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Document No.
MIE-QMS WP-14-10
Issue no.02
Page:
of
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit % of compl. per station/ shop % of completion per total
S/no
Sub-Open. name
(level-5)
Task description
Produ. cost
1 2
Cutting procedure on 16 03.01.01.01 mm thickness Cutting procedure on 12 03.01.01.02 mm thickness Cutting procedure on 10 03.01.01.03 mm thickness Cutting procedure on 8 03.01.01.04 mm thickness Cutting procedure on 6 03.01.01.05 mm thickness
03.01.01.01.01 King Pin Plate 03.01.01.01.02 Bottom Reinforcement 03.01.01.01.03 Web plate
1500x1130x16
2950x230x12
12390x420x10
3 4
Document No.
MIE-QMS WP-14-10
Issue no.02
Page:
of
Station: Rectification & Grinding Station Code:-03.01.02 % of completion per station/ shop
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost
S/no
Sub-Open. Name
(level-5)
Task description
1 2 3 4 5
03.01.01.02.01 King Pin Plate 03.01.01.02.02 Bottom Reinforcement Recificaion & Grinding 03.01.01.02.03 Web plate 03.01.01.02.04 Landing Plate Cover Plate 03.01.01.02.05 drainge) (Water
2950x230x12
12390x420x10
2
2
370x370x8 1130x848x6
Document No.
MIE-QMS WP-14-10 Issue Page: of no.02
Form No:-WF/PIT/060 Station: Big Shearing Machine Station Code:-03.01.03 Cost Element( in Birr/hrs) Item dimension (LxWxT) Qty/unit (in pcs) Labor cost/unit Machine cost/unit Material cost/unit Production cost % of completion per station/ shop
S/no
Sub-Open. name
(level-5)
Task description
1 2 3
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
03.01.03.01
03.01.03.01.03 Rinfortcement plate-3 03.01.03.02.01 Vertical Reinforcement 03.01.03.02.02 Pocket 03.01.03.02.03 Pocket Cover 03.01.03.02.04 Reinforcement Plate 03.01.03.02.05 Cover plate 03.01.03.02.06
Triangular winch Support Plate
98x82x8
320x270x8 75x75x8
110x88x8
03.01.03.02.09 axle 03.01.03.02.10 Side plate for side board 03.01.03.02.11 Upper side board Protector 03.01.03.02.12 Lower side board Protector 03.01.03.02.13 Upper rear board Protector 03.01.03.02.14 Lower rear board Protector 03.01.03.02.15 Reinforcement plate-2
Connecting plate (Reserve
480x158x8
800x45x8 180x64x8 200x45x8
Document No.
MIE-QMS WP-14-10
Issue no.02
Page:
of
Station: Big Shearing Machine Station Code:-03.01.03 % of completion per station/ shop
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost
S/no
Sub-Open. name
(level-5)
Task description
20 21 22 23 24
03.01.03.04.01 03.01.03.04.02 03.01.03.04.03 03.01.03.04.04 03.01.03.04.05 03.01.03.04.06 03.01.03.04.07 03.01.03.04.08 03.01.03.04.09 03.01.03.04.10 03.01.03.04.11
Item-7 Connecting U-channel-1 Connecting U-channel-2 Connecting U-channel-3 Connecting U-channel-4 Vertical Support plate Reinforcement plate-4 Reinforcement plate-1 Landing gear support foot plate Top cover plate Triangular reinforcement
388x50x6 1402x246x6 668x136x6 458x136x6 886x246x6 202x135x6 224x60x6 200x200x6 540x200x6 219x205x6 162x94x6
2 1 2 2 1 4 4 2 4 2 4
Document No.
MIE-QMS WP-14-10
Issue no.02
Page:
of
Station: Big Shearing Machine Station Code:-03.01.03 % of completion per station/ shop
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost
S/no
Sub-Open. name
Task description External cross member at front External cross member at rear Reinforcement at corner of platform Front Stand Central stand Rear stand Side plate for rear board Connecting plate-2 (Reserve wheel carrier) Triangular reinforcement plate (Reserve wheel carrier) Side plate of front board Column Insert Support (Rear Fender)
31 32 33 34 35
03.01.03.05.01 03.01.03.05.02 03.01.03.05.03 03.01.03.05.04 03.01.03.05.05 03.01.03.05.06 03.01.03.05.07 03.01.03.05.08 03.01.03.05.09 03.01.03.05.10 03.01.03.05.11 03.01.03.05.12 Sub -Total
10 28 8 2
8
800x345x5
2 2 3 5 12 2
Document No.
MIE-QMS WP-14-10 Issue no.02
Form No:-WF/PIT/060
Page:
of
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost
S/no
Sub-Open. name
(level-5)
Task description
03.01.04.01.01 Front beam 03.01.04.01.02 Side Beam 03.01.04.01.03 Rear Beam 03.01.04.01.04 Internal cross member small 03.01.04.01.05 Internal cross member big
Internal cross member 03.01.04.01.06 reinforcement
2470x332x4
1 10 1 3 7 4 2 1 2 2
8
2476x325x4
2470x332x4
03.01.04.01
03.01.04.01.07 Side Omega 03.01.04.01.08 Central Omega 03.01.04.01.09 Front Stand seal 03.01.04.01.10 Front stand Cover plate 03.01.04.01.11 Central Stand seal 03.01.04.01.12 Central stand cover plate
150x50x4
Document No.
MIE-QMS WP-14-10 Issue no.02
Form No:-WF/PIT/060
Page:
of
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost
S/no
Sub-Open. name
(level-5)
Task description
03.01.04.01.13 Rear stand seal 03.01.04.01.14 Rear stand Cover plate 03.01.04.01.15 Cover plate (Insert) 03.01.04.01.16 Omega for front board 03.01.04.01.17 Rear Sheet 03.01.04.01.18 Side plate (Tool box) 03.01.04.01.19 Vertical part of bumper 03.01.04.01.20 Horizontal part of bumper
Cover plate for horizontal part 03.01.04.01.21 of bumper-1 Cover plate for horizontal part 03.01.04.01.22 of bumper-2 Reinforcement connecting 03.01.04.01.23 plate (bumper)
2 2 12 2
1 2 2 1 1 2 2
Document No.
MIE-QMS WP-14-10 Issue no.02
Form No:-WF/PIT/060
Page:
of
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost
S/no
Sub-Open. name
(level-5)
Task description Connecting bracket Chequer plate Spacer (Insert) Belt (Water tanker) Tool Box door Rear & Bottom Sheet Number plate holder Junction box support plate Front board sheet Upper & lower seal of front board seal Side board Sheet Upper & lower side board seal Rear board sheet Upper & Lower rear board seal Reserve fuel tanker Side & Bottom Sheeting Reserve fuel tanker Top Sheeting Reserve fuel tanker Front & Rear Sheeting Reserve fuel tanker Internal Panel Rear fender sheet Rear light holder
24 25 26 27 03.01.04.02 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
03.01.04.02.01 03.01.04.02.02 03.01.04.02.03 03.01.04.02.04 03.01.04.02.05 03.01.04.02.06 03.01.04.02.07 03.01.04.03.01 03.01.04.03.02 03.01.04.03.03 03.01.04.03.04 03.01.04.03.05 03.01.04.03.06
500x353x3
12300x2400x(3+2)
1 1 24
132x50x3
4 1 1 2
1
2428x946x2
2 2 10 20
2428x209x2
2261x1032x2 2261x226x2
2458x1020x2 2458x214x2
1931x1500x2 1500x228x2 800x346x2 798x344x2
1 2
1 1 2
03.01.04.03
842x760x2 600x425x2
2 2
Issue no.02
Page:
of
Station: Band Saw Machine Station Code:-03.01.05 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost % of completion per station/ shop % of completion per total
S/no
Sub-Open. name
Task description
1 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 Cutting of Uchannels
03.01.05.01.01 Twist lock support long 03.01.05.01.02 Twist lock support short 03.01.05.01.03 03.01.05.01.04 03.01.05.01.05 03.01.05.01.06 03.01.05.01.07 03.01.05.01.08 03.01.05.01.09 03.01.05.01.10 03.01.05.01.11 03.01.05.01.12 03.01.05.01.13 03.01.05.01.14 03.01.05.01.15 03.01.05.01.16 03.01.05.01.17 03.01.05.01.18 03.01.05.01.19
Reserve wheel support frame Item-2 (Reserve wheel carrier) Item-3 (Reserve wheel carrier) Item-4 (Reserve wheel carrier) Item-5(Reserve wheel carrier) Item-6(Reserve wheel carrier) Item-10(Reserve wheel carrier) Item-11(Reserve wheel carrier) Item-12(Reserve wheel carrier) Item-12' (Reserve wheel carrier) Item-13 (Reserve wheel carrier) Item-14 (Reserve wheel carrier) Horizontal support (Reserve wheel carrier) Vertical support-1 (Reserve wheel carrier) Vertical support-2 (Reserve wheel carrier) U-profile support cylinder) (Air
300x50x25x5 135x50x25x5
1931x60x30x5 1050x60x30x6 2000x60x30x6
16 8 4 2 2
1022x50x25x5 370x60x30x6 200x60x30x6 710x50x25x5 950x50x25x5 156x100x50x5 206x100x50x5 115x60x30x6 85x60x30x6 460x60x30x6 979x60x30x6 794x60x30x6 500x60x30x6 795x60x30x6
2 2 2 4 2 8 8 4 4 5 1 3 2 2
03.01.05.01
Document No.
