MFG 240 - Manufacturing Design Final Project Scope of Project You must develop a manufacturing plan to machine the part to the final dimensions. The company is a small company of about 30 workers currently. Product Design You will design 1 tensile test bar using the following diagram Develop a part print WITH tolerancing for this part Material Cost The raw material will be a material you specify. It will come as 1 diameter bar stock at a length you specify Labor Cost The labor cost for your plant is $15 per hour for all employees, except maintenance personnel, which cost $22 per hour. Volume Your manufacturing facility must provide 200,000 of the tensile test specimens The equipment will be a stand alone cell or line. No other parts will flow though this area at this time. Operational Plan The facility is scheduled to operate 250 days per year and run two 8 ½ hour shifts per day. The workers must be given 30 minutes for lunch and two 15-minute breaks. The product life cycle is expected to be 5 years or more. Reports Reports must be written using a word processor and spreadsheet when appropriate. All drawings must be completed using CAD. 1) Title Page 2) Table of Contents 3) Executive Summary 4) A written report detailing the manufacturing plan. The individual manufacturing deliverables must support all information presented in the manufacturing plan summary. i) Part prints (components plus assembly) ii) Initial investment required and projected cost per part iii) Conclusions, Recommendations 5) Manufacturing Plan Deliverables including all supporting data Manufacturing Plan Deliverables TAKT Time Calculations - TAKT is a German word for pace. TAKT time is the rate at which your customer requires the product. TAKT time defines the manufacturing line speed and the cycle time for the manufacturing operations. TAKT time is computed as: Available work time per day / Daily required demand (parts/day) Design Cycle Time Calculations – Design cycle time is the cycle time at which you design your manufacturing operations after considering contractual breaks, setup time, planned maintenance, estimated downtime, reject rates, etc. All of the items above reduce your actual work time available per day and reduce the required cycle time. Each team must also consider the reject produced by the system and increase the required production to offset the loss. The team must report the manufacturing cells planned operational availability. Operational availability is the Planned operating time /Available work time. Process Plan Block Diagram – After reviewing the product prints, develop a process plan block diagram that represents the product flow through the various machines and processes. Include equipment, material handling, material flow, quality checks, repair loops, etc.. Equipment Sequence of Operations and Balance Chart – Develop a detailed step-by-step sequence of operations for each process or piece of equipme ...

1. MFG 240 - Manufacturing Design
Final Project
Scope of Project
You must develop a manufacturing plan to machine the part to
the final dimensions. The company is a small company of about
30 workers currently.
Product Design
You will design 1 tensile test bar using the following diagram
Develop a part print WITH tolerancing for this part
Material Cost
The raw material will be a material you specify. It will come as
1 diameter bar stock at a length you specify
Labor Cost
The labor cost for your plant is $15 per hour for all employees,
except maintenance personnel, which cost $22 per hour.
Volume
Your manufacturing facility must provide 200,000 of the tensile
test specimens
The equipment will be a stand alone cell or line. No other parts
will flow though this area at this time.
Operational Plan
The facility is scheduled to operate 250 days per year and run
two 8 ½ hour shifts per day. The workers must be given 30

2. minutes for lunch and two 15-minute breaks. The product life
cycle is expected to be 5 years or more.
Reports
Reports must be written using a word processor and spreadsheet
when appropriate. All drawings must be completed using CAD.
1) Title Page
2) Table of Contents
3) Executive Summary
4) A written report detailing the manufacturing plan. The
individual manufacturing deliverables must support all
information presented in the manufacturing plan summary.
i) Part prints (components plus assembly)
ii) Initial investment required and projected cost per part
iii) Conclusions, Recommendations
5) Manufacturing Plan Deliverables including all supporting
data
Manufacturing Plan Deliverables
TAKT Time Calculations - TAKT is a German word for pace.
TAKT time is the rate at which your customer requires the
product. TAKT time defines the manufacturing line speed and
the cycle time for the manufacturing operations. TAKT time is
computed as:
Available work time per day / Daily required demand
(parts/day)

