1. LOGO Working Process analysis - 3 team - 20052411 고견석 20052412 장금혁 20052431 황인성 CapStone Design

2. Contents Reason Of Subject Selection 1 Introduction of Company 2 Project Objective 3 Project Plan 4 www.themegallery.com Company Logo

3. Reason Of Subject Selection www.themegallery.com Company Logo

4.  Company Name : The Pride  Address : 258 -4, Song ha dong, Nam gu, in Kwang Ju  Category : KIA automobile subcontractor  Production Iteam : automobile - Sheet cover  Owner : Sun il kim  Annual Revenues : 10bilion  The number of employees : one hundred twenty : one hundred twenty Introduction Of Company www.themegallery.com Company Logo

5. Project Objective EconomyAnalysis Error Process Analysis Lead Time Analysis Process Optimization CostAnalysis www.themegallery.com Company Logo

6. Analysis of Cost & Productivity Team meeting Based Data Collection Visit and process flow understanding understanding of Process problems Error Process Analysis Economic Analysis Evaluation & Revision Nov Oct Sep Project Plan Dec www.themegallery.com Company Logo

7. Contents Process Flow 1 Details Of Process 2 Following Plan 3 www.themegallery.com Company Logo

8. 1. Process Flow www.themegallery.com Company Logo

9. Material input 원단을 입고하는 공정 Materialinspection 원단의 색상, 폭, LAMI 상태, Fabric work Needlework 재단된 형태를 맞대고 Cutting work Finished product inspection 완성품을 품질 기준 및 Waiting for shipping 1. Process Flow www.themegallery.com Company Logo

10. Put and arrange the materials which have been stocked from partnership companies Material input 2. Details Of Process www.themegallery.com Company Logo

11. Process that identifies a kind and thickness of materials Material inspection 2. Details Of Process www.themegallery.com Company Logo

12. Work to spread rolled materials to cut in fixed size Fabric work 2. Details Of Process www.themegallery.com Company Logo

13. Work to cut the materials in the same shape with a paper pattern by using Cam-machine Cutting work 2. Details Of Process www.themegallery.com Company Logo

14. Work to sew the material NeedleworkNeedlework 2. Details Of Process www.themegallery.com Company Logo

15. Inspection for finished products Finished product inspection inspection 2. Details Of Process www.themegallery.com Company Logo

16. Stock of finished products completed from final inspection Waiting for shipping 2. Details Of Process www.themegallery.com Company Logo

17. www.themegallery.com Company Logo 3. Following Plan 1.Working time analysis at each process line 2.Quantity of equipment at each process line 3.Equipment efficiency analysis

18. Contents Error Process Analysis 1 Selection Of Alternative 2 Analysis Of Alternative 3 4 www.themegallery.com Company Logo Analysis Direction

19. 3EA23min3EA23min 3EA15min3EA15min 60EA1min60EA1min 10EA0.6min10EA0.6min Process 1 Process 2 Process 1 Overtime Work Process 2OvertimeProduction Week day08:00~17:003 hour08:00~17:00Nothing7200 Satury day08:00~12:00 1hour 30minite 08:00~12:00Nothing3600 1. Error Process Analysis www.themegallery.com Company Logo

20. 1. Error Process Analysis  Components Defective Ratio www.themegallery.com Company Logo

21. One Process – One machine 1. Error Process Analysis www.themegallery.com Company Logo

22. 3,125 EA per month 5,625 EA per month 3,125 EA per month 3,125 EA per month 14,580 EA per month 8,100 EA per month 8,100 EA per month 8,100 EA per month So we realized that work has to be operated for three more hours to achieve the quantity goal, 900 products, 1. Error Process Analysis Process 2 Process 1 Output : 11(hour) X 6750 = 74250 – (74250x 0.0025) = 74064 Process 2 Output : 8(hour) X 900 = 7200 www.themegallery.com Company Logo

23. www.themegallery.com Company Logo alternatives : Fabric work and Cutting work alternatives for increasing process efficiency 1.Fabric work will increase workplace 2.Fabric work and a CAM plant will increase Process, the error analysis Process analysis Fabric work and Cutting work a lot of processing time, delays in operations were supposed to have been analyzed. 2. Selection Of Alternative