MIE-QMS WP-14-10 Issue no.02
Form No:-WF/PIT/060
Page:
of
Station: Band Saw Machine Station Code:-03.01.05 % of completion per station/ shop
Tasks code (level-5) Item dimension (LxWxT) 845x100x60x4 Qty/unit (in pcs) 2
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost
S/no
Sub-Open. name
Task description
12 13 14 15 16 03.01.05.02
Cutting of RHS
2 2 2 2 2
4
03.01.05.03.01 Item-8 (Reserve wheel carrier) Dia. 24x350 03.01.05.03.02 Item-9 (Reserve wheel carrier) Dia. 20x269
Pin (Landing gear foot 03.01.05.03.03 support)
2 1
40x40x40x2
228x40x40x2
2 1
Cutting of pipe
40x40x40x2
Station: Power hacksaw Machine Station Code:-03.01.06 % of completion per station/ shop
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost
S/no
Sub-Open. name
Task description
03.01.06.01.01 Ring Fixing I-beam King pin reinforcement I03.01.06.01.02 beam (longe) King pin reinforcement I03.01.06.01.03 beam (Short)
886x190x200x6.5x10
740x160x160x8x13
436x160x160x8x13
740
912
56,103
57,755
22%
of
Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-03 Sub-Open. code-(level-4) Tasks code Item dimension (LxWxt) Qty/unit (in pcs) 2 Shop:Material preparation Shop Code:-03.01
Form No:-WF/PIT/060 Station: Big Bending Machine Station Code:-03.01.07 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost % of completion per station/ shop
S/no
Sub-Open. name
(level-5)
Task description
03.01.07.01
03.01.07.01.01 Lower plate External cross member 03.01.07.02.01 at front External cross member 03.01.07.02.02 at rear 03.01.07.02.03 Front stand 03.01.07.02.04 Central stand
12412x250x15
2 3 4 5 6 7 8 9 10 11
779x260x5 779x300x5
1200x345x5
800x294x5
10
28
03.01.07.02
800x345x5 400x188x5
12
03.01.07.02.07 Side plate for front board 1400x85x5 03.01.07.02.08 Side plate for rear board 03.01.07.02.09 Front beam 03.01.07.02.10 Rear beam 800x45x2 2470x332x4
2476x325x4
Station: Big Bending Machine Station Code:-03.01.07 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost % of completion per station/ shop
S/no
Sub-Open. name
(level-5)
Task description
12 13 14 15 16 17
03.01.07.02.11 Side beam 03.01.07.02.12 Side omega 03.01.07.02.13 Side omega 03.01.07.02.14 Side omega 03.01.07.02.15 Side omega 03.01.07.02.16 Side omega 03.01.07.02.17 Central omega short 03.01.07.02.18 Central omega long 03.01.07.02.19 Central omega long 03.01.07.02.20 Central omega long 03.01.07.02.21 Central omega long 03.01.07.02.22 Upper side board protector 03.01.07.02.23 Upper rear board protector
Station: Big Bending Machine Station Code:-03.01.07 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost % of completion per station/ shop
S/no
Sub-Open. name
(level-5)
Task description
25 03.01.07.03 26
27
28
2458x1020x2
2428x946x2
30
2261x1032x2
10
Station: Big Bending Machine Station Code:-03.01.07 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost % of completion per station/ shop
S/no
Sub-Open. name
(level-5)
Task description
32 32 33 33 34 34 35 35 36 36 37 37 38 03.01.07.05
03.01.07.05.01 Upper front board seal 03.01.07.05.02 Lower front board seal
2 2 2 10 10 2 1 1 1 2 1 2
03.01.07.05.03 Upper rear board seal 03.01.07.05.04 Lower rear board seal 03.01.07.05.05 Upper side board seal 03.01.07.05.06 Lower side board seal 03.01.07.05.07 Rere Fender sheet 03.01.07.05.08 Tool box door 03.01.07.05.09 Bottom & side Side & Bottom 03.01.07.05.10 2
1402x246x6 668x136x6
Station: Big Bending Machine Station Code:-03.01.07 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost % of completion per station/ shop
S/no
Sub-Open. name
(level-5)
Task description
39 40 41 42 03.01.07.05 43 44 45 46
Connecting U-channel-3 03.01.07.05.14 (Landing gear support) Connecting U-channel-4 gear support) Reinforcement plate-3 03.01.07.05.15 (Landing
(Landing gear foot support) plate-4 03.01.07.05.16 Reinforcement (Landing gear foot support) 03.01.07.05.17 Vertical Support Plate
(Landing gear foot support 03.01.07.05.18 plate) Reserve wheel support 03.01.07.05.19 frame
Front & rear sheet 03.01.07.05.20 (Reserve fuel tanker) 03.01.07.05.21 Fender Support
27.2%
Document No.
MIE-QMS WP-14-10
Issue no.02
Page:
of
Tasks code Item dimension (LxWxt) Qty/unit (in pcs) Labor cost/unit
Cost Element( in Birr/hrs) Machine cost/unit Material cost/unit Material cost/hrs Production cost % of completion per station/ shop
S/no
Sub-Open. name
(level-5)
Task description
1 2 3 03.01.04'.01 4
Notching
415x110x8 798x344x2
16 2
0.2
0.13 0.13
458x136x6 540x200x6
2 4
Document No.
MIE-QMS WP-14-10
Issue no.02
Page:
of
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material Cost/unit Production cost
S/no
Sub-Open. name
(level-5)
Task description
Work Break Down Structure for 3-Axle Dry cargo Semi-Trailer in Machine Shop
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 03.02.01.01 03.02.01.02 03.02.01.03 03.02.01.04 03.02.01.05 03.02.01.06 03.02.01.07 03.02.01.08
Gusset plate at front Connecting plate Horizontal part ram holder Air valve support Plate no support Rear light holder Connecting brackt (Landing gear support) Landing gear support Reinforcement plate-1 Belt (Aluminum tanker) Support Connecting plate-1 (Reserve fuel carrier) Connecting plate-2 (Reserve fuel carrier) Horizontal Supporting frame (Reserve fuel carrier) Item-6 (Reserve wheel carrier) Junction box support 100x60x10 100x60x5 460x60x30x6 200x60x30x6 418x150x2 714x319x10 540x200x6 200x200x6 1101x40x3
2 4 2 4
03.02.01
3 2 5 2 1
Document No.
MIE-QMS WP-14-10
Issue no.02
Page:
of
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material Cost/unit Production cost
S/no
Sub-Open. name
(level-5)
Task description
17 18 19 20
Item-8 (Reserve fuel tanker) Pin (Landing gear foot support) Bushing for landing gesr Suspension support reinforcement plate
03.02.02.01
Turning
Total Production cost of Drilling Turnning & Milling Processes (Birr) Total Production Cost of Material Preparation (Birr)
27.4% 27.4%
Document No.
MIE-QMS WP-14-10
Issue no.02
Page:
of
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost
S/no
Sub-Open. name
Task description
IV-Work Break Down Structure of 3-Axle Dry cargo Semi-Trailer in welding shop
1 2 3 4 5 03.03.01.01 6 03.03.01.01.06 7 03.03.01.01.07 8 03.03.01.01.08 9 03.03.01.01.09 Longutidinal Beam Tacking 03.03.01.01.01 03.03.01.01.02 03.03.01.01.03 03.03.01.01.04 03.03.01.01.05
Before you start tacking of longutidinal beam adjust the following parameters Ensur that the diameter of the elecroide is 3.2 mm
Adjust the current (150-170 A) Polish & Put upper plate properly on tackingclearance jig. Check and tack to the jig frame with 500mm gap and 70mm weld size.Finaly inspect the straightness. Put vertical plate on upper plate properly and tack it with 500mm gap and weld size of 70mm
12280x250x15
12390x420x10
Mount lower plate on vertical plate and tack it with 500mm gap and weld size of 70mm 12412x250x15 Ensure the diagonal measurements are correct & transfer to the next station
1,369
2,034
75,411
78,814
30.52%
Document No.
MIE-QMS WP-14-10 Issue no.02
Form No:-WF/PIT/060
Page:
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Station: Longutidunal Beam Welding Station Code:-03.03.02 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost % of completion per station/ shop % of completion per total
S/no
Sub-Open. name
Task description Before you start welding of longitudinal beam adjust the following parameters Ensur that the diameters of the elecroide is 1.2m Adjust the voltage (32-36 V) Adjust the current (220-350 A) Adjust the wire speed from 3 meter/minute up to 10 meter/minut Use shelding gas=co2 at a flow rate (12) litter/minut Inspect the quality of work the both visually & using measerment Mounting on welding jig and tightening firmly welding as per Final staggered shown in the drawing weld A1 & A1, B1 & B1, C1 & C1 and D1 & D1, E1 & E1 and F1 & F2 at the same time consequentively. Weld bottom reinforcement plate with longutidinal beam Unload the frame from jig after cooling for (30min-60 min). Ensure all things are right & transfer to the next station
2 3 4
03.03.02.01.05
03.03.02.01
7 8
9 10 12 13
2959x230x12
1,549
2,101
75,591
79,242
30.7%
mSFN x!NSTL x!n!NNG `.yt.yG.k#N Mesfin Industrial Engineering PLC Title of document:Procedure for Process planning
of
Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-03 Sub-Open. code-(level4) Tasks code (level-5) Item dimension (LxWxt) Qty/unit (in pcs) Shop:Welding Shop Shop Code:-03.03
Form No:-WF/PIT/060 Station: Frame Tacking Station Code:-03.03.03 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost % of completion per station/ shop % of completion per total
S/no
Sub-Open. name
Task description Before you start tacking of frame adjust the following parameters Ensur that the diameter of the welding wire is 1.2 mm Adjust the volttage ( 21-28V.) Adjust the current (127-291A) Adjust wire speed 2 meter/minut up to 8 meter/minut) Put two longitidunal beams on jig by maintaining parallel. Put Ring fixing I-beam on the same level & tack with longtidunal beam by maintaining less than 1mm clearance. Fix front vertical reinforcement Tack the front beam by firmly tighting to the frame by C-clamp to maintain levelness of top part of the beam with upper plate. Tack internal cross mebers 1. Internal cross members small 2. Internal cross members big 3. Internal cross members reinforcement
1 2 3 4
5 6 03.03.03.01 7 8
03.03.03.01.05 03.03.03.01.06
Frame tacking
03.03.03.01.07
886x190x200x6.5x102 415x110x8 16
9 10 11 12 13
03.03.03.01.08 03.03.03.01.09
2470x332x4
3 7 4
mSFN x!NSTL x!n!NNG `.yt.yG.k#N Mesfin Industrial Engineering PLC Title of document:Procedure for Process planning
of
Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-03 Sub-Open. code-(level4) Tasks code Item dimension (LxWxt) Qty/unit (in pcs) Shop:Welding Shop Shop Code:-03.03
Form No:-WF/PIT/060 Station: Frame Tacking Station Code:-03.03.03 Cost Element( in Birr/hrs) Labor cost/hrs Machine cost/unit Material cost/unit Production cost % of completion per station/ shop % of completion per total
S/no
Sub-Open. name
(level-5)
Task description
14 15 16 03.03.03.01 17 18
Tack side beams with the (frame) by mainting 03.03.03.01.13 parallelness of the beams
10 2476x325x5
Tack external cross 03.03.03.01.14 members 1. External cross members at front 779x260x5
10 28
Frame tacking
2. External cross members 779x300x5 03.03.03.01.15 at rear Inspect the quality of the work both visually & using measerment to avoid rework & reject
1819
2199
75663.2
79681
30.9%
Page:
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Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-03 Sub-Open. code-(level-4)
Shop Code:-03.03
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost
S/no
Sub-Open. name
Task description
1 2 3 4
Before you start welding of frame adjust the following parameters Ensure that the diameter of welding wire is 1.2mm.
