AUTOMATION TRENDS
per part. The cost per part multiplied by the annual demand is summed to the total cost of machine replacement and labor. When this costing method was applied to the three cell con- figurations, dramatically different results can be observed.”
The cost model showed the following results—keep in mind that all three configurations have the same machine
cycle time and same machine hours: t Current Benchmark Cell: $ 145/part t Three-Machine Cell: $ 190/part t Two-Machine Flexible Cell: $ 120/part
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AdvancedManufacturing.org | March 2016
“Analysis reveals that the current cell has higher cost because of the different number of days the cell operates to meet monthly demand. The current cell configuration must operate 25 days per month whereas the flexible cell oper- ates 21 days per month. “The three-machine cell cost per part is high because of the replacement cost of three machines instead of two machines. The additional replacement cost of the third machine could be absorbed with higher demand but de- mand is not going up, and so the same demand must absorb the replacement cost of the third machine.
“For decision makers, the implica-
tions are clear. Including efficient use of capacity and direct labor into a future cost provides a justification for an advanced automation alternative. Cost modeling can lead to justifying the impact of advanced automation on cost per part into their future-oriented manu- facturing decision making,” said Lenz.
Lay a Good Step-by-Step Foundation for Automation
“A lot of people think that they have to make a big investment to get into auto- mation to be cost effective and produc- tive, especially with skilled labor being so scarce,” said Gisbert Ledvon, director of business development, GF Machining Solutions (Lincolnshire, IL). “Robots may be a solution in the long run, but there is a lot to be said for getting started by tak- ing a step-by-step approach with basics. For example, installing a good reference system, a tooling system of a chuck and
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