24. 3. Analysis Of Alternative www.themegallery.com Company Logo

25. 3,125 EA per month 5,625 EA per month 3,125 EA per month 3,125 EA per month 14,580 EA per month 8,100 EA per month 8,100 EA per month 8,100 EA per month We can see that work hour is decreased about 1hour and half because of increasing the quantity of production of components in first process line. 3. Analysis Of Alternative Process 2 Process 1 Output : 9.5(hour) X 7875 = 74813 –(74813)x 0.0025 = 74625 Process 2 Output : 8(hour) X 900 = 7200 www.themegallery.com Company Logo

26. 3. Analysis Of Alternative www.themegallery.com Company Logo

27. 3,125 EA per month 5,625 EA per month 3,125 EA per month 3,125 EA per month 14,580 EA per month 8,100 EA per month 8,100 EA per month 8,100 EA per month Inventory for the extra 30 minutes at a 1process must be no overtime. 3. Analysis Of Alternative Process2 Process 1 Output : 8(hour) X 9000 = 72000 – (72000x0.0025) = 71820 Process 2 Output : 8(hour) X 900 = 7200 www.themegallery.com Company Logo

28. www.themegallery.com Company Logo 4. Analysis Of Direction  Follwing Plan 1.Of each alternative over time, labor costs, overtime 2.Equipment costs by improving facilities. 3.Labor costs due to hiring personnel. 4. Labor costs for each alternative for the next ten years, depreciation, taxes, Inflation,electricity, and cash flow statement written in. 5. Due to production targets due to the cost of each alternative analysis of the economics.

29. Contents Condition Of Analysis 1 Method of Economical Analyze 2 Analysis Of Each Alternative 3 www.themegallery.com Company Logo Economical Analyze 4 Conclusion 5

30. 1. Condition Of Analysis  Objective : Figure out the equipment costs and the labor costs with effective productivity and select the most reasonable alternative Alternative A : Existing Process Alternative B : 3 worktable and 3 workers increment Alternative C : 1 Equipment and 4 workers increment www.themegallery.com Company Logo 3EA23min3EA23min3EA15min3EA15min 60EA1min60EA1min 10EA0.6min10EA0.6min Process 1 Process 2 Process 1 is need to improve for efficient work 31

31.  terms We analysised each project whether it is economically proper or not. We excluded the matter that occurred in other process because we only made the error process better Apply equally to all employees on wages were computed for 10 years average inflation rate last year was applied. Calculate wage the employee the same salary was 5,000 won per hour. (Overti me hours only 7,500 won). www.themegallery.com Company Logo 1. Condition Of Analysis 32

32. 2. Method of Economical Analyze  Depreciation(Decline-balance method) ND-factorDnBn 00050,000,000 10.2588Bn x factor = 12,940,000Bn – Dn1 = 37,060,000 20.2588Dn1 x factor = 12,662,376Bn1 – Dn2 = 36,252,498. 10 0.2588. 0.2588. Dn9 x factor. Bn 8 – Dn9 2,502,212(Salvage value) N=Machine’s durable years(10) 0.05 = Salvage value  A Compound Interest www.themegallery.com Company Logo

33. www.themegallery.com Company Logo NYearAverage Inflation Rate 02011- 120127.48% 220137.48% 320147.48% 420157.48% 520167.48% 620177.48% 720187.48% 820197.48% 920207.48% 1020217.48% To 2011 from 2001 for ten years of the average inflation rate. 2. Method of Economical Analyze

34.  Alternative A : Analysis Of Existing Process www.themegallery.com Company Logo Analysis List 1.Labor Costs : 5000won/per-hour 2.Overtime wage : time and a half 3.Overtime : 20hour 30minutes/per-week 4.Total Worker : 12 people ClassificationWageEA/People/HourTotal Costs Labor costs 5000won/ per-hour 12 people X 8hour480,000won Per - day Overtime wage 7500won/ per-hour 12 people X 3hour27,0000won 3. Analysis Of Each Alternative

35.  Costs Calculation Weekday(12 worker) : 480,000(8h) + 270000(3h ) = 750,000 750,000 x 22(day) = 16,500,000(month) Weekend(12worker) : 75,00 x (5.5h) x12(worker) = 495,000 495,000 x 4(day) = 1,980,000(month) 1year = 18,480,000 x 12(month) = 221,760,000 1month = 16,500,000+1,980,000 = 18,480,000 www.themegallery.com Company Logo 3. Analysis Of Each Alternative

