1. LOGO Capstone Design Economical analysis of Decrepit equipment change Team No.1 Presenter 이호정

2. LOGO Contents Introduction to Team 1 Introduction to Topic 2 Direction of Project 3 4 Schedules 5 Research & Requirements Analysis

3. LOGO Introduction to Team 1 Lee ho jung (Master) Collection of data, Analyze, Report drawing up Lee young lok(Member) Collection of data, Arrangement, Analyze Na ui seong(Member) Data arrangement, Report drawing up Team No.1 Chun jin won(Member) Data arrangement

4. LOGO Introduction to Topic 1 3,125 EA per month 5,625 EA per month 3,125 EA per month 8,100 EA per month 8,100 EA per month 14,580 EA per month 8,100 EA per month 8,100 EA per month 2 Economical analyze of Decrepit machine change All-night work

5. LOGO Introduction to Topic 1 5,625 EA per month 3,125 EA per month 8,100 EA per month 14,580 EA per month 14,580 EA per month 8,100 EA per month 2 Economical analyze of Decrepit machine change Through analysis of number-one increase in equipment, number-one increase in Worker

6. LOGO Introduction to Topic 1 3,125 EA per month 5,625 EA per month 8,100 EA per month 8,100 EA per month 14,580 EA per month 14,580 EA per month 8,100 EA per month 8,100 EA per month 2 Economical analyze of Decrepit machine change Last semester working on a project and that results, was submitted to company representative. Satisfaction of the project was higher in the future there will be equipment investment. In addition, through interviews with representatives and was given another requirement. Because of the decrepit equipment failures, repairs, loss of production, idle time occurs. For this reason, the production decreased and there is overtime. Through replacement of decrepit equipment that can solve the problem whether asked.

7. LOGO Introduction to Topic 1 3,125 EA per month 5,625 EA per month 8,100 EA per month 8,100 EA per month 14,580 EA per month 14,580 EA per month 8,100 EA per month 8,100 EA per month 2 Economical analyze of Decrepit machine change Decrepit Machine New Machine Replacement equipment ( 주 ) 동양이노텍 ’s was established most equipment was purchased new. However, some equipment were used to purchase the product. Replacement of equipment in operation for seven years the worker satisfaction and financial satisfaction can be achieved at the same time that will be analyzed.

8. LOGO Research & Requirements Analysis 1 2 3 Results of 10 workers interviews 불만족 보통 만족 Satisfaction of equipments For current workers to use equipment that has been largely unsatisfactory.

9. LOGO Research & Requirements Analysis 1 2 3 Results of 10 workers interviews 교체 불필요 상관없다 Replacement equipment is needed? Due to the failure of decrepit equipment, increasing the number of overtime, the accumulation of fatigue and slow down there closing hour. So half of the workers they want to use the replacement of equipment

10. LOGO Research & Requirements Analysis 1 2 3 Results of 10 workers interviews TAP Press-in 연마기 선반 Replacement equipment rankings Workers want to replace the equipment top priority was a polishing machine. Next, TAP machine, centering machine, was followed by the lathe-turning machine. The reasons are decrepit polishing machine most frequent failures and speed of the operation falls.

11. LOGO Increase satisfaction of worker Reduce the Defective rate Increase the productivity Change the Machine Direction of Project 3 Increase Profitability Reduced idle time 4

12. LOGO Schedules Week345678910111213141516 Report the plan Visit to field Worker Requirements Analysis Distribution of each equipment failure Equipment failure costs estimated Selection of new Equipment / cost estimate Comparative Analysis Submit report PlanRun 4 5

13. LOGO Q & A Have any Question ?

14. LOGO

15. Capstone Design Economical analysis of Decrepit equipment change Team No.1 Presenter 천진원

16. LOGO Contents Production Flow 1 Analyze of Equipment Failure 2 3 Result 4 Method of equipment failure analysis Schedule 5

17. LOGO Production Flow MaterialsCentering Process Lathe turning Process Heat treatment Process Press-in Process Form rolling Process Polishing Process TAP Process Product 1

18. LOGO Method of equipment failure analysis 1 2 2 Accumulate failure rate Equipment operating time <Equipment operating time Per Accumulate failure rate Curve> <Life-cycle of Equipment (Bath-tube curve)>

