ProjectO-guía

7/25/2019 ProjectO-gua

1/22

Integrantes:Mara Gabriela Cando Castillo

Juan Ramn Roca CastroLuis Daniel Zambrano Palma

FORML!"IO# !#D

$%!L!"IO# OF

PROJ$C"

&PRI#G COIL& M!#F!C"RI#G


2/22

Contents'( Introduction(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((()

'('( Ob*ecti+es(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((()

'()( Pro*ect summar,(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((())( Mar-et stud,((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((()

)('( Product c.aracteristics(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((()

)()( Determination o/ target mar-et(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((0

)(0( &tud,ing national demand(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((0

)(1( Prices(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((1

0( "ec.nical stud,(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((2

0('( P.,sical c.aracteristics o/ t.e 3roduct((((((((((((((((((((((((((((((((((((((((((((((((((((((2

0()( Materials /or s3ring coils((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((4

0(0( ses(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((5

0(1( Production 3rocess((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((5

0(2( &election o/ tec.nolog,(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((6

0(4( Descri3tion and diagrams 3rocess((((((((((((((((((((((((((((((((((((((((((((((((((((((((((('1

0(5( 7andling and distribution o/ materials((((((((((((((((((((((((((((((((((((((((((((((((((((('2

ra8 material and su33lies((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((('2

8aste(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((( '4

0(6( Plant la,out((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((('4

1( Pro*ect costs and sales income((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((('5

1('( Manu/acturing costs((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((('5

1()( General and administrati+e e93enses(((((((((((((((((((((((((((((((((((((((((((((((((('6

1(0( &elling e93enses((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((('

1(1( Interest e93ense((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((('

1(2( Cost;+olume;3ro


3/22

1. INTRODUCTION1.1. Objectives

De+elo3 a ne8 design o/ .elical s3rings> in order to raise u3 a com3an,>

8.ic. uses materials t.at .as our countr,( &earc. /or in/ormation about t.e mar-et stud,> to -no8 t.e demand o/

our 3roduct and ta-e decisions t.at .el3 to .a+e good bene t.e materials t.at it?s

made o/> and some ot.ers s3eci)) tons and 2>)AA tons b, t.e

,ear )A'5 and )A))> res3ecti+el,(

".e 3rinci3al ra8 materials reEuired are 8ires o/ .ig. carbon steel 8it.

diameters o/ A('2mm u3 to 1 mm> 8.ic. .a+e to be im3orted(

".e total in+estment cost o/ t.e 3ro*ect including 8or-ing ca3ital is estimated

at =irr )0(15 million &ee "able 5('( From t.e total in+estment cost t.e .ig.est

s.are =irr ''()6 million or 16(A5 is accounted b, initial 8or-ing ca3ital

/ollo8ed b, conical or in Flat> Zig@ag

)


4/22

s.a3es to ser+e +arious 3ur3oses in mac.ine 3arts or c.air cus.ions and

ot.er 3laces( In t.is 3ro*ect> our 3roduct is t.e .elical s3ring( It is also

im3ortant to -no8 some c.aracteristics o/ t.e com3ression s3rings t.at are

detailed in t.is scri3t( Finall, it is im3ortant to remar- t.at t.e t.e industrial sector> 8.ic. includes t.e manu/acturing and

construction sectors> is e93ected to gro8 at an a+erage annual gro8t. rate o/ )A(

Im3ortantl,> our countr, does not 3roduce an, -ind o/ .elical s3rings but rat.er

t.e, are being im3orted commonl, /orm a bad Eualit, > /or t.is reason it needs

a good maintenance t.at in+ol+es an amount o/ mone, 8asted /or

a33ro9imatel, t.ree times 3er ,ear( Considering t.is items our idea is to

encourage our countr, to .a+e t.e


5/22

)A'' 15

)A') 2)

)A'0 465)A'1 40

Source: Trade statistics for international business development

!s can be seen /rom "able '> im3ort o/ bolts and nuts /or t.e 3eriod )AA0;)A'1

ranges /rom t.e lo8est )'' tons ,ear )AA0 to t.e .ig.est 40 tons ,ear

)A'1 8it. annual a+erage o/ about 05A> tons( ".oug. im3ort o/ s3rings

uctuates /rom ,ear to ,ear> a general gro8t. trend can be obser+ed( For

e9am3le a+erage im3ort during t.e t.e 3rices 3er unit our 3ro*ect is

going to use must be e93licitl, establis.ed( Reasons /or t.is must be also e93lained