36.  Alternative B : 3 worktable and 3 workers increment www.themegallery.com Company Logo Analysis List 1. Addition of three worktable 2. Addition of three workers 3. Labor Costs : 5000won/per-hour 4. Overtime Wage : time and a half 5. Overtime : 12hour /per-week 6. Total Worker : 15 people ClassificationWage & CostsEA/People/HourTotal Costs Worktable300,000won3EA900,000won Per - day Labor Costs 5000won/ per-hour 15 people X 8hour600,000won Overtime Wage 7500won/ per-hour 15 people X 1.5 hour168750won 3. Analysis Of Each Alternative

37.  Costs calculation Weekday(15 worker) : 600,000(8h) + 168750(1.5h) = 768,750 768,750 x 22(day) = 16,912,500(month) Weekend(15 worker) : 75,00 x (4.5h) x 15(worker) = 506,250 506250 x 4(day) = 2,025,000(month) 1year = 18,937,500 x 12(month) = 227,250,000 1month = 16,912,500+2,025000 = 18,937,500 Worktable= 300,000 x 3EA = 900,000 www.themegallery.com Company Logo 3. Analysis Of Each Alternative

38.  Alternative C : 1 Equipment and 4 workers increment www.themegallery.com Company Logo Analysis List 1. Addition of one cam equipment 2. Addition of one worktable 3. Addition of four workers 4. Overtime : 30 minutes/per-week 5. Total worker : 16 people ClassificationWage & CostsEA/People/HourTotal Costs Cam Equipment50,000,000won1EA50,000,000won Worktable300,000won1EA300,000won Labor Costs 5000won/ per-hour 16 people X 8hour640,000won Per-day Overtime wage 7500won/ per-hour 16 people X 0.5hour60,000won Analysis Of Each Alternative

39.  Costs calculation Weekday(16 worker) : 80,000(8h) = 640,000 640,000x 22(day/month) = 14,080,000 Weekend(16worker) : 75,00 x (4h) x16(worker) = 480,000 480,000 x 4(day/month) = 1,920,000 1year = 16,000,000 x 12(month) = 192,000,000 1month = 14,080,000+1,920,000 = 16,000,000 Worktable = 300,000 x 1EA = 300,000 Cam machine = 500,00,000 x 1EA = 500,000,000 www.themegallery.com Company Logo 3. Analysis Of Each Alternative

40. www.themegallery.com Company Logo NYearAverage Inflation RateLabor Costs 02011- ₩ 221,760,000 120127.48% ₩ 238,347,648 220137.48% ₩ 256,176,052 320147.48% ₩ 275,338,021 420157.48% ₩ 295,933,305 520167.48% ₩ 318,069,116 620177.48% ₩ 341,860,686 720187.48% ₩ 367,431,865 820197.48% ₩ 394,915,769 920207.48% ₩ 424,455,468 1020217.48% ₩ 456,204,737 Total Costs ₩ 3,590,492,666 4. Economical Analyze  Alternative A NYearAverage Inflation RateLabor Costs 02011- ₩ 227,250,000 120127.48% ₩ 244,248,300 220137.48% ₩ 262,518,073 320147.48% ₩ 282,154,425 420157.48% ₩ 303,259,576 520167.48% ₩ 325,943,392 620177.48% ₩ 350,323,958 720187.48% ₩ 376,528,190 820197.48% ₩ 404,692,498 920207.48% ₩ 434,963,497 1020217.48% ₩ 467,498,767 Total Costs ₩ 3,679,380,674  Alternative B  Total Costs Of Alternative A : 3,590,492,666 : 3,590,492,666  Total Costs Of Alternative B = 3,680,280,674 3,679,380,674 + 900,000 = 3,680,280,674 Total labor costs : 3,679,380,674 Worktable : 900,000

