CHAPTER 1

INTRODUCTION

1.1

PROJECTBACKGROUND
Manufacturing integrated project (MIP) is the project which is we need to
apply the Reverse Engineering approach towards exploring, analyzing and
applying various scientific engineering tools that can be categorized under design
and manufacturing engineering elements. The advancement of technologies
nowadays has results that most of the components are reduced into smaller size
hence the function become more advance compared to before. Many innovative
inventions had born due to these. For an example is water spray nozzle hose. Water
spray nozzle hose is new technology and product improvement that provide the user
to watering their plant, pets as well as vehicle in different water patterns with
controlling water pressure. Moreover, make consumers life nowadays become
easier.
Therefore in this project, we are required to unravel manufacturing, industry
and design problems that are being confronted by any organization in the
community as well as to prepare a practical solution for the problems. The
sustainable issue is the main driver to be considered in the project as we should
compile the sustainability elements in our improvement solution. The requirement
of the project is we need to submit on time according to the completion date.
Besides that, from the project, we will have an opportunity to expose ourselves with
industry prospect and gain the knowledge by implemented this project well as a
basic or fundamental to solve the complex engineering problems.
1

1.2

PROBLEMSTATEMENTS

1.3

Low strength of ABS plastic.

Hazardous environment of ABS plastic.
Long cycle time of production.

OBJECTIVES

1.4

To find sustainable material that high strength in order to replace ABS plastic.
To find suitable material that not contributes hazardous to environment.
To reduce the long cycle time production by reducing part of our product.

SCOPES

Reverse engineering analysis the part of the product (Water Spray Nozzle Grip).
Screening method to analyse the part of the product.
Life cycle analysis the part of the product.
Researches the sustainable material which have high strength and does not pollute
the environment.

CHAPTER 2

PRODUCT REVIEW

2.1

INTRODUCTION

The product that has been chosen in this project is the Water Spray Nozzle
Grip. The product chosen will be analyses in order to substitute some of the original
material to a better material. By improving the material selection, the sustainability
of the product will improve. Water Spray Nozzle Grip is a handheld mechanical tool
uses to convey water using hose and is enable customer to change is water flow. The
mechanism applied is called Locking mechanism which allows water to constantly
flows and the spray nozzle allows customer to adjust water spray in 8 individual
patterns. This product is used for various purposes. For instance, it can be used for
Watering plant, car wash, outdoor cleaning, landscaping purpose and daily domestic
related activities.
I.

Watering plant

Water Spray Nozzle Grip is suitable to be used in watering plant. The 8 different
types of water flow patterns available can be used in any type of plant there is from
smaller to larger plant. For instance, the mist setting is great for delicate plants and
seedlings.
II.

Car Washing

The 8 different types of water flow patterns available allows users to wash they car
without worrying that they will scratch their vehicle when using high pressure water
flow. Each of the car compartments may need different water pressure during
cleaning process.
III.

Outdoor cleaning

Outdoor cleaning usually involves in a spacious area. Outdoor cleaning may

involves in cleaning different types of structures from cement, wood, ceramics and
glass. By having the advantages to change the water flows, it will be an ideal tools
for users to have as each structural needs different types of water flows for cleaning
purposes.
IV.

Landscaping purpose
3

This Turret Pistol Hose Nozzle is ideal tools to have for landscaping purpose as it is
easy to be connected to a main water supply hose thus enables users to use it in a
large area. The 8 different water flows, will ensure that the water flows out can
reach far enough to water the whole area. Example, lawn watering.
V.

Daily domestic related activities

The Turret Pistol Hose Nozzle is very much useful in all daily activities. The
product flexibility to adjust the water flows is very ideal in an everyday task. For
instance, showering your pet, and washing clothes.
The advantages of Water Spray Nozzle Grip:

Quick change patterns

Ergonomic insulated grip

Heavy-duty construction

The mist setting is great for delicate plants and seedlings, and the soak
pattern is helpful when watering large containers.

Application:

Watering plants

Car washing

Showering pet

2.2

CURRENTENGINEERINGDESIGNANDANALYSIS

2.2.1

SPECIFICATIONOFTHEPRODUCT

No
.
1.

Specifications

Description

Type of hose nozzle

Pistol grip

2.
3.

Color
Pattern

5.

Pressure

Green
8 patterns includes: cone, jet, mist,
soaker, flat, quad, fan and shower
High Pressure of water
4

6.
7.
8.
9.

Flow rate of water

Product Dimension
(mm)
Item weight
Hose diameter

9 to 20 liters per minute

64 x 93 x 142
0.25 kg
15.8 mm

Figure 2.1: Water Spray Nozzle Grip

2.2.2

PRODUCTINFORMATION

Product Dimensions
item weight
Color
Hose Diameter

64mm x 93mm x 142 mm

0.25 kg
Green
15.8 mm

2.2.3

PRODUCTDISASSEMBLIES

2.2.4

EXPLODEDVIEWOFTHEPRODUCT

Figure 2.2: Catia drawing exploded view

2.2.5

CURRENTPRODUCTANALYSIS

2.2.5.1 FUNCTIONABILITYMETHOD
N
o.
1.

Name

Functions

Material
ABS plastic

Manufactur Component
ing Process Categories
Die casting
Main
(Permanent
component
Mold)

Spray
Body

As a body of the
product

2.

Spray
Nozzle

To change the flow ABS plastic

pattern of water such as
shower, flat, jet, quad,
fan, soaker, cone, and
mist

Injection
moulding /
extrusion

Main
component

3.

Nozzle
Support

Support the spray ABS plastic

nozzle so it able to
change the style of
spraying.

Injection
moulding /
extrusion

Main
component

4.

Slide
Threaded
Rod

Act as a valve to Low Carbon

control the open and Steel
close of water flow

Powder
metallurgy

Main
component

5.

Body
Presser

To control water flow.

ABS plastic

Injection
moulding /
extrusion

Main
component

6.

Large
Spring

To work together
with Stainless
Steel rod

Stainless
Steel

CNC Coiling
Machinery
(Cold
Winding)

Sub
Component

7.

Small
Spring

To force a pin to bear

against spray nozzle in
order to maintain the
flow channel.

Stainless
Steel

CNC Coiling
Machinery
(Cold
Winding)

Sub
Component

8.

Rubber
Gasket

To stop the flow of

water.

Fluoroelastomer Compression
moulding.

Sub- Component

9.

Plastic
Washer

Used to support a
fastener like a screw or
to function as a spacer

ABS plastic

Sub- Component

Injection
moulding /
extrusion

or lock.
10
.

Flow
Control
Knob

Adjustment pressure

Low Carbon
steel

Powder
metallurgy

Sub- component

11
.

Connect
Fitting

-Used to connect the

spray body to the main
water supply (Hose).
-As a body for the Oring to be placed.

ABS plastic

Injection
moulding /
extrusion

Sub- component

12
.

Rivet

Fastened the handle

with the spray body

Aluminum

Cold forming

Sub- component

13
.

Screw

Fastened the head

nozzle and nozzle
support with spray
body

Stainless Steel

CNC Coiling
Machinery
(Cold
Winding)

Sub- component

14
.

Hold Clip

-Handle/Trigger can be
fastened and watering
can is more laborsaving.

Low carbon
steel

Powder
metallurgy/
Extrusion

Sub- component

EPDM
Rubber

Rubber
injection
moulding

Main
component

-Allows for continuous

spray without
squeezing
15
.

Grip

As a coating to
hold the pistol
handle

16
.

Washer
(14mm)

To stop the flow of EPDM

water
Rubber

Compression
moulding

Sub- component

17
.

Pin

-Act as the small spring ABS plastic

body.

Injection
moulding/
extrusion

Sub- component

- Act as a stopper when

changing the spray
nozzle type.
9

18
.

Washer
(12mm)

-Reduce vibration in EPDM

the product. When Rubber
contact with water
pressure.

Compression
moulding.

Sub- component

Compression
moulding.

Sub- component

Die casting

Main
component

-Act as wear pad

between the screw and
the nozzle support.
19
.

O-Ring

-Used to tighten the EPDM

connect fitting with the Rubber
hose.
-Prevent water leakage,
when connecting the
connect fitting to the
hose.

20
.

Stopper

-Located at connect
fitting groove and
usually
compressed
between two material,
as a seal to prevent
water leaking out.
To control the
Stainless
water flow out the Steel
hose

2.2.5.2 SCREENINGMETHOD
12%

15%

RA

15%

WEI

20%

RESULTS
BAS

WEIGHTS

CRITERIA
18% 20
%

10

Function

Material

Ease of Manufacture

Performance

Shortage

Cost

E SCORE (Out of 60)

GHTED SCORE

NK OF IMPORTANCE

PART
NAME
Spray Body
Spray
Nozzle
Nozzle
Support
Body
Presser
Large Spring
Small Spring
Screw
Flow Control
Knob
Rivet
Hold Clip
O-Ring
Slide
Threaded
Rod
Washer
(14mm)
Washer
(12mm)
Plastic
Washer
Rubber Grip
Pin
Connect
Fitting
Stopper
Rubber
Gasket

10

10

49

8.24

10

10

46

7.73

10

46

7.72

10

45

7.61

10
7
8

8
6
9

7
7
7

8
6
8

7
6
7

3
4
5

43
36
44

7.35
6.08
7.4

8
17
6

42

7.02

14

6
5
7

7
7
9

9
8
9

6
6
8

6
6
8

4
3
3

38
35
44

6.39
5.86
7.38

16
18
7

10

47

7.85

43

7.22

12

43

7.22

13

44

7.35

7
4

9
8

4
5

9
4

9
5

6
2

44
28

7.25
4.6

11
20

43

7.29

10

32

5.36

19

42

7.02

15
11

Ratings for the decision matrix were ranked from the scale of 1
10,

with

ratings

characterized

respectively

and

weighted

accordingly in importance as follows:

Function: 1 (Lowest Function) 10 (Highest Function)
Material: 1 (Least Suitable Material) 10 (Most Suitable Material)
Ease of Manufacture: 1 (Lowest Feasibility) 10 (Highest
Feasibility)
Performance: 1 (Lowest Performance) 10 (Highest Performance)
Shortage: 1 (Lowest Effect) 10 (Highest Effect)
Cost: 1 (Lowest Cost) 10 (Highest Cost)
From the rank of importance, rank from 1 until 5 is taken to be part
improvement.
2.2.5.3 LIFECYCLEASSEMENTMETHOD(LCA)
Life cycle assessment determines the environmental impacts of products,
processes or services, through production, usage, and disposal. Climate change is
the ultimate effect of large carbon footprints. Greenhouse gases, whether natural or
human-produced, contribute to the warming of the planet. From 1990 to 2005,
carbon dioxide emissions increased by 31 percent. By 2008, the emissions had
contributed to a 35 percent increase in radiative warming, or a shift in Earths
energy balance toward warming, over 1990 levels. The decade from 2000 to 2009
was the warmest decade on record worldwide, according to the U.S. Environmental
Protection Agencys Climate Change Indicators Report.
Therefore, it is important to reduce the carbon footprint release.

Each

product that we produce release carbon footprint, but we can reduce it by using a
12

suitable material and process. Now there software that can be used to calculate the
carbon footprint over the life cycle of industrial activities. This software can be
used to determine suitable material and process that can reduce carbon footprint
release.

PART NAME
SPRAY BODY
NOZZLE
SUPPORT
SPRAY NOZZLE
CONNECT
FITTING
BODY PRESSER
TOTAL=1.07KG

TOTAL CARBON
FOOTPRINT (KG) OLD
MATERIAL
1.86

TOTAL CARBON
FOOTPRINT (KG) NEW
MATERIAL
1.12

REDUCE
0.74

1.33

1.23

0.1

1.89

1.75

0.14

1.64

1.60

0.04

1.70

1.65

0.05

From table above, the new material can reduce the carbon footprint from original
material. This shown that new material is more suitable to use.