PRODC" PRIC$"o,ota .ilu9 .elical s3rings 62AResortes !g Qit Per/ormance Ford

Mustang '5 ! )AA1

)1

Coilo+er Resortes !*ustables Caribe

Gol/ Jetta !' !) !0

'01

Resortes #eus3eed %8 =ora Gti Gli

Passat Cc Len

222A

t.e /oreign mar-et 3ro+ides re/erence +alues 3rices> 8.ic. lead to a roug. idea o/ t.e

3rice o/ our 3roduct> as 8e see +ar, according to t.e s3eci but /or t.is 3art 8e *ust /ocus on t.e 3rice 8.ic. a+erages a33ro9imatel,

)>24)(

1


6/22

".is leads to t.in- t.at our 3roduct is acce3ted t.at 3rice s.ould range around t.e

abo+e;mentioned> t.e com3etition is e9tremel, strong because large automoti+e

industries in ot.er countries .a+e great e93erience and reliabilit, in its 3roducts> 8.ic.

is 8., 8e are reEuired to o3timi@e t.e reEuirements /or an acce3table 3rice(

2.+. ,ua$ti-catio$ o% u$met "ema$".

".e demand is e9tremel, .ig. because in $cuador t.ere is one t.at is

dedicated to t.e manu/acture o/ .elical com3ression s3rings industr, sim3l,

com3ete against distributors o/ large /oreign com3anies t.at o/ten t.eir

3roducts are not t.e most o3timal and time it ta-es to get t.e 3roduct

re3resent lost 8.en doing an, 8or-(

t.is 3roduct t.ere is no direct com3etition> in ot.er 8ords 8e can sa, t.at is an

abandoned mar-et 3er.a3s due to .ig. costs and lo8 demand generated

because i/ sumanete e93ensi+e 3rices are bu,ers 8ill be +er, /e8 8.ic.

ultimatel, not ".e, re3resent an, income to continue 3roduction(

(. Tec#$ica) tu"y(.1. P#ysica) C#aracteristics o% t#e ro"uct

".e 3roduct t.at is going to be 3roduced is .elical s3rings /or Industrial and

!utomoti+e sectors( ".e 3ro*ect 8ill be 3lanned to 3roduce one t,3e o/ .elical

s3rings: com3ression s3rings( ".ere 8ill be 3roduced in series b, standard DI#

)A6 and on reEuest /or s3eci material

and com3lementar, in/ormation(

Identi


7/22

".e #ot ground O3en ends> Ground Closed and Ground ends O3en ends> #ot ground

(.2. Materia)s %or sri$& coi)sMateria) Descritio$Music ire !I&I 'A62 It?s t.e best material /or little s3ring?s

/abrication( It .as an e9cellent tensile

strengt. and it can .andle re3eated

stresses( ".e 8ire gauges goes /rom

A>') mm to 0 mm(

4


8/22

H " ire !I&I 'A42 ".is material is /or general use> 8.en

music 8ire is not adeEuate( Its note

recommended /or s.oc- or im3act

loads( ".e 8ire gauges goes /rom 0

mm to ') mm(

C.romium %anadium !I&I 4'2A C.romium %anadium steel is t.ematerial /or .ig. strengt. .elical

s3rings( It can .andle .ig. stresses>

a33ro3riate /or s.oc- and im3act

load> and commonl, used /or /atigue

stresses( ire gauges goes /rom A>6

mm to ') mm(C.romium &ilicon !I&I )4A It .as t.e same a33lications as Crome

%anadium> but it .as .ig.er

3er/ormance( !/ter .eat treatment it

can ac.ie+e Roc-8ell C2A to C20(

ire gauges goes /rom A>6 mm to ')

mm(

(.(. Uses

Com3ression s3rings .a+e a large +ariet, o/ uses:

!ll .,draulic and +a3or s,stem accessories: t.e, .a+e s3rings in t.eir

mec.anisms> li-e securit, +al+es> 3ressure relie/ +al+es> instruments>

and ot.er t,3es o/ mec.anisms(

%ibration absorbers /or .ea+, mac.iner,: t.e, are 8idel, used /ormac.iner, /oundations 3rotection(

