DESCRIPTION OF THE PROCESS OF MANUFACTURING THE BALL HAMMER

DESCRIPTION OF THE PROCESS OF MANUFACTURING THE BALL HAMMER

The process begins with the arrival of 6-foot-long unpolished carbon steel bars, which are sent to the raw material warehouse after order verification. The bars are shipped from the raw material warehouse to each of the manufacturing cells in batches of 14 bars per pallet in a hydraulic skate to complete 100 bars a day.

The roadmaps of the machining process of the 3 parts in the corresponding cells are shown, the times shown are standard and per piece.

Table 1 of consumption of the first semester of the year of the hammer ball

2014    2015 2016 2017

Raw Material ($ / bar)	$619.95	$619.39	$619.88	$623.50
Machinery ($/hr)	$248.49	$258.63	$264.14	$273.01
labor ($/hr)	$13.52	$13.48	$13.47	$13.50
Energy ($/kWh)	$0.0588	$0.0589	$0.0583	$0.0668
Production of the 1st semester	24,000	20,500	20,500	22,000
Sale price	$1418.60	$1425.73	$1427.16	$1432.60
Total hours worked per year	9,600	9,600	10,560	9,600
KWh per year	7,920	7,920	8,712	7,920
Pieces per Steel bar	3	3	3	3
Total workers	7	7	7	7

Road map 1

Company:	MARTINILLO S.A de C.V.	Made by:
	Name of the part:	Plug	Part number	10A
Product:	Hammer ball	Date:	30/Agosto/2017
Operation number	Operation Description	Machine tipe	Departament	Standard time (min)
1	Verify measures	Bank	Machining – C1	0.5
2	Face extremes	Lathe	Machining – C1	2
3	Open center at one end	Lathe	Machining – C1	1
4	Roll	Lathe	Machining – C1	4
5	Machining bevel	Lathe	Machining – C1	0.5
6	Mechanize radio	Lathe	Machining – C1	2
7	Drill hole	drill	Machining – C1	3
8	Mecanize thread	Lathe	Machining – C1	3
9	roll	Lathe	Machining – C1	1
10	Mecanize radio	Lathe	Machining – C1	3
11	Perform the knurling	Lathe	Machining – C1	2
12	Rectifiy measure and polish	Bank	Machining – C1	1

The operator carries out the verification and rectification of the piece in the inspection bench that is at a distance of 2 steps from the lathe (1.08 min). The drill and the bench are at the same distance from 2 steps. The finished pieces are sent to the assembly line in batches of 50 units).

Company:	MARTINILLO S.A de C.V.	Made by:	Ing. Ríos
	Name of the part:	Mango	Part number	20B
Product:	Hammer ball	Date:	30/Agosto/2017
Operation number	Operation description	Machine type	Departament	Standard time (min)
1	Verify measures	Bank	Machining- C2	0.5
2	Face extremes	Lathe	Machining – C2	3
3	Open center at one end	Lathe	Machining – C2	1
4	roll	Lathe	Machining – C2	10
5	Machining bevel	Lathe	Machining – C2	0.5
6	Perform knurling	Lathe	Machining – C2	3
7	Drill hole	drill	Machining – C2	6
8	Machining bevel	Lathe	Machining – C2	0.5
9	Machining thread	Lathe	Machining – C2	5
10	Roll	Lathe	Machining – C2	2
11	Roll	Lathe	Machining – C2	2
12	Machining bevel	Lathe	Machining – C2	0.5
13	Machining cone	Lathe	Machining – C2	5
14	Machining thread	Lathe	Machining – C2	4
15	Rectify measures and polish	Bank	Machining – C2	2

The operator carries out the verification and rectification of the piece in the inspection bench that is at a distance of 2 steps from the lathe (1.08 min). The drill and the bench are at the same distance from 2 steps. The finished pieces are sent to the assembly line in batches of 50 units).

Roadmap 3

Company:	MARTINILLO S.A de C.V.	Made by:	Ing. Ríos
	Name of the part:	Double head	Part number	30C
Product:	Hammer ball	Date:	30/Agosto/2017

Operation number	Operation description	Machine type	Departament	Standard time (min)
1	Verify measures	Bank	Machining – C3	0.5
2	Face extremes	Lathe	Machining – C3	2.5
3	Roll	Lathe	Machining – C3	2
4	Mechanize radios	Lathe	Machining – C3	5
5	Mechanize bisel	Lathe	Machining – C3	0.5
6	Roll	Lathe	Machining – C3	1
7	Mechanize radio	Lathe	Machining – C3	2
8	drill hole	Milling machine	Machining – C3	4
9	Mechanize hole	Milling machine	Machining – C3	3
10	Mechanize thread	Lathe	Machining – C3	4
11	Rectify measures and polish	Bank	Machining – C3	1

The operator carries out the verification and rectification of the piece in the inspection bench that is at a distance of 2 steps from the lathe (1.08 min). The drill and the bench are at the same distance from 2 steps. The finished pieces are sent to the assembly line in batches of 50 units). The milling machine is two steps away from the bench and two steps away from the lathe. The pieces (lot of 50 units) that leave cell 3 are sent to the assembly line.

The assembly process begins when the handle (piece 20B and the double head (piece 30C) are finished.) Both pieces arrive at the assembly line from the department from the corresponding cell in batches of 50 pieces. the handle to form the subassembly 40 (3 min) subsequently the plug (piece 10A) is assembled in the subassembly 40 (1.5 min) finally inspected (1 min) and packed individually (2 min) and then in batches of 10 hammers (20 sec per hammer).

The assembly line is divided into 4 stations, the number of operators assigned is to cover the volume of 22,000 hammers a semester, working shifts of 8 hours a day, 25 days a month. The plant supervisor has been able to quantify that the workers lose an average of 10 minutes a day in the change of shift, in addition to the 30 minutes they are given to eat. Table 2 shows information about the assembly line:

Table 2: Assembly line stations

Station Labor Standard time (min) Number of operators

1	Assemble the double head in the handle to form a subassembly 40	3	1
2	Assemble the plug in subassembly 40	1.5	1
3	Inspect and pack individually	3	1
4	Pack lot of 10 hammers	3.33	1
	Total	10.83	4

A) Determine the possibility of reducing processing times and increasing production by coupling more machines to each operator of the manufacturing cells.
How many more machines could the worker operate? What would be the benefits in terms of cycle time and parts produced? Is it possible to increase machines from the economic point of view? (Diagrams man machine of each cell, cycle time, number of pieces, maximum number of machines that can attend, besides answering the analysis questions).

B) If the company wants to increase its production for the second semester of the year to 200 hammers, what would be the changes that would occur in the assembly line? (Operators, cycle time, efficiency). From the point of view of productivity what would be the percentage change for this second semester? It agrees or not to do the increase in the production. (Line balancing, cycle time, efficiency, number of operators)