Faculty of Engineering – Cairo University

Mechanical Design and Production Engineering

Two Semesters System – 4th Year

MDP 406 – Plant Engineering and Maintenance

Assignment (1)
Fabrication Shop Example

Submitted To

Dr.Sief A.Y. Khorshid

Prepared by B.N

Mahmoud Ahmed El-Sayed Kassab 28

April 11, 2021

 Process Analysis Steps

1- Input material calculations

a. Horizontal Angle ×2
b. Inclined Angle ×2
c. Back Strip ×1
d. Saddle ×1
e. Blade ×1
f. Arc welding rods
g. Paint

2- Sequence of operations
a. Cut to size
b. Drill
c. Tacking to dimensions
d. Weld tacked frames
e. Clean weld defects
f. Clean surfaces
g. Paint frames
h. Frame paint drying

3- Machines to perform operations.

a. Cutting machine
b. Drilling machine
c. Welding machine
d. Hand grinding
e. Paint machine Dim in mm materials : st-37

4- Layout of Fabrication shop

a. Shaded and open areas
b. Proposed work center layout
c. Material flow
d. Temporary and fixed stores
 Product section Inputs
Per 1 piece
L-Angle L50×50×5: 6m = 2 pcs×2112 +1776mm
L-Angle: [Horizontal and inclined angles]
2 pcs * 0.405+2 pcs * 0.651=2.112m
20mm sheet: 1m= 5 pcs ×200 + 0mm
20 mm sheet: [Blade]
25 mm strip: 6m= 8pcs ×674 + 608mm
1 pcs*0.2= 0.2 m

25 mm strip: Pipe thickness 10mm ⌀324mm: 5m= 133pcs ×37.5 + 12.5mm

1 pcs*0.674= 0.674 m

Pipe thickness 10mm ⌀324mm:[saddle]

¼ pcs*0.15=.0375m

Per Lot
L-Angle: [Horizontal and inclined angles]
250/2= 125bar
=125×6×3.77=2827.5kg

20 mm sheet: [Blade]
250/5= 50 sheet
=50×1×24=1200kg

25 mm strip:
250/8= 31.25=32 strip
=32×6×24=4608kg

Pipe thickness 10mm ⌀324mm:[saddle]

250/133= 1.88=2 pipe
=2×5×41.3=413kg

Waste Analysis

L-Angle: [Horizontal and inclined angles]

waste/bar= 1.776m
=1.776*125=222m
=222*3.77=836.94kg

20 mm sheet: [Blade]
waste/sheet= 0m

25 mm strip:
waste/strip= .608m
=.608*31.25=19m
=19*24=456kg

Pipe thickness 10mm ⌀324mm:[saddle]

waste/pipe= .0125m
=2*.0125*41.3=1kg
 Weld rods for product
1- Weld seam
Length= s1+s2+s3+s4
50*4+200*4+200*2+50*4=1600mm
Total welds = 250*1.6=400m

2- Weld section
Fillet weld 7*7 mm
Weld area =.5*7*7=24.5mm^2

3- Weld mass
Weld vol=400*24.5/1000
=9.8 liters
Weld mass=9.8*7.85
=76.93kg
Weld bars=76.93*250/200=96kg
=100kg
=20 boxes * 5kg/box

Product paint materials

L-Angle surface=.05*4*4*(0.651+0.405)
=.8448m^2

20 mm sheet surface=2*.2*.15=.06m^2

25 mm strip surface=2*(.025*.12+.674*.025+
.674*.12)=.2m^2

Pipe thickness 10mm ⌀324mm surface=

.25*3.14*.324*.15=.038m^2

Total /pc =.8448+.06+.2+.038=1.1428m^2

Volume /pc=1.1428*.1=.11428 lit/pc

Total volume=.11428*250=28.57lit
Waste volume=.1*28.57=2.857lit
Supplied volume=28.57+2.857=31.427lit
Supplied mass=.9*31.427=28.28kg
=29kg
=5 cans *5kg + 4 cans *1kg
Required machines and tools

