23

9 Hole Milling Makino Holemill 5 25 0.3 142.9 476 16.7 50 2 0.7

10 Reaming Makino Reamer 5 25 0.3 140.4 468 17 50 2 0.712

11 Tapping Makino Tap 7 2.5 309.4 124 18 80 4 1.034

12 Tapping Makino Tap 7 2 278.5 139 16 80 18 5.171

12 Makino Setting, Inspection & Loading-Unloading Time

13 Rough Milling Mazak Cutter 8 180 0.7 401 573 100 2000 3 14.96

14 Drilling Mazak Drill 2 60 0.2 347.2 1736 11 20 2 0.115

15 Drilling Mazak Drill 2 60 0.15 424.4 2829 6.75 20 22 1.037

16 Drilling Mazak Drill 2 60 0.2 381.9 1910 10 25 3 0.196

17 Counter Mazak Endmill 4 60 0.4 424.4 1061 18 30 6 0.424

18 Drilling Mazak Drill 2 60 0.15 337 2247 8.5 25 2 0.148

19 Tapping Mazak Tap 7 1.25 348.1 278 8 40 22 2.528

20 Fnish Milling Mazak Cutter 8 180 0.6 343.7 573 100 2000 1 5.819

21 Drilling Mazak Drill 2 60 0.2 218.2 1091 17.5 80 4 1.466

22 Chamfer Mazak Counter 4 20 0.3 76.38 255 25 2 11 0.288

23 Tapping Mazak Tap 7 2.5 278.5 111 20 120 4 1.724

24 Drilling Mazak Drill 2 60 0.2 318.3 1591 12 20 4 0.251

25 Tapping Mazak Tap 7 2 318.3 159 14 40 4 0.503

26 Counter Mazak Endmill 4 60 0.4 424.4 1061 18 30 12 0.848

26 Mazak Setting, Inspection & Loading-Unloading Time

 Total time
Hand. Setting Concd Total
time time . Time. Time Total
TH PR Rate
Cost
min min min min min min

3.5 19.46 475 154.05

0.7 1.59 475 12.59

1.5 4.80 475 37.99

0.6 1.02 475 8.07

0.6 1.01 475 7.96

0.8 0.94 475 7.45

1 2.18 475 17.24

0.8 1.03 475 8.15

0.6 1.30 475 10.29

0.6 1.31 475 10.39

0.8 1.83 475 14.52

1.5 6.67 475 52.81

5.00 475 39.58

48.14 381.11

1 15.96 1050 279.33

0.4 0.52 1050 9.02

1.2 2.24 1050 39.15

0.6 0.80 1050 13.94

0.5 0.92 1050 16.17

0.5 0.65 1050 11.35

1.3 3.83 1050 66.99

0.4 6.42 1050 112.32

0.8 2.27 1050 39.66

0.6 0.89 1050 15.54

0.8 2.52 1050 44.16

0.8 1.05 1050 18.40

0.6 1.10 1050 19.30

1 1.85 1050 32.35

5.00 1050 87.50

46.01 805.17
 TOTAL PROCESS SHEET

Ref.No.CS109- 1 of 2 Rev. No. 0 Date : 25/09/2012

Component: Front Axle Bracket Drawing No.

Customer International Tractors Ltd. Material

Part No 10071461 AA

1 Set Up ( Makino) 2nd Set up (M

S. No. Process Tool Type Time Remarks S. No. Process

1 Facing Dia 80 Milling Cutter 9.20 1 R/Facing
2 Drilling Dia 14 Drill Carbide 3.30 2 F/Facing
3 Drilling Dia 16 Drill Carbide 1.05 3 R/Milling
4 Drilling Dia 17 Drill Carbide 1.75 4 F/Milling
5 Drilling Dia 15.5 Drill Carbide 1.65 5 Drilling
6 Drilling Dia 6.8 Drill Carbide 1.00 6 Drilling
7 Chamfering Dia 25 Chamfer Tool 2.75 7 Drilling
8 Reaming Dia 17 Rimmer Carbide 2.75 8 Chamfering
9 Drilling Dia 37 U Drill 2.35 9 Taping
10 S/F Boaring DIA 39.7 BORING BAR 2.50 10 Taping
11 F/Boaring Dia 40 Boaring Bar 4.50 11
12 Taping M16 X 2 Tap 4.15
13 Taping M18X 2.5 Tap 1.65
14 Taping M8 X 1.25 1.00
15 Setting Time 5.00
44.60
1050.00
Total Cost 780.50
1528.63
Casting