3. Design Cycle Time Calculations – Design cycle time is the
cycle time at which you design your manufacturing operations
after considering contractual breaks, setup time, planned
maintenance, estimated downtime, reject rates, etc. All of the
items above reduce your actual work time available per day and
reduce the required cycle time. Each team must also consider
the reject produced by the system and increase the required
production to offset the loss. The team must report the
manufacturing cells planned operational availability.
Operational availability is the Planned operating time
/Available work time.
Process Plan Block Diagram – After reviewing the product
prints, develop a process plan block diagram that represents the
product flow through the various machines and processes.
Include equipment, material handling, material flow, quality
checks, repair loops, etc..
Equipment Sequence of Operations and Balance Chart –
Develop a detailed step-by-step sequence of operations for each
process or piece of equipment. Calculate the time required for
each cut or step in the process. This document is required to
determine if the operation can produce parts at the required rate.
Do not forget to include operator load and unload times. When
the sequence-of-operation charts are complete, use a graph to
compare the cycle time of each process against the design cycle
time for the line. The line should be balanced without any
process above or well below the design cycle time of the line.
Tooling – A list of all cutting tools with holders must be
specified. Also include speeds and feeds. Be specific
Fixture – A fixture concept must be specified. This does not
have to be drawn
Machining Equipment Specifications – Select the actual
machines required to produce the parts including manufacture
and model number. Make sure the machines can meet the

4. required horsepower, federates, and spindle speeds to make the
cuts. Investigate the standard work holding device, turret and
spindle supplied with the machine and make sure the selected
tooling will mate appropriately. Consider the following factors:
tool change time, MCU manufacturer, machine work envelope,
machine footprint, cost, HP, etc…. Also specify the required
chip removal system. Include any sales information you deem
helpful on why you made your choice.
Cost Estimate – Develop a detailed cost estimate of the initial
investment required to purchase and install the manufacturing
cell. Then determine the approximate unit cost of the product
based on your manufacturing cell design. Include the following
items in your calculations:
a) Direct Material Cost – Include the initial purchase price of
each component ($/unit).
b) Direct Labor Cost – Calculate the total labor cost per shift
divided by the number of parts produced per shift ($/unit).
c) Burden Rate – The manufacturing facility has a burden rate
of 250%. The burden rate includes such items as employee
benefits, taxes, insurance, etc… Multiple the direct labor cost
per unit (item b) by the burden rate to determine the burden rate
cost per piece ($/unit).
d) Depreciation Cost – Use straight-line depreciation to
determine the impact of the initial investment. Assume the
usable life of the equipment is 5 years with a salvage value of
15% at the end of the life span. Divide the initial cost minus
the salvage value by five to determine the depreciation cost per
year. Divide the annual depreciation cost by the annual volume
to determine the cost per piece ($/unit)
e) Add all of the above items together to determine the

5. estimated unit cost of the product.
Research Theory, Design, and Methods Walden University
© 2016 Laureate Education, Inc. Page 1 of 2
Purpose Statement Checklist
Use the following criteria to evaluate an author’s purpose
statement.
Look for indications of the following:
• Does the statement begin with signaling words?
• Does the statement identify the research approach
(quantitative,
qualitative, or mixed)?
• Does the statement clearly state the intent of the study?
• Does the statement mention the participants?
• Does the statement mention the research site?
• Is the statement framed in a way that is consistent with the
identified
problem?
If the study is qualitative, does the purpose statement do as
follows?
• Focus on a single phenomenon

6. • Use an action verb to convey how learning will take place
• Use neutral, nondirectional language
• Provide a general definition of the central phenomenon
If the study is quantitative, does the purpose statement do as
follows?
• Identify the variables under study
• Provide a general definition of each key variable
• Use words that connect the variables
• Identify a theory
If the study is mixed methods, does the purpose statement do as
follows?
• Discuss the reason(s) for mixing both quantitative and
qualitative data
• Include the characteristics of a good qualitative purpose
statement (as
listed above)
Research Theory, Design, and Methods Walden University
© 2016 Laureate Education, Inc. Page 2 of 2
• Include the characteristics of a good quantitative purpose
statement (as

7. listed above)
• Indicate the specific method of collecting both quantitative
and qualitative
data
2
Table of Contents
1. Executive
Summary………………………………………………………………
…….....1
2.
Scope…………………………………………………………………
…………………....1
3.
Deliverables…………………………………………………………
………………….....2
a. TAKT Time
Calculations…………………………………………………………2
b. Design Cycle Time
Calculations………………………………………………….3
c. Process Plan Block
Diagram……………………………………………………...4
d. Equipment Sequence of Operation and Balance
Chart…………………………...4
e.
Fixture…………………………………………………………………
……….....5
f. Machining Equipment
Specifications…………………………………………….6
g. Material Handling, Containerization and Scheduling Plan
……………………...7
h. Quality

8. Plan…………………………………………………………………...
…9
i. Manufacturing Cell
Layout………………………………………………………10
j. Cost
Estimate………………………………………………………………
…….11
4.
Conclusion……………………………………………………………
………………….11
5.
References……………………………………………………………
………………….12
1.
2. Executive Summary
Tensile bar specimen, also known as “dog bone”, is a
standardized cross-section used to in tensile testing to
determine the tension of the material. The tensile bar has two
shoulders to mate the grips in various machines. Tensile bars