13

2.2.5.3.1

CURRENTDESIGNANALYSIS

2.2.5.3.1.1

NOZZLESUPPORT(absplastic,0.0105kg)

14

2.2.5.3.1.2

SPRAYNOZZLE(abs0.0297kg)

15

2.2.5.3.1.3

BODYPRESSER(ABS0.015KG)

16

2.2.5.3.1.4

CONNECTFITTING(ABS0.001KG)

17

2.2.5.3.1.5

SPRAYBODY(ABS0.05KG)

18

2.2.5.3.2

PROPOSEDDESIGNANALYSIS

2.2.5.3.2.1

SPRAYBODY(ZINCALLOY0.08KG)

19

2.2.5.3.2.2

SPRAYNOZZLE(PBT0.03KG)

20

2.2.5.3.2.3

NOZZLESUPPORT(PBT0.0105KG)

21

2.2.5.3.2.4

CONNECTFITTING(PBT0.001KG)

22

2.2.5.3.2.5

2.3

BODYPRESSER(PBT0.015KG)

MATERIALSUBSTITUTION
Materials are finite resources and should be carefully chosen and efficiently
used in operations. Material substitution is replacement of one material in a product
by another. Material substitution can be necessary for technical reason or a better
23

improvement. It is occasionally necessary to allow substitution of one material for

another within a sales order. This is due to inventory shortages resulting from higher
than usual consumer demand. The ability to identify and substitute acceptable
products in such situations helps to avoid lost sales and increases customer
satisfaction with time deliveries.
Material substitution is a constant and ongoing part of any industry. In our
project, we will suggest some material for substitution so it can be a sustainable,
stronger and environmental friendly product. As stated at Product Analysis, the
materials used to produce are ABS plastic, aluminium, Stainless Steel, rubber,
nylon, low carbon steel and non-slip rubber grip. Aluminum and Stainless Steel
might look similar, but they are different in mechanical properties. Stainless steel is
stronger than Aluminum as aluminum is only one third of the weight of stainless
steel. Stainless steel is made up of iron, chromium, nickel, manganese and copper.
The chromium is added as an agent to provide corrosion resistance as it is nonporous the resistance to corrosion is increased. When aluminum is oxidized, its
surface will turn white and will sometimes pit. In some extreme acidic or base
environments, aluminum may corrode rapidly. Aluminum is fairly soft compared to
stainless steel. Stainless steels are harder and stronger than Aluminum, hence it has
longer life time. Stainless steel can be used at much high temperatures as this nozzle
will be used at outdoor.
An alloy of Zinc that contains between 55% and 95% Copper, is among the
best known alloy. Zinc is used as a protective coating to copper that experiencing
corrosion. The zinc can be applied to the object by dipping the copper into a pool of
molten zinc, but most often this is accomplished through electroplating. Zinc alloys
offer high strengths and superior elongation for strong designs and formability for
bending, crimping and riveting operations. Zinc alloys provide significantly higher
impact resistance. Virtually any part configuration can be molded using zinc. High
casting fluidity, regardless of part configuration, allow for thinner wall sections to
be cast in zinc compared to other metals. Zinc is among the cleanest melting
materials. Zinc metal is non-toxic. Scrap of zinc is a reusable resource which is
efficiently recycled. Zinc alloys provide excellent strength and extreme fluidity.
24

Zinc alloys can be easily recycled compared to plastic substrates, making zinc a
more sustainable manufacturing material.
Polybutylene terephthalate (PBT) is a thermoplastic engineering polymer.
Polybutylene terephthalate is used for housings in electrical engineering, but also in
automotive construction as plug connectors and in households for example in
showerheads or irons. It is also found processed into fibers in toothbrushes and is
used in the keycaps of some high end computer keyboards because the texture is
highly resistant to wear. PBT is resistant to solvents, shrinks very little during
forming, is mechanically strong, heat-resistant up to 150C and can be treated with
flame retardants to make it noncombustible.
For improvement of the product in performance and higher sustainability, we
changed the material of the product. Although this will increase the manufacturing
cost during production, but due to higher performance and durability, the total cost
of the usage, maintenance and disposal cost for the product life is lower in overall.
ABS Plastics
ABS plastic is also known as Acrylonitrile Butadiene Styrene. ABS is an
ideal material wherever superlative surface quality, colorfastness and luster are
required. ABS is a two phase polymer blend. A continuous phase of styreneacrylonitrile copolymer gives the materials rigidity, hardness and heat resistance.
The toughness of ABS is the result of sub-microscopically fine poly-butadiene
rubber particles uniformly distributed in the SAN matrix. ABS standard grades have
been developed specifically to meet the requirements of major customers. ABS is
readily modified both by the addition of additives and by variation of the ratio of the
three monomers Acrylonitrile, Butadiene and Styrene, hence grades available
include high and medium impact, high heat resistance, and electroplatable. Fibre
reinforcement can be incorporated to increase stiffness and dimensional stability.
Advantages
Very sturdy and hard.

Disadvantages
Made out of oil, so more damaging to the

environment.
Suitable for machine or car Deform when not being print on a heated
parts.

surface.
25

Higher melting point.

Longer lifespan.

Hot plastic fumes when printing

Not suitable for using with food.

Polybutylene terephthalate (PBT)

Polybutylene terephthalate (PBT) is a synthetic semi-crystalline engineered
thermoplastic with similar properties and composition to polyethylene terephthalate
(PET). It is part of the polyester group of resins and share similar characteristics to
other thermoplastic polyesters. Additionally, it is a high performance material
with high molecular weight and is often characterized as being a strong, stiff, and
engineerable plastic. PBT is present in everyday life and is common in electrical,
electronic and automotive components. PBT resin and PBT compound are the two
types of products that are used across various applications. PBT compound is
comprised of various materials that can include PBT resin, fiber glass filing and
additives, whereas the PBT resin only includes the base resin.
Advantages
Excellent stain resistant.
Excellent machining characteristics.
High strength.

Disadvantages
Prone to warp when glass is used as a filler.
Does not present satisfactory resistance to
acids, bases and hydrocarbons.

Toughness
Excellent stiffness-to-weight ratio.
Resistance to environmental changes.
High electrical insulation properties.
Thermoplastic polyester elastomer (TPE-E)
TPE-E referred to as thermoplastic rubbers, are a class of copolymers or a
physical mix of polymers which consist of materials with both thermoplastic and
elastomeric properties. While most elastomers are thermosets, thermoplastics are in
contrast relatively easy to use in manufacturing, for example, by injection molding.
Thermoplastic elastomers show both advantages typical of rubbery and plastic
materials. The principal difference between thermoset elastomers and thermoplastic
elastomers is the type of crosslinking bond in their structures. In fact, crosslinking is
a critical structural factor which contributes to impart high elastic properties. The
crosslink in thermoset polymers is a covalent bond created during the vulcanization
process. On the other hand the crosslink in thermoplastic elastomer polymers is a
26

weaker dipole or hydrogen bond or takes place in one of the phases of the material.
TPE is a plastic that bends, squeezes, breaths, seals, bounces. It is an elastomer with
a very broad temperature range of use. The materials show excellent low
temperature ductility combined with sufficient stiffness and tear strength at high
temperatures. Moreover the TPE-E show very good thermo-oxidative stability and
good chemical resistance especially against apolar chemicals like greases and oils.
Another very strong property of Copolyetheresters is its excellent fatigue resistance.
Aluminium
Aluminium is a silvery-white metal, the 13 element in the periodic table.
One surprising fact about aluminium is that it's the most widespread metal on Earth,
making up more than 8% of the Earth's core mass. It's also the third most common
chemical element on our planet after oxygen and silicon. The most common form of
aluminium found in nature is aluminium sulphates. These are minerals that combine
two sulphuric acids. The use of aluminium in objects of everyday use is economical,
safe and ecologically sensible.
Advantages
Wont swell, chip or rust.
Does not deteriorate.
Reduced weight.

Disadvantages
It is expensive.
It can corrode quickly if suitable
precautions against electrolysis are not

taken.
Increased strength and durability.
It can be water-stained easily.
Covers can be retrofitted for existing
structures.
Low surface hardness.

Stainless Steel
'Stainless' is a term coined early in the development of these steels for
cutlery applications. It was adopted as a generic name for these steels and now
covers a wide range of steel types and grades for corrosion or oxidation resistant
applications. Stainless steels are iron alloys with a minimum of 10.5% chromium.
Other alloying elements are added to enhance their structure and properties such as
27

formability, strength and cryogenic toughness.

Advantages
Strong.
Relatively ductile.

Disadvantages
Susceptibility to crevice and stress
corrosion.

Biocompatible.
Relatively cheap.
Reasonable corrosion resistance.
2.4

PROPOSEDPRODUCTCHANGESANDJUSTIFICATION

2.4.1

SPRAYBODY

Figure 2.3: Spray Body of the product

Material
Function

Bad feature

Environment
Social

ABS plastic
As water container before water been release from nozzle
spray. Besides, use to hold to spray nozzle and connect
fitting while provide a handle for human hand to hold.
1) If exposed to sunlight, it will become brittle.
2) Low strength and will crack if exposed to force
Sustainability Problem
derived from natural gas and petroleum
1) At higher temperatures (400 C) ABS can decompose
into its constituents: butadiene (carcinogenic to
humans), acrylonitrile (possibly carcinogenic to
humans), and styrene.
2) Concerns have been raised regarding airborne
ultrafine particle (UFP) concentrations generated
while printing with ABS, as UFPs have been linked
28

Economic

with adverse health effects.

Production of 1 kg (2.2 lb) of ABS resin in Europe uses an
average of 95.34 MJ (26.48 kWh)

FINITE ELEMENT ANALYSIS

When exposed to 400N which is 41 kg. Von Mises stress dont exceed ABS yield stress.
7
ABS yield stress is 6.89 10 . This shown that ABS can still withstand 400N force.

Meanwhile, when exposed to 625N (63.7kg). Von Mises stress exceed ABS yield stress.
This can be concluded that ABS only can withstand force below 623N. more than that will
cause ABS part break.

29

2.4.2

SLIDETHREADEDROD

Item
Material
Young's modulus
Poisson's ratio
Density
Coefficient of thermal
expansion
Yield strength
Von Mises Stress
Min:
Max:
Energy
Global Error Rate (%)

Current Design
Low Carbon Steel
21011 N/m2
0.266
7860kg/m3
1.1710 -5 K-1deg

Proposed Design
Stainless Steel
2.031011 N/m2
0.275
8000kg/m3
2010 -6 K-1deg

3.710 7 N/m2

2.910 7 N/m2

1.85756 N/m2
207029 N/m2
4.97310-7 J
1.35%

0.774773 N/m2
84135.4 N/m2
8.30510-8 J
1.33%

For this parts, we are focusing in reducing the number of part of the slide threaded rod, by
combining the two part with different material together into one type of material. Thus,
reducing the insertion and handling time( further discussion in DFMA Analysis) and the
manufacturing cost. The material costing are also taken into consideration.
By comparing the material type, we can clearly see that is a difference in the maximum von
mises stress. For low carbon steel, the maximum value for von mises stress is 207029 N/m 2
while 84135.4 N/m2 for Stainless Steel. Low carbon steel has higher yield strength, but
higher von mises stress. While, stainless steel are lower in yield strength, but the von mises
stress is lower in the analysis been made, and it have 1.33% of global error rate compare to
30

1.35% error rate for low carbon steel.

Current Design

Proposed Design

Sustainability Threaded Manufacturing

Substantial Material Saving
When a thread is produced by rolling, material saving are inevitable. A rolled thread
requires a smaller blank. The finished parts major thread diameter is produced by the
outward flow of displaced material. On the other hand, a cut threads blank diameter and
31

thread diameter are equal to another. Thread rolling produces no waste material. It could be
stated that thread rolling is good for the environment. There are many other advantages, as
follow:
i.

Greater accuracy and uniformity

The thread rolling dies of today are ground and polished to exacting specifications.
In fact, it is possible to maintain a pitch diameter tolerance 0.001 in. However, the
major advantage thread rolling has over other types of thread production is the
ability to remain extremely accurate over very long production runs. The thread
rolling dies does not erode over time because the contact point is not concentrated
on a sharp cutting edge, but is instead distributed over a broad surface. Also, the
thread rolling itself is relatively friction free, so adhesion does not case problems
either. Therefore, if each of the blanks dimension are uniform, the first part
produced will be the same as the one-thousandth part produced.

ii.