19. LOGO Analyze of Equipment Failure 1 2 2 Process Name : Centering Process Drill holes on both sides of materials center Equipment operating time 01000 2000 5000 3000 40006000 0.005 0.02 0.025 0.015 0.01 0.03 0.035 0.04 0.0025 0.0055 0.0085 0.0115 0.0185 0.015 Accumulate failure rate 3

20. LOGO Analyze of Equipment Failure 1 2 3 Process Name : Lathe turning Process Using a CNC lathe machining 01000 2000 5000 3000 40006000 0.005 0.02 0.025 0.015 0.01 0.03 0.035 0.04 0.002 0.004 0.007 0.009 0.014 0.012 Equipment operating time Accumulate failure rate 3

21. LOGO Analyze of Equipment Failure 1 2 3 Process Name : Heat treatment Process Heat treatment 01000 2000 5000 3000 40006000 0.005 0.02 0.025 0.015 0.01 0.03 0.035 0.04 0.0015 0.0025 0.0035 0.0055 0.008 0.0065 Equipment operating time Accumulate failure rate 3

22. LOGO Analyze of Equipment Failure 1 2 3 Process Name : Press-in process Put the bearings 01000 2000 5000 3000 40006000 0.005 0.02 0.025 0.015 0.01 0.03 0.035 0.04 0.004 0.008 0.013 0.017 0.025 0.022 Equipment operating time Accumulate failure rate 3

23. LOGO Analyze of Equipment Failure 1 2 3 Process Name : Form rolling Process Screw Machining 01000 2000 5000 3000 40006000 0.005 0.02 0.025 0.015 0.01 0.03 0.035 0.04 0.004 0.007 0.01 0.014 0.023 0.019 Equipment operating time Accumulate failure rate 3

24. LOGO Analyze of Equipment Failure 1 2 3 Process Name : Polishing Process Trim surface 01000 2000 5000 3000 40006000 0.005 0.02 0.025 0.015 0.01 0.03 0.035 0.04 0.0055 0.0105 0.0155 0.0215 0.036 0.0295 Equipment operating time Accumulate failure rate 3

25. LOGO Analyze of Equipment Failure 1 2 3 Process Name : TAP Process Screw Machining 01000 2000 5000 3000 40006000 0.005 0.02 0.025 0.015 0.01 0.03 0.035 0.04 0.0055 0.0105 0.016 0.023 0.0395 0.0305 Equipment operating time Accumulate failure rate 3

26. LOGO Result 3 4 Number of Equipment Failure Centering Process : 18.5 Lathe turning Process : 14 Heat treatment Process : 8 Press-in process : 25 Form rolling Process : 23 - - - - - - - ③ Polishing Process : 37 - - - - - - - - - ② TAP Process : 39.5 - - - - - - - - - - - ① Number of Total Failure : 165 Failure rate was selected to prioritize the results of a calculation. High number of failures in the second half of life-cycle replacement of machine for review will be focused. 4

27. LOGO Schedules Week345678910111213141516 Report the plan Visit to field Worker Requirements Analysis Distribution of each equipment failure Equipment failure costs estimated Selection of new Equipment / cost estimate Comparative Analysis Submit report PlanRun 4 55

28. LOGO Q & A Have any Question ?

29. LOGO Capstone Design Economical analysis of Decrepit equipment change Team No.1 Presenter 나의성

30. LOGO Contents Method of Failure Time Measure 1 2 3 Result 4 What is Effect of Failure? 5 Failure-time measurement of the selected equipment Schedule

31. LOGO What is Effect of Failure? 1 1.An increase in defective units and scrap 2.Delivery delays due to customer complaints 3.Loss of stock due to sales opportunities 4.Parts / process products for subsequent processing congestion of supply disruptions 5.Causes idle labor costs 6.Causes idle cost of capital 7.Causes the cost of repairs 8.Causes industrial pollution and etc

32. LOGO Time of Failure 1 2 2 M·T·T·R = Mean Time To Repair (Failure Time + Repair Time) M·T·T·F = Mean Time To Failure (Operating Normally Time) M·T·B·F = Mean Time Between Failure (M·T·T·R + M·T·T·F) Failure Operating normally M·T·T·RM·T·T·RM·T·T·F M·T·B·F