2nd Set up (Mazak)

Tool Type Time

Dia 100 Face Mill Cutter 14.00
Dia 100 Face Mill Cutter 4.00
Dia 80 Cutter 5.50
Dia 40 End Mill 5.25
Dia 18 End Mill 1.25
Dia 6.8 Drill Carbide 1.00
Dia 8.5 Drill Carbide 1.00
Dia 25 X 90 Counter Shenk 2.00
M8 X 1.25 Tap 2.50
M10 X 1.5 Tap 1.25
Setting Time 5.00

2 nd Set up Total Time 42.75

Machine Hour Rate 1050.00
Total Cost 748.125
 `
PART NO. Casing Rear Axle D RH
DRG NO. D10229370 A
LOT SIZE 50 Nos.
No. Of Mach. time
Cutting
Feed Feed RPM DIA LOC passes/
Operation speed
Machin Usage stroke TH PR
S. No. Tool used
Description e Used /tips

Met/min mm / rev mm/min mm mm Nos' min min

1 Drilling VMC Drill 2 70 0.2 342.8 1714 13 23 12 0.805

2 Drilling VMC Drill 2 70 0.2 469 2345 9.5 23 2 0.098

3 Chamfer VMC Counter 4 60 0.3 229.2 764 25 3 20 0.262

4 Tapping VMC Tap 7 1.75 324.9 186 12 23 2 0.142

5 Hole Milling VMC Holemill 5 20 0.3 194.9 650 9.8 23 2 0.236

6 Reaming VMC Reamer 5 20 0.3 191 637 10 23 2 0.241

7 Drilling VMC Drill 2 70 0.2 469 2345 9.5 23 2 0.098

8 VMC Setting, Inspection & Loading-Unloading Time

13 Rough Milling Mazak Cutter 5 180 1 909.3 909 63 2000 3 6.598

14 Drilling Mazak Drill 2 60 0.2 347.2 1736 11 20 2 0.115

15 Drilling Mazak Drill 2 60 0.15 424.4 2829 6.75 20 22 1.037

16 Drilling Mazak Drill 2 60 0.2 381.9 1910 10 25 3 0.196

17 Counter Mazak Endmill 4 60 0.4 424.4 1061 18 30 6 0.424

18 Drilling Mazak Drill 2 60 0.15 337 2247 8.5 25 2 0.148

19 Tapping Mazak Tap 7 1.25 348.1 278 8 40 22 2.528

20 Fnish Milling Mazak Cutter 8 180 0.6 343.7 573 100 2000 1 5.819

21 Drilling Mazak Drill 2 60 0.2 218.2 1091 17.5 80 4 1.466

22 Chamfer Mazak Counter 4 20 0.3 76.38 255 25 2 11 0.288

23 Tapping Mazak Tap 7 2.5 278.5 111 20 120 4 1.724

24 Drilling Mazak Drill 2 60 0.2 318.3 1591 12 20 4 0.251

25 Tapping Mazak Tap 7 2 318.3 159 14 40 4 0.503

26 Counter Mazak Endmill 4 60 0.4 424.4 1061 18 30 12 0.848

26 Mazak Setting, Inspection & Loading-Unloading Time

 Total time
Hand. Setting Concd Total
time time . Time. Time Total
TH PR Rate
Cost
min min min min min min