Other cost saving features

Thread rolling dies do not require sharpening. There is no downtime for sharpening
or resetting.

Thread rollings uniformity saves money on inspection labor.

Rolling can be performed on the collect end behind a parts shoulder, often saving a
secondary threading operation.

Smoother surfaces of the product

Better fatigue resistance due to compressive stresses introduced by rolling

The advantages of generating thread at high production rates and without any scrap.

The process induces compressive residual stresses on the surfaces, thus improving
fatigue life.

32

2.4.3

SPRAYNOZZLE

Item
Material
Young's modulus
Poisson's ratio
Density
Coefficient of thermal
expansion
Yield strength
Von Mises Stress
Min:
Max:
Energy
Global Error Rate (%)

Current Design
ABS Plastic
(Acrylonitrile Butadiene Styrene)
2.2 109 N/m2
0.38
1200kg/m3
6.8410 -5 K-1deg

Proposed Design
PBT
(Polybutylene terephthalate)
2.2 109 N/m2
0.38
1310kg/m3
6.8410 -5 K-1deg

410 6 N/m2

4.610 6 N/m2

13092.5 N/m2
7.96991 106 N/m2
0.006J
10.40%

6762.82 N/m2
4.11679 106 N/m2
0.001J
10.41%

For this part, we are focusing in choosing cheaper material with better specification and
properties in order to increase the life span of the product.Thus, increasing the sustainability
of the overall product and directly reduce the manufacturing cost involves.
By comparing the material type, we can clearly see that is a great difference in the
maximum von mises stress. For ABS Plastic, the maximum value for von mises stress is
7.96991 106 N/m2 while 4.11679 106 N/m2 for PBT. Given the fact that PBT have higher
yield strength, and lower von mises stress, it is proven that failure are unlikely to occur in
this design,thus it is far better choice in material selection. Other than the other material
properties been taking into considerasion.
CURRENT DESIGN

2.4.4
Item

PROPOSED DESIGN

NOZZLESUPPORT
Current Design

Proposed Design
33

Material

ABS Plastic
PBT
(Acrylonitrile
Butadiene (Polybutylene terephthalate)
Styrene)
Young's modulus
2.2 109 N/m2
2.2 109 N/m2
Poisson's ratio
0.38
0.38
3
Density
1200kg/m
1310kg/m3
-5
-1
Coefficient of thermal 6.8410 K deg
6.8410 -5 K-1deg
expansion
Yield strength
410 6 N/m2
4.610 6 N/m2
Von Mises Stress
Min:
49.1971 N/m2
458.01 N/m2
7
2
Max:
2.21072 10 N/m
1.50787 107 N/m2
Energy
0.006J
0.003J
Global Error Rate (%) 23.83%
24.68%
For this part, we are focusing in choosing cheaper material with better specification and
properties in order to increase the life span of the product. Thus, increasing the
sustainability of the overall product and directly reduce the manufacturing cost involves.
By comparing the material type, we can clearly see that is a difference in the maximum von
mises stress. For ABS Plastic, the maximum value for von mises stress is 2.21072 10 7
N/m2 while 1.50787 107 N/m2 for PBT. Given the fact that PBT have higher yield strength,
and lower von mises stress, it is proven that failure are unlikely to occur in this design, thus
it is far better choice in material selection. Other than the global error rate a slightly lower
in ABS Plastic with 23.83% compare to 24.68% in PBT. But the energy needed in PBT is
lower than in ABS Plastic.
CURRENT DESIGN

2.4.5

PROPOSED DESIGN

BODYPRESSER

Function: Control the flow of water.

34

Current material: ABS plastic

Proposed Material: Polypropylene
Material Properties
-

Lower weight and density

Melting point of 171 C

Polypropylene is liable to chain degradation from exposure to heat and UV radiation

such as that present in sunlight.

Manufacturing Process
Based on our reverse engineering activities and applying the procedure of manufacturing
processes selection for nozzle support PBT (Polybutylene Teraphthalate), the result table
shows that several manufacturing can be using to produce this part with their respective
type of material used. The preferred manufacturing process for this part is injection
moulding.
Normal Practice
Less Common

Injection Moulding
Structural Foam Moulding
Machining (from stock)

Sustainability in Injection Moulding

Environmental friendly
With sustainability being a main concern these days, it is important for manufacture
to choose manufacturing processes that benefit the environment. Injection molding
not only an efficient, effective process, but it is also resourceful. That is because:
a) Only as much plastic as is necessary is used to create the part/product.
b) Injection molding process minimizes the waste of product, with the correct
machine specification.
c) Excess thermoplastic can be ground up and recycled after use.

Economics
Injection moulding process can reduce the part weight up to 10% and 30%, resulting
in lower material costs without affecting structural integrity. It is also have the
35

ability to use different types of plastic simultaneously, thus, a same machine can be
used in producing same part with different material.

2.5

FEASIBILITYSTUDYFORMANUFACTURING(DFM)

2.5.1

PROCESSCAPABILITIES
Each process can be analyzed to determine the range of its capabilities in
terms of attributes of the parts that can be produced. Included in these capabilities
are shape features that can be produced, natural tolerance ranges, surface roughness
capabilities, and so on. These capabilities determine whether a process can be used
to produce the corresponding part attributes.
GENERALSHAPEATTRIBUTE

Shape Criteria

2.5.2

Slide
Threade
d Rod

Head
Nozzle

Nozzle
Support

Body
Presser

Spray
Body

1 Depression

Yes

Yes

Yes

Yes

Yes

2 Uniform Wall

No

No

No

No

No

No

Yes

No

No

No

Yes

Yes

Yes

No

No

Yes

Yes

No

No

No

No

No

No

No

No

No

No

No

No

No

3
4
5
6
7

Uniform Cross
Section
Axis of
Rotation
Regular Cross
Section
Captured
Cavity
Enclosed
Cavity

36

8 No Draft

2.5.3

NO.
1

No

No

No

No

TABLEOFPARTLISTWATERSPRAYNOZZLEGRIP
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

2.5.4

Yes

PART NAME
Spray Body
Spray Nozzle
Nozzle Support
Slide Threaded Rod
Body Presser
Spring (Large)
Spring (Small)
Rubber Gasket
Plastic Washer
Flow Control Knob
Connect Fitting
Rivet
Screw
Hold Clip
Grip
Washer 14mm
Pin
Washer 12mm
O-ring
Stopper

QUANTITY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

TABLEOFALPHAANDBETAFORMANUALHANDLING
PART NAME
Spray Body

QTY

ALPHA ()

BETA ()

360

360

720
37

2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

2.5.5

NO.
1
2
3
4
5
6
7
8

Spray Nozzle
Nozzle Support
Aluminum Rod
Body Presser
Spring (Large)
Spring (Small)
Rubber Gasket
Seal
Strainer
Connect Fitting
Rivet
Screw
Hook
Grip
Washer 14mm
Pin
Washer 12mm
O-ring
Stopper

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

360
360
360
360
180
180
180
180
360
360
360
360
360
360
180
360
360
180
360

360
360
0
360
0
0
0
0
0
0
0
90
180
360
0
0
0
0
90

720
720
360
720
180
180
180
180
360
360
360
450
540
720
180
360
360
180
450

TABLEOFESTIMATEDHANDLINGTIME

PART NAME
Spray Body
Spray Nozzle
Nozzle Support
Aluminum Rod
Body Presser
Spring (Large)
Spring (Small)
Rubber Gasket

QT
Y
1
1
1
1
1
1
1
1

ALPHA BETA
+
()
()
360
360
360
360
360
180
180
180

360
360
360
0
360
0
0
0

720
720
720
360
720
180
180
180

Manual
Handling
Code
30
30
30
10
33
03
03
00

Manual
Handling
Time
1.95
1.95
1.95
1.5
2.51
1.69
1.69
1.13
38

9
10
11
12
13
14
15
16
17
18
19
20

2.5.6

Seal
Strainer
Connect Fitting
Rivet
Screw
Hook
Grip
Washer 14mm
Pin
Washer 12mm
O-ring
Stopper

1
1
1
1
1
1
1
1
1
1
1
1

180
360
360
360
360
360
360
180
360
360
180
360

0
0
0
0
90
180
360
0
0
0
0
90

180
360
360
360
450
540
720
180
360
360
180
450

03
11
10
10
10
23
35
01
03
03
03
13

1.69
1.8
1.5
1.5
1.5
2.36
2.73
1.43
1.69
1.69
1.69
2.06

TABLEOFESTIMATEDINSERTIONTIME

NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

PART NAME
Spray Body
Spray Nozzle
Nozzle Support
Aluminum Rod
Body Presser
Spring (Large)
Spring (Small)
Rubber Gasket
Seal
Strainer
Connect Fitting
Rivet
Screw
Hook
Grip
Washer 14mm
Pin

QTY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

Manual
Insertion
Code
00
31
00
00
09
00
00
00
00
31
31
35
39
03
08
00
00

Manual
Insertion
Time
1.5
5
1.5
1.5
7.5
1.5
1.5
1.5
1.5
5
5
7
8
3.5
6.5
1.5
1.5
39

18
19
20

1
1
1

00
00
07

1.5
1.5
6.5

Assembly Time

360

360

720

30

Time Manual Handling

Manual Insertion
Time

Code Manual Handling

Manual Insertion
Code

Spray Body

1.95

00

1.5

3.45

Spray Nozzle

360

360

720

30

1.95

31

6.95

Nozzle Support

360

360

720

30

1.95

00

1.5

3.45

Aluminum Rod

360

360

10

1.5

00

1.5

Body Presser

360

360

720

33

2.51

09

7.5

10.01

Spring (Large)

180

180

03

1.69

00

1.5

3.19

Spring (Small)

180

180

03

1.69

00

1.5

3.19

Rubber Gasket

180

180

00

1.13

00

1.5

2.63

Seal

180

180

03

1.69

00

1.5

3.19

10

Strainer

360

360

11

1.8

31

6.8

11

Connect Fitting

360

360

10

1.5

31

6.5

12

Rivet

360

360

10

1.5

35

8.5

13

Screw

360

90

450

10

1.5

39

9.5

14

Hook

360

180

540

23

2.36

03

3.5

5.86

15

Grip

360

360

720

35

2.73

08

6.5

9.23

NO.

QUANTITY

PART NAME

BETA ()

TABLEOFESTIMATEDASSEMBLYTIMEFORPARTS

ALPHA ()

2.5.7

Washer 12mm
O-ring
Stopper

40

16

Washer 14mm

180

180

01

1.43

00

1.5

2.93

17

Pin

360

360

03

1.69

00

1.5

3.19

18

Washer 12mm

360

360

03

1.69

00

1.5

3.19

19

O-ring

180

180

03

1.69

00

1.5

3.19

20

Stopper

360

90

450

13

2.06

07

6.5

8.56

C5

C6

C7

CodeManual Insertion

TimeManual Insertion

Operational Time
C2(C4+C6)

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

13
03
03
03
01
35
23
10
10
10
11
03
00
03
03
33
10
30
30
30

2.06
1.69
1.69
1.69
1.43
2.73
2.36
1.5
1.5
1.5
1.8
1.69
1.13
1.69
1.69
2.51
1.5
1.95
1.95
1.95

07
00
00
00
00
08
03
39
35
31
31
00
00
00
00
09
00
00
31
00

6.5
1.5
1.5
1.5
1.5
6.5
3.5
8
7
5
5
1.5
1.5
1.5
1.5
7.5
1.5
1.5
5
1.5
Total :

8.56
3.19
3.19
3.19
2.93
9.23
5.86
9.5
8.5
6.5
6.8
3.19
2.63
3.19
3.19
10.01
3
3.45
6.95
3.45
106.51
TM

C8

C9
theoretical minEstimation of

C4

0.4(C7)Operational Cost

C3

TimeManual Handling

20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1

C2

CodeManual Handling

Part ID

C1

TABLEOFTHEDESIGNEFFICIENCY(CURRENTDESIGN)
operation is carriedNo. of times the

2.5.8

3.42
1.28
1.28
1.28
1.17
3.69
2.34
3.80
3.40
2.60
2.72
1.28
1.05
1.28
1.28
4.00
1.20
1.38
2.78
1.38
42.60
CM

0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
19
NM

Name of Assembly

Stopper
O-Ring
Washer 12 mm
Pin
Washer 14 mm
Grip
Hook
Screw
Rivet
Connect Fitting
Strainer
Seal
Rubber Gasket
Spring (small)
Spring (large)
Body Presser
Aluminium Rod
Nozzle Support
Spray Nozzle
Spray Body
Design Efficiency
3 NM/TM = 0.535

