M16MAE‐ Engineering ProjectM16MAE‐ Engineering Project Management 

Fabrication Of Rolling Chassis

Khot Mahantesh‐ 5313329  Afroze Ahamed Aejaz Ahmed‐ 5169302

Presented By: GROUP‐1

Afroze Ahamed Aejaz Ahmed 5169302 Abdulsamad Ahmed Gobir‐ 5440463 

Anoop Vellithirut Ayyappan‐ 5349292 Ikechukwu Owunna‐ 4745239 

Yang Zhang‐ 3917729Yang Zhang‐ 3917729 Zhou Xiao‐ 5258592 

Introduction

bFabrication Management Team‐ Coventry 

d f ll hEnquiry received for 20 to 300 rolling chassis

i h iVarious Management Techniques 

S f lli Ch i b i i lStages of Rolling Chassis Fabrication plan

Aim

Process plan for fabricating first phase of 20Process plan for fabricating first phase of 20rolling chassis and ensuring delivery in end ofMarch 2015March 2015.

Demonstrate the process plan for deliveringDemonstrate the process plan for delivering100 ,200 and 300 rolling chassis per year.

Objectives

Check initial feasibility study Using Management tools 

b l h k f h hFeasibility check of in‐house CNC machining 

Cost implications of In‐house and Outsourced components

To determine the total cost for manufacturing rolling chassis

Eliminate or reduce unnecessary risks and cost implications to theEliminate or reduce unnecessary risks and cost implications to the 

business

Complete the project within time frame of 24 weeks

Make profit

Parameter  Diagram Fabrication of rolling ChassisINPUT

CAD modelIdeal Structure Plan

OUTPUTMaterial variation

Machining parameters

NOISE:

FSAE Standards

BOM

Management tools:

Accurate BOM

Accurate Prices and profits 

Potential risks in the process

Human factors

SYSTEMtools:

Gantt chart/ CPA/ SWOT/ Belbin / Pugh /QFD/ RASCII/ 

p

Breakeven point

Ideal Manufacturing techniques

Resource capacity and allocation

Fabrication of rolling chassis

/Q / /FMEA/ RAIDD

Materials used

Quality Expectations

Material Cost

Manufacturing Techniques

CONTROL VARIABLESAchieve Quality

Customer Satisfaction

Expectations

Assumptions

Purchasing of CNC machines old /new? 

Workers absence

Process settings

Missing programme milestones

High fabrication cost

ERROR STATE

Assumptions

The order for the initial 20 chassis are confirmed and PO

received from the customer

The order projections for next 200 and 300 chassis areThe order projections for next 200 and 300 chassis are

confirmed by the customer, although this will be based on

our findings and feasibility study.

Each department has sufficient budget to constructEach department has sufficient budget to construct

prototype and test it, for Phase‐1 Phase‐1 : 20 Rolling chassisPhase‐2 : 100 to 300 Rolling Chassis

Enough space availability for plant expansion

GANTT CHART

Phase‐1: CNC Machine Feasibility Comparison Chartp

S/N Represent Predeces Duration/D S/N Representa Predecess Duration/D/O Activities

pations  sor

/AYS

1 Corporate planning  A 102 Process planning B 103 Estimation C B 134 Finance D B 13

S/O Activities

ep ese ations 

edecessor

u a o /AYS

1 Corporate planning  A 102 Process planning B 103 Estimation C B 134 Finance D B 13

5 Procurement E B, C, D 30

6

Manufacturing tubular chassis and suspension control arms in house F E 38

4 Finance D B 135 Procurement E B, C, D 60

5

Manufacturing tubular chassis and suspension control arms in house F E 38

I h f t i

7Outsource manufacturing uprights hubs and driveshafts G E 36

8Purchasing standard parts and wheels H E 30

9 Assembly  I F,G,H 36

6In house manufacturing uprights hubs and driveshafts G E 80

7Purchasing standard parts and wheels H E 30

8 Assembly  I F,G,H 90I ti t ti d fi l

10Inspection, testing and final documentation  J I 28

11 Delivery K J 180

9Inspection, testing and final documentation  J I 28

10 Delivery  K J 210

Phase‐1: Initial Cost and CPA(Prototype and 20 chassis)

• Outsourcing  CNC Machining 

Process

• Prototype BuildPrototype Build

• Test before 25th Dec 14

• Feedback to Manufacturing Dept

• Production Assembly starts from 

28th Dec 1428 Dec 14

• Total Cost

Phase‐2: 100 to 300 chassis

• Discounts on All components from suppliers

• Increase in Production line –Assembly  Fixtures Increased

• Additional Supply chain – Accessed

• Increase in Inventory space ‐Tangible

• Offered discounted prices to 

customer 

• Total Cost

Breakeven Analysis and Fixed OverheadsFor Phase‐1 &2

Expenses for 3 months = £257100 

Fixed Cost=(Total Plant Expenses for 3 months/ total chassis Phase‐1)*chassis per month

= (£257100 / 20) *6( / )

= £77130  FIXED COSTS / Month

Capex Plan for Phase‐2

Fixed Over Heads = £77130 FIXED COSTS / MonthFixed Over Heads   £77130  FIXED COSTS / MonthConsidering new Employees (machinists) + Electricity +  Tools + Fixtures + Coolants + Misc + maintenance + M/c Depreciations = £ 35000/ Month

Fishbone Diagram – Phase 2

Profit

In-house ComponentsIn-house Components

Tubular ChassisSuspension Control Arm

Outsourced ComponentsDrive shaftUprightsHubs

Bought out ComponentsBearingsWheelsWheelsFasteners

Conclusion

Initial feasibility study has been performed and break even point hasdetermined for Phase1 and Phase‐2 rolling chassis

Plan for the procurement of CNC machines has been abandoned asthis will increase company’s fixed overheads to an additional cost of£35000 per month on the fixed costs.

Components will be outsourced for CNC machining

Route has been found to identify potential risks and actions

The work is completed in 24 weeks for Phase‐1

Discussed findings with internal customersDiscussed findings with internal customers

Report is handed over to the Management

Q&A….

Thank You………