9. have different shapes, typically round or square.
The project is to produce round tensile bars that come in round
bar stock in 1 inch diameter x 12 foot length. This project will
focus on the tooling and the machining. It will also include a
part design, a layout design, a cost estimate, a potential failure
mode effect analysis, cycle time calculations, and cost estimate
analysis.
The part is to be produced at the lowest cost possible with high
standards and high quality. Quality plans and techniques will be
used in order to assure that the part will meet the criteria of our
client.
Material handling equipment will be used including storage
racks, fork-lifts, conveyers, horizontal carousels, and waste
containers. These equipment will assure high flow-efficiency.
The project is also to calculate the TAKT time and the design
cycle time. Time standards and time studies are used to
calculate the total cycle time a part takes to be produced from
raw material to a finish product.
3. Scope
The scope of this project includes designing a facility that can
efficiently run three main operation, facing, turning, and
threading the tensile bar specimen. The plant will not have any
tensile bar testing machines. The scope is only machining down
the bar stock to the required material and inspecting the
finished parts. Moreover, we are to design the tensile bar to
demanded dimension, and specify tolerances.
4. Deliverables
a. TAKT Time Calculations
TAKT Time is the first element to be delivered. In order to

10. calculate the TAKT Time we first need to find the available
time per work day. The available time per is calculated by
multiplying the number of workers available per day by the
operating hours. The annual demand of tensile bars is 200,000
units per year. The available time is calculated as the following:
Available Time= (2 shifts/day) (8.5 hours/shift-1 hour
break/shift) (30 workers per day) = 450 hours/day
Therefore, the amount of available hours per day is 450 hours.
Daily Demand = (200,000 parts/year) / (250 working days/year)
= 800 parts/day
TAKT Time= (450 hours/day) / (800 parts/day) = 0.56
hours/part → 33.75 min/part
b. Design Cycle Time Calculations
The cycle time includes many factors such as the machining
time, setup time, handling time. From previous courses,
Personal, Fatigue and Delay (PFD) are times that reduce the
cycle time used in most manufacturing plants.
Starting with machining time, the part needs three main
operations to be produced. Facing both ends, reducing the
radius, and threading the two ends of the tensile bar specimen.
Using the formula below, the machining times are calculated in
the table following it.
tm= LπD / 12fV
L= Ld + Ls
Operation Time Calculations

11. Element
Dimension
Depth of Cut
Length of Cut, Ld
Safety Stock, Ls
Length L
Diameter D
Velocity, V, fpm
feed,
f, (ipr)
Minutes, tm
1. Face Ends
1.000
1.000
0.200
1/32
0.231
1.000
120
0.007

12. 0.072
2. Rough turn (Entire Part)
1.000
0.125
7.000
1/32
7.031
1.000
160
0.015
0.767
3. Finish turn (Entire Part)
0.875
0.125
7.000
1/32
7.031
0.875
160
0.007
1.438
4. Rough Turn (Middle)
0.750
0.125
2.000
1/32
2.031
0.750
160
0.015
0.166
5. Finish turn (Middle)
0.625
0.125
2.000
1/32

13. 2.031
0.625
160
0.007
0.297
6. Thread End 1
0.750
0.125
1.500
1/32
1.531
0.750
160
0.007
0.268
7. Thread End 2
0.750
0.125
1.500
1/32
1.531
0.750
160
0.007
0.268
Subtotal of machining times
3.009

14. · Machining Time: the machining time per part is 3.009.
· Setup and Handling Time: setup and handling time is
estimated to be 3.5 hours/shift → (7 hr/day) / (800 parts/day) =
5.25 min/part
· PFD: Including downtimes of machines, under delays, PFD are
estimated to be 12% of available time = 12% of 450 hours = 54
hours/ day → (54hrs *60 min)/ (200,000 parts/day)= .0162 min/
part
· Maintenance: 40 hours per day = (4 hours * 60 min)/(200,000
parts/day)= .012 min per part
· Quality Check is estimated to take 0.6 min/part
· Packaging : 0.2 min/part
Total Cycle Time per part = 3.009 min + 5.25 min + 0.0162 min
+ 0.012 min + 0.6 min + 0.2 = 9.0872 min per part
c. Process Plan Block Diagram
i.
d. Equipment Sequence of Operation and Balance Chart
i.
ii.
When comparing the actual time to the calculated TAKT time,

