FACILITY DESIGN ASSIGNMENT 2022-2023 (EVENING CLASS)

Figure 1. Toolbox (front)

Cover

tray end

hinge
hinge
Body end
catch

Tray bracket

Figure 2.a. Exploded Drawing of Toolbox

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Figure 2.b. Exploded Drawing of Toolbox

Table 1. Part List dari Toolbox

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 Figure 3. Make or Buy Decision

Table 1. Route Sheet

1. Body (3) (350 gr)
No Process Name Machine Processing Time Reject
(min)
(%)
1 Cut to the width Strip shear 0,039 1
2 Cut to the length Chop shear 0,046 1
3 Punch catch four holes Punch press 0,083 2
4 Form two legs Press brake 0,114 2
2. Body Ends (1) (150 gr)
No Process Name Machine Processing Time Reject
(min)
(%)

1 Cut to the width Strip shear 0,029 1

2 Cut to the length Chop shear 0,057 1
3 Punch hinge holes Punch press 0,065 2
4 Form three sides Press brake 0,091 2

3. Tray Bracket (2) (40 gr)

No Process Name Machine Processing Time Reject
(min) (%)

1 Cut to the width Strip shear 0,02 1

2 Cut to the length Chop shear 0,039 1
3 Form Press brake 0,064 2

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4. Cover (5) (200 gr)
No Process Name Machine Processing Time Reject
(min) (%)

1 Cut to the width Strip shear 0,031 1

2 Cut to the length Chop shear 0,041 1
3 Punch eight holes for hinge and clip Punch press 0,071 2
4 Form two sides Press brake 0,102 2

5. Cover End (4) (60)

No Process Name Machine Processing Time Reject
(min) (%)

1 Cut to the width Strip shear 0,026 1

2 Cut to the length Chop shear 0,051 1
3 Punch for hinge holes Punch press 0,062 2
4 Form three sides Press brake 0,088 2

6. Tray Body (7) (300 gr)

No Process Name Machine Processing Time Reject
(min)
(%)
1 Cut to the width Strip shear 0.029 1
2 Cut to the length Chop shear 0.038 1
3 Form two sides Press brake 0.095 2

7. Tray Ends (8) (80 gr)

No Process Name Machine Processing Time Reject
(min)
(%)
1 Cut to the width Strip shear 0,024 1
2 Cut to the length Chop shear 0,044 1
3 Form Press brake 0,086 2

8. Tray Handle (9) (70 gr)

No Process Name Machine Waktu Proses (mnt) Reject
(%)
1 Form handle Roll former 0,144 2

9. Hinge (17) (75 gr)

No Process Name Machine Waktu Proses (mnt) Reject
(%)
1 Cut to the size Chop shear 0,07 1

10. Divider (22) (50 gr)

No Process Name Machine Waktu Proses (mnt) Reject
(%)
1 Cut to the size Chop shear 0,02 2
2 Hang on overhead conveyor 0,07 0
3 Paint Oven AUTO 0
4 Release from hanger 0,07 0
5 Bag loose parts (name tag, divider, Assembly 3 0,35 0
registration, packing list and plastic
Bag) (SA3)

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Tray Assembly (SA2)
No Process Name Machine Processing Time Reject
(min)
(%)
1 Weld tray ends to tray body and add Spot weld 0,415 1
handle,
2 Hang on overhead conveyor
3 Clean, paint, and bake Oven AUTO

Assembly of Body End (SSSA1)

No Process Name Machine Processing Time Reject
(min)
(%)
1 Assemble and spot/weld two tray Spot weld 0,306 1
brackets with two body ends

Body Assemby (SSA1)

No Process Name Machine Processing Time Reject
(min)
(%)
1 Weld body end (SSSA1) to body Spot weld 0,291 1

Cover Assembly (SSA2)

No Nama Proses Nama Mesin Processing Time Reject
(min)
(%)
1 Weld two cover ends to cover body Spot weld 0,26 1

Final Assembly of Toolbox

No Process Name Machine Processing Time Reject
(mnt)
(%)
1 Weld hinge to Body Assemby (SSA1), Spot weld 0,356 1
weld Cover Assembly (SSA2) to hinge,
and hang on overhead conveyor
2 Paint Oven Auto 1
3 Rivet handle (11) and clips (12) to Assembly 1 0,31 1
Cover
4 Rivet two cathces (14) to cover two Assembly 1 0,555 1
strikes (15) to body
5 Rivet two hinges to body and cover Assembly 1 0,25 1

6 Pack parts bag (SA3), tray (SA2) into Assembly 2 0,5 0

toolbox and close. Form carton (25)
and pack toolbox with tape 24” (24)

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 Table 2. Machine Dimensions
No Machine L x W (ft)
1 Chop shear 4x3
2 Strip shear 12 x 3
3 Press brake 6x4
4 Punch press 4x4
5 Oven 25 x 20
6 Roll former 6x4

Table 3. Part Weight per unit)

No Nama Part Weight
(gr)
1 Body 350
2 Body Ends 150
3 Tray brackets 40
4 Hinge 75
5 Cover 200
6 Cover Ends 60
7 Tray 300
8 Tray Ends 80
9 Handle 70
10 Divider 50
11 Packing list, Name plate, bag 10
12 Handle, clips, rivets 100
13 Catch, strike, rivets 75
14 Hinge,Rivets 20
15 Bage, cartoon, tape, pack out 10