33. LOGO Failure-time measurement of the selected equipment 3 Failure Operating normally M·T·T·R=5 M·T·T·F=106.11 M·T·B·F=111.11 Process : TAP

34. LOGO 3 Failure Operating normally M·T·T·R=5 M·T·T·F=128.33 M·T·B·F=133.33 Process : Polishing Failure-time measurement of the selected equipment

35. LOGO 3 Failure Operating normally M·T·T·R=3 M·T·T·F=247 M·T·B·F=250 Process : Form Rolling Failure-time measurement of the selected equipment

36. LOGO Result 1 2 4 We replace the equipment in accordance with the priorities of the equipment failure times and operating time were calculated. Shorter MTBF frequent failures and have a short operating time. Next week will calculate the cost of failure and replacement costs.

37. LOGO Schedules Week345678910111213141516 Report the plan Visit to field Worker Requirements Analysis Distribution of each equipment failure Equipment failure costs estimated Selection of new Equipment / cost estimate Comparative Analysis Submit report PlanRun 4 55

38. LOGO Q & A Have any Question ?

39. LOGO Capstone Design Economical analysis of Decrepit equipment change Team No.1 Presenter 이호정

40. LOGO Contents Trend of Failure 1 2 3 A one-time failure cost estimate 4 Failure rate Forecasting method 5 Equipment failure factors & Repair cost The cost of failure & Result Schedule 6

41. LOGO Failure rate Forecasting method 1 Time series analysis – Using for Trend and failure forecast

42. LOGO Trend of Failure 1 2 2 설비운영시간 1000(1)2000(2)3000(3)4000(4)5000(5)6000(6) 고장발생수 5.55 77.59 XYX^2XYn=6 15.51 sumX=21 25410sumY=39.5 35.5916.5sumX^2=91 471628 sumXY=151. 5 57.52537.5 693654 sum2139.591151.5 Process : TAP 01000 2000 5000 3000 40006000 4 7 8 6 5 9 10 11 Equipment operating time 7000 8000 900010000 12 8.6412 9.2293 9.8173 10.4053 Number of failure

43. LOGO Trend of Failure 1 2 2 Process : Polishing 설비운영시간 1000(1)2000(2)3000(3)4000(4)5000(5)6000(6) 고장발생수 5.555687.5 XYX^2XYn=6 15.51 sumX=21 25410sumY=37 35915sumX^2=91 461624 sumXY=139. 5 582540 67.53645 sum213791139.5 01000 2000 5000 3000 40006000 4 7 8 6 5 9 10 11 Equipment operating time 7000 8000 900010000 12 8.1665 8.7379 9.3093 9.8807 Number of failure

44. LOGO Trend of Failure 1 2 2 Process : Form Rolling 설비운영시간 1000(1)2000(2)3000(3)4000(4)5000(5)6000(6) 고장발생수 433454 XYX^2XYn=6 1414sumX=21 2346sumY=23 3399sumX^2=91 4416 sumXY=84 5525 643624 sum21239184 01000 2000 5000 3000 40006000 4 7 8 6 5 9 10 11 Equipment operating time 7000 8000 900010000 12 4.533 4.733 4.933 5.133 Number of failure 3

45. LOGO Equipment failure factors & Repair cost 3 TAPPolishingForm – rolling 1. 수치인식오차발생 (Frequency:65% Repair cost: ₩ 200,000) 2. 베어링파손 (Frequency:15% Repair cost: ₩ 100,000) 3. 수치입력회로고장 (Frequency:5% Repair cost: ₩ 150,000) 4. 축 이탈 (Frequency:5% Repair cost: ₩ 180,000) 1. 수치인식오차발생 (Frequency:80% Repair cost: ₩ 200,000) 2. 축 이탈 (Frequency:15% Repair cost: ₩ 180,000) 3. 조임쇠 파손 (Frequency:5% Repair cost: ₩ 300,000) 1. 로봇 팔 오작동 (Frequency:45% Repair cost: ₩ 150,000) 2. 컨베이어 정지 (Frequency:30% Repair cost: ₩ 100,000) 3. 수치인식오차발생 (Frequency:25% Repair cost: ₩ 200,000)

46. LOGO A one-time failure cost estimate 1 2 4 TAP:(200,000*0.65)+(100,000*0.15)+(150,000*0.05)+(180,000*0.05) ₩ 161,500 Polishing:(200,000*0.8)+(180,000*0.15)+(300,000*0.05) ₩ 202,000 Form rolling:(150,000*0.45)+(100,000*0.3)+(200,000*0.25) ₩ 147,500 The incidence failure compared to the cost of repairs was calculated. Results of the Polishing had the highest repair costs.