0.7 1.51 475 11.92

0.7 0.80 475 6.32

1 1.26 0 0.00

0.8 0.94 475 7.45

0.6 0.84 475 6.62

0.6 0.84 475 6.66

0.8 0.90 475 7.11

5.00 475 39.58

12.08 85.66

1 7.60 475 60.15

0.4 0.52 1050 9.02

1.2 2.24 1050 39.15

0.6 0.80 1050 13.94

0.5 0.92 1050 16.17

0.5 0.65 1050 11.35

1.3 3.83 1050 66.99

0.4 6.42 1050 112.32

0.8 2.27 1050 39.66

0.6 0.89 1050 15.54

0.8 2.52 1050 44.16

0.8 1.05 1050 18.40

0.6 1.10 1050 19.30

1 1.85 1050 32.35

5.00 1050 87.50

37.65 585.99
 PART NO. Casing Rear Axle D RH
DRG NO.
LOT SIZE
No. Of Mach. time
Cutting
Feed Feed RPM DIA LOC passes/
Operation speed
Machin Usage stroke TH PR
S. No. Tool used
Description e Used /tips

Met/min mm / rev mm/min mm mm Nos' min min

1 Turning Rough CNC Turning 1 200 0.4 391.7 979 65 195 1 0.498

2 Turning Rough CNC Turning 1 200 0.2 195.9 979 65 125 1 0.638

3 Finish Turning CNC Turning 1 200 0.2 195.9 979 65 195 1 0.996

8 VMC Setting, Inspection & Loading-Unloading Time

13 Rough Milling Mazak Cutter 5 180 1 909.3 909 63 2000 3 6.598

14 Drilling Mazak Drill 2 60 0.2 347.2 1736 11 20 2 0.115

15 Drilling Mazak Drill 2 60 0.15 424.4 2829 6.75 20 22 1.037

16 Drilling Mazak Drill 2 60 0.2 381.9 1910 10 25 3 0.196

17 Counter Mazak Endmill 4 60 0.4 424.4 1061 18 30 6 0.424

18 Drilling Mazak Drill 2 60 0.15 337 2247 8.5 25 2 0.148

19 Tapping Mazak Tap 7 1.25 348.1 278 8 40 22 2.528

20 Fnish Milling Mazak Cutter 8 180 0.6 343.7 573 100 2000 1 5.819

21 Drilling Mazak Drill 2 60 0.2 218.2 1091 17.5 80 4 1.466

22 Chamfer Mazak Counter 4 20 0.3 76.38 255 25 2 11 0.288

23 Tapping Mazak Tap 7 2.5 278.5 111 20 120 4 1.724

24 Drilling Mazak Drill 2 60 0.2 318.3 1591 12 20 4 0.251

25 Tapping Mazak Tap 7 2 318.3 159 14 40 4 0.503

26 Counter Mazak Endmill 4 60 0.4 424.4 1061 18 30 12 0.848

26 Mazak Setting, Inspection & Loading-Unloading Time

 Total time
Hand. Setting Concd Total
time time . Time. Time Total
TH PR Rate
Cost
min min min min min min

0.7 1.20 300 5.99

0.7 1.34 300 6.69

0.7 1.70 300 8.48

5.00 475 39.58

9.23 60.74

1 7.60 475 60.15

0.4 0.52 1050 9.02

1.2 2.24 1050 39.15

0.6 0.80 1050 13.94

0.5 0.92 1050 16.17

0.5 0.65 1050 11.35

1.3 3.83 1050 66.99

0.4 6.42 1050 112.32

0.8 2.27 1050 39.66

0.6 0.89 1050 15.54

0.8 2.52 1050 44.16

0.8 1.05 1050 18.40

0.6 1.10 1050 19.30

1 1.85 1050 32.35

5.00 1050 87.50

37.65 585.99
 PART NO. Front Axle Bracket
DRG NO. 10090792 FB
LOT SIZE
No. Of Mach. time
Cutting
Feed Feed RPM DIA LOC passes/
Operation Machine Usage speed stroke TH PR
S. No. Tool used
Description Used /tips
Met/min mm / rev mm/min mm mm Nos' min min