41

C8

C9

1
1
1

07
00
00

6.5
1.5
1.5

8.56
3.19
3.19

3.42
1.28
1.28

theoretical partsEstimation of

C7

0.4(C7)Operational Cost

C6

Operational Time
C2(C4+C6)

C5

TimeManual Insertion

15
14
13
12
11
10
9
8
7
6
5
4
3
2
1

C4

CodeManual Insertion

16

C3

TimeManual Handling

19
18
17

C2

CodeManual Handling

Part ID

C1

TABLEOFTHEDESIGNEFFICIENCYFORPROPOSEDDESIGN
operation is carriedNo. of times the

2.5.9

1.8

00

1.5

3.3

1.32

1.43
2.73
2.36
1.5
1.5
1.5
1.8
1.69
1.13
1.69
1.69
2.51
1.5
1.95
1.95

00
08
03
39
35
31
31
00
00
00
00
09
00
00
31

1.5
6.5
3.5
8
7
5
5
1.5
1.5
1.5
1.5
7.5
1.5
1.5
5

2.93
9.23
5.86
9.5
8.5
6.5
6.8
3.19
2.63
3.19
3.19
10.01
3
3.45
6.95
103.17
TM

1.17
3.69
2.34
3.80
3.40
2.60
2.72
1.28
1.05
1.28
1.28
4.00
1.20
1.38
2.78
41.27
CM

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
19
NM

13
03
03

2.06
1.69
1.69

11

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

01
35
23
10
10
10
11
03
00
03
03
33
10
30
30

Total :

1
1
1

Name of Assembly

Spray Body
Spray Nozzle
Nozzle Support
Slide Threaded Rod
and Stopper
Trigger
Spring (Large)
Spring (Small)
Rubber Washer
Plastic Washer
Flow Control Knob
Connect Fitting
Rivet
Screw
Hold Clip
Gripper
Washer 14 mm
Pin
Washer 12 mm
O-Ring
Design Efficiency
3 NM/TM = 0.55

CHAPTER 3

MANUFACTURING PROCESS DESIGN, ANALYSIS AND DISCUSSION

3.1

PROCESS CAPABILITY STUDY

a) Process Capabilities Study
42

Process capability is the repeatability and consistency of a manufacturing process

relative to the customer requirements in terms of specification limits of a product
parameter. This measure is used to objectively measure the degree to which your
process is or is not meeting the requirements. Process capability is a Cp and Cpk are
considering short-term potential capability measures for a process. Industries also
have used Cp and Cpk as statistical measures of process quality capability.
Index
Definition
Cpk Process capability for two-sided specification limits taking into account where
the process is centered.
What a process is capable doing in future, assuming it remains in a state of
statistical control.
The closeness to target and consistent around the average performance.
Cpk measures not only the process variation with respect to
allowable specifications, it also considers the location of the
process average.
Formula:
C pk =min

USL LSL
,
where is process mean.
3
3

The figure above shows the bell shape graph for Cpk.
Cp

Process capability index that relates the allowable spread of

the specification limits (specification range or the difference
between the upper spec limit, USL and the lower specification
limit, LSL) to the measure of the actual, or natural, variation
of the process, represented by 6 sigma, where sigma is the
estimated process standard deviation.

43

Formula of Cp:
Cp=

USLLSL
6

The figure above shows the bell shape graph for Cp.
Value of Cp
Cp<1: The process variation exceeds specification, and a
significant number of defects are being made.
Cp=1: The process is just meeting specifications. A minimum of
.3% defects will be made and more if the process is not
centered.
Cp>1: The process variation is less than the specification,
however, defects might be made if the process is not centered
on the target value.
Relationship between Cpk and Cp

If Cp = Cpk, then the process is perfectly centered.

Cpk accounts for centering where Cp does not, Cpk can never be larger than Cp.
Both assume a stable process.

Process Capability Studies are designed to see what the process is

capable of doing under controlled conditions. The studies look at how
capable the process is given ideal conditions over a short period of
time such as an eight hour production. The individual who is mainly
responsible for the process capability study is a Process Engineer. The
44

Process Engineer must keep in mind the following two considerations

when conducting the study.

Eliminate or minimize special causes of variation, for example,

using the same operator, the same batch of material, same
machine and so on.

Collect a minimum of 50 consecutive pieces in at least 10

subgroups of 5.

The benefits of conducting a Process Capability Study is to determine

the short term stability and capability of a process.

3.1.1

ProcessCapabilityonHuman
Station

Assembly part
Packaging
Grinding
Machine
(Finishing
Process)

Operator

Cumulative
Operator

4
2
2

4
6
8

Cumulativ
e
Percentag
es
33%
50%
67%

45

Injection Molding
Machine
Die Casting
Machine
Cold Heading
Machine
Thread Rolling
Machine
Total =

75%

10

83%

11

92%

12

100%

12
Table 3.1: Operator per Station

Operator per Station

4.5
4
3.5
3
2.5
2
1.5
1
0.5
0
Operator

80%
70%
60%
50%
40%
30%
20%
10%
0%
Operator

Cumulative Percentages

Station

Figure 3.1: Pareto Chart of Operator per Station

3.1.2

ProcessCapabilityonMachine
Machine

Thread Rolling
Cold Heading
Die Casting
Machine
Injection

Part Produces
Per day (unit)

Cum Part
Produces Per
day (unit)

6000
3600
1345

6000
9600
10945

Cumulativ
e
Percentag
es
50%
80%
91%

1030

11975

100%
46

Molding
Machine
Total =
11975
Table 3.2: Part produces per day based on each machine

Production Part Per Day

7000
6000
5000
4000
3000
2000
1000
Part Produces per
day
0 (units)
Part Produces Per day (units)

120%
100%
80%
60%
40%
20%
Cumulative Percentages 0%

Machine

Figure 3.2: Pareto Chart for production part per day

3.1.3

ProcessCapabilityonProcess

Manufacturing
Process

Cycle time
(seconds)

Cumulative
Cycle Time
(seconds)

Injection Molding
Die Casting
Cold Heading
Thread Rolling
Machine

17.46
13.38
5
3

17.46
30.84
34.84
38.84

Cumulativ
e
Percentag
es
45%
79%
92%
100%

47

Total =
38.84
Table 3.3: Cycle time of Manufacturing Process

Cycle Time of Manufacturing Process

20
18
16
14
12
10
8
6
Cycle Time
4 (s)
Cycle Time (Seconds)
2
0

Cumulative Percentages

120%
100%
80%
60%
40%
20%
0%

Manufacturing Process

Figure 3.3: Pareto Chart for Cycle Time of Manufacturing Process

48

3.2

PROCESSANDMACHINESELECTION

3.2.1

PROCESSOFTHEPRODUCT

Figure 3.4: Flow chart of the manufacturing process of the water spray nozzle grip
This session will discuss about the manufacturing process of the product, water spray
nozzle grip. We decide to make 5 components of the product, which are spray body, spray
nozzle, nozzle support, body presser and connect fitting. Spray body of the product is made
by zinc alloy that will undergoes die casting process and grinding machine. The spray
nozzle, nozzle support, body presser and connect fitting are made by PBT plastic using
injection molding machine and grinding machine. Stainless steel rod that we outsourced
from other company will go thru the cold heading machine and thread rolling machine to
become a slide threaded rod. Then, all part will go thru assemblies process which from
49

screwing and riveting. Before packaging, there will be an operator to do inspection for
quality control.
Total assembly time = 103.17seconds
Total cycle time = 103.17 + 13.38 = 116.55s
Operating hours = 8 hours
60 60
Total part produced per hours = 103.17 = 34 units
Total part produced per day = 348hours= 272units
Total part produced per month = 27226=7072 units

3.2.2

MACHINESELECTION

3.2.2.1 PLASTICINJECTIONMOULDINGMACHINE

Machine Type
Machine Dimension
Model Number
Material Type
Injection Rate
Injection Weight
Clamping Force
Injection pressure
Ejector Stroke
Opening Stroke
Ejector force
Mould Thickness
System Pressure
Machine Weight
Power
Heating power
Machine Capacity

Fully Electric Injection Molding Machine

4300mm*1500mm*1600mm
ZSJ
Thermoplastics
62 1175g/s
101g 6280g
1000 kN
139MPa 182MPa
140mm
475mm
70 kN
150mm 400mm
16 MPa
3.4 Ton
55 kW
7.6 kW
50 Ton

50

3.2.2.2 DIECASTINGMACHINE

Machine Type
Machine Dimension
Model Number
Material Type
Injection Rate
Injection Weight
Clamping Force
Injection pressure
Ejector Stroke
Opening Stroke
Ejector force
Mould Thickness
System Pressure
Machine Weight
Power
Heating power
Machine Capacity

Hydraulic system pressure

7000mm 1700mm 3000mm
LK400
Zinc Alloy
1800 g/s
6280 g
4000 kN
156 MPa
120 mm
550 mm
430 kN
300 mm 750 mm
14 MPa
18 Ton
22 kW
9.5 kW
400 Ton

3.2.2.3 COLDHEADINGMACHINE

Machine Type
Machine Dimension
Model Number
Material Type
Die Size
Machine weight
Power
Machine Capacity
Capacity Rate

Cold Heading Machine

1100mm 700mm 750mm
TX-5
Stainless Steel 304
20 mm 35 mm
520 KG
1100 W
700 KG
155 pcs/min

51

3.2.2.4 THREADROLLINGMACHINE

Machine Type
Machine Dimension
Model Number
Material Type
Diameter of rebar
Rotate speed
Length of thread
Machine weight
Power
Capacity
Heating power
Machine Capacity

Thread Rolling Machine

4300mm 1500mm 1600mm
DY-40
Stainless Steel 304
5mm 35mm
40 62 r/min
80mm
560 KG
4 kW
60 pcs/min
7.6 kW
50 Ton

3.2.2.5 GRINDERMACHINE

Grinding Wheel
A60P, A80P
Abrasive Wheel Dimensions (mm)
(Thickness)

19 (right), 6.4 (left)

Abrasive Wheel Dimensions (mm) (OD)

150
Cord Length (m)

1.8

Revolution (min-1[r.p.m])

3000/3500

Weight (KG)

6.2
52

Cycle(Hz)

50/60

Power (W)

150 W

3.3

PRODUCTIONPLANNING,SCHEDULINGANDCONTROL
Production planning and control is concerned with directing production
along the lines set by the planning department. The administrative process that takes
place within a manufacturing business and which involves making sure that
sufficient raw materials, staff and other necessary items are procured and ready to
create finished products according to the schedule specified. A typical large
manufacturing business engaging in production planning will aim to maximize
profitability while maintaining a satisfied consumer base.

Figure 3.5: Summary of Production Planning

53

3.3.1

COMPANYORGANIZATIONAL

Figure 3.6: Organizational Chart of our company

3.3.2

ORDERMANAGEMENTSYSTEM
Order management is the administration of business processes related to
orders for goods or services. An order management system (OMS) automates and
streamlines order processing for businesses. An OMS provides constantly updated
inventory information, a database of vendors, a database of customers, a record of
customer returns and refunds, information on billing and payments, order processing
records, and general ledger information. Order management is important primarily
in the retail industry. Benefits of a well-implemented OMS include improved sales
visibility, improved customer relations, and efficient order processing with a
minimum of delays and back-orders.