Farm mac.iner,: s3rings are 3resent in man, mec.anisms o/ t.ese t,3e

o/ mac.ines Manu/acturing mac.iner,: s3rings are 8idel, used /or steel 3rocessing

mac.ines> te9tile industries mac.ines> mec.ani@ation mac.ines> and

man, ot.er t,3es o/ industries( !utomoti+e: t.e, are not used onl, in t.e sus3ension mec.anism> a lot

o/ t.e internal s,stems o/ t.e cars> truc-s and road eEui3ment Mattresses industr,: all t.e internal s3rings o/ mattresses .a+e to be

manu/actured> actuall, t.is is a 8ide s3read mar-et $le+ators: ele+ators installations> at t.e bottom o/ t.e ele+ator?s 3it is a

strong .elical s3ring it?s installed /or a+oid im3act loads /or t.e users( Piers: large and strong .elical s3rings are used> to a+oid im3act loads

/rom boats to t.e 3ier structure( %ibration absorbers /or edi and because o/ t.at it?s necessar, to install

+ibration absorbers to a+oid resonance 3.enomenon(

5


9/22

(.*. Pro"uctio$ Process

".e 3roduction 3rocess can be b, t8o 8a,s: cold coiled and .ot coiled t.is

de3ends on 8ire diameter and design considerations( De3ending on design

reEuirements /or 8ire diameters belo8 de 26 '2> 65 mm t.e, could be coldcoiled and abo+e t.is +alue t.e, .a+e to be .ot coiled( =ut i/ t.e client

s3eci generall, @inc or c.romium to 3re+ent

corrosion(

(.+. e)ectio$ o% Tec#$o)o&y =ridge Crane: ".e bridge crane is going to be t.e 3rinci3al mac.iner, /or

mo+ing and storage o/ ra8 materials and and t.e, .a+e to be cut and uncoiled de3ending on

3roduction da,( ".e decoiler .a+e t.is /unction> it allo8 us to gi+e a t.e s3ring /orming( Furnace: t.is is t.e eEui3ment in c.arge o/ .eating t.e bars /or .ig.

3er/ormance coil s3rings( It .as to maintain a certain tem3erature during

all t.e 3rocess and be correctl, dimensioned /or a continuous 3rocess( uenc.ing 3ool: It .as to .a+e t.e correct si@e adeEuate +olume /or

t.e .eat treatment> also it .a+e to be in oB big /or t.e diBerent t,3e o/

s3rings t.at 8e are going to 3roduce( "em3ering /urnace: t.is mac.ine is in c.arge o/ gi+e bac- t.e elasticit,

o/ t.e steel lo8ering t.e .ardness it .as to o3erate in a continuous

mode( &.ot 3eening cabin: t.is mac.ine im3acts s3ring sur/ace 8it. little metal

3articles at .ig. +elocities> gi+ing t.e 3ro3ert, o/ a+oid crac-ing and

/atigue resistance to t.e s3ring( Com3ressor: t.is eEui3ment is /or gi+ing t.e 3ainting> it 8ill gi+e corrosion 3rotection(

6


10/22

ri"&e Cra$e:

Technical Specications:


11/22

Decoi)er

Technical Specications

Item #ame &L=;'2AA !utomatic &3ring Decoiler

&t,le &L=;'2AA

Ma9( ire Feed &3eed ')mminDiameter o/ ".e Feeding "ra,mm

)4AA

Mac.ine Po8er-8 2(2

Mac.ine eig.t-g )AAA

Po8er ))A%(!C(2A7Z

Mac.ine &i@emm )5AAS)5AAS''2A

Pac-age &i@emm )6AAS)6AAS')AA

3eati$& /ur$ace

'A


12/22


",3e idt. o/ mes.belt

mm

$Becti+e.eig.t

mm

7eatinglengt.

mm

Feedinglengt.

mm

Disc.arginglent.

mm

RatedPo8er

-8

TLA4;

5!')AA 'AA 'AAAA 'AAA '2AA 'A;0AA

ri$& Coi)er0


''


13/22

Model COM 20

Wire diameter acc. to. EN 10270-1 DH ph 10 - 20 mm

.393" - .787"

Max. wire diameter

(CrSi - ca. 1800 N/mm!"