41. www.themegallery.com Company Logo NYearAverage Inflation RateLabor CostsD-FactorDnBn 02011- ₩ 192,000,000 0 ₩0₩0 ₩ 50,000,000 120127.48% ₩ 206,361,600 0.2588 ₩ 12,940,000 ₩ 37,060,000 220137.48% ₩ 221,797,448 0.2588 ₩ 9,591,128 ₩ 27,468,872 320147.48% ₩ 238,387,897 0.2588 ₩ 7,108,944 ₩ 20,359,928 420157.48% ₩ 256,219,311 0.2588 ₩ 5,269,149 ₩ 15,090,779 520167.48% ₩ 275,384,516 0.2588 ₩ 3,905,493 ₩ 11,185,285 620177.48% ₩ 295,983,278 0.2588 ₩ 2,894,752 ₩ 8,290,533 720187.48% ₩ 318,122,827 0.2588 ₩ 2,145,590 ₩ 6,144,943 820197.48% ₩ 341,918,414 0.2588 ₩ 1,590,311 ₩ 4,554,632 920207.48% ₩ 367,493,912 0.2588 ₩ 1,178,739 ₩ 3,375,893 1020217.48% ₩ 394,982,456 0.2588 ₩ 873,681 ₩ 2,502,212 Total Costs ₩ 3,108,651,659 ₩ 47,497,788 4. Economical Analyze  Alternative C : 1 Equipment and 4 workers increment Salvage Value : 2,502,212/50,000,000 = 0.05 = 5%  Total Costs Of Alternative B + 3,108,651,659 +300,000 +47,497,788 3,156,449,447 = 3,156,449,447 Total labor costs : 3,108,651,659 Worktable : 300,000 Depreciation Costs : 47,497,788

42. Alternative A (Operation like present) For worker wages during 10 years the future 3,590,492,666 won occurrence Alternative B ( 3 worktable and 3 workers increment) As equipment investment expense, worker wages and warehouse investment expense during 10 years the future 3,680,280,674 won occurrence  Therefore, it is reasonable that select alternative C www.themegallery.com Company Logo 5. Conclusion Alternative C (1 Equipment and 4 workers increment) As equipment investment expense, worker wages and warehouse investment expense during 10 years the future 3,156,449,447 won occurrence

43. www.themegallery.com Company Logo 6. Simulation analysis  Entire Simulation Module of The Pride

44. www.themegallery.com Company Logo 6. Simulation analysis  Failure Factor 1

45. www.themegallery.com Company Logo 6. Simulation analysis  Failure Factor 2

46. A A B B C C H H K K D D I I L L E E J J M M F F G G INPUT 1 1 1 23 18 17 15 11 1 1 1 0.6 0 1 1 6 1 10 24 19 24 18 28 39 34 39 29 39 40.6 40 Fabric work Cutting work NeedleworkNeedlework Finished product inspection inspection Waiting for shipping 7. Pert/CPM analysis ※ Figure out surplus time, S(TL-TE). Calculate surplus time, S by using TL and TE 1.Positive slack : TL-TE>0 = S>0 (Excessive time resource) 2.Zero slack : TL-TE=0 = S=0 (Proper time resource) 3.Negative slack : TL-TE<0 = S<0 (Insufficient time resource)

47. www.themegallery.com Company Logo A A B B C C H H K K D D I I L L E E J J M M F F G G INPUT 1 1 1 23 18 17 15 11 1 1 1 0.6 0 1 1 6 1 10 24 19 24 18 28 39 34 39 29 39 40.6 40 7. Pert/CPM analysis  Process blueprint Alternative B: A→B → H → I →J →F →G :TL-TE=6-1=5>0 Alternative C: A →B →K →L →M →F →G : TL-TE=10-1=9>0 CP(Critical Path) : A →B →C →D →E →F →G Conclusion : Alternative C whose surplus time is 9 is the most efficient way

48. www.themegallery.com Company Logo 8. Simulation Module  Alternative A

49. 8. Simulation Module www.themegallery.com Company Logo  Alternative A

50. www.themegallery.com Company Logo 8. Simulation Module  Alternative B (1/10)

51. 8. Simulation Module www.themegallery.com Company Logo  Alternative B (1/10)  We’ve decided to reduce the entities with regular ratio

52. 8. Simulation Module  Alternative B (1/100)

53. 8. Simulation Module www.themegallery.com Company Logo  Alternative C (1/100)

54. www.themegallery.com Company Logo 8. Simulation Module FABRIC WORKCAM WORK Alternative A23Min(Per 750EA)15Min(Per 750EA) Alternative B1815 Alternative C1711 FABRIC WORKCAM WORK Alternative A0.030.02 Alternative B0.0240.02 Alternative C0.0220.01 1/101/100 71269 X87 X93  Variables(into simulation)  Result  Real output per time

55. www.themegallery.com Company Logo 8. Simulation Module 1/101/00 Alternative A71269 Alternative BX87 Alternative CX93 11/101/00 720071269 900089087 960095093  Result  Exchange result(Output) ∴ When Alternative C is cosidered, The Pride can produce 9,600 of car-seat per day. The Pride can produce 9,600 of car-seat per day.

56. LOGO