47. LOGO A one-time failure cost estimate 1 2 4 TAP worker wage : 4320*5 ₩ 21,600 Polishing worker wage : 4320*5 ₩ 21,600 Form rolling worker wage : 4320*3 ₩ 12,960 The incidence failure compared to the cost of repairs was calculated. Results of the Polishing had the highest repair costs.

48. LOGO The cost of failure & Result 4 55 Polishing TAP Form-Rolling PolishingTAPForm-Rolling Showed the flow of current to the cost of failure. The cost of repair of the Polishing with the TAP was higher.

49. LOGO The cost of failure & Result 4 55 Mean Time to Repair TAP : 5 (hour) Polishing : 5 (hour) Form-rolling : 3 (hour) PolishingTAPForm-Rolling The loss that occurs on the wages of workers during MTTR Polishing TAP Form-Rolling

50. LOGO 일정 1 2 6 Week345678910111213141516 Report the plan Visit to field Worker Requirements Analysis Distribution of each equipment failure Equipment failure costs estimated Selection of new Equipment / cost estimate Comparative Analysis Submit report PlanRun

51. LOGO Q & A Have any Question ?

52. LOGO Capstone Design Economical analysis of Decrepit equipment change Team No.1 Presenter 나의성

53. LOGO Contents Cost of purchasing new equipment 1 2 3 Result 4 Failure Cost 5 The new equipment cost and failure cost comparison Schedule

54. LOGO Failure Cost 1 TAP : Failure cost ₩ 161,500 + worker wage ₩ 21,600 + Overtime wage ₩ 32,400 = ₩ 215,500 Polishing : Failure cost ₩ 202,000 + worker wage ₩ 21,600 + Overtime wage ₩ 32,400 = ₩ 256,000 Form rolling : Failure cost ₩ 147,500 + worker wage ₩ 12,960 + Overtime wage ₩ 19,440 = ₩ 179,900

55. LOGO Cost of purchasing new equipment 1 2 2 New TAP machine cost : ₩ 60,000,000 New Polishing machine cost : ₩ 45,000,000 New Form rolling machine cost : ₩ 38,000,000

56. LOGO The new equipment cost and failure cost comparison 3 TAP : 60,000,000 / 215,500 = 279 회 분기 14151617181920 고장횟수 16.285316.873317.461318.049318.637319.225319.8133 분기별고장비용 3,509,4823,636,1963,762,9103,889,6244,016,3384,143,0524,269,766 누적고장비용 37,601,75541,237,951 45,000,86 1 48,890,48 5 52,906,82357,049,8756,1319,641 At five years and four quarters Equipment purchase costs and intersection the cumulative cost of failure New machine cost

57. LOGO The new equipment cost and failure cost comparison 3 polishing : 45,000,000 / 256,000 = 176 회 분기 121314151617 고장횟수 14.451915.023315.594716.166116.737517.3089 분기별고장비용 3,699,6863,845,9653,992,2434,138,5224,284,8004,431,078 누적고장비용 34,741,86238,587,82742,580,07046,718,59251,003,392 55,434,47 0 New machine cost Four years when the third quarter Equipment purchase costs and the intersection of the cumulative cost of failure

58. LOGO The new equipment cost and failure cost comparison 3 Form rolling : 38,000,000 / 179,900 = 212 회 분기 20212223242526 고장횟수 13.73314.53314.73315.53315.73316.53316.733 분기별고장비용 2,470,5672,614,4872,650,4672,794,3872,830,3672,974,2873,010,267 누적고장비용 32,860,53435,475,02138,125,487 40,919,87 4 43,750,24146,724,52849,734,794 Six years at the second quarter Equipment purchase costs and the intersection of the cumulative cost of failure New machine cost

