XLS www.production-solutions.com
User Directions: Fill in Yellow Data FieldsA. Number of Shift per Day1D. Estimated Equipment Opportunity Cost/Hr.:500B. Number of Days per Week5E. Total Number of SMT lines2C. Number of Weeks per Year50F. Personnel per line2CHANGEOVER PER LINEREWORK DUE TO IMPROPER SUPPORTG. Number of changeovers per day, per line (all shifts):5K. Average Quantity of Boards per Shift:500H. Est. Equipment Cost/Hr.: use cost of all equip affected by downtime200L. Average Yield:0.95I. Est. Burdend Labor Cost/Hr.:40M. Est. Cost of Rework per Board: Parts & Labor20J. Est. Equip. Downtime per Changeover due to tooling changeover (% of hr.):0.5N. % of Support Related Defects:0.15Total Rework CostTotal number of hours down due to tooling changeover=SUM((60*E12)*E9)/60DayWeekMonthYear=SUM(K9*(1-K10)*K11)*E3=SUM(H16*E4)=SUM(I16*4.3)=SUM(I16*E5)Equipment Downtime and Labor Costs:Fixture Related Rework Costs per DayDayWeek MonthYear=SUM(H16*K12)=SUM(I16*K12)=SUM(J16*K12)=SUM(K16*K12)Downtime=SUM(E9*E12*E10)*E3=SUM(B19*E4)=SUM(C19*4.3)=SUM(C19*E5)Total Cost of Fixture Related Rework per Average Working Yr.=SUM(K18)Labor=SUM(E9*E12*E11*K5)=SUM(B20*E4)=SUM(C20*4.3)=SUM(C20*E5)Total=SUM(B19:B20)=SUM(C19:C20)=SUM(D19:D20)=SUM(E19:E20)OPPORTUNITY COST LOSS DUE TO CHANGEOVERTotal Cost of Equipement Downtime and Labor Costs Per Line:=SUM(E21)DayWeekMonthYearTotal Cost of Equipement Downtime and Labor Costs ALL Line:=SUM(E22*K4)=SUM(K3*E15)=SUM(H23*E4)=SUM(I23*4.3)=SUM(I23*E5)Downtime in HoursHrs/Lines=SUM(E15*E3)=SUM(E15*E4)=SUM(C25*4.3)=SUM(C25*E5)Decrease in Changeover Time With Red-E-SetHrs/All Lines=SUM(B25*K4)=SUM(B26*E4)=SUM(C26*4.3)=SUM(C26*E5)1. Percent improvement in Changeover with RES (%of hour)0.3Cost per Hour due to Downtime and Labor Costs=SUM(F23/E25)2. Percent improvement in Quality using RES0.3Total Savings due to Decreased Changeover Time=SUM(E23*K26)Est. Capital Cost of Red-E-Sets10000Total Savings due to Decreased Rework=SUM(K19*K27)ROI in Weeks=SUM(K29/(I33/52))Total Revenue due to Improved Uptime=SUM(K23*K26)ANNUAL SAVINGSROI WEEKSTotal Savings and Revenue Increase Implementing Red-E-Set=SUM(E29:E31)=SUM(K30) ................
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