Old Main Members: KaLee Allen Mike Berry Jen Dronetti Greg Hofmann Charlie Miracola

Redesign

Manufacturing Method Front Face Bolt a 2’ x 3’ piece of 1/8” thick aluminum on table Will be getting 4 sheets of this aluminum for one order Will be able to get 16 faces and 11 back pieces per sheet

Manufacturing Method (cont.) Side Pieces Will be using rectangular tube aluminum 1.5” wide x 3” deep, 1/8” thick Will be getting six 4’ pieces, which will be cut from there Use a box fixture and machine 4 sides at once. Need to make this fixture. Will be able to get 95 Old Mains from this 24’ tube.

Manufacturing Method (cont.) Roof The bottom plate is 5.5”x3.125” The top plate is 5.25”x2.875” Both plates are 0.375” thick The only machining to be done will be with a cut-off saw and a slight finishing pass There will only be 2 cuts per plate, making this a relatively simple process The Cost per Old Main will be $8.18

Manufacturing Method (cont.) Triangular Roof Initial Stock is 1.25” x 1.25” x 6’ solid square 6061 Aluminum Cut into 12” sections using bar feeder Cut each 12” section in half (diagonally) on band saw using 45 degree wedges for guidance Mount 12” triangular sections in rotary vise on machining center Cut off 4 individual roof components using 1/8” end mill

Manufacturing Method (cont.) Tower The tower will be machined on the 5-axis machining center The machining will be completed in three portions (top, middle, base) and then assemble with the columns

Cost Breakdown Front Face and Back will be able to produce a total of 66 faces and 44 backs from total sheet. Total sheet cost is $118 Cost per Old Main will be $2.28. Sides Will be able to produce 95 Old Mains from one 24’ tube. Cost of tube is $67.50 Cost per Old Main is $0.71 or $0.35 per side (two sides per Old Main).

Cost Breakdown (cont.) Roof (Sheet) Will buy a 4”x6’x0.375” of 6061 Al from McMaster Carr for $49.10 From this size, we can make the two plates for 6 Old Main roofs The Cost per Old Main will be $8.18 Roof (Triangular) Will be able to get 12 roofs per 6’ length. Piece of 6’ length costs $ Cost per Old Main is $4.27

Costs Breakdown (cont.) Tower The top portion will be a 1” square stock and 2.5” long Will be able to produce 24 of this component Each 6’ section costs $40.75 Cost per Old Main will be $1.70 The middle section will be 1.25” square stock and 2” long Will be able to produce 28 of this component Each 6’ section costs $51.24 Cost per Old Main will be $1.80

Cost Breakdown (cont.) Tower (cont.) The base will be 2.25” square and 0.5” long Will be able to produce 10 of this component Each 1’ section costs $38.10 Cost per Old Main will be $3.80 The columns will be 0.125” and 1.6” long Will be able to produce 5 sets of 8 columns each Each 6’ section will cost $1.63 Cost per Old Main will be $0.36 Total Cost of Tower per Old Main will be $7.30

Cost Breakdown (cont.) Base of Structure Going to outsource all wood working from Houts. Will use pine as base 1’ x 6’ piece of 1” thick pine board. Will be cut into 12” x 5” sections Will get 12 Old Mains per board. Cost per board is $8.06. $32 per hour is cost of labor and machining. Houts estimates 0.5 hour machine time. Stain will cost $0.50 per Old Main Cost per Old Main is $2.50

Final Cost Breakdown Material Cost (per Old Main): $27.98 Roof: $12.45 Building (sides, front, back): $3.39 Tower: $7.30 Base: $2.50 Columns (8): $2.47 Clock: $6.95 Machine time and Labor: $90 Total Cost: $125.04

Costs of Goods Sold

Market Survey

Old Main Sensitivity and Break- Even Analysis

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