54

Figure 3.7: Summary of Order Management

No

Material

Required for 7072 units

Unit per order

PBT

418 kg

1000 kg

Zinc Alloy

1839 kg

1000 kg

Stainless steel Rod

7072 units

1000 units

Flow Control Knob

7072 units

100 units

Spring (large)

7072 units

100 units

Spring (small)

7072 units

100 units

Screw

7072 units

100 units

O-Ring

7072 units

100 units

Rivet

7072 units

100 units

10

Hold Clip

7072 units

100 units

11

Washer (14mm)

7072 units

100 units

12

Washer (12mm)

7072 units

100 units

13

Plastic Washer

7072 units

100 units

14

Rubber Grip

7072 units

1000units

15

Pin

7072 units

100 units

16

Seal

7072 units

100 units

Order and Reorder

Table 3.4: Order and reorder Lead Time
No

Parts / Materials

Order Lead Time

55

3.3.3

PBT

2 month

Zinc Alloy

2 week

Stainless steel Rod

1 week

Flow Control Knob

1 week

Spring (large)

1 week

Spring (small)

1 week

Screw

1 week

O-Ring

1 week

Rivet

1 week

10

Hold Clip

1 week

11

Washer (14mm)

1 week

12

Washer (12mm)

1 week

13

Plastic Washer

1 week

14

Rubber Grip

1 week

15

Pin

1 week

16

Seal

1 week

MATERIALANDINVENTORYMANAGEMENT
Material management is simply the process by which an organization is
supplied with the goods and services that it needs to achieve its objectives of
buying, storage and movement of materials. It is also related to planning, procuring,
storing and providing the appropriate material of right quality. Right quality at right
place in right time so as to coordinate and schedule the production activity in an
integrative way for an industrial. The material requirements planning, purchasing,
inventory planning, storage, inventory control, material supply, transportation and
material handling are the activities of materials management. Before the production
begins, it is necessary to ensure the availability of all the types of materials needed
for production and its supply at the various production stations.
Inventory management is primarily about specifying the size and placement
of stocked goods. It is required at different locations within a facility to protect the
regular and planned course of production against the random disturbance of running
56

out of materials or finished goods. It is a system and processes that identify

inventory requirements, set targets, provide replenishment techniques and report and
projected inventory status. It involves a retailer seeking to acquire and maintain a
proper merchandise assortment while ordering, shipping, handling and related costs
are kept in check. It can improve in customers relationship due to of the timely
delivery of goods and services. Besides that, it also smooth the production and
hence no stock out situation happen. It also helps in minimizing loss due to
deterioration, obsolescence damage and pilferage.
Safety stock is the stock to assure a company from uncertainties. The reason
for keeping inventories is to stabilize production, take advantage of price discounts
and also to meet the demand during the replenishment period. When an optimal
order quantity is calculated, a proper safety stock can be established. The demand is
assumed to be normally distributed and deterministic, even if actual demand is
stochastic. The safety inventory is estimated 20 % for inventory level.

57

Figure 3.8: Product Structure

58

Figure 3.9: Product Structure Tree

Table 3.5: Material Requirement Planning

Item: Water Spray Nozzle Grip
Lot Size: Lot-for-lot
Week
4
Gross Requirement
Projected on Hand
0
Net Requirement
Planned order Receipts
Planned order Releases
1768
3.3.4

1
1768
0
1768
1768
1768

2
1768
0
1768
1768
1768

Lead Time: 1 Week

3
4
1768
1768
0
0
1768
1768
1768
1768
1768
-

AGGREGATEPLANNING
Aggregate planning is an operational activity that does an aggregate plan for
the production process, in advance of 6 to 18 months, to give an idea
to management as to what quantity of materials and other resources are to be
59

procured and when, so that the total cost of operations of the organization is kept to
the minimum over that period.
The quantity of outsourcing, subcontracting of items, overtime of 304labour,
numbers to be hired and fired in each period and the amount of inventory to be held
in stock and to be backlogged for each period are decided. All of these activities are
done within the framework of the company ethics, policies, and long term
commitment to the society, community and the country of operation.
Aggregate planning has certain pre-required inputs which are inevitable.
They include:

Information about the resources and the facilities available

Demand forecast for the period for which the planning has to be done.

Cost of various alternatives and resources. This includes cost of holding inventory,
ordering cost, cost of production through various production alternatives, like
subcontracting and overtime.

Organizational policies regarding the usage of above alternatives.

Aggregate Planning is concerned with matching supply and demand of
output over the medium time range, up to approximately 12 months into the future.
The term aggregate implies that the planning is done for a single overall measure of
output or, at the most, a few aggregated product categories. The aim of aggregate
planning is to set overall output levels in the near to medium future in the face of
fluctuating or uncertain demands. Aggregate planning might seek to influence
demand as well as supply.

60

The table below show the forecast demand for each month of our product:
Table 3.6: Forecast Production Demand monthly

MONTH

EXPECTED
DEMAND

PRODUCTION
DAYS

DEMAND PER
DAY

6000
7000
5000
5000
6500
7200
7500
8000
6000
7500
7500
7000
80200 units

26
23
27
26
23
24
23
26
24
24
27
25
298 days

231
305
185
193
283
300
326
308
250
313
278
280

January
February
March
April
May
June
July
August
September
October
November
December
TOTAL

Average requirement=

total expected demands

number of productiondays

(3.1)

350

326

305
283

300
250

270
231

270

200

80200
298

270

270

185

193

MAR

APR

300

270

270

270

270

313

308
270 250
270

270

278 280
270 270

150
100
50
0

JAN

FEB

MAY

JUN

DEMAND PER DAY

JUL

AUG

SEP

OCT

NOV

DEC

expected production

Figure 3.10: Comparison of forecast demand and expected production volume

61

3.3.4.1 Plan1Constantworkforce
Table 3.7: Cost Information for all plan
Cost Information
Inventory Carrying Cost
Subcontracting cost per unit
Average Pay rate
Overtime pay rate
Labour-hours to produce a unit
Cost of increasing daily production rate

RM 3 per unit per month

RM 25
RM 4.30 per hour (RM38.70 per day)
RM7 per hour (above 9 hours per day)
2.5 hours per unit
RM 100 per unit

(hiring and training)

Cost of decreasing daily production rate

RM 200 per unit

(layoffs)
Table 3.8: Plan 1 inventory Calculation
Month
January
February
March
April
May
June
July
August
September
October
November
December

Production at
270 units per day
7020
6210
7290
7020
6210
6480
6210
7020
6480
6480
7290
6750

Demand
forecast
6000
7000
5000
5000
6500
7200
7500
8000
6000
7500
7500
7000

Monthly
inventory change
+1020
-790
+2290
+2020
-290
-720
-1290
-980
+480
-1020
-210
-250

Ending Inventory
1020
230
2520
4540
4250
3230
2240
1260
1740
720
510
260
22520

Table 3.9: Summary of Plan 1

Costs
Inventory carrying
Regular time labor
Other costs
Total costs

Calculation
22520 units carried RM3
= 12 workers RM38.70
298 days
-

= RM 67,560.00
= RM 138,391.20
RM 205,951.20

62

3.3.4.2 Plan2Subcontracting
From table3.6 at page 67, the minimum requirement per day is 185 units.
house production=185units per day 298 days
55130units
Subcontract units=8020055130=25070 units

Table 3.10: Summary of Plan 2

Costs
Regular time labor

Calculation
= 8 workers RM38.70
298 days
= 25070 units RM 25

Subcontracting
Total Cost

= RM 92,260.80
= RM 626,750.00
RM 719,010.80

3.3.4.3 Plan3HiringandFiring
Production volume = expected demand
Table 3.11: Costing for Plan 3
Month
January
February
March
April
May
June
July
August
September
October
November
December

Deman
d
forecast
6000
7000
5000
5000
6500
7200
7500
8000
6000
7500
7500
7000

Daily
Productio
n Rate
231
305
185
193
283
300
326
308
250
313
278
280

Hiring
Cost

Layoff
cost

RM 300
RM 100
RM 400
RM 100
RM 100
RM 200
RM 11,000

RM 1,000
RM 200
RM 400
RM 200
RM 1,800

3.3.4.4 Comparisonofthreeplan
Cost
Inventory carrying
Regular Labour

Plan 1
RM 67,560.00
RM 138,391.20

Plan 2
RM 92,260.80

Plan 3
RM 138,391.20
63

Overtime labor
Hiring
Layoffs
Subcontracting
Total cost

RM 205,951.20

RM 626,750.00
RM 719,010.80

RM 11,000
RM 1,800
RM 151,191.20

Plan 3 is the lowest cost option.

3.4

LAYOUTANDFACITLIYDESIGN
A model facility layout should be able to provide an ideal relationship between raw
material, equipment, manpower and final product at minimal cost under safe and
comfortable environment. An efficient and effective facility layout can cover
following objectives:

To provide optimum space to organize equipment and facilitate movement of goods

and to create safe and comfortable work environment.

To promote order in production towards a single objective

To reduce movement of workers, raw material and equipment

To promote safety of plant as well as its workers

To facilitate extension or change in the layout to accommodate new product line or

technology upgradation
In order to fulfil the objective above, Simio software were used. Two layout have
been drawn and simulated using simio software.

64

Figure 3.8: Process oriented layout using Simio

Figure 3.9: Result for process oriented layout using Simio

Figure 3.10: Work-cell layout using Simio

65

Figure 3.11: Result for work cell layout using Simio

Even though, total production for both of layout is same but the work cell layout is
much better compared to process oriented layout because the total worker can be
reduce, the work area can be efficiently balanced, worker can reach more of the
work area and communication is enhanced.

Figure 3.12: Plant layout for factory

3.5

MAINTENANCESYSTEMMANAGEMENT

3.5.1

TOTALPRODUCTIVEMAINTENANCE(TPM)

In industry, total productive maintenance (TPM) is a system of maintaining and improving

the integrity of production and quality systems through the machines, equipment, processes,
66

and employees that add business value to an organization. TPM focuses on keeping all
equipment in top working condition to avoid breakdowns and delays in manufacturing
processes. One of the main objectives of TPM is to increase the productivity of plant and
equipment with a modest investment in maintenance. Total quality management (TQM) and
total productive maintenance (TPM) are considered as the key operational activities of the
quality management system. In order for TPM to be effective, the full support of the total
workforce is required. This should result in accomplishing the goal of TPM: "Enhance the
volume of the production, employee morale, and job satisfaction.
Besides that, the objective of TPM is to increase the overall equipment effectiveness
(OEE) of plant equipment. TPM addresses the causes for accelerated deterioration while
creating the correct environment between operators and equipment to create ownership.
Total productive maintenance includes:

Designing machine that is reliable, easy to operate, and easy to maintain.

Emphasizing total cost of ownership when purchasing machines, so that service and

maintenance are included in the cost.

Developing preventive maintenance plans that utilize the best practices of operators,

maintenance department, and depot service.

Training for autonomous maintenance so operators maintain their own machines and

partner with maintenance personnel.

3.5.2

SPECIFICTERMOFTPM

Total
Productive

Maintenance

Signifies to consider every aspect and involving everybody from top to

bottom.
Emphasis on trying to do it while production goes on and minimize
troubles for production.
Means equipment upkeep autonomously by production operators in
good condition (repair, clean, grease, and accept to spend necessary
time on it).

67

3.5.3

IMPLEMENTATIONSTAGESOFTPMANDITACTIVITIES

a) Stage A: Preparatory Stage

1. Step 1: Announcement by management to all about TPM introduction in the
organization
Proper understanding, commitment and active involvement of the top management in
needed for this step. Senior management should have awareness programs, after which
announcement is made. Decision the implement TPM is published in the in house magazine
displayed on the notice boards and a letter informing the same is send to suppliers and
customers.
2. Step 2: Initial education and propaganda for TPM
Training is to be done based on the need. Some need intensive training and some just
awareness training based on the knowledge of employees in maintenance.
3. Step 3: Setting up TPM and departmental committees
TPM includes improvement, autonomous maintenance, quality maintenance etc., as part of
it and when the committees are set up it should take care of all those needs.
4. Step 4: Establishing the TPM working system and a target
Each area/workstation is benchmarked and target is fixed up for achievement.
5. Step 5: A master plan for institutionalizing
Next step is implementation leading to institutionalizing wherein TPM becomes an
organizational culture which is achieving PM award is the proof of reaching a satisfactory
level.
b) Stage B: Introduction Stage
A small get-together, which includes our suppliers and customers participation, is
conducted. Suppliers as they should know that we want quality supply from them. People
from related companies and affiliated companies who can be our customers, sisters
concerns etc. are also invited. Some may learn from us and some can help us and customers
will get the message from us that we care for quality output, cost and keeping to delivery
schedules.
68

c) Stage C: TPM Implementation

In this stage eight activities are carried which are called eight pillars in the development of
TPM activity. Of these four activities are for establishing the system for production
efficiency, one for the initial control system of new products and equipment, one for
improving the efficiency of administration and are for control of safety, sanitation as a
working environment.
d) Stage D: Institutionalizing Stage
At this stage the TPM implementation activities would have reached maturity stage and it is
the time to apply for preventive maintenance award.