1 Milling Mazak Cutter 8 180 0.6 343.7 573 100 900 2 5.237
2 Drilling Mazak Drill 2 60 0.2 198.9 995 19.2 30 6 0.905
3 Chf 1x45 Mazak Drill 2 60 0.2 173.6 868 22 1 6 0.035
4 Drilling 17.8 Mazak Drill 2 60 0.15 160.9 1073 17.8 14 2 0.174
5 Chf 1x45 Mazak Drill 2 60 0.2 191 955 20 1 2 0.01
6 Reaming 18 Makino Reamer 5 25 0.3 132.6 442 18 14 2 0.211
7 Milling Mazak Cutter 8 180 0.6 343.7 573 100 820 2 4.771
8 Drilling 13.5 Mazak Drill 2 60 0.2 282.9 1415 13.5 50 5 0.884
9 Chf 1x45 Mazak Drill 2 60 0.2 238.7 1194 16 2 5 0.042
10 Tapping M16 Mazak Tap 4 7 2 278.5 139 16 45 5 0.808
11 Drilling 12 Mazak Drill 2 60 0.2 318.3 1591 12 55 2 0.346
12 Chf 1x45 Mazak Drill 2 60 0.2 272.8 1364 14 2 2 0.015
13 Tapping M14 Mazak Tap 4 7 2 318.3 159 14 50 2 0.314
14 Milling Mazak Cutter 8 180 0.6 343.7 573 100 820 2 4.771
15 Drilling 13.5 Mazak Drill 2 60 0.2 282.9 1415 13.5 50 5 0.884
16 Chf 1x45 Mazak Drill 2 60 0.2 238.7 1194 16 2 5 0.042
17 Tapping M16 Mazak Tap 4 7 2.5 348.1 139 16 45 5 0.646
18 Drilling 12 Mazak Drill 2 60 0.2 318.3 1591 12 55 2 0.346
19 Chf 1x45 Mazak Drill 2 60 0.2 272.8 1364 14 2 2 0.015
20 Tapping M14 Mazak Tap 4 7 2 318.3 159 14 50 2 0.314
21 Milling Mazak Cutter 8 180 0.6 343.7 573 100 690 2 4.015
22 Drilling 15.5 Mazak Drill 2 60 0.2 246.4 1232 15.5 45 4 0.731
23 Chf 1x45 Mazak Drill 2 60 0.2 212.2 1061 18 2.5 4 0.047
24 Tapping M18 Mazak Tap 4 7 2.5 309.4 124 18 45 4 0.582
25 Mazak Setting, Inspection & Loading-Unloading Time

No. Of Mach. time

Cutting
Feed Feed RPM DIA LOC passes/
Operation Machine Usage speed stroke TH PR
S. No. Tool used
Description Used /tips
Met/min mm / rev mm/min mm mm Nos' min min

1 Milling Mazak Cutter 8 180 0.6 343.7 573 100 1504 2 8.751
2 Drilling 6.5 Mazak Drill 2 60 0.2 587.6 2938 6.5 12 23 0.47
3 Chf 1x45 Mazak Drill 2 60 0.2 477.4 2387 8 1 23 0.048
4 Tapping Mazak Tap 7 1.25 348.1 278 8 12 23 0.793
5 Drilling 8.5 Mazak Drill 2 60 0.15 337 2247 8.5 12 4 0.142
6 Chf 1x45 Mazak Drill 2 60 0.2 381.9 1910 10 1 4 0.01
7 Tapping Mazak Tap 7 1.5 334.2 223 10 12 4 0.144
8 Milling Mazak Cutter 8 180 0.6 343.7 573 100 320 2 1.862
9 Milling Mazak Cutter 8 180 0.6 343.7 573 100 320 2 1.862
10 Holemill 29.8 Mazak Holemill 4 60 0.4 256.3 641 29.8 8.6 4 0.134
11 Chf 1x45 Mazak Counter 4 60 0.2 119.4 597 32 1 4 0.034
12 Reaming 30 Makino Reamer 5 25 0.1 26.52 265 30 8.6 4 1.297
13 Drilling 17.5 Mazak Drill 2 60 0.2 218.2 1091 17.5 55 4 1.008
14 Chf 1x45 Mazak Drill 2 60 0.2 191 955 20 2 4 0.042
15 Tapping Mazak Tap 7 2.5 278.5 111 20 50 4 0.718
16 Setting, Inspection & Loading-Unloading Time
 Total time
Hand. Setting
time time TH PR Total
Rate
Cost
min min min min