1-Cutting machines and tools Abrasive Cutting machine

Power 2.2KW
Speed 4200 rpm
Rate 220 m^3/sec

Protection googles

Protection gloves
 2- Drilling machine

Drilling machine
Power .55KW
Spindle Speed 2550 rpm

3-Welding machine and tools

Welding machine
Power rate 12KW
Max weld Amp 160 amps
 Electrode holder

Welding table

Weld clamp

Welding shield

Welding gloves
Weld cleaning brushes
4-Hand grinding and tools

Hand Grinding machine

cleaning brushes

5-Paint machine

Painting machine
Power 2HP
Max pressure 8bar
Tank volume 50litr
Manual painting tools
Key
WRd: Weld Rods C: Cutting
Angl: L- Angle D: Driling
Sht: 20mm Sheet M: Mixing
Sp: 25mm Strip T: Tacking
Pip: Pipe W: Welding
Pnt: Paint CL: Cleaning
P: Painting
Key
MS: Material Store
CT: Cutting machine
DR: Drilling machine
TK: Tacking table
AS: Assembly table
GW: Grinding wheel
Pnt: Painting table
FP: Final product store
Summary of plant machines and tools:
Items Qty Description
1- Cutting off abrasive machine 1/each PS= 2.2KW - 4200 rpm
2- Protection googles
3- Protection gloves
1- Drilling machine 1/each PS= .55KW - 2550 rpm
2- Protection googles
3- Protection gloves
1- Welding transformer 2/each PS =12KW- 100-160 amps
2- Electrode holder
3- Welding shield
4- Welding gloves
5- Weld cleaning brushes
1- Welding table 2/each
4/each
2- Weld clamp
1- Hand grinding machine 2/each PS= .6KW - 1100 rpm
2- Protection googles
3- Cleaning brushes
1- Painting machine 2/each PS= 2HP - P= 8bar
2- Paint brush
3- Cleaning cloth
 Summary of input materials:
Item Qty Input material Waste material
Horizontal and inclined angles 125 bar Wt= 2827.5 kg Wt= 836.94 kg

Blade 50 sheet Wt= 1200 kg Wt= 0 kg

Strip 32 strip Wt= 4608 kg Wt= 456 kg
Pipe 2 pipe Wt= 413 kg Wt= 1 kg
Weld rods 3000 rod Wt= 100 kg Wt= 4 kg
Protective coat 5 cans (5kg/can) + Wt= 25.71 kg Wt= 3.29 kg
4 cans (1kg/can)

Total weight of final product = 9174.21kg =9.2 ton

Manpower:
Job function No.of Work time
8hr/day shift
Transportation, loading & unloading materials and products 2 21 days
(Normal Worker)
Cutoff machine operator (Semi-skilled Worker) 1 7 days
Drilling machine operator (Semi-skilled Worker) 1 7 days
Weld machine operator (Highly skilled Worker) 2 14 days
Cleaning machine operator (Normal Worker) 1 14 days
Painting operator (Semi-skilled Worker) 1 14 days

Transportation:
Vehicles 1.5 ton pick up 4 tons truck
Payload 1.5 tons 4 tons
Curb weight 1.2 Tons 1.60Tons
G.V.W 2.70Tons 5.60 Tons
Power 110HP 130 HP
Wheel base 2300 mm 2545 mm
Wheel Track 1410 mm 1435 mm
Length 4020 mm 4515 mm
Width 1850 mm 1900 mm
Height 1700 mm 1750 mm
*So we need 2 trips using (4 tons truck) [8ton] and 1 trip using (1.5 ton pick up) [1.5ton] So total 9.5ton payload
Purchasing Plan:
1- All material (bars & sheets & strips) will be bought before beginning the work by 7 days at least
2- 50% of the welding and painting materials can be bought 7 days before the beginning
of the work and the other 50% at the first working day. (assuming that it takes 7 days to
be delivered).
Cost analysis

1-material cost
a- Strip and sheet metal st-37 cost 40Egp/kg total cost = 40*(1200+4608)=232,320Egp
b- L-angles st-37 cost 10.5Egp/kg total cost = 10.5*(2827.5)=29,688Egp
c- Pipes st-37 cost 42Egp/kg total cost = 42*(413)=17,346Egp
d- Weld rods cost 125Egp/box(150rod) total cost = 125*(20)=2,500Egp
e- Protective coating cost 75Egp/litre total cost=75*29*1.11=2,414Egp
*total material direct and indirect cost =284,268Egp

2-Labor cost
a- Normal Worker total cost = 2*21*8*20+1*14*8*20=8,960Egp
b- Semi-skilled Worker total cost = 2*7*8*40+1*14*8*40=8,960Egp
c- Highly-skilled Worker total cost = 2*14*8*60=13,440Egp
*total Labor cost =31,360Egp

3- Transportation cost
Distance from 6th October industrial area to EL-Hawamdia= 55km which in normal traffic
takes 1.5 hr

a- 4 ton truck total cost =2*2*1.5*400=2,400Egp

b- 1.5 ton pickup total cost =1*2*1.5*200=600Egp
*total Transportation cost =3,000Egp

Estimated total cost of commissioning =284,268+31,360+3,000=318,628Egp + energy cost