3.5.4

IMPLEMENTATIONOFTPMACTIVITIES

The following is the brief description of each of the TPM implementation activities:
i.

Master Plan: The TPM team, along with manufacturing and maintenance

management, and union representatives determines the scope/focus of the TPM program.
The selected equipment and their implementation sequence are determined at this point.
Baseline performance data is collected and the programs goals are established.
ii.

Autonomous Maintenance: The TPM team is trained in the methods and tools of

TPM and visual controls. The equipment operators assume responsibility for cleaning and
inspecting their equipment and performing basic maintenance tasks. The maintenance staffs
trains the operators on how to perform the routine maintenance, and all are involved in
developing safety procedures. The equipment operators start collecting data to determine
equipment performance.
iii.

Planned Maintenance: The maintenance staffs collects and analyzes data to

determine usage/need-based maintenance requirements. A system for tracking equipment

performance metrics and maintenance activities is created (if one is not currently available).
Also, the maintenance schedules are integrated into the production schedule to avoid
schedule conflicts.
iv.

Maintenance Reduction: The data that has collected and the lessons learned from

TPM implementation is shared with equipment suppliers. This design for maintenance
69

knowledge is incorporated into the next generation of equipment designs. The maintenance
staffs also develop plans and schedules for performing periodic equipment analysis (burner
pump, fuel filter, rotary cup atomizer, furnace tube and valve, etc.). This data from analysis
is also fed into the maintenance database to develop accurate estimates of equipment
performance and repair requirements. These estimates are used to develop spare parts
inventory policies and proactive replacement schedules.
v.

Holding the Gains: The new TPM practices are incorporated into the organizations

standard operating procedures. These new methods and data collection activities should be
integrated with the other elements of the production system to avoid redundant or
conflicting requirements. The new equipment management methods should also be
continuously improved to simplify the tasks and minimize the effort required to sustain the
TPM program.
3.6

INDUSTRIALSAFETYSTANDARDS

3.6.1

SafetyandHealthProgram

A workplace safety and health program is a systematic plan to identify and control hazards
and respond to emergencies. The program lays out responsibilities, resources, and
procedures for keeping the workplace safe and healthy. Its objective is to integrate safety
and health into all work practices and conditions. Moreover, it is one of the general duties
as prescribed under the Occupational Safety and Health Act 1994 (Act 514) for the
employer to provide a safe workplaces to their employees and other related person. The
purpose of managing safety and health is:

To steadily improved health and safety at work.

Applying our normal principle that prevention is better than cure.
Moral and Ethical Issues
a. Respect Human Resources - morale, commitment, image
b. Respect their family pride
c. Ethical Issues as a professional
Legal Issues (MACHINERY AND FACTORY ACT 1967; OSH ACT 1994)
a. Claims for compensation
b. Disruption during the legal process
Financial Issues
70

a. Increase of Insurance Premium

b. Direct Lost
c. Indirect Lost

3.6.2

OccupationalSafetyandHealthActof1994(OSHA1994)

3.6.3

OSHA1994Requirement

For all industries

If > 5 employees
Safety & Health Policy
If 40 employees
Safety & Health Policy + Safety & Health Committee
For high risk industries (i.e. construction, ship building, gas etc.)
If > 100 employees
Safety & Health Policy + Safety & Health Committee + a
Certified Safety & Health Officer
For low risk industries (other than the above mentioned industries)
If > 500 employees
Safety & Health Policy + Safety & Health Committee + a
Certified Safety & Health Officer

3.6.4

Provision&DutyofEmployerunderOSHA1994

a) Ensure our safety, health and welfare at our workplace.

b) Formulate safety and health policy.
c) Establish a Safety and Health Committee at the place of work if there are 40 or more
persons employed at the place of work.
d) Consult the Safety and Health Committee.
e) Notify the nearest Occupational Safety and Health Office of any accident,
dangerous occurrence, occupational poisoning or occupational disease which has
occurred or is likely to occur at the place of work.
f) General duties of employers and self-employed persons to persons other than their
employees and general duties of manufacturers as regards plants for use at work.

3.6.5

BenefitsGoodOccupationalSafety&Health
Reduce lost time.
Reduced need to provide cover for personnel absent from work because of injury.
Reduce sick pay payments.
71

Reduce need for time-consuming accident investigation and consequent saving in

management time and production down-time.

Reduce potential for prosecution and other enforcement action by authorities.
Reduction in the number of claims for compensation by injured personnel.
Reduce employers liability insurance premiums.
Improved morale.
Improved image of company both in terms of employer and competent contractor.

3.6.6

FactoryandMachineryAct1967

a) Without prejudice to any law with respect to local authorities, in respect of any
factory, the following provisions relating to safety shall apply:
Foundation and floor
Every openings, sump, pit or fixed vessel in a floor , or working level shall be
securely fenced so as to prevent risk of persons falling
b) In a factory in which persons are exposed to risk of bodily injury from explosive,
inflammable, poisonous or corrosive substances or ionizing radiations, such
measures as may be prescribed shall be taken as will eliminate the risk.
c) No person shall be employed to lift, carry or move any load so heavy as to be likely
to cause injury to him.
d) All machinery and every part thereof including all fittings and attachment shall be
of sound construction and sound material free from defect and suitable for the
purpose and shall be properly maintained.
e) In respect to such machinery as may be prescribed, any part of any material carried
by that machinery while it is working thereon which projects beyond any part of the
machinery shall be effectively fenced unless it is in such a position as to be safe to
any person employed or working on or renting the premises.
f) No person shall manufacture, repair or install machinery in such a manner that it
does not comply with the provisions of this Act and any regulations made
thereunder applicable to such machinery
g) Without prejudice to any law to public health, in respect of any factory the
following provisions relating to health of persons shall apply:
Every factory shall be kept in a clean state and free from offensive effluvia

arising from any drain, sanitary convenience or other sources.

The maximum number of persons employed at any one time in any work-room
72

in any factory shall be such that the amount of cubic feet of space and
superficial feet of floor area.

3.6.7

OHSAS1800andMS1722

The OHSAS 18001 standard specifies requirements for an occupational health and safety
management system. It is the most widely used standard for Occupational Health and
Safety Management System. MS 1722 is the Malaysian Standard for Occupational safety
and health Management System. The requirements of these standards are directed to
address occupational health and safety issues of permanent or temporary employees, from
contractor to other personnel on site rather than the safety of products and services.
Conformance to these standards will provide a more effective method of employee
protection against workplace injuries and illnesses. It will also demonstrate the
managements commitment in meeting legal requirements relating to occupational health
and safety.

3.6.8

NationalPolicyforOccupationalSafetyandHealthManagementSystems

The national policy on OSH management systems should establish general principles and
procedures to:
a) Promote the implementation and integration of OSH management systems as part of
the overall management of an organization.
b) Facilitate and improve voluntary arrangements for the systematic identification,
planning, implementation and improvement of OSH activities at national and
organization levels.
c) Promote the participation of workers and their

representatives at organization

level.
d) Implement continual improvement while avoiding unnecessary bureaucracy,
73

administration and costs.

e) Promote collaborative and support arrangements for OSH management systems at
the organization level by labour inspectorates, occupational safety and health
services and other services, and channel their activities into a consistent framework
for OSH management.
f) Evaluate the effectiveness of the national policy and framework at appropriate
intervals.
g) Evaluate & publicize the effectiveness of OSH management systems and practice by
suitable means.
h) Ensure that the same level of safety and health requirements applies to contractors
and their workers as to the workers, including temporary workers, employed
directly by the organization.

Figure 3.13: Occupational Safety and Health Management Systems in the Organization
74

Note: Red arrow represents the interaction between each main elements of Occupational
Safety & Health Management System, whereas the blue arrow represents the systematic
interaction between the sub elements respectively.

Figure 3.14: Model Implementation Framework

75

3.7

SUPPLYCHAINMANAGEMENT

Supply chain management (SCM) is the oversight of materials, information, and finances as
they move in a process from supplier to manufacturer to distributers to retailer to consumer.
Supply chain management involves coordinating and integrating these flows both within
and among companies. It is said that the ultimate goal of any effective supply chain
management system is to reduce inventory (with the assumption that products are available
when needed).

Figure 3.15: Supply Chain Management Process.

3.7.1

Kanban(PullSystem)

Kanban is a visual signal thats used to trigger an action. The word kanban is Japanese and
roughly translated means card you can see ,visible record or visible part .This system is one
of the tools under lean manufacturing system that can achieve minimum inventory at any
one time. Kanban system provides many advantages in managing operations and business
in the organization. Using Kanban system is a strategic operational decision to be used in
76

the production lines, because it save costs by eliminating over production, developing
flexible work stations, reducing waste and scrap, minimizing the waiting times and logistics
costs, thus reducing the inventory stock levels and overhead costs
Factor contributes in implementation of Kanban system:

Inventory management

Supplier

Quality improvement and quality control

3.7.2

JustInTimeInventory

Just in time (JIT) inventory is system in which material and products are produce or
acquired based on demand requires. The purpose is to avoid exceed in inventory demand.
Manufacturers using JIT processes want to use materials for production at levels that meet
distributor or retailer demand but not in excess.
For manufacturers, using materials and producing products in excess of what distributors
and retailers demand means you have to hold onto the inventory. This requires warehousing
of finished goods, thus increasing the costs.

3.7.3
NO.
1
2
3
4

BillofMaterial
PART NAME
Spray Body
Spray Nozzle
Nozzle Support
Slide Threaded Rod

QUANTITY
1
1
1
1
77

5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

Body presser
Spring (Large)
Spring (Small)
Rubber Gasket
Plastic Washer
Flow Control Knob
Connect Fitting
Rivet
Screw
Hold Clip
Rubber Grip
Washer 14mm
Pin
Washer 12mm
O-ring

3.7.4

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

Outsourcing

Outsource implies an agreement (typically a legally binding contract) with an external

organization.
Building the supply base
Certification and qualification of supplier are determined based on:

Qualification

Education

The certification performances

For the raw material and outsourcing supplier, we used several of vendors to full fill our
requirement need. These were information about our raw material used.
Outsourcing Parts
PARTS

SUPPLIER

SUPPLY
ABILITY/UNI
TS

Spring (Large)

Spring (Small)

John Zhang Botou City Juneng

1000
Spring Company Ltd.
John Zhang Botou City Juneng
1000
Spring Company Ltd.

PRICE
(RM)/PER
UNIT
4.00
1.80
78

3
4
5
6
7
8
9
10
11
12

Screw

James Zhan Jiangsu Zhenya

Special Screw Co., Ltd.
Flow Control Sam Zhao Machining Matrix
Knob
Trade (Shanghai) Co., Ltd.
Rivet
Lassie
Chen
Guangzhou
Acoolda Bags Industry Firm
Hold Clip
John Zhang Botou City Juneng
Spring Company Ltd.
O-Ring
Xiaojun
Liu
Shenzhen
Kunyang Rubber & Plastic
Products Co., Ltd.
Washer
Xiaojun
Liu
Shenzhen
(14mm)
Kunyang Rubber & Plastic
Products Co.Ltd.
Washer
Xiaojun
Liu
Shenzhen
(12mm)
Kunyang Rubber & Plastic
Products Co., Ltd.
Plastic Washer Xiaojun
Liu
Shenzhen
Kunyang Rubber & Plastic
Products Co., Ltd.
Rubber grip
Xiaojun
Liu
Shenzhen
Kunyang Rubber & Plastic
Products Co., Ltd.
Pin
Xiaojun
Liu
Shenzhen
Kunyang Rubber & Plastic
Products Co., Ltd.