Adjust the current (127-230A) Adjust wire speed (2 meter/minut up to 10meter /minute)
5 6 7 8 03.03.04.01
031.03.04.01.05
Frame Welding
Weld flat position of tacked items Tack & Weld ring fixing I-beam with frame Tack & Weld king pin reinforcement I-beam with frame (Long)
886x200x6.5x10
740x160x160x8x13 1
9 10 11
Tack & Weld king pin reinforcement I-beam with frame (Short)
436x160x160x8x13 2 1500x1130x6 1
Weld cover plate with pin on floor Tack & weld the cover plate with ring fixing I-beams
Page:
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Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-03 Sub-Open. code-(level-4) Tasks code Item dimension (LxWxt) Qty/unit (in pcs)
Shop Code:-03.03
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost
S/no
Sub-Open. name
(level-5)
Task description
03.03.04.01.01
1130x848x6 500x353x3
1 1
03.03.04.01.04 bracket
Tack & weld the reinforcement
98x82x8
17 18
03.03.04.01.06
Finally unload the frame from the jig and transferred to next 03.03.04.01.07 station
Standard Item
King pin
3 1/2" 1
2,022
2,272
83,231
87,524
33.9%
Page:
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Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-03 Sub-Open. code-(level-4)
Shop Code:-03.03
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost
S/no
Sub-Open. name
Task description Check that all the necessary parts are available
12 13 14 15 16
03.03.04'.01
03.03.04.01.01
1130x848x6 500x353x3
1 1
03.03.04.01.04 support
Assemble the landing gear to
98x82x8
Standard Item
Landing gear
24-25 ton 1
mSFN x!NSTL x!n!NNG `.yt.yG.k#N Mesfin Industrial Engineering PLC Title of document:Procedure for Process planning
Page:
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Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-03 Sub-Open. code(level-4) Shop:Welding Shop Shop Code:-03.03
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost
S/no
Sub-Open. name
(level-5)
Task description
03.03.05.01.01
Maker ready all parts 1. Side & Bottom sheet-1 2. Front & Rear sheet 3. Internal Pannels 2000x809x2 2000x925x2 494x434x2 1 1 2
2
3
4
5
03.03.05.01 6
7
Position & Tack internal 03.03.12.01.02 pannel & side partirtions Weld internal pannel & side
03.03.12.01.03 partirtions 03.03.12.01.04 Tack top, covet plates & side 03.03.12.01.05 Weld top, covet plates & side
Weld inlet Pipe & Discharge
8
9
mSFN x!NSTL x!n!NNG `.yt.yG.k#N Mesfin Industrial Engineering PLC Title of document:Procedure for Process planning
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Tasks code Sub-Open. name (level-5) Task description Item dimension (LxWxt) Qty/unit (in pcs)
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost
S/no
10 11 12 03.03.06.01 13
03.03.06.01.01 Mounting Axles on the axle jig 03.03.06.01.02 Mounting leaf spring 03.03.06.01.03 Inserting U-bolt
Axle Assembling
14
15
mSFN x!NSTL x!n!NNG `.yt.yG.k#N Mesfin Industrial Engineering PLC Title of document:Procedure for Process planning
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Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-03 Sub-Open. code-(level4) Tasks code Sub-Open. name (level-5) Task description
Shop Code:-03.03
S/no
2 3 03.03.06.02 4 5 6 7
Maintain parallity by taking measurement from reference axle cup 03.03.06.02.01 of Maintain equality by Measurement axially and diagonally from center of axle 03.03.06.02.02 cup. Mounting the frame on
Frame Mounting
Keep balance equally in both side with reference to axle cap 03.03.06.02.04 centers and tack welding. Welding guesset plate at rear
220x250x8
2 2 2
480x158x8 Assembling and welding of the 845x100x60x4 03.03.06.02.07 axle reinforcement Unloading from the jig to temporary stand with over head 03.03.06.02.08 crane.
Standard Item
Axle with suspension (Set) 1
4,110
2,931
176,439
183,479
71.1%
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Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Shop:Welding Shop
Shop Code:-03.03
Station Code:-03.03.07 Cost Element( in Birr/hrs) Item dimension (LxWxt) Qty/unit (in pcs) Labor cost/unit Machine cost/unit Material cost/unit Production cost % of completion per station/ shop
S/no
Sub-Open. name
Task description
1 2 3 4
Befor starting of tacking & 03.03.07.01.01 welding adjust the following parametrs
meter/minute
Tack board seal, side plates & angle iron Inspect the quality of the work
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Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-03 Sub-Open. code-(level4) Tasks code (level-5) Item dimension (LxWxt) Qty/unit (in pcs) Shop:Welding Shop Shop Code:-03.03
Station: Board Fabrication Station Code:-03.03.07 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost % of completion per station/ shop
S/no
Sub-Open. name
Task description
10 11 03.03.07.01
Rear Board tacking & welding
Mount the corrugated sheet on 03.03.07.01.01 perpendicularity check & rectify the bottom side Tack board seal ,side plates & 03.03.07.01.02 angle iron
03.03.07.01.03 12 13
Inspect the quality of the work both visually & using measurment to avoide rework & reject
14 15 03.03.07.01
Front Board tacking & welding
4,279
2,960
176,692
183,930
71.2%
mSFN x!NSTL x!n!NNG `.yt.yG.k#N Mesfin Industrial Engineering PLC Title of document:Procedure for Process planning
Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-03 Sub-Open. code-(level-4) Shop:Welding Shop Shop Code:-03.03 Form No:-WF/PIT/060
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost
S/no
Sub-Open. name
Task description
Befor you start tacking & welding activities adjust the following parameters
Adjust the current (105-190A)) Adjust wire speed from 0.5 meter/minute up to 4 meter/minute. Make ready all the parts 1. Insert 2. Cover plate 3. Spacer Tacking and welding insert 400x188x5 400x125x4 132x50x3 12 12 24
mSFN x!NSTL x!n!NNG `.yt.yG.k#N Mesfin Industrial Engineering PLC Title of document:Procedure for Process planning
Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-03 Sub-Open. code-(level-4) Shop:Welding Shop Shop Code:-03.03 Form No:-WF/PIT/060
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost
S/no
Sub-Open. name
Task description
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 03.03.09.01
03.03.09.01.01 03.03.09.01.02
Make ready all parts of front stand 1. Front stand 2. Front stand seal 3. Front stand Cover plate Tack & Weld all the parts Make ready all parts of central stand 1. Central stand 2. Central stand seal 3. Central stand Cover plate Tack & Weld all the parts Make ready all parts of rear stand 1. Rear stand 2. Rear stand seal 3. Rear stand Cover plate Tack & Weld all the parts Latch cath 22 800x345x5 800x120x4 150x50x4
Front Stand
2 2 2
Central Stand
8 8 8
Rear Stand
Standared Item
Assembling and welding front stand with insert. Assembling and welding central stand with insert. Assembling and welding rear stand with insert. 4,364 2,991 176,872
16 17 18
03.03.09.02
184,227
71.3%
mSFN x!NSTL x!n!NNG `.yt.yG.k#N Mesfin Industrial Engineering PLC Title of document:Procedure for Process planning
Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-03 Sub-Open. code-(level-4) Shop:Welding Shop Shop Code:-03.03
Station: Plat form assembly & Board fitting Station Code:-03.03.10 % of completion per station/ shop
Cost Element( in Birr/hrs) Labor cost/hrs Machine cost/unit Material cost/unit Production cost
S/no
Sub-Open. name
Task description
1 2
03.03.10.01.01 03.03.10.01.02
Assembling the reserve wheel and fuel carrier Prepar the reserve wheel carrier bed on floor
3 4 5 03.03.10.01
03.03.10.01.03 03.03.10.01.04
By taking the right measurment 1931x60x30x6 from the front beam tack & weld the reserve wheel support frames (Item-1) Assemble & tack item-12 to the 156x100x50x5 frame Assemble & tack item-12' to the frame Prepar the reserve wheel carrier bed on floor as follows ItemAssembling and tacking the 2=1050x60x30x6 two pieces of Items-2 and two Itempieces of item-3 by maintaining 3=2000x60x30x6 perpendicularity. Assemble and tack two pcs of 950x50x25x5 horizontally u-channel (Item-11) with item-2 and item-3
8 8
206x100x50x5
03.03.10.01.06
2 pcs each
03.03.10.01.07
03.03.10.01.08
Station: Plat form assembly & Board fitting Station Code:-03.03.10 % of completion per station/ shop
Cost Element( in Birr/hrs) Labor cost/hrs Machine cost/unit Material cost/unit Production cost
S/no
Sub-Open. name
Task description
03.03.10.01.09
Assemble and tacking item 10 in the same way 710x50x25x5 Assemble and tacking diagonally item-4 with other parts Assemble & tack Item-5 to the other parts
10 11 12
03.03.10.01 13 14
Assembl & tack Item-6, item13, & item-14 togther & assemble it with item-8 & 9.
Assemble & weld the prepared bed with frame on the plate Tacking and welding both side omegas ( 5 Pcs with 2453mm length & 2.5mm weld gap) 12275x216x4 Assemble Twist lock support and fixing twist lock Assembling of two front corner rinf. 265x123x5
15 16 17
Station: Plat form assembly & Board fitting Station Code:-03.03.10 % of completion per station/ shop
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost
S/no
Sub-Open. name
Task description
Tacking and welding central omegas (weld 4 Pcs long=2453mm & 1 Pcs=742mm short with welding gap 2.5mm) 10546 Sheeting of chequred plate ( 8 Pcs=2400x1500x3x2) & 1 Pcs 2400x300x3+2) with welding gap rear 1.5mm Assembling beam. Check 12300x2400x3+1.5 and mark the lower plate, to maintain levelness with upper plate cut the lower plate with manual flame cutting 2470x332x4 Assemble two rear winches,& valve support.
