Case 1: Mounting of electric boards

Current situation; screw fastening:

board_assembly

An operator grabs a product part and the electrical board which has to be mounted on the part, places it on the mounting table and positions the two parts. The operator mounts the electrical board with 5 screws and removes the assembled product. Due to the use of an electric screwdriver, the following table describes the assembly process:

Activity Inlay, positioning 5 mounting points Removal
Parts Base plate, electrical board 5 screws, electrical screwdriver Assembled product
Process time 10 sec. 50 sec. 5 sec.

Conclusion:

Assembly time is 65 seconds per electric board. In 6 hours effective operating time 332 products are assembled a day. In a year this comes to 66.461 products, the cost of labour per product is +/- 0.45 euro with 30.000 euro annual labour costs per operator.

New situation; CNC riveting:

Universele Klink CNC

An operator grabs 5 product parts and 5 electrical boards which has to be mounted on the 5 parts, places it on the indexed turntable and positions these parts. Pressing the start button, the CNC Riveting machine will turn the table a 180 degrees and starts riveting. In the mean time the operator removes the assembled products and places the new parts and presses the button again. Now the following table will describe the assembly process:

Activity Inlay, positioning Automatic Riveting Removal
Parts 5 Base plates, 5 electrical boards 25 rivets, CNC controlled Assembled products
Process time 50 sec. - 25 sec.

Conclusion:

Assembly time is 75 seconds per 5 electric boards, 15 seconds for one board. In 6 hours effective operating time 1440 products are assembled a day. In a year this adds up to 288.000 products, the cost of labour per product is +/- 0.10 euro with 30.000 euro annual labour costs per operator.

Return on Investment

In order to calculate the R.O.I. we take into account:

Production a year   50.000 products 150.000 products 288.000 products
Cost savings on labour per year 17.500 euro 52.500 euro 100.800 euro
Investment costs CNC Riveting machine 65.000 euro 65.000 euro 65.000 euro
R.O.I. in: 44 months 15 months 8 months
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