1# mm"

.630"*

Spri$% &D diameter '0 - 2'0 mm1.969" - 9.842"

eedi$% )$*imited

Coi*i$% directio$ ri%ht / *e+t

Max. ,peed o+ wire +eedi$% 0 m/mi$

131 ft. / min

rod)ctio$ tp o+ the pitch ,ide

xe, - eedi$% (Sero!

- Spri$% diameter (Sero!

- C)tti$% pitch (top/3ottom! - (Sero!

- itch (ce$tre! - (Sero!

re,,)re co$tro* o+ +eedi$% ro**, hdra)*ic

4i,io$/camera ,pri$% %a%e mea,)ri$%

,,tem SCC aai*a3*e5

e, - more i$+ormatio$

o) ca$ +i$dhere

Sta$dard too*i$% ,et (i$c*)ded i$ the

price! - coer, the prod)ctio$

pro%ram +or EN 10270-1 DH

eedi$% ro**, Wire %)ide,

Coi*i$% pi$, itch 6$ie,

C)ttti$% 6$ie,

Max. power co$,)mptio$ 0 6W

Wei%ht ca. 1'.000 6%

~ 33,000 pound

Temeri$& /ur$ace

')
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14/22

Technical

Specications:

Place o/ Origin: Z.e*iang> C.ina

Mainland

=rand #ame: #J Model #umber: #J;

51A

C#C

!/ter;sales &er+ice

Pro+ided:

$ngineers

a+ailable to

ser+ice

mac.iner,

o+erseas

&ort: C#C

"em3ering

Furnace

Inner &i@e

Lmm:

1AAA

Inner &i@e mm: 5AA Inner &i@e

7mm:

')A Outsi@e &i@e

Lmm:

4'AA

Outsi@e &i@e mm: '))A Outsi@e &i@e

7mm:

'AA Po8er -8: 42

"em3erature UC: 1 =elt &3eed

min:

'A;4A

'0


15/22

#ot Pee$i$& Mac#i$e

Technical Specication

P)ace o% Ori&i$0 &.andong> C.ina Mainland ra$"

Name0

Ru+ii

4o)ta&e0 ))A;4AA% Po5er670 diBerent

eit0 DiBerent Certi-catio

$0

C$> C$

A%ter8sa)es ervice

Provi"e"0

$ngineers a+ailable to ser+ice mac.iner,

o+erseas

Mac#i$e

Tye0

!brator

C)ea$i$& Process0 s.ot blasting Use0 descalin

g

/ue)0 $lectric Materia)0 Metal Coil

,ua$tity o%ime))or#ea"0

';)

'1


16/22

Comressor

Technical Specications

Condition: #e8 ",3e: &cre8 Con C.inaMainland

=rand #ame: "uo8ei Model #umber: &G0A

%oltage: 06A%2A7Z0

P7

DimensionLSS

7:

''AAS62AS'0AA

MM

eig.t: 24AQG&

Certi "%> I&O arrant,: 8.ole

com3ressor /or

',ear

!/ter;sales &er+ice

Pro+ided:

O+erseas t.ird;

3art, su33ort

a+ailable

Po8er: 0A-8- 1A.3 Outlet diameter: G' '1V Dri+e: belt dri+e

!ir end: German,

tec.inical

Cooling: !ir cooling Ca3acit,

Disc.arge:

2m0min

or-ingPressure:

A(6MPa

(.9. Descritio$ a$" Dia&rams Process

'2


17/22

In t.e diagram belo8 are re3resented t.e basic 3rocesses o/ eac. stage o/ t.e

/abrication( ".e 3roduction unit is going to 3roduce coil s3rings /orm /our

diBerent t,3es o/ ra8 material: !I&I 'A62> !I&I 'A42> !I&I 4'2A> !I&I )4A( ".e

standard coil s3rings are going to be 3roduced /orm t.e !I&I 'A62 8ire( !nd on

reEuest coil s3rings are going to be /abricated /rom !I&I 'A42> !I&I 4'2A or !I&I

)4A de3ending on client?s s3eci /or trans3ortation and loading( ".e lists o/ ra8 materials t.at

are going to be used in t.e /actor, are:

'4


18/22

ire coil o/ steel !I&I;&!$ 'A62 ire coil o/ steel !I&I;&!$ 'A42 &teel bars o/ !I&I;&!$ 4'2A &teel bars o/ !I&I;&!$ )4A