22 03.03.10.01.22
Assemble the remain two corner reinforcement at rear. Remove the plate from the rear beam from internal side by following the edge of web for vertical cut and for horizontal cut along the edge of bend Removing the plate with manual flame cutting and grinding the edge.
4 265x123x5
23 03.03.10.01.23 24 03.03.10.01.24
Station: Plat form assembly & Board fitting Station Code:-03.03.10 % of completion per station/ shop
Cost Element( in Birr/hrs) Labor cost/hrs Machine cost/unit Material cost/unit Production cost
S/no
Sub-Open. name
Task description
25 26 27
Assemble the rear & bottom sheeting through opening Weld the rear & bottom sheeting. Weld the rear sheeting.
1 1 1
Assembling vertical bumper by maintaining perpendicularity and alignment 384x375x4 Assembly tool box door Assembly the angle iron for locking 938x403x3
2
1 1
40x40x40x2 1
Assembling horizontal bumper 2500x224x4 Tacking and welding central small omega & checkred plate remaining at rear. Marking the twist lock position and cut with manual flame cutting.
32
03.03.10.01.32
33
03.03.10.01.33
Station: Plat form assembly & Board fitting Station Code:-03.03.10 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost % of completion per station/ shop % of completion per total
S/no
Sub-Open. name
Task description
2 3
4 5 03.03.11.02
Positioned side boards properly on place and tack to columns and side beam (by maintaining equal gap from 03.03.11.02.06 both side) Tack the assembled pin hinges and hinges (pin hinges to 03.03.11.02.07 beams and hinges to boards) Tack the assembled latch and latch catch with reference of placing the latch catch at the edge of bend of columns and latch aligned with upper edge 03.03.11.02.08 of bend of boards
Station: Plat form assembly & Board fitting Station Code:-03.03.10 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost % of completion per station/ shop % of completion per total
S/no
Sub-Open. name
Task description Assemble of rear board by maintaining equal clearance from both side and tacking to rear column and rear beam Tacking and welding hinges and pin,catch and latch catch after inspecting the clearance & gap.
03.03.11.02.09
03.03.11.02.10
03.03.11.03.01
Trye fitting
Standard Item Rim Tyre with inner tupe Winch Small hook Big Hook Latch adjustable(left) Latch adjustable(right) Latch catch Steel hinge with pin Twist lock Self lock nut Nut Bolt (M14) 13 13 12 22 13 7 7 14 34 8 2 2 28 1114 2435 2190 114 112
5,579
3,431
233,872 242,882
94.1%
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Station: Painting shop Station Code:-03.04.01 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost
S/no
Sub-Open. name
(level-5) 03.04.01.01.01
Task description Remove the welding spots,spatter,& slugs usings chisels Polish welding joints & rusts using canvas, sand paper,wire brush,wire disc& polishing disc Remove grease ,oils & asphalt using solvents with cleaning rages Wash the product/work using OMO,water,sand paper & dry it by abojedid Prepare the composition of one liter antirust with one liter thinner Stir continuously untill it should be homogenous Cover the part or parts that have different colors in order to protect from the unnecessary paint Clean the spray gun using thinner & then fill the antirust paint Adjust the proper pressurized air for painting Start antirust painting by maintining the distanse as the spray gun moves across the surface of the work with constant flow rate Keep the painted product/work until it drys complately Inspect the product & take corrective action if any
03.04.01.01
03.04.01.01.04
03.04.01.02.01 03.04.01.02.02
03.04.01.02.03
Anti-rust painting
03.04.01.02
03.04.01.02.04
03.04.01.02.05
03.04.01.02.06
03.04.01.02.07 03.04.01.02.08
Document No.
MIE-QMS WP-14-10
Issue no.02
Form No:-WF/PIT/060
Page:
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Station: Painting shop Station Code:-03.04.01 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost % of completion per station/ shop % of completion per total
S/no
Sub-Open. name
Task description Polish,blow,wash & dry the anti-rust painted product/work before filling metallic stucco ( body filler) Prepare metallic stucco & dried with proper composition Fill groove & irregularities with metal stucco using Japanese spoon Keep metallic stucco filled product until to drys completely Polish the product using apporopriate sand papers Blow,wash & dry Prepare spursso paint with apporoprate composition of one liter nitro paint,half liter normal stucco & one and half liter of thinner Stir continuously untill to be homogenous Clean the spray gun using thinner & then fill the nitro paint Adjust the proper pressurized air for painting Start corrective paint by maintining the distanse as the spray gun moves across the surface of the work with constant flow rate Keep the painted product/work until it dry complately Blow,wash & dry
03.04.01.03.01
03.04.01.03
03.04.01.03.02
03.04.01.03.03
03.04.01.03.04
03.04.01.03.05 03.04.01.03.06
03.04.01.04.01
03.04.01.04
03.04.01.04.05
03.04.01.04.06 03.04.01.04.07
Issue no.02
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Station: Painting shop Station Code:-03.04.01 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost % of completion per station/ shop % of completion per total
S/no
Task description Fill normal stucco on the surface of the work to be smoothened Keep the normal stucco filled product/work untill to drys completely
03.04.01.05.01
03.04.01.05
03.04.01.05.02
03.04.01.05.03
Wash using water proof sand paper with water & allow to dry it Prepare corrective paint with apporoprate composition of one liter nitro paint & one liter of thinner Stir continuously untill to be homogenous Clean the spray gun using thinner & then fill the nitro paint Adjust the proper pressurized air for painting
03.04.01.06.01 03.04.01.06.02
03.04.01.06.03
03.04.01.06
03.04.01.06.04
03.04.01.06.05
Start corrective paint by maintining the distanse as the spray gun moves across the surface of the work with constant flow rate Keep the painted product/work until drys complately Blow,wash & dry Iinspect the product & take corrective action
Issue no.02
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Station: Painting shop Station Code:-03.04.01 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Production cost % of completion per station/ shop % of completion per total
S/no
Sub-Open. name
Task description Prepare final paint with the apporopraiate composition of four liter paint with hardener & one litter thinner Stir continuously untill to be homogenous Clean the spray gun using thinner & then fill the final paint Adjust the proper pressurized air for painting Start corrective paint by maintining the distanse as the spray gun moves across the surface of the work with constant flow rate Keep the painted product/work until it drys complately Inspect and take corrective action
03.04.01.07.01
03.04.01.07.02 03.04.01.07.03
Final painting
03.04.01.07
22
03.04.01.07.04
03.04.01.07.05
03.04.01.07.06 03.04.01.07.07
Total Production
7,611
3,565
236,503
247,679
95.92%
mSFN x!NSTL x!n!NNG `.yt.yG.k#N Mesfin Industrial Engineering PLC Title of document:Procedure for Process planning
Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-03 Sub-Open. code(level-4) Shop:Finishing Shop Shop Code:-03.05 Form No:-WF/PIT/060
Issue no.02
Page:
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Tasks code
Cost Element( in Birr/hrs) Labor cost/hr Machine cost/hrs Material cost/hrs % of completion per station/ shop % of completion per total
S/no
Sub-Open. name
(level-5)
Task description
Production cost
Mounting reserve wheel tyre Mounting reserve fuel tank .Laminating with mastije . Laminating with rupper. Fixing (riveting) number plate Fixing (riveting) MIE logo Fixing flaps Fixing rectangular reflector Assembling dismantled parts of the Semi-trailers during painting process
Mechanical fitting
03.05.01.09
mSFN x!NSTL x!n!NNG `.yt.yG.k#N Mesfin Industrial Engineering PLC Title of document:Procedure for Process planning
Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-03 Sub-Open. code-(level-4) Tasks code Shop:Finishing Shop Shop Code:-03.05 Form No:-WF/PIT/060
Issue no.02
Page:
of
Station: Finishing shop Station Code:-03.05.01 Cost Element( in Birr/hrs) Labor cost/hr Machine cost/hrs Material cost/hrs % of completion per station/ shop % of completion per total
S/no
Sub-Open. name
(level-5)
Task description Mounting of breaking chamber type 30 on 1st Axle ( Contains:-break lever,coil spring & small yoke) Mounting of breaking chamber type 24 on middle Axle ( Contains:-break lever,coil spring & longer yoke) Mounting of breaking chamber type 24 on rear Axle ( Contains:-break lever,coil spring & longer yoke) Assembly of emergency rely with load valve ( fitting elbow, nipple & "T" distributor)
Production cost
03.05.02.01
03.05.02.02
03.05.02.03
03.05.02.04 03.05.02
03.05.02.05 03.05.02.06
03.05.02.07 03.05.02.08
Installation of hose with its connectors(#1=out let,#2(right)=fits to front axle break chamber, #2 (left) fits to middle axle then to rear axle,#3(large ) fits to air reservoir tanker & #4=inlet Fitting of 3 way & 4 way hose Connecting Steel cable with mechanical hand break & break lever at rear axle
03.05.02.09
mSFN x!NSTL x!n!NNG `.yt.yG.k#N Mesfin Industrial Engineering PLC Title of document:Procedure for Process planning
Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-03 SubOpen. code(level-4) Tasks code Sub-Open. name (level-5) Task description Fitting red & yellow break coils with the same color of coupling head (Inlet=yellow,Outlet=red) Fixing junction box with screws on rear longitudinal beam Installing Seven lines electrical Cable from junction box to a driver Fitting protection grid & parking light on rear beam Item dimension (LxWxt) Qty/unit (in pcs) Shop:Finishing Shop Shop Code:-03.05 Labor cost/hr Machine cost/hrs Form No:-WF/PIT/060
Issue no.02
Station: Finishing shop Station Code:-03.05.01 Cost Element( in Birr/hrs) Material cost/hrs Production cost
Page:
of
S/no
03.05.02.10 03.05.03.01
03.05.03.04 03.05.03.05
Connecting the junction box's cables to parking light,plate number light(square cable) & side Light
12 2 1 1 1
1 4 1 1 1 1 1 1 2 1 1 1
7,783
3,565
258,217 246,869 Trolley Longutidinal Frame Stand Axle assembling fabrication tacking G
100%
Plate Front Draw form Longutidinal board bar assembling fabrication fabrication Frame beam and
Document No.
