lecture 12 - IED Lecture 12 Class Goals For your Team...

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Unformatted text preview: IED Lecture 12 Class Goals For your Team Project Evaluate systems concepts using a Decision Analysis Matrix Costing a Project Develop a Project Plan IED Present your Project Plan Next class Team Project Plans Laptop presentations need to be setup quickly or use transparencies Speak loudly and clearly Questions to be asked at end IED Present your Project Plan 20 minutes per team 5 minutes for questions and comments IED Evaluate systems concepts Critical to get Team consensus May need to run quick tests May need to estimate and calculate When in doubt, ask for assistance from Instructor ! IED Cost Estimation for Manufacturing In practice, the manufacturing costs can kill a design In IED manufacturing costs are less critical Need to keep them in mind, but IED is to learn basics of Design IED Cost Categories Component Standard (ex. switches, motors, nuts and bolts) Custom Raw Materials (ex. sheet steel, plastic pellets) Processing (ex. stamping, injection molding) Tooling (ex. punches, molds) IED Cost Categories Assembly Labor Equipment and Tooling (ex. fixtures) Overhead IED Support (ex. material handling, quality assurance) Indirect Allocation (ex. security, maintenance) Product Complexity Depending on product complexity and manufacturing process control, one may need to test every item and recycle bad ones IED Keep things simple !! Product Inspection Required IED Cost Estimating Assumptions (1) A guideline for estimating manufacturing cost: Assume manufacturing cost is approximately one half to one third of the purchase price IED Cost Estimating Assumptions (2) Some rough distributions of costs to assume for your product: 1. Raw Materials and Purchased Parts: 50 to 60 % of manufacturing cost 2. Direct Factory Labor: 10 to 15% of total manufacturing cost 3. Manufacturing Overhead: 2 to 3 times the direct factory labor IED Cost Estimating Assumptions (3) For raw materials, find the weight (in lbs) of the product and multiply by the following $/lb: 1. Common Steel: $0.35/lb 2. Stainless Steel: $1.50/lb 3. Aluminum: $3.00/lb 4. Titanium: $4.50/lb 5. Copper: $4.00/lb 6. Polycarbonate and ABS: $3.00/lb 7. Polystyrene and Polypropylene: $.50/lb 8. Rubber: $25/lb 9. Fiberglass: $4.00/lb IED Project Planning A good plan is an asset Most likely revised weekly An OK plan is better than no plan ! IED Overview of Project Planning Identify & Analyze Deliverables Identify Associated Activities Identify & Estimate Resources Needed Develop a Schedule IED Identify & Analyze Deliverables Identify major deliverables Decompose them to manageable components Review Did we miss anything? IED Create an Activity List Identify all activities that must be performed to the deliverables identified in the previous step Decompose a task to a set of subtasks as needed Review IED Did we miss anything? Can we eliminate any unnecessary tasks? Example - Part of a Task List Prepare a user manual Design the cover Write a Chapter 1- Introduction Write the text Get screen shots A, B, and C IED Write a Chapter N Proofread the entire manual Print and bind x copies Identify & Estimate Resources Resources Anything that is assigned to an activity/task or required to complete an activity/task Examples Time, money, people, equipment, and material IED For each task, identify required resources and their availability Create new tasks as needed Example: Procure material Availability Consideration Examples Time: Holidays; Other courses People: Skills Equipment/Facility: a fabrication equipment taken by another team when you need it Material: Out of stock IED Problems & Possible Solutions Lack of skills in the team Allocate time for learning the new skills Select another solution that does not require the skills Material is not available Find another supplier Use another material You may have to redesign. IED Equipment is not available Reschedule the task Negotiate Use another tool Scheduling Overview Determine sequences of the tasks and assign resources Determine calendar dates & create preliminary schedule Adjust resources and schedule Review and distribute IED Determine sequences of tasks Example User Manual Preparation Assumption: 1 writer, 1 artist, & 1 print shop A total duration: 11 working days Design a Cover 2d Write Chapter 1 1d Write Chapter 2 4d Write Chapter 3 2d Proofread 2d Print & Bind 2d Gantt Chart for User Manual Preparation 8/29 8/30 8/31 9/1 9/2 9/3 9/4 9/5 9/6 9/7 9/8 9/9 Write Chapter 1 Write Chapter 2 Write Chapter 3 Proofread Design a cover Print & Bind IED Task Float Latest Start to Latest Finish Summary Did we miss any deadlines? Is anyone over loaded? Is the schedule realistic? For IED, sooner is always better than later ! IED ...
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