".e /actor, 8ill need some materials t.ese materials are going to be stored in

t.e same 3lace o/ t.e ra8 materials and /uels and c.emicals and

metals( ".ere 8ill be t.ree containers in e+er, sector o/ t.e /actor, /or 8aste

.andling(

(.;. P)a$t


19/22

*. Project Costs a$" a)es I$come

*.1. Ma$u%acturi$& Costs

Direct costso Direct Material:

!I&I &!$ 'A62: '>6-g9 '5'52A -gW0A'2A !I&I &!$ 'A42: '>11-g9 '5'52A -gW)150)A !I&I &!$ 4'2A: '>4)-g9 '5'52A -g W)56)02 !I&I &!$ )4A: )>1A-g9 '5'52A -gW1'))AA

o "otal 3er ,ear: ')14A2o Direct Labor:

7eating Furnace 8or-ers: 0543er T ) W 52) &3ring Coilers;"em3ering Furnace 8or-ers: 0543er T )

3er W 52) ire ncoiler 8or-er: 0543erT' 3erW054 &torage 8or-er: 0543erT' 3erW054

o "otal 3er ,ear: )5A5) Indirect costs

o Indirect Materials: uenc.ing Oil: 2Agal9''66 galW2 112>)

$3o9, Paint: 5Agal9)A5 galW'11A &.ots /or s.ot 3eening: 0>44-g9'AAAW044A

o "otal 3er ,ear: 5522>)o Indirect Labor:

Cleaner o/ uenc.ing Pool: 0543ersonaT' 3erW054 Re3air and Maintenance 3ersonal: 0453er T)

3erW52)o "otal 3er ,ear: '0204

o &er+ices: $lectricit,: 66A -.da,sT0A da,sTA>A5-. W

'666

ater: 'A m0da,T0A da,s TA>'Am0 W 0Ao "otal 3er ,ear: ))46'04

o De3reciation: It?s calculated in /unction o/ t.e use/ul li/e o/ t.e

mac.iner,: '2 ,ears &3ring Coilers: 16AAAA'2 W 0)AAA 7eating Furnace: 'AAAAA'2 W 4444>45 "em3ering and &tress Relie+ing Furnaces: 4AAAA'2 W

1AAA

'6


20/22

ire ncoiler: )AAAA'2 W '000>0 =ridge Crane: 02AAA'2 W )000>0

o "otal 3er ,ear: 14000>)5o Re3air and Maintenance: !33ro9imated> Maintenance Plan

#eeded &3are Parts: 'AAAA

o "otal 3er ,ear: 'AAAAo Insurance: !33ro9imated

Insurance o/ all t.e Mac.ines: 601AAA'2 W 224AAo "otal 3er ,ear: 224AA

Ma$u%acturi$&costs

Tota) eryear

Direct material ')14A2

direct labor )5A5)

Indirect materials 5522>)

Indirect labor '0204

&er+ices ))46'04

De3reciation 14000>)5Re3air andMaintenance 'AAAA

Insurance 224AA

TOTA< 0512'55>15

*.2. =e$era) a$" a"mi$istrative e>e$ses

&r( #o( Descri3tion #o(

&alar, =irr

Mont.l,!nnual

!( !DMI#I&"R!"IO#

' Plant Manager ' 2AAA4AAA

A

) &ecretar, ' )2AA0AAA

A

0 !ccountant ' )2AA0AAA

A

1&alesman3urc.aser ' )2AA

0AAAA

2 Cler- ' '2AA'6AA

A

4 Cas.ier ' )AAA)1AA

A

5 General &er+ice 0 6AA)66A

A

&= "O"!L ))A6

AA

'


21/22


22/22

Interest ca3itali@ed 621)12

Interest income 5240)1

Tota) '612'00

*.+. Cost8vo)ume8ro-t a$a)ysis. rea'eve$ oi$t".e brea-;e+en anal,sis establis.es a relations.i3 bet8een o3eration costs

and re+enues( It indicates t.e le+el at 8.ic. costs and re+enue are in

eEuilibrium( "o t.is end> t.e brea-;e+en 3oint /or ca3acit, utili@ation and

sales +alue estimated b, using income statement 3ro*ection are com3uted

as /ollo8ed(

Break Even SalesValue=Cost+Financial Cost

Variable Margin ratio ( )=23765000

Break EvenCapacity utilization=Break even SalesValue

Sales revenue x 100=18.67

)'

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ProjectO-guía