MIE-QMS WP-14-10
of
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Produ. cost % of compl. per station/ shop % of completion per total
S/no
Sub-Open. name
(level-5)
Task description
1 2
Cutting procedure on 16 01.01.01.01 mm thickness Cutting procedure on 12 01.01.01.02 mm thickness Cutting procedure on 10 01.01.01.03 mm thickness Cutting procedure on 8 01.01.01.04 mm thickness Cutting procedure on 6 01.01.01.05 mm thickness
01.01.01.01.01 King Pin Plate 01.01.01.02.01 Bottom Reinforcement 01.01.01.03.01 Web plate
1500x1130x16
2950x230x12
12390x420x10
3 4
370x370x8 1130x848x6
Document No.
MIE-QMS WP-14-10
of
Station: Rectification & Grinding Station Code:-01.01.02 % of completion per station/ shop
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost
S/no
Sub-Open. Name
(level-5)
Task description
1 2 3 4 5
01.01.01.02.01 King Pin Plate 01.01.02.02.01 Bottom Reinforcement Recificaion & Grinding 01.01.02.03.01 Web plate 01.01.02.04.01 Landing Plate Cover Plate 01.01.02.05.01 drainge) (Water
2950x230x12
12390x420x10
2
2
370x370x8 1130x848x6
Document No.
MIE-QMS WP-14-10 Issue Page: of no.02
Form No:-WF/PIT/060 Station: Big Shearing Machine Station Code:-01.01.03 Cost Element( in Birr/hrs) Item dimension (LxWxT) Qty/unit( in pcs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost % of completion per station/ shop
S/no
Sub-Open. name
(level-5)
Task description
1 2 3
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
01.01.03.01
01.01.03.01.03 Rinfortcement plate-3 01.01.03.02.01 Vertical Reinforcement 01.01.03.02.02 Pocket 01.01.03.02.03 Pocket Cover 01.01.03.02.04 Reinforcement Plate
Cover plate
98x82x8
320x270x8 75x75x8
01.01.03.02.05
110x88x8
01.01.03.02.08 axle 01.01.03.02.09 Side plate for side board 01.01.03.02.10 Upper side board Protector 01.01.03.02.11 Lower side board Protector 01.01.03.02.12 Upper rear board Protector 01.01.03.02.13 Lower rear board Protector 01.01.03.02.14 Reinforcement plate-2
Connecting plate (Reserve
480x158x8
800x45x8 180x64x8 200x45x8
Document No.
MIE-QMS WP-14-10
of
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost
S/no
Sub-Open. name
(level-5)
Task description
20 21 22 23 24
01.01.03.04.01 01.01.03.04.02 01.01.03.04.03 01.01.03.04.04 01.01.03.04.05 01.01.03.04.06 01.01.03.04.07 01.01.03.04.08 01.01.03.04.09 01.01.03.04.10 01.01.03.04.11
Item-7 Connecting U-channel-1 Connecting U-channel-2 Connecting U-channel-3 Connecting U-channel-4 Vertical Support plate Reinforcement plate-4 Reinforcement plate-1 Landing gear support foot plate Top cover plate Triangular reinforcement
388x50x6 1402x246x6 668x136x6 458x136x6 886x246x6 202x135x6 224x60x6 200x200x6 540x200x6 219x205x6 162x94x6
2 1 2 2 1 4 4 2 4 2 4
Document No.
MIE-QMS WP-14-10
of
Station: Big Shearing Machine Station Code:-01.01.03 % of completion per station/ shop
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost
S/no
Sub-Open. name
Task description External cross member at front External cross member at rear Reinforcement at corner of platform Front Stand Central stand Rear stand Side plate for rear board Connecting plate-2 (Reserve wheel carrier) Triangular reinforcement plate (Reserve wheel carrier) Side plate of front board Column Insert Support (Rear Fender)
31 32 33 34 35
01.01.03.05.01 01.01.03.05.02 01.01.03.05.03 01.01.03.05.04 01.01.03.05.05 01.01.03.05.06 01.01.03.05.07 01.01.03.05.08 01.01.03.05.09 01.01.03.05.10 01.01.03.05.11 01.01.03.05.12 Sub -Total
10 28 8 2
8
800x345x5
2 2 3 5 12 2
Document No.
MIE-QMS WP-14-10 Issue no.02
Form No:-WF/PIT/060
Page:
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Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost
S/no
Sub-Open. name
(level-5)
Task description
01.01.04.01.01 Front beam 01.01.04.01.02 Side Beam 01.01.04.01.03 Rear Beam 01.01.04.01.04 Internal cross member small 01.01.04.01.05 Internal cross member big
Internal cross member
2470x332x4
1 10 1 3 7 4 2 1 2 2
8
2476x325x4
2470x332x4
01.01.04.01.06 reinforcement 01.01.04.01.07 Side Omega 01.01.04.01.08 Central Omega 01.01.04.01.09 Front Stand seal 01.01.04.01.10 Front stand Cover plate 01.01.04.01.11 Central Stand seal 01.01.04.01.12 Central stand cover plate
150x50x4
Document No.
MIE-QMS WP-14-10 Issue no.02
Form No:-WF/PIT/060
Page:
of
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost
S/no
Sub-Open. name
(level-5)
Task description
01.01.04.01.13 Rear stand seal 01.01.04.01.14 Rear stand Cover plate 01.01.04.01.15 Cover plate (Insert) 01.01.04.01.16 Omega for front board 01.01.04.01.17 Rear Sheet 01.01.04.01.18 Side plate (Tool box) 01.01.04.01.19 Vertical part of bumper 01.01.04.01.20 Horizontal part of bumper
Cover plate for horizontal part 01.01.04.01.21 of bumper-1 Cover plate for horizontal part 01.01.04.01.22 of bumper-2 Reinforcement connecting 01.01.04.01.23 plate (bumper)
2 2 12 2
1 2 2 1 1 2 2
Document No.
MIE-QMS WP-14-10 Issue no.02
Form No:-WF/PIT/060
Page:
of
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost
S/no
Sub-Open. name
(level-5)
Task description Connecting bracket Chequer plate Spacer (Insert) Belt (Water tanker) Tool Box door Rear & Bottom Sheet Number plate holder Junction box support plate Front board sheet Upper & lower seal of front board seal Side board Sheet Upper & lower side board seal Rear board sheet Upper & Lower rear board seal Reserve fuel tanker Side & Bottom Sheeting Reserve fuel tanker Top Sheeting Reserve fuel tanker Front & Rear Sheeting Reserve fuel tanker Internal Panel Rear fender sheet Rear light holder
24 25 26 27 01.01.04.02 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
01.01.04.02.01 01.01.04.02.02 01.01.04.02.03 01.01.04.02.04 01.01.04.02.05 01.01.04.02.06 01.01.04.02.07 01.01.04.03.01 01.01.04.03.02 01.01.04.03.03 01.01.04.03.04 01.01.04.03.05 01.01.04.03.06
500x353x3
12300x2400x(3+2)
1 1 24
132x50x3
4 1 1 2
1
2428x946x2
2 2 10 20
2428x209x2
2261x1032x2 2261x226x2
2458x1020x2 2458x214x2
1931x1500x2 1500x228x2 800x346x2 798x344x2
1 2
1 1 2
01.01.04.03
842x760x2 600x425x2
2 2
Issue no.02
Page:
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Station: Band Saw Machine Station Code:-01.01.05 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost % of completion per station/ shop % of completion per total
S/no
Sub-Open. name
Task description
01.01.05.01.01 Twist lock support long 01.01.05.01.02 Twist lock support short 01.01.05.01.03 01.01.05.01.04 01.01.05.01.05 01.01.05.01.06 01.01.05.01.07 01.01.05.01.08 01.01.05.01.09 01.01.05.01.10 01.01.05.01.11 01.01.05.01.12 01.01.05.01.13 01.01.05.01.14 01.01.05.01.15 01.01.05.01.16 01.01.05.01.17 01.01.05.01.18 01.01.05.01.19
Reserve wheel support frame Item-2 (Reserve wheel carrier) Item-3 (Reserve wheel carrier) Item-4 (Reserve wheel carrier) Item-5(Reserve wheel carrier) Item-6(Reserve wheel carrier) Item-10(Reserve wheel carrier) Item-11(Reserve wheel carrier) Item-12(Reserve wheel carrier) Item-12' (Reserve wheel carrier) Item-13 (Reserve wheel carrier) Item-14 (Reserve wheel carrier) Horizontal support (Reserve wheel carrier) Vertical support-1 (Reserve wheel carrier) Vertical support-2 (Reserve wheel carrier) U-profile support cylinder) (Air
300x50x25x5 135x50x25x5
1931x60x30x5 1050x60x30x6 2000x60x30x6
16 8 4 2 2
1022x50x25x5 370x60x30x6 200x60x30x6 710x50x25x5 950x50x25x5 156x100x50x5 206x100x50x5 115x60x30x6 85x60x30x6 460x60x30x6 979x60x30x6 794x60x30x6 500x60x30x6 795x60x30x6
Checked By: Gizaw B.
2 2 2 4 2 8 8 4 4 5 1 3 2 2
Approved By: Nicodemos A.
01.01.05.01
Document No.