59. LOGO Result 1 2 4 TAP machine change Occur cost : 45,000,000(New polishing Machine) +60,000,000(New TAP machine) +10,578,119.2(Cumulative TAP repair cost) +6,080,260(Cumulative form-rolling repair cost) Total cost : 121,658,379 Polishing machine change Occur cost : 45,000,000(New polishing machine) +1,862,179(TAP repair cost) +815,486.7(form-rolling repair cost) Total cost : 47,677,665 Form-Rolling machine change Occur cost : 45,000,000(New polishing Machine) +60,000,000(New TAP machine) +38,000,000(New form-rolling Machine) +10,578,119.2(Cumulative TAP repair cost) +7,435,446.9(Cumulative form-rolling repair cost) Total cost : 161,013,566 Relationship of equipment replacement and repair costs

60. LOGO Schedule 1 2 6 Week34567891011121314 Report the plan Visit to field Worker Requirements Analysis Distribution of each equipment failure Equipment failure costs estimated Selection of new Equipment / cost estimate Comparative Analysis Submit report PlanRun 5

61. LOGO Q & A Have any Question ?

62. LOGO Capstone Design Economical analysis of Decrepit equipment change Team No.1 Presenter 이호정

63. LOGO Content Analysis of alternatives 1 2 3 Schedule 4 Alternatives Result

64. LOGO Alternative 1 1 Assume : The new machine does not failure Form-Rolling machine change Occur cost : 45,000,000(New polishing Machine) +60,000,000(New TAP machine) +38,000,000(New form-rolling Machine) Total cost : 143,000,000

65. LOGO Alternative 2 1 TAP machine change Occur cost : 45,000,000(New polishing Machine) +60,000,000(New TAP machine) +10,578,119.2(Cumulative TAP repair cost) +6,080,260(Cumulative form-rolling repair cost) Total cost : 121,658,379 Polishing machine change Occur cost : 45,000,000(New polishing machine) +1,862,179(TAP repair cost) +815,486.7(form-rolling repair cost) Total cost : 47,677,665 Form-Rolling machine change Occur cost : 45,000,000(New polishing Machine) +60,000,000(New TAP machine) +38,000,000(New form-rolling Machine) +10,578,119.2(Cumulative TAP repair cost) +7,435,446.9(Cumulative form-rolling repair cost) Total cost : 161,013,566 Assume : The new machine does not failure

66. LOGO Analysis of alternatives 1 2 2 Form-Rolling machine change Occur cost : 45,000,000(New polishing Machine) +60,000,000(New TAP machine) +38,000,000(New form-rolling Machine) Total cost : 143,000,000 - Alternative 1 occurs a lot of initial investment capital. - The company's size is not large that occurrence burden of high cost. - In addition to the initial investment capital of failure cost does not occur.

67. LOGO Analysis of alternatives 1 2 2 TAP machine change Occur cost : 45,000,000(New polishing Machine) +60,000,000(New TAP machine) +10,578,119.2(Cumulative TAP repair cost) +6,080,260(Cumulative form-rolling repair cost) Total cost : 121,658,379 Polishing machine change Occur cost : 45,000,000(New polishing machine) +1,862,179(TAP repair cost) +815,486.7(form-rolling repair cost) Total cost : 47,677,665 Form-Rolling machine change Occur cost : 45,000,000(New polishing Machine) +60,000,000(New TAP machine) +38,000,000(New form-rolling Machine) +10,578,119.2(Cumulative TAP repair cost) +7,435,446.9(Cumulative form-rolling repair cost) Total cost : 161,013,566 - Alternative 2 does not happen a lot of initial investment capital. - Instead, the initial investment capital does not occur, the cumulative of failure cost occurs. - As a result, approximately 17,000,000won in excess of the cumulative of failure cost occurs.

68. LOGO 3 Result - We analyzed the Alternative 1 and Alternative 2. - Alternative 1 total cost 143,000,000 won Alternative 2 total cost 161,013,566 won - In terms of companies initial investment capital to have much of a burden. -So economically disadvantage, but in order to replace the machine include the corporate Alternative 2 is more efficient. 불만족 보통 만족 Satisfaction of equipments 불만족 보통 만족

69. LOGO Schedule 1 2 6 Week34567891011121314 Report the plan Visit to field Worker Requirements Analysis Distribution of each equipment failure Equipment failure costs estimated Selection of new Equipment / cost estimate Comparative Analysis Submit report PlanRun 5 4

70. LOGO Q & A Have any Question ?