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Q.

No.of Gears machined ( ready to be put in heat treatment)


No.of Shafts machined ( ready to be put in heat treatment)
No. Of Assemblies (these are from the heat treatment which have been loaded 2 shifts bef

Total Gear Boxes


Total Gear Boxes With 85% efficiency taken into account

The capacity can be increased in the following manner

1. Number of gear sets < Number of shafts, so converting to H2 and S2 to gear hobbing an
shaving machines can be done for every 4-5 shifts
2. The extra shafts that have been produced can be used
with extra gears manufactured by the shifts in step 1

Morning Shifts Evening Shift Night shift Total


90
90
78
258
56
56
48
160
22
19
22
63

63
53.55 53(approx)

Gear Box Manufacturing Cost

S.No

Item
1 Gear Blanks
2 Cost of Gear Shaft blanks
3 Grear Housing
4 Gear Box Assembly Kit
5 Other Tools and consumables
6 packaging material
Total Cost Price of Gear Box
Selling Price of the Gear Box
Units Sold in 2013-14
Closing Stock of year
Total Units manufactured in 2013-14
Total Units to be manufactured in 2014-15
Total Cost of Manufacturing

Working hours per day = (450+450+390)*.85


1 gear box = 4 gears + 2 gear shafts
Monthly Capactiy of H1 = (1096/(5*4))*25
Monthly Capacity of H2 = (1096/(8*2))*25
Monthly Capacity of S1 = (1096/(3*4))*25
Monthly Capacity of S2 = (1096/(5*2))*25
Monthly Capacity of FG1 and FG2
=(1096/(2*4))*25
Monthly Capacity of FG1 and FG2 =
(1096/(6*2))*25
Monthly Capacity of Heat Treatment
Monthly Capacity of Heat Treatment
Assembly Capacity monthly for a complete gear Box

Annual Capacity of the Plant = 1370*12


Total Units to be manufactured in 2014-15
therefore units to be manufactured per month

Cost

S.No
2400
2800
6000
800
340
160
12500

1
2a
b
c
d
3
a
b
4
5
6
7
8
9
10
11

20000
11700
1125
12825
14580
160312500

1096

1350 GBE
1700 GBE
2275 GBE
2725 GBE

for gear
for shaft
for gear
for shaft

3425 GBE

for gear

2275 GBE
2130 GBE
1710 GBE
6075 GBE

for
for
for
for

shaft
gears
shafts
gear box

(capacity) Capacity-(Units
Units manf
16200 manf)
-closing stock
14580
1620
495
1215

Capacity for
entire plant

Factor
Sales Realization
Raw Material Cost
Bougt out items
Rejections
packing material costs
Manpower
Direct
Indirect
Other cost tools and consumables
Plant O H and Power etc.
Repairs and Maintenance
Depreciation
Interest
Administrative and selling costs
welfare costs
[1-(2 to 10)] PBT
Profitability

After Changes(for 25%


Current
increase in profitability
256500000
291600000
66690000
75816000
87210000
99144000
1333800
1516320
2052000
2332800
11760000
0
4360500
21600000
5130000
7480000
7200000
5130000
1000000
35553700
Target PBT
13.861091618
PBT growth

11760000
0
4957200
21600000
5832000
7480000
7200000
5832000
1000000
47129680
44442125
16.162441701
32.5591429303

Q.1 (Part 1)

No.of Gears machined ( ready to be put in heat treatment)


No.of Shafts machined ( ready to be put in heat treatment)
No. Of Assemblies (these are from the heat treatment which have been loaded 2 shifts bef

Total Gear Boxes


Total Gear Boxes With 85% efficiency taken into account

Part 2
The capacity can be increased in the following manner
1. The number of gear sets of gear box is less compared to the shafts needed for a gear bo
2. the shafts extra that have been produced can be used along the extra gears that we have

Morning SEvening Sh
Night shift
90
90
78
56
56
48
22
19
22

63
53.55

box, so we can choose after every 4-5 shifts to convert H2 and S2 to geart hobbing and shaving ma
ve manf. in this shift

bing and shaving machines

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