MIE-QMS WP-14-10 Issue no.02
Form No:-WF/PIT/060
Page:
of
Station: Band Saw Machine Station Code:-01.01.05 % of completion per station/ shop
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost
S/no
Sub-Open. name
Task description
12 13 14 15 16 01.01.05.02
Cutting of RHS
2 2 2 2 2
4
01.01.05.03.01 Item-8 (Reserve wheel carrier) Dia. 24x350 01.01.05.03.02 Item-9 (Reserve wheel carrier) Dia. 20x269
Pin (Landing gear foot
2 1
40x40x40x2
228x40x40x2
2 1
Cutting of pipe
40x40x40x2
Station: Power hacksaw Machine Station Code:-01.01.06 % of completion per station/ shop
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost
S/no
Sub-Open. name
Task description
01.01.06.01.01 Ring Fixing I-beam King pin reinforcement I01.01.06.01.02 beam (longe) King pin reinforcement I01.01.06.01.03 beam (Short)
886x190x200x6.5x10
740x160x160x8x13
436x160x160x8x13
740.00
26%
Issue no.01
Page:
of
Station: Big Bending Machine Station Code:-01.01.07 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost % of completion per station/ shop
S/no
Sub-Open. name
(level-5)
Task description
01.01.07.01
01.01.07.01.01 Lower plate External cross member 01.01.07.02.01 at front External cross member 01.01.07.02.02 at rear 01.01.07.02.03 Front stand 01.01.07.02.04 Central stand
12412x250x15
2 3 4 5 6 7 8 9 10 11
779x260x5 779x300x5
1200x345x5
800x294x5
10
28
01.01.07.02
800x345x5 400x188x5
12
01.01.07.02.07 Side plate for front board 1400x85x5 01.01.07.02.08 Side plate for rear board 01.01.07.02.09 Front beam 01.01.07.02.10 Rear beam 800x45x2 2470x332x4
2476x325x4
Station: Big Bending Machine Station Code:-01.01.07 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost % of completion per station/ shop
S/no
Sub-Open. name
(level-5)
Task description
12 13 14 15 16 17
01.01.07.02.11 Side beam 01.01.07.02.12 Side omega 01.01.07.02.13 Side omega 01.01.07.02.14 Side omega 01.01.07.02.15 Side omega 01.01.07.02.16 Side omega 01.01.07.02.17 Central omega short 01.01.07.02.18 Central omega long 01.01.07.02.19 Central omega long 01.01.07.02.20 Central omega long 01.01.07.02.21 Central omega long 01.01.07.02.22 Upper side board protector 01.01.07.02.23 Upper rear board protector
Station: Big Bending Machine Station Code:-01.01.07 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost % of completion per station/ shop
S/no
Sub-Open. name
(level-5)
Task description
25 01.01.07.03 26
27
28 01.01.07.04 29
2458x1020x2
2428x946x2
30
2261x1032x2
10
Station: Big Bending Machine Station Code:-01.01.07 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost % of completion per station/ shop
S/no
Sub-Open. name
(level-5)
Task description
32 32 33 33 34 34 35 35 36 36 37 37 38 01.01.07.05
01.01.07.05.01 Upper front board seal 01.01.07.05.02 Lower front board seal
2 2 2 10 10 2 1 1 1 2 1 2
01.01.07.05.03 Upper rear board seal 01.01.07.05.04 Lower rear board seal 01.01.07.05.05 Upper side board seal 01.01.07.05.06 Lower side board seal 01.01.07.05.07 Rere Fender sheet 01.01.07.05.08 Tool box door
01.01.07.05.09 Bottom & side sheet-1 2000x809x3 Side & Bottom sheet01.01.07.05.10 2 2000x925x2 Conneting bracket 01.01.07.05.11 (Landing gear) 714x319x10
Connecting U-channel-1 01.01.07.05.12 (Landing gear support) Connecting U-channel-2 01.01.07.05.13 (Landing gear support)
1402x246x6 668x136x6
Station: Big Bending Machine Station Code:-01.01.07 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost % of completion per station/ shop
S/no
Sub-Open. name
(level-5)
Task description
39 40 41 42 01.01.07.05 43 44 45 46
Connecting U-channel-3 01.01.07.05.14 (Landing gear support) Connecting U-channel-4 gear support) 01.01.07.05.15 (Landing Reinforcement plate-3
2 1 4 4 4 4 2 2
(Landing gear foot support) 01.01.07.05.16 Reinforcement plate-4 (Landing gear foot support) 01.01.07.05.17 Vertical Support Plate
(Landing gear foot support
01.01.07.05.18 plate)
Reserve wheel support 01.01.07.05.19 frame
Front & rear sheet 01.01.07.05.20 (Reserve fuel tanker) 01.01.07.05.21 Fender Support
191.5
837.9
0.3%
Document No.
MIE-QMS WP-14-10
Issue no.02
Page:
of
Cost Element( in Birr/hrs) Machine cost/unit Material cost/unit Material cost/hrs Production cost % of completion per station/ shop
S/no
Sub-Open. name
(level-5)
Task description
1 2 3 01.01.04'.01 4
Notching
415x110x8 798x344x2
16 2
0.2
0.13 0.13
458x136x6 540x200x6
2 4
0.07
Document No.
MIE-QMS WP-14-10
Issue no.02
Page:
of
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material Cost/unit Productio n cost
S/no
Sub-Open. name
(level-5)
Task description
Work Break Down Structure for 3-Axle Dry cargo Semi-Trailer in Machine Shop
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 01.02.01.01 01.02.01.02 01.02.01.03 01.02.01.04 01.02.01.05 01.02.01.06 01.02.01.07 01.02.01.08
Gusset plate at front Connecting plate Horizontal part ram holder Air valve support Plate no support Rear light holder Connecting brackt (Landing gear support) Landing gear support Reinforcement plate-1 Belt (Aluminum tanker) Support Connecting plate-1 (Reserve fuel carrier) Connecting plate-2 (Reserve fuel carrier) Horizontal Supporting frame (Reserve fuel carrier) Item-6 (Reserve wheel carrier) Junction box support 100x60x10 100x60x5 460x60x30x6 200x60x30x6 418x150x2 714x319x10 540x200x6 200x200x6 1101x40x3
2 4 2 4
01.02.01
3 2 5 2 1
Document No.
MIE-QMS WP-14-10
Issue no.02
Page:
of
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material Cost/unit Productio n cost
S/no
Sub-Open. name
(level-5)
Task description
17 18 19 20
Item-8 (Reserve fuel tanker) Pin (Landing gear foot support) Bushing for landing gesr Suspension support reinforcement plate
2 2 2 4
01.02.02.01
Turning
Total Production cost of Drilling Turnning & Milling Processes (Birr) Total Production cost of Material Preparation (Birr)
303 1234
Document No.
MIE-QMS WP-14-10
of
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost
S/no
Sub-Open. name
Task description
IV-Work Break Down Structure of 3-Axle Dry cargo Semi-Trailer in welding shop
1 2 3 4 5 01.03.01.01 6 01.03.01.01.06 7 01.03.01.01.07 8 01.03.01.01.08 9 01.03.01.01.09 Longutidinal Beam Tacking 01.03.01.01.01 01.03.01.01.02 01.03.01.01.03 01.03.01.01.04 01.03.01.01.05
Before you start tacking of longutidinal beam adjust the following parameters Ensur that the diameter of the elecroide is 3.2 mm
Adjust the current (150-170 A) Polish & Put upper plate properly on tacking jig. Check clearance and tack to the jig frame with 500mm gap and 70mm weld size.Finaly inspect the straightness. Put vertical plate on upper plate properly and tack it with 500mm gap and weld size of 70mm
12280x250x15
12390x420x10
Mount lower plate on vertical plate and tack it with 500mm gap and 12412x250x15 weld size of 70mm Ensure the diagonal measurements are correct & transfer to the next station
135
48.9
36.08
Document No.
MIE-QMS WP-14-10 Issue no.02
Form No:-WF/PIT/060
Page:
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Station: Longutidunal Beam Welding Station Code:-01.03.02 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost % of completion per station/ shop % of completion per total
S/no
Sub-Open. name
Task description Before you start welding of longitudinal beam adjust the following parameters Ensur that the diameters of the elecroide is 1.2m Adjust the voltage (32-36 V) Adjust the current (220-350 A) Adjust the wire speed from 3 meter/minute up to 10 meter/minut Use shelding gas=co2 at a flow
2 3 4
01.03.02.01.05
01.03.02.01
7 8
rate (
) litter/minut
Inspect the quality of work the both visually & using measerment Mounting on welding jig and tightening firmly welding as per Final staggered shown in the drawing weld A1 & A1, B1 & B1, C1 & C1 and D1 & D1, E1 & E1 and F1 & F2 at the same time consequentively. Weld bottom reinforcement plate with longutidinal beam Unload the frame from jig after cooling for (30min-60 min). Ensure all things are right & transfer to the next station
9 10 12 13
2959x230x12
180
67.2
180.4
mSFN x!NSTL x!n!NNG `.yt.yG.k#N Mesfin Industrial Engineering PLC Title of document:Procedure for Process planning
Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-01 Sub-Open. code-(level4) Tasks code (level-5) Item dimension (LxWxt) Qty/unit( in pcs) Shop:Welding Shop Shop Code:-01.03 Form No:-WF/PIT/060
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Station: Frame Tacking Station Code:-01.03.03 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost % of completion per station/ shop % of completion per total
S/no
Sub-Open. name
Task description Before you start tacking of frame adjust the following parameters Ensur that the diameter of the welding wire is 1.2 mm Adjust the volttage ( 21-28V.) Adjust the current (127-291A) Adjust wire speed (2 meter/minut up to 8 meter/minut) Put two longitidunal beams on jig by maintaining parallel. Put Ring fixing I-beam on the same level & tack with longtidunal beam by maintaining less than 1mm clearance. Fix front vertical reinforcement Tack the front beam by firmly tighting to the frame by C-clamp to maintain levelness of top part of the beam with upper plate. Tack internal cross mebers 1. Internal cross members small 2. Internal cross members big 3. Internal cross members reinforcement
1 2 3 4
5 6 01.03.03.01 7 8
01.03.03.01.05 01.03.03.01.06
Frame tacking
01.03.03.01.07
886x190x200x6.5x10 2 415x110x8 16
9 10 11 12 13
01.03.03.01.08 01.03.03.01.09
2470x332x4
3 7 4
mSFN x!NSTL x!n!NNG `.yt.yG.k#N Mesfin Industrial Engineering PLC Title of document:Procedure for Process planning
Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-01 Sub-Open. code-(level4) Tasks code Item dimension (LxWxt) Qty/unit( in pcs) Shop:Welding Shop Shop Code:-01.03 Form No:-WF/PIT/060
Page:
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Station: Frame Tacking Station Code:-01.03.03 Cost Element( in Birr/hrs) Labor cost/hrs Machine cost/unit Material cost/unit Productio n cost % of completion per station/ shop % of completion per total
S/no
Sub-Open. name
(level-5)
Task description
14 15 16 01.03.03.01 17 18
Tack side beams with the (frame) by mainting 01.03.03.01.13 parallelness of the beams
10 2476x325x5
779x260x5
10 28
Frame tacking
2. External cross members 01.03.03.01.15 at rear Inspect the quality of the work both visually & using measerment to avoid rework & reject
779x300x5
270
98
72.16
Page:
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Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-01 Sub-Open. code-(level-4)
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost
S/no
Sub-Open. name
Task description
1 2 3 4
Before you start welding of frame adjust the following parameters Ensure that the diameter of welding wire is 1.2mm.