2000
6000

0.90
1.60

30000

0.30

2000

0.50

1000

0.90

1000

0.50

1000

0.20

1000

0.90

1000

2.00

1000

0.50

SUPPLY

PRICE(R

ABILITY/KG

M)/PER

Produce Parts (Raw material)

PARTS

1
2
3
4
5

Spray Body
Spray Nozzle
Nozzle Support
Body Presser
Connect fitting

SUPPLIER

Beryl Yang Chengdu Best New

Materials Co., Ltd.
Owen Wu Shanghai TuHuang
International Trading Co., Ltd.
Owen Wu Shanghai TuHuang
International Trading Co., Ltd.
Owen Wu Shanghai TuHuang

60
20000
20000
20000

International Trading Co., Ltd.

Owen Wu Shanghai TuHuang 20000

KG
10.70
4.80
4.80
4.80
4.80

International Trading Co., Ltd.

79

Slide threaded Camy Liu Shanghai Beall Metal 1000

Rod

3.7.5

4.86

Co., Limited

Logisticmanagement

Delivery system
1) Local area
Delivery of our product is by using trucking system to each of retailer because this is a vast
majority of manufactured goods. The flexibility and advantages using this system is low
cost and reduce fuel cost.
2) International
Delivery area made using shipping transportation. (Container)

3.8

ASSEMBLYANALYSIS

REDESIGN SLIDE THREADED ROD USING ASSEMBLY EVALUATION

METHOD
In order to improve design efficiency, part were redesign by using assembly evaluation
80

mehod. This method will determine the best design that can increase efficiency of design.

Set Stopper A
Bring down Slide threaded
rod B. (orientation
maintained by stopper hole)
Insert Large spring C into B
Insert Plastic washer D into
B

Original design
Part assembly evaluation
score
100

Assemblability evaluation
score
95

80
100
100

Assemblability evaluation score for this is 95 which is can be acceptable but also can still
be improve. Therefore, the new design is tthat the stopper and slide threaded rod is
combine. This can be done because the stopper and slide threaded rod is move in same
direction with each other and can be made from same material.

81

Set Stopper with rod A

Insert Large spring C into A
Insert Plastic washer D into
A

Redesign
Part assembly evaluation
score
100
100
100

Assemblability evaluation
score
100

After redesign, the assemblability score increase to 100 which is the maximum score that
can be reach. This show that the new design is better than the original design.
Assembly chart for spray nozzle pistol grip

82

3.9

OTHERSTANDARDS

3.9.1

QualityStandard
A product is said to be of quality if it is free from any manufacturing defect

deficiency or significant variation in order to do so certain specific standards need to be set

so that uniformity is achieved in the entire set of products being manufactured. The
standard defined should be such that the features and specifications offered by the product
should be capable to meet the implied need of the product. A quality standard is a detail of
the requirements, specifications, the various guidelines and characteristics to be able to
meet its quality by the product in order to meet the purpose of the product, process or the
service. ISO international standards are the most widely accepted set of quality standards
adopted by majority of firms across countries. In case if a company fails to meet its quality
standard, it may end up losing the trust of the customer and henceforth its market share. For
83

example a car manufacturer found some major issue with its car and calls for a product
recall, by doing so it can lose its long built brand equity. By investing in quality one can cut
down on huge loses and win a satisfied customer base.
3.9.2

ISOInternationalStandards

ISO International Standards ensure that products and services are safe, reliable and of good
quality. For business, they are strategic tools that reduce costs by minimizing waste and
errors, and increasing productivity. It help companies to access new markets, level the
playing field for developing countries and facilitate free and fair global trade.
Economic Benefits of Standards
a) For business
International Standards are strategic tools and guidelines to help companies tackle
some of the most demanding challenges of modern business. They ensure that business
operations are as efficient as possible, increase productivity and help companys access new
markets. ISO standards help businesses to:

Cut costs, through improved systems and processes

Increase customer satisfaction, through improved safety, quality and processes

Access new markets, through ensuring the compatibility of products and services

Reduce their impact on the environment.

ISO 9001, for example, has been shown to improve sales, customer satisfaction,

corporate image and market share (Manders 2014) and ISO 14001 has been shown to have
a positive impact on environmental performance (de Vries et al, 2012).
b) For Consumers
ISO has over 21000 standards touching almost all aspects of daily life. When
products and services conform to International Standards consumers can have confidence
that they are safe, reliable and of good quality. For example, ISO's standards on road safety,
toy safety and secure medical packaging are just a selection of those that help make the
world a safer place. To make sure that the benefits of ISO International Standards are as
broad as possible, ISO supports the involvement of consumers in standard development
work with its Committee on consumer policy (COPOLCO). International Standards on air,
84

water and soil quality, on emissions of gases and radiation and environmental aspects of
products contribute to efforts to preserve the environment and the health of citizens.
International Standards on air, water and soil quality, on emissions of gases and radiation
and environmental aspects of products contribute to efforts to preserve the environment and
the health of citizens.
c) For government
ISO standards draw on international expertise and experience and are therefore a vital
resource for governments when developing public policy. National governments can use
ISO standards to support public policy, which has a number of benefits, including:

Getting expert opinion - By integrating an ISO standard into national regulation,

governments can benefit from the opinion of experts without having to call on their
services directly.

Opening up world trade - ISO international standards are adopted by many

governments, so integrating them into national regulation ensures that requirements
for imports and exports are the same the world over, therefore facilitating the
movement of goods, services and technologies from country to country.
ISO standards can also remove barriers to world trade by providing the technical

basis on which political trade agreements can be put into practice, whether they are at the
regional or international level.
3.9.3

ISO9001
ISO 9001 is a standard that sets out the requirements for a quality management

system. It helps businesses and organizations to be more efficient and improve customer
satisfaction. A quality management system is a way of defining how an organization can
meet the requirements of its customers and other stakeholders affected by its work. ISO
9001 is based on the idea of continual improvement. It doesnt specify what the objectives
relating to quality or meeting customer needs should be, but requires organizations to
define these objectives themselves and continually improve their processes in order to reach
them.

85

3.9.3.1 FunctionofISO9001
ISO 9001 is suitable for organizations of all types, sizes and sectors. In fact, one of
the key improvements of the newly revised ISO 9001:2015 was to make it more applicable
and accessible to all types of enterprises. Smaller companies that do not have staff
dedicated to quality can still enjoy the benefits of implementing the standard

3.9.3.2 BenefitstoOrganization
Implementing a quality management system will help you:

Assess the overall context of your organization to define who is affected by your
work and what they expect from you. This will enable you to clearly state your
objectives and identify new business opportunities.

Put your customers first, making sure you consistently meet their needs and enhance
their satisfaction. This can lead to repeat custom, new clients and increased business
for your organization.

Work in a more efficient way as all your processes will be aligned and understood
by everyone in the business or organization. This increases productivity and
efficiency, bringing internal costs down.

Meet the necessary statutory and regulatory requirements.

Expand into new markets, as some sectors and clients require ISO 9001 before
doing business.

3.9.4

Identify and address the risks associated with your organization.

ISO14001

ISO 14001 is an internationally agreed standard that sets out the requirements for an
environmental management system. It helps organizations improve their environmental
performance through more efficient use of resources and reduction of waste, gaining a
86

competitive advantage and the trust of stakeholders. An environmental management system

helps organizations identify, manage, monitor and control their environmental issues in a
holistic manner. Like other ISO management systems, it uses a High-Level Structure. This
means it can be integrated easily into any existing ISO management system. It also includes
the need for continual improvement of an organizations systems and approach to
environmental concerns.
3.9.4.1 FunctionofISO14001
ISO 14001 is suitable for organizations of all types and sizes, be they private, not-for-profit
or governmental. It requires that an organization considers all environmental issues relevant
to its operations, such as air pollution, water and sewage issues, waste management, soil
contamination, climate change mitigation and adaptation, and resource use and efficiency.
3.9.4.2 BenefitstoOrganization
Users of the standard have reported that ISO 14001 helps:

Demonstrate compliance with current and future statutory and regulatory

requirements

Increase leadership involvement and engagement of employees

Improve company reputation and the confidence of stakeholders through strategic

communication

Achieve strategic business aims by incorporating environmental issues into business

management

Provide a competitive and financial advantage through improved efficiencies and

reduced costs

Encourage better environmental performance of suppliers by integrating them into

the organizations business systems

3.9.5

WorkplaceHazardousMaterialsInformationSystem(WHMIS)

The Workplace Hazardous Materials Information System (WHMIS) provides information

87

about many hazardous materials used in the workplace. WHMIS calls these hazardous
materials controlled products. Under WHMIS, workers have the right to receive
information about each controlled product they use which is, its identity, hazards, and safety
precautions. The goal of WHMIS is to reduce injury and disease by communicating specific
health and safety information about controlled products so that the information can be used
to reduce exposure to hazardous materials.
Workplace
Hazardous Materials
Information System

Deals only with products used in the workplace

Dangerous products that may cause fires, explosions, or health
problems
Provides information about hazardous materials

3.9.5.1 WHMISBasicThreeElements
WHMIS controlled products are classified by their hazard. There are six hazard classes and
eight hazard symbols that identify the specific hazards. (There are three symbols in Class
D). The eight hazard symbols identify the specific hazards of controlled products. After a
controlled product has been classified, the following three WHMIS elements are used to
communicate health and safety information:

WHMIS labels: Labels on controlled products alert workers to the identity of the
product, hazards, and precautionary measures.

Material Safety Data Sheets (MSDS): Technical bulletins provide detailed hazard
and precautionary information.

WHMIS education and training programs: The employer provides education and
training for workers so that they can work safely with and near controlled products.
Workers need to know how WHMIS works, the hazards of controlled products in
their workplace, and the safe work procedures they must follow.

88

3.9.5.2 Classification
CLASS A

If a pressurized container is punctured because it is

Compressed

dropped or exposed to excessive heat, the exploding

Gas

fragments or rocket-like projectiles present a serious

physical hazard. Examples include chlorine contained in a
pressurized cylinder and used as a disinfectant at
swimming pools, and oxygen used in oxyacetylene
welding.
These materials can pose a danger of fire and explosion.

CLASS B

Flammables are more dangerous than combustibles

Flammable/

because they ignite more easily. During use, they must be

Combustible

kept away from ignition sources such as sparks or open

Materials

flames. When not in use, they must be stored in fire

resistant cabinets or other specified storage areas.
Oxidizing materials greatly increase the risk of fire if they
come in contact with materials that can burn. They should

CLASS C

never be stored near flammable or combustible materials.

Oxidizers

CLASS D1

Materials causing death or immediate injury. Examples

Material

include highly toxic sodium cyanide, used in the

causing

electroplating industry, which can be absorbed through the

immediate
serious

&

skin. The toxic gas, hydrogen sulphide, used in

toxic

laboratories and present in petroleum and pulp and paper

effect
CLASS D2
Materials
causing other
toxic effect

industries, can cause death when inhaled.

Poisonous and infectious materials causing immediate
skin or eye irritation or long-term health problems, such as
skin/lung

allergic

response,

birth

defects,

cancer,

reproductive problems, or impairment of body organs and

systems.

89

Microorganisms (includes viruses, bacteria, fungi) causing

CLASS D3
Biohazardous
infection
materials

disease in persons and animals. They may be present in

cultures. Products containing biohazardous infectious
materials may be found in laboratory and research
facilities associated with the medical or agricultural
sectors.
Corrosive materials include caustics such as lye and acids.

CLASS E

They can cause permanent damage (e.g., burns) to skin

Corrosive

and eyes.

Materials

CLASS F
Dangerously
Reactive
Materials

This class includes products that can undergo vigorous

polymerization reaction on their own, or become selfreactive when exposed to shock or to increase in pressure
or temperature. It also includes products that react
vigorously with water to release a toxic gas.

3.9.5.3 WHMISLabels
The purpose of labels is to alert workers to the main hazards of controlled products and
provide instructions for safe handling and to direct workers to the MSDS for more
information. The two types of WHMIS labels are the supplier label and the workplace label.
Other means of identification may be used where appropriate (such as warning signs, colour
codes, placards).
a) Supplier Label
Suppliers must provide supplier labels on containers of all controlled products sold or
imported for use in the workplace.

Supplier labels will show seven types of information within the WHMIS hatched
90

borders.

The written information must be shown in both English and French.