15. we find that the actual time is a lot less than the TAKT time.
This means that at the current production rate with this
available time, the plant will be able to produce 200,000 tensile
bar specimens annually.
In the graph i, the total calculated TAKT time is divided by the
number of elements and compared to each actual element. Graph
ii shows the total actual time compared to the total TAKT time.
e. Fixture
i. The fixture used to produce the tensile bar specimens is a
turning fixture. The reason this type of fixture is selected is
because the tensile bar is a round one. All operation can be done
using the turning fixture including facing, turning, and
threading. An adjustable fixture is to be used in order to
accommodate the dimensions of the tensile bar specimen.
f. Machining Equipment Specifications
In order to calculate the horsepower required to perform the
proper machining operations, the following equation is to be
used:
Using this equation, the following table demonstrates the hp
required for each machine.
No.
Operation
Ft (lbf)
V (ft/min)
HP
1
Facing
115
120
0.42

16. 2
Rough Turn
65
160
0.32
3
Finish Turn
65
160
0.32
4
Rough Turn
65
160
0.32
5
Finish Turn
65
160
0.32
6
Threading End 1
65
160
0.32
7
Threading End 2
65
160
0.32
The equipment to be used is a lathe machine from Alibaba with
a HP of 2.
Height of center

17. 8"
Distance between centers
40"
Spindle bore
2"
Spindle nose
D1-5
Spindle drive motor
2 hp
overall pkg
760/840 kg
Model Number
CQ6240
g. Material Handling, Containerization and Scheduling Plan
The plant will have four main material handling equipment in
order to ensure the highest efficiency and material flow.
1.
Stacking racks: to be used for storing bar stock once the raw
material arrives at the manufacturing plant in the receiving/
storage department.
2.
Conveyer belts: this material handling equipment is very
efficient in delivering materials from one station to another. For
our particular plant design and requirements, the conveyer belts
are designed to have dividers and edges in order to prevent the
round material from falling off the belt as it is moving.
3.
Defects and scrap container: this material handling equipment is
needed at every station to contain the waste chips produced
from machining every tensile bar. Such container will also be at
the inspection department in order to dispose the defective
parts. The container will have wheels to be easily moved
outside of the manufacturing plant and properly dispose the

18. material.
4.
Horizontal carousel: this equipment is a storage equipment. For
our plant, the carousels will be placed in the shipping
department. Their design will consist of movable racks that can
carry the packaged boxes of the finished and inspected parts
that are ready to be shipped.
5.
Fork-lift: Fork-lifts will be present at the receiving and
shipping departments. Their duty is to transport material
between the delivery trucks and the plant area.
h. Quality Plan
Tools:
1. GO/NO-GO gauge in a form of a nut to assure that the
dimensions of the threads meet the criteria
2. Venier Calipers to measure the overall length and the length
of the threaded part of the tensile bar specimen
3. Brinell hardness testing machine to measure the hardness of
the material before it leaves the manufacturing plant
i. Manufacturing Cell Layout

19. j. Cost Estimate
Total Cost Per Part
$45.83
5. Conclusion
In conclusion, the determined cost is $45.83 per tensile bar
specimen. The layout of the plant is designed in a U-shape with
a conveyer that goes through each department from receiving to
shipping. Material handling equipment are used to assure flow
efficiency and time saving. TAKT time is calculated to 33.75
min/part which is less than the design cycle time, 9.1 min/part.
The process plan is simply (receiving/storage, loading, facing,
turning reduced section, turning shoulders, threading,
inspection, packaging, and finally packaging/storage). The
machines are selected based on the horsepower required. Tools
along with feeds and speeds where also selected, they were also
used in determining the design cycle time.

20. 6. Refrences
a. Tompkins, James A., and John A. White. Facilities Planning.
New York: Wiley, 1984. Print.
b. Ostwald, Fillip F., and Timothy S. McLaren, PhD. Cost
Analysis and Estimating for Engineering and Management. N.p.:
Prentice Hall, 2003. Print.
Balance Chart
Actual Time Setup and Handling Face EndsRough Turn
(Entire Part) Finish Turn (Entire Part) Rough Turn (Middle)
Finish Turn (Middle) Thread End 1 Thread End 2
Maintenance PFD Quality Check Packaging5.25
7.1999999999999995E-2 0.76700000000000002
1.4379999999999999 0.16600000000000001
0.29699999999999999 0.26800000000000002
0.26800000000000002 1.2E-2
1.6199999999999999E-2 0.6 0.2 TAKT Time Setup
and Handling Face EndsRough Turn (Entire Part) Finish Turn
(Entire Part) Rough Turn (Middle) Finish Turn (Middle)
Thread End 1 Thread End 2 Maintenance PFD Quality
Check Packaging2.8125 2.8125 2.8125 2.8125
2.8125 2.8125 2.8125 2.8125 2.8125 2.8125
2.8125 2.8125
Element
Time (Min)

21. Total Actual Time TAKT Time 9.3542000000000005
33.75