Adjust the current (127-230A) Adjust wire speed (2 meter/minut up to 10meter /minute)
5 01.03.04.01 6 7 8
01.03.04.01.04
Frame Welding
Weld flat position of tacked items Tack & Weld ring fixing I-beam with frame Tack & Weld king pin reinforcement I-beam with frame (Long) Tack & Weld king pin reinforcement I-beam with frame (Short)
886x200x6.5x10 740x160x160x8x13
2 1
9 10 11
436x160x160x8x13 1500x1130x6
2 1
Weld cover plate with pin on floor Tack & weld the cover plate with ring fixing I-beams
Page:
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Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-01 Sub-Open. code-(level-4)
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost
S/no
Sub-Open. name
01.03.04.01.01
1130x848x6 500x353x3
1 1
01.03.04.01.04 bracket
Tack & weld the reinforcement
98x82x8
17 18
01.03.04.01.06
Finally unload the frame from the jig and transferred to next 01.03.04.01.07 station
Standard Item
King pin
3 1/2" 1
202.5
73.35
3549.6
Document No.
Page:
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Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-01 Sub-Open. code-(level-4)
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost
S/no
Sub-Open. name
Task description Check that all the necessary parts are available
12 13 14 15 16
01.03.04'.01
01.03.04.01.01
1130x848x6 500x353x3
1 1
01.03.04.01.04 support
Assemble the landing gear to
98x82x8
Standard Item
Landing gear
24-25 ton 1
mSFN x!NSTL x!n!NNG `.yt.yG.k#N Mesfin Industrial Engineering PLC Title of document:Procedure for Process planning
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Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-01 Sub-Open. code-(level-4)
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost
S/no
Sub-Open. name
(level-5)
Task description
01.03.05.01.01
Maker ready all parts 1. Side & Bottom sheet-1 2. Front & Rear sheet 3. Internal Pannels
Position & Tack internal
2
3
1 1 2
4
5
6
7
Reserve fuel 01.03.12.01.04 Tack top, covet plates & side tanker preparation
01.03.12.01.05 Weld top, covet plates & side
Weld inlet Pipe & Discharge
8
9
Standard Item
Cup for inlet pipe Drainage pipe Cup for drainade pipe Fuel inlet pipe 3'x60 1''x60 1' 3"
1 1 1 1
68
33
290.24
mSFN x!NSTL x!n!NNG `.yt.yG.k#N Mesfin Industrial Engineering PLC Title of document:Procedure for Process planning
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Tasks code Sub-Open. name (level-5) Task description Item dimension (LxWxt) Qty/unit( in pcs)
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost
S/no
10 11 12 01.03.06.01 13
01.03.06.01.01 Mounting Axles on the axle jig 01.03.06.01.02 Mounting leaf spring 01.03.06.01.03 Inserting U-bolt
Axle Assembling
14
15
mSFN x!NSTL x!n!NNG `.yt.yG.k#N Mesfin Industrial Engineering PLC Title of document:Procedure for Process planning
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Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-01 Sub-Open. code-(level4) Tasks code Sub-Open. name (level-5) Task description
S/no
2 3 01.03.06.02 4 5 6 7
Maintain parallity by taking measurement from reference axle cup 01.03.06.02.01 of Maintain equality by Measurement axially and diagonally from center of axle 01.03.06.02.02 cup. Mounting the frame on
Frame Mounting
Keep balance equally in both side with reference to axle cap 01.03.06.02.04 centers and tack welding. Welding guesset plate at rear
2 2 2
Standard Item
Axle with suspension (Set) 1
270
97.8
92915
Page:
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Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-01 Sub-Open. code-(level4) Tasks code (level-5) Item dimension (LxWxt) Qty/unit( in pcs) Shop:Welding Shop Shop Code:-01.03
Station: Board Fabrication Station Code:-01.03.07 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost % of completion per station/ shop
S/no
Sub-Open. name
Task description
5 01.03.07.01
01.03.07.01.05 meter/minutr up to 4
meter/minute Mount the corrugated sheetes side
Tack board seal, side plates & angle iron Inspect the quality of the work both visually & using measurment to avoide rework & reject
01.03.07.01.08 8 9
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Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-01 Sub-Open. code-(level4) Tasks code (level-5) Item dimension (LxWxt) Qty/unit( in pcs) Shop:Welding Shop Shop Code:-01.03
Station: Board Fabrication Station Code:-01.03.07 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost % of completion per station/ shop
S/no
Sub-Open. name
Task description
Mount the corrugated sheet on the bottom side Tack board seal ,side plates & angle iron Inspect the quality of the work both visually & using measurment to avoide rework & reject
01.03.07.01.03 12 13
14 15 01.03.07.01
Front Board tacking & welding
168.75
28.525
252.56
mSFN x!NSTL x!n!NNG `.yt.yG.k#N Mesfin Industrial Engineering PLC Title of document:Procedure for Process planning
Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-01 Sub-Open. code-(level-4) Shop:Welding Shop Shop Code:-01.03 Form No:-WF/PIT/060
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost
S/no
Sub-Open. name
Task description
Befor you start tacking & welding activities adjust the following parameters
Adjust the current (105-190A)) Adjust wire speed from 0.5 meter/minute up to 4 meter/minute. Make ready all the parts 1. Insert 2. Cover plate 3. Spacer Tacking and welding insert 400x188x5 400x125x4 132x50x3 12 12 24
mSFN x!NSTL x!n!NNG `.yt.yG.k#N Mesfin Industrial Engineering PLC Title of document:Procedure for Process planning
Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-01 Sub-Open. code-(level-4) Shop:Welding Shop Shop Code:-01.03 Form No:-WF/PIT/060
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost
S/no
Sub-Open. name
Task description
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 01.03.09.01
01.03.09.01.01 01.03.09.01.02
Make ready all parts of front stand 1. Front stand 2. Front stand seal 3. Front stand Cover plate Tack & Weld all the parts Make ready all parts of central stand 1. Central stand 2. Central stand seal 3. Central stand Cover plate Tack & Weld all the parts Make ready all parts of rear stand 1. Rear stand 2. Rear stand seal 3. Rear stand Cover plate Tack & Weld all the parts Latch cath 22 800x345x5 800x120x4 150x50x4
Front Stand
2 2 2
Central Stand
8 8 8
Rear Stand
Standared Item
Assembling and welding front stand with insert. Assembling and welding central stand with insert. Assembling and welding rear stand with insert.
16 17 18
01.03.09.02
84.75
30.5625
180.4
mSFN x!NSTL x!n!NNG `.yt.yG.k#N Mesfin Industrial Engineering PLC Title of document:Procedure for Process planning
Page:
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Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-01 Sub-Open. code-(level-4)
Shop Code:-01.03
Cost Element( in Birr/hrs) Labor cost/hrs Machine cost/unit Material cost/unit Productio n cost
S/no
Sub-Open. name
Task description
1 2
01.03.10.01.01 01.03.10.01.02
Assembling the reserve wheel and fuel carrier Prepar the reserve wheel carrier bed on floor
3 4 5 01.03.10.01
01.03.10.01.03 01.03.10.01.04
By taking the right measurment 1931x60x30x6 from the front beam tack & weld the reserve wheel support frames (Item-1) Assemble & tack item-12 to the 156x100x50x5 frame Assemble & tack item-12' to the frame Prepar the reserve wheel carrier bed on floor as follows ItemAssembling and tacking the 2=1050x60x30x6 two pieces of Items-2 and two Itempieces of item-3 by maintaining 3=2000x60x30x6 perpendicularity. Assemble and tack two pcs of horizontally u-channel (Item11) with item-2 and item-3
8 8
206x100x50x5
01.03.10.01.06
2 pcs each
01.03.10.01.07
950x50x25x5
01.03.10.01.08
Page:
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Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-01 Sub-Open. code-(level-4)
Shop Code:-01.03
Cost Element( in Birr/hrs) Labor cost/hrs Machine cost/unit Material cost/unit Productio n cost
S/no
Sub-Open. name
Task description
01.03.10.01.09
Assemble and tacking item 10 in the same way 710x50x25x5 Assemble and tacking diagonally item-4 with other parts
10 11 12
Assemble & tack Item-5 to the other parts 370x60x30x6 Assemble & tack Item-8 & item- Item-2=24x350 Item-3=20x269 9
Item-6=200x60x30x6 (2Pcs) Item-13=115x60x30x6 (4Pcs) Item-14=85x60x30x6 (4 pcs)
01.03.10.01 13 14
Assembl & tack Item-6, item13, & item-14 togther & assemble it with item-8 & 9.
Assemble & weld the prepared bed with frame on the plate Tacking and welding both side omegas ( 5 Pcs with 2453mm length & 2.5mm weld gap) 12275x216x4 Assemble Twist lock support and fixing twist lock Assembling of two front corner rinf. 265x123x5
15 16 17
Page:
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Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-01 Sub-Open. code-(level-4)
Shop Code:-01.03
Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost
S/no
Sub-Open. name
Task description
Tacking and welding central omegas (weld 4 Pcs long=2453mm & 1 Pcs=742mm short with welding gap 2.5mm) 10546 Sheeting of chequred plate ( 8 Pcs=2400x1500x3x2) & 1 Pcs 2400x300x3+2) with welding gap rear 1.5mm Assembling beam. Check 12300x2400x3+1.5 and mark the lower plate, to maintain levelness with upper plate cut the lower plate with manual flame cutting 2470x332x4 Assemble two rear winches,& valve support.
22 01.03.10.01.22
Assemble the remain two corner reinforcement at rear. Remove the plate from the rear beam from internal side by following the edge of web for vertical cut and for horizontal cut along the edge of bend Removing the plate with manual flame cutting and grinding the edge.