The label must stand out from the container itself and other markings on the
container (for example, the size of the label should be appropriate for the size of the
container).

3.9.5.4 WorkplaceLabels
Workplace labels are required on containers of controlled products produced on site, and on
secondary containers where the product has been transferred from the original container.
Workplace labels are applied to:

Secondary containers

Containers of products received in bulk

Employer-produced products

Containers with missing or illegible supplier labels

Figure: Acceptable Format for the Supplier Label

91

3.9.6

MaterialSafetyDataSheet(MSDS)

A Material Safety Data Sheet is a technical bulletin that provides specific hazard
information, safe handling information, and emergency procedures for a controlled product.
Since the MSDS contains detailed health and safety information specific to each controlled
product, it should be used as a key source of information for developing training programs
and safe work procedures. It is also a valuable reference source of health and safety
information for workers, health and safety committees, and emergency service personnel.
The information from MSDS is:

Hazardous ingredients

Hazards (fire, explosion, reactivity)

Health effects of exposure (acute and chronic)

Hazard evaluation related to storage and handling

Measures to protect workers

Emergency procedures

92

CHAPTER 4

COST ANALYSIS

4.1

FIXEDCOST

Table 4.1: Equipment cost

EQUIPMENT
Forklift
Pallet Jet
Lorry
Overhead Crank
Injection Molding Machine
Die Casting Machine
Cold Heading Machine
Thread Rolling Machine
Swivel head hand riveter

1
2
3
4
5
6
7
8
9
1
0 Electric Screw Driver
11 Grinding Machine
1
2 Fiskar Scissors

UNIT
1
1
1
1
1
1
1
1
2

MYR
MYR
MYR
MYR
MYR
MYR
MYR
MYR
MYR

PRICE
8,000.00
980.00
20,000.00
15,000.00
40,000.00
52,000.00
21,000.00
3,200.00
80.00

1
1

MYR
MYR

800.00
200.00

MYR
160.00
MYR 161,420.00

Table 4.2: Fixed costs

Company registration, License, Agreement fees,
Certification
Factory Rental per month
Property Taxes per month
Insurance per month

MYR

2,500.00

MYR
MYR
MYR

5,000.00
5,000.00
5,000.00

TOTAL FIXED COST = RM 161,420.00 + RM 5,000.00

= RM 166,420.00
93

4.2

OVERHEADCOST

Overhead refers to the ongoing operating expenses necessary to running a business, but are
not attributed to a specific business activity. Generally, overhead expenses include expenses
that do not directly generate revenues, such as labor and materials, but are needed to
maintain the business operations. Overhead expenses include expenses such as accounting,
advertising, depreciation, insurance, interest, legal, rent, repairs, office supplies, taxes,
information and communications, utilities, research and development, customer relations
and service, and travel. These overhead expenses are listed on the company's income
statement. Overhead costs are considered fixed costs, that is, they do not rise or fall directly
with the cost of goods sold. Overhead costs are important to monitor and control. Since
they are not directly related to revenues, they can become a larger share of the total
expenses and burden a company, soaking up net income and profits.
Table 4.3: overhead cost summary
1

Description
Material Handlers
Forklift Operator
Jet Pallet Operator
Lorry Driver

cost

unit

Total

MYR
MYR
MYR

1,200.00
1,200.00
1,200.00

1
1
1

MYR
MYR
MYR

1,200.00
1,200.00
1,200.00

Engineer
Manufacturing Process Engineer
Quality Control Engineer
Technician

MYR
MYR
MYR

3,200.00
3,200.00
1,400.00

1
1
1

MYR
MYR
MYR

3,200.00
3,200.00
1,400.00

Nontechnical Service
Security Guard
General Manager
Accountant

MYR
MYR
MYR

1,000.00
2,000.00
2,500.00

1
1
1

MYR
MYR
MYR

1,000.00
2,000.00
2,500.00
94

Utilities and telecommunications

Electricity
Water Bill
Telecommunication Bill
TOTAL

MYR 5,169.14
MYR 1,816.65
MYR
299.00
MYR 24,184.79

Air

Figure 4.1: Electricity tariff category

conditioning = 2 unit 1100watts 9hours 26days = 514.8kWh
Fan = 20 75watts 9hours 26days = 351kWh
Computer and Monitor = 15 unit 300watts 9hours 26days = 1053kWh
Light bulb = 100 units 150watts 9hours 26 days = 3510kWh
Injection molding machine = 1 13600watts 9hours 26days = 842.4kWh
Die casting machine = 1 22000watts 9hours 26days = 5148kWh
Rubber injection molding machine = 1 7500watts 9hours 26days =1755kWh
Power metallurgy machine = 1 750watts 9hours 26days = 175.5kWh
Thread rolling machine = 1 4000watts 9hours 26days = 936kWh
Equipment = 3 1500watts 9hours 26days = 1053kWh
Total electricity cost = 15338.7kWh RM 0.3370 = RM5169.14

95

Figure 4.2: Price of water usage of industrial

Industrial water use includes water used for such purposes as fabricating, processing,
washing, diluting, cooling, or transporting a product; incorporating water into a product; or
for sanitation needs within the manufacturing facility. Assume water usage = 800m3
Table 4.4: Water usage calculation expenses
0-35m3
>35m3
TOTAL

Band 1
Band 2

RM72.45
RM1744.20
RM1816.65

Figure 4.3: Price of internet usage for business

Internet connection for business = RM 299/month

4.3

SELLINGEXPENESES

Selling expense includes any costs incurred by the sales department. These costs typically
include the following:

Salesperson salaries and wages

Wages = RM2000/month
96

Number of person = 2
Total cost = RM4000

Sales administrative staff salaries and wages

Wages = RM2000/month
Number of person = 1
Total cost = RM2000

Advertising
TV advertising rate card (30sec) = RM5000

TOTAL SELLING EXPENCES PER MONTH

= RM4000 + RM2000 + RM5000
= RM11000
Table 4.5: Summary of selling expenses
1 Salesperson
2 Sales administrative staff
3 Advertising

MYR
MYR

2,000.00
2,000.00

2
1
TOTAL

MYR 4,000.00
MYR 2,000.00
MYR 5,000.00
MYR 11,000.00

97

4.4

DIRECTLABORCOST

Total operators required = 12

Total working hours per day = 9 hours (8am 5pm)
Total working days per month = 26 days
Break times = morning + lunch + evening
Operator salary per month = RM1000

Calculations for Direct Labor Cost

Table 4.6: Direct labor cost calculation
No.
1.

Descriptions
The Operator salary per day

2.

Total working hours per day

3.

Lunch

4.

Calculations
RM 1000 1month

1 month 26 days
9 hours

3600 sec
1hour

60 sec
60min 1min

= RM38.46
= 32,400 sec

= 3600 sec

Total working hour Total break

Total working hour

= 32,400 3600
= 28,800 sec
Operator salary per day/total working hour

5.
Salary (RM/sec)

per day
= RM 38.46/28,800

RM 38.46
27,000

= RM 0.001335 /sec
= RM 38.46 x 12
Total salary operator per day

= RM 461.52

Total salary operator per hour = RM 461.52/8 = RM 57.69/hour

Salary operator per hour = RM57.69/12 person = RM 4.81/per operator

98

4.5

MAINTENANCECOST
Maintenance cost assumed to be 10% of the total machine cost.
Table 4.7: Maintenance cost for each equipment
Overhead Crank
Injection Molding Machine
Die Casting Machine
Cold Heading Machine
Thread Rolling Machine
Total

RM
15,000.00
RM
40,000.00
RM
52,000.00
RM
21,000.00
RM
3,200.00
RM 131,200.00

Maintenance Cost = RM 131,200 10% = RM 13,120

4.6

MATERIALCOST
Table 4.8: Outsources material costing
PART NAME
Spring (Large)
Spring (Small)
Screw
Flow Control Knob
Rivet
Hold Clip
O-Ring
Washer (14mm)
Washer (12mm)

1
2
3
4
5
6
7
8
9
1
0 Plastic Washer
11 Rubber grip
1
2 Pin

Price
RM 4.00
RM 1.80
RM 0.90
RM 1.60
RM 0.30
RM 0.50
RM 0.90
RM 0.50
RM 0.20
RM
RM

TOTAL

0.90
2.00

RM 0.50
RM 14.10

Table 4.9: Expenses of part produced by own company

PART NAME

MATERIAL
PRICE/ KG

WEIGHT

PRICE

MANUFACTURING
COST

labor cost

Total Price

99

1
2
3
4
5
6

Spray Body
Spray Nozzle
Nozzle Support
Body Presser
Connect Fitting
Slide Threaded
Rod

RM 10.70
RM 4.80
RM 4.80
RM 4.80
RM 4.80
-

260.0g
29.7g
10.5g
15.0g
3.9g

RM 0.20

MYR
MYR
MYR
MYR
MYR

0.07
0.05
0.05
0.05
0.05

RM 0.20

MYR

0.03

RM 2.80
RM 0.30
RM 0.20
RM 0.20

RM 0.28
RM 0.28
RM 0.28
RM 0.28
RM 0.28
RM 0.28
TOTAL

RM 3015
RM 0.63
RM 0.53
RM 0.53
RM 0.53
RM 4.86
RM 10.23

Total cost of material Cost = RM 14.10 + RM 10.23 = RM 24.33

4.7

COMPANYPROFIT
Table 4.10: Summary of company profit

Bank Loan
Interest Rate
Interest Pay in 10year

RM

TOTAL=

RM
RM

160,000.00
6%
96,000.00
256,000.00

Total Profit=

RM
RM
RM
RM
RM
RM
RM
RM

35.00
3.42
1.56
24.33
0.71
0.15
2.12
2.71

Clean Profit =

RM
RM
RM
RM

870,885.60
256,000.00
2,500.00
612,385.60

Market price
Overhead per unit price
Selling expenses per unit price
Product cost per unit price
Labor cost per unit
Maintenance cost per unit
Fixed cost per unit

Profit in 10years
Interest payback
Fixed Cost
4.8

RETURNOFINVESTMENT(ROI)

Table below shows the expenses of the product production and the net sales profit:
Table 4.11: First time expenditure in RM
ITEM
Fixed Cost
Material Cost

PRICE(RM)
178920
2064741.12
100

Overhead Cost
Labor Cost
Machine Cost
TOTAL

290234.88
60253
179912
2774061

Table 4.12: Net Sales Profit

CASH
FLOW
(YEAR)
0
1
2
3
4
5
6
7
8
9
10

EXPENDITURE
(RM)
-2774061
-2740258
-2740258
-2740258
-2740258
-2740258
-2740258
-2740258
-2740258
-2740258
-2740258

SALES
SALES
INCOME(RM) PROFIT(RM)
0
0
3224832
484574
3224832
484574
3224832
484574
3224832
484574
3224832
484574
3224832
484574
3224832
484574
3224832
484574
3224832
484574
3224832
484574

NET SALES
PROFIT(RM)
0
484572
969146
1453720
1938294
2422868
2907442
3392016
3876590
4361164
4845738

ROI

Figure 3.10: Return of investment

Based on Table 4.12 and Figure 4.4, it is shown that the return of investment will occur at
Figure 4.4: Return of investment

101

the 6th year. At this particular year, the net profit obtained is RM 2907442, which already
surpasses the total expenses used at the early beginning of production which is RM
2774061. Therefore, we have achieve our ROI point on the 6th year.

4.9

BREAKEVENPOINT(BEP)

Fixed cost = RM 178920

Selling price/ per unit = RM 38
Cost price/ per unit = RM 32.29
Table 4.13: Break-even point:
UNIT
0
5000
10000
15000
20000
25000
30000
35000
40000
45000
50000

SALES
0
190000
380000
570000
760000
950000
1140000
1330000
1520000
1710000
1900000

FIXED COST
178920
178920
178920
178920
178920
178920
178920
178920
178920
178920
178920

VARIABLE COST
178920
340370
501820
663270
824720
986170
1147620
1309070
1470520
1631970
1793420

102
BEP
Figure 1: Break-Even Point

From Table 4.13 and Figure 4.5, the break-even point of our product is when the unit
produce reach 30,000 units. At this particular point, it is the point where the sales and cost
are intercepting. At this point, we neither obtain any income or loss.

103