0.5 5.74 1100 105.17

0.3 1.20 1100 22.09
0.3 0.33 1100 6.13
0.3 0.47 1100 8.69
0.3 0.31 1100 5.69
0.3 0.51 1100 9.37
0.5 5.27 1100 96.64
0.3 1.18 1100 21.70
0.3 0.34 1100 6.27
0.3 1.11 1100 20.31
0.3 0.65 1100 11.84
0.3 0.31 1100 5.77
0.3 0.61 1100 11.26
0.5 5.27 1100 96.64
0.3 1.18 1100 21.70
0.3 0.34 1100 6.27
0.3 0.95 1100 17.35
0.3 0.65 1100 11.84
0.3 0.31 1100 5.77
0.3 0.61 1100 11.26
0.5 4.51 1100 82.77
0.3 1.03 1100 18.89
0.3 0.35 1100 6.36
0.3 0.88 1100 16.16
g-Unloading Time 5.00 1100 91.67
39.14 717.62

Hand. Setting Total time

time time TH PR Total
Rate
Cost
min min min min

0.5 9.25 1100 169.60

0.3 0.77 1100 14.11
0.3 0.35 1100 6.38
0.3 1.09 1050 19.13
0.3 0.44 1100 8.11
0.3 0.31 1100 5.69
0.3 0.44 1050 7.76
0.5 2.36 1100 43.30
0.5 2.36 1100 43.30
0.3 0.43 1100 7.96
 0.3 0.33 1100 6.11
0.3 1.60 1100 29.28
0.3 1.31 1100 23.98
0.3 0.34 1100 6.27
0.3 1.02 1100 18.67
g-Unloading Time 5.00 1100 91.67

27.42 501.33

Total 66.56 Rs. 1218.95

 EMMBROS AUTOMOTIVE PVT. LTD.
COST ESTIMATION
CUSTOMER - ITL
PART NAME Front Axle Bracket
PART NO. ( Casting ) NA
Sr.No Description / Item PART NO. ( MACHINING ) 10090792 FB
BLANK NO. NA
01 Material FG260
02 Finish weight ( Finish Part After Machining ) ( Kg )
10 Srcap genrated (Kg) after mc

11 Srcap Rate / Kg. (Rs )

12 Value of Total Srcap
14 Machining Process Cost 1248.95
18 Packing ( Individual or Bulk ) Detail attached 10.00
19 Overheads @ 10% of process cost 124.89
20 Profit @ 20% of process cost 249.79
21 Freight @ Rs. 3/Kg on Finish wt 120.00

TOTAL COST ( Finish Part ) / Pc 1753.63

TOOLING COST One Time 50 % Advance & 50 % at the 0.00
time of sample approval ( DIE + GAUGES )
MACHINING COST
M/C HOUR
OPN.NO. OPERATION MACHINE M/C TIME
RATE
010 Machining Process Cost CNC TURNING 66.56
070 MARKING PIN MARKING 125
090 FINAL INSPECTION INSPECTION

Total Process Cost

These rate are included freight
Front Axle Bracket
NA
10090792 FB
NA
FG260

1248.95
10.00
124.89
249.79
120.00

1753.63
0.00

M/C COST
1218.95

30.00
1248.95