4 265x123x5
23 01.03.10.01.23 24 01.03.10.01.24
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Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-01 Sub-Open. code-(level-4)
Shop Code:-01.03
Cost Element( in Birr/hrs) Labor cost/hrs Machine cost/unit Material cost/unit Productio n cost
S/no
Sub-Open. name
Task description
25 26 27
Assemble the rear & bottom sheeting through opening Weld the rear & bottom sheeting. Weld the rear sheeting.
1 1 1
Assembling vertical bumper by maintaining perpendicularity and alignment 384x375x4 Assembly tool box door Assembly the angle iron for locking 938x403x3
2
1 1
40x40x40x2 1
Assembling horizontal bumper 2500x224x4 Tacking and welding central small omega & checkred plate remaining at rear. Marking the twist lock position and cut with manual flame cutting.
32
01.03.10.01.32
33
01.03.10.01.33
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Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-01 Sub-Open. code-(level4) Tasks code (level-5)
Shop Code:-01.03
S/no
Sub-Open. name
Task description
2 3
4 5 01.03.11.02
Positioned side boards properly on place and tack to columns and side beam (by maintaining equal gap from 01.03.11.02.06 both side) Tack the assembled pin hinges and hinges (pin hinges to 01.03.11.02.07 beams and hinges to boards) Tack the assembled latch and latch catch with reference of placing the latch catch at the edge of bend of columns and latch aligned with upper edge 01.03.11.02.08 of bend of boards
Page:
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Shop Code:-01.03
S/no
Sub-Open. name
Task description Assemble of rear board by maintaining equal clearance from both side and tacking to rear column and rear beam Tacking and welding hinges and pin,catch and latch catch after inspecting the clearance & gap.
01.03.11.02.09
01.03.11.02.10
01.03.11.03.01
Trye fitting
Standard Item Rim Tyre with inner tupe Winch Small hook Big Hook Latch adjustable(left) Latch adjustable(right) Latch catch Steel hinge with pin Twist lock Self lock nut Nut Bolt (M14) 13 13 12 22 13 7 7 14 34 8 2 2 28 17379 31652 2190 114 112
1215
440.1
67,780
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Station: Painting shop Station Code:-01.04.01 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost
S/no
Sub-Open. name
(level-5) 02.04.01.01.01
Task description Remove the welding spots,spatter,& slugs usings chisels Polish welding joints & rusts using canvas, sand paper,wire brush,wire disc& polishing disc Remove grease ,oils & asphalt using solvents with cleaning rages Wash the product/work using OMO,water,sand paper & dry it by abojedid Prepare the composition of one liter antirust with one liter thinner Stir continuously untill it should be homogenous Cover the part or parts that have different colors in order to protect from the unnecessary paint Clean the spray gun using thinner & then fill the antirust paint Adjust the proper pressurized air for painting Start antirust painting by maintining the distanse as the spray gun moves across the surface of the work with constant flow rate Keep the painted product/work until it drys complately Inspect the product & take corrective action if any
02.04.01.01
02.04.01.01.04
02.04.01.02.01 02.04.01.02.02
02.04.01.02.03
Anti-rust painting
02.04.01.02
02.04.01.02.04
02.04.01.02.05
02.04.01.02.06
02.04.01.02.07 02.04.01.02.08
Document No.
MIE-QMS WP-14-10
Issue no.02
Form No:-WF/PIT/060
Page:
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Station: Painting shop Station Code:-01.04.01 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost % of completion per station/ shop % of completion per total
S/no
Sub-Open. name
Task description Polish,blow,wash & dry the anti-rust painted product/work before filling metallic stucco ( body filler) Prepare metallic stucco & dried with proper composition Fill groove & irregularities with metal stucco using Japanese spoon Keep metallic stucco filled product until to drys completely Polish the product using apporopriate sand papers Blow,wash & dry Prepare spursso paint with apporoprate composition of one liter nitro paint,half liter normal stucco & one and half liter of thinner Stir continuously untill to be homogenous Clean the spray gun using thinner & then fill the nitro paint Adjust the proper pressurized air for painting Start corrective paint by maintining the distanse as the spray gun moves across the surface of the work with constant flow rate Keep the painted product/work until it dry complately Blow,wash & dry
02.04.01.03.01
02.04.01.03
02.04.01.03.02
02.04.01.03.03
02.04.01.03.04
02.04.01.03.05 02.04.01.03.06
02.04.01.04.01
02.04.01.04
02.04.01.04.05
02.04.01.04.06 02.04.01.04.07
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Station: Painting shop Station Code:-01.04.01 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost % of completion per station/ shop % of completion per total
S/no
Task description Fill normal stucco on the surface of the work to be smoothened Keep the normal stucco filled product/work untill to drys completely
02.04.01.05.01
02.04.01.05
02.04.01.05.02
02.04.01.05.03
Wash using water proof sand paper with water & allow to dry it Prepare corrective paint with apporoprate composition of one liter nitro paint & one liter of thinner Stir continuously untill to be homogenous Clean the spray gun using thinner & then fill the nitro paint Adjust the proper pressurized air for painting
02.04.01.06.01 02.04.01.06.02
02.04.01.06.03
02.04.01.06
02.04.01.06.04
02.04.01.06.05
Start corrective paint by maintining the distanse as the spray gun moves across the surface of the work with constant flow rate Keep the painted product/work until drys complately Blow,wash & dry Iinspect the product & take corrective action
of
Station: Painting shop Station Code:-01.04.01 Cost Element( in Birr/hrs) Labor cost/unit Machine cost/unit Material cost/unit Productio n cost % of completion per station/ shop % of completion per total
S/no
Sub-Open. name
Task description Prepare final paint with the apporopraiate composition of four liter paint with hardener & one litter thinner Stir continuously untill to be homogenous Clean the spray gun using thinner & then fill the final paint Adjust the proper pressurized air for painting Start corrective paint by maintining the distanse as the spray gun moves across the surface of the work with constant flow rate Keep the painted product/work until it drys complately Inspect and take corrective action
02.04.01.07.01
02.04.01.07.02 02.04.01.07.03
Final painting
02.04.01.07
22
02.04.01.07.04
02.04.01.07.05
02.04.01.07.06 02.04.01.07.07
Total Production
2032
134.4
2,631
mSFN x!NSTL x!n!NNG `.yt.yG.k#N Mesfin Industrial Engineering PLC Title of document:Procedure for Process planning
Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-01 Sub-Open. code(level-4) Shop:Welding Shop Shop Code:-01.05 Form No:-WF/PIT/060
of
Tasks code
Cost Element( in Birr/hrs) Labor cost/hr Machine cost/hrs Material cost/hrs % of completion per station/ shop % of completion per total
S/no
Sub-Open. name
(level-5)
Task description
Qty/unit( in pcs)
Productio n cost
Mounting reserve wheel tyre Mounting reserve fuel tank .Laminating with mastije . Laminating with rupper. Fixing (riveting) number plate Fixing (riveting) MIE logo Fixing flaps Fixing rectangular reflector Assembling dismantled parts of the Semi-trailers during painting process
Mechanical fitting
01.05.01.09
mSFN x!NSTL x!n!NNG `.yt.yG.k#N Mesfin Industrial Engineering PLC Title of document:Procedure for Process planning
Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-01 Sub-Open. code-(level-4) Tasks code Shop:Welding Shop Shop Code:-01.05 Form No:-WF/PIT/060
of
Station: Finishing shop Station Code:-01.05.01 Cost Element( in Birr/hrs) Labor cost/hr Machine cost/hrs Material cost/hrs % of completion per station/ shop % of completion per total
S/no
Sub-Open. name
(level-5)
Task description Mounting of breaking chamber type 30 on 1st Axle ( Contains:-break lever,coil spring & small yoke) Mounting of breaking chamber type 24 on middle Axle ( Contains:-break lever,coil spring & longer yoke) Mounting of breaking chamber type 24 on rear Axle ( Contains:-break lever,coil spring & longer yoke) Assembly of emergency rely with load valve ( fitting elbow, nipple & "T" distributor)
Qty/unit( in pcs)
Productio n cost
01.05.02.01
01.05.02.02
01.05.02.03
01.05.02.04 01.05.02
01.05.02.05 01.05.02.06
01.05.02.07 01.05.02.08
Installation of hose with its connectors(#1=out let,#2(right)=fits to front axle break chamber, #2 (left) fits to middle axle then to rear axle,#3(large ) fits to air reservoir tanker & #4=inlet Fitting of 3 way & 4 way hose Connecting Steel cable with mechanical hand break & break lever at rear axle
mSFN x!NSTL x!n!NNG `.yt.yG.k#N Mesfin Industrial Engineering PLC Title of document:Procedure for Process planning
Work Breake Down Structure Product Name:-Dry cargo Semi-trailer Product Code:-01 SubOpen. code(level-4) Tasks code (level-5) Item dimension (LxWxt) Qty/unit( in pcs) Shop:Welding Shop Shop Code:-01.05 Form No:-WF/PIT/060
of
Station: Finishing shop Station Code:-01.05.01 Cost Element( in Birr/hrs) Labor cost/hr Machine cost/hrs Material cost/hrs Productio n cost % of completion per station/ shop % of completion per total
S/no
Sub-Open. name
Task description Fitting red & yellow break coils with the same color of coupling head (Inlet=yellow,Outlet=red)
01.05.02.10 01.05.03.01
Fixing junction box with screws on rear longitudinal beam Installing Seven lines electrical Cable from junction box to a driver Fitting protection grid & parking light on rear beam
01.05.03.04 01.05.03.05
Connecting the junction box's cables to parking light,plate number light(square cable) & side Light
Standard Item
Bolt with nut,M8x25 Bolt with nut,M8x40 Nut,M24 Flat washer ,M8 Grease gun Cross wrench Aluminum Plate Hydrualic jack Anti skid rupper Cup for in let pipe Cup for drainage pipe Union for drainage
24x27x30x32, L=700mm
12 2 1 1 1
1 4 1 1 1
Union for fuel tapout let Fuel tap for out let Aluminum water tanker Rectangular reflector Air Brake System Mechanical hand brake Electrical system
1 1 1 2 1 1 1
172
Plate Front Draw form Longutidinal board bar assembling fabrication fabrication Frame beam and
31652 17379