Southern Machinery

Fill in “Green Areas” on Summary Sheet Below & Production Need Sheet
Calculations in “Blue” or “White” and should not be changed
INPUTS
Financial	Machine Price	Depreciation Time (Years)	Electricity Cost ($/kWHr)
	US$ 205,000	5	US$ 0.1200
Machine Data	Configuration	Pass Thru / Non Pass Thru	Spec Speed
	Sm Triple Span (2.5/5.0/7.5)	Pass Thru (Automatic BDH)	22,000
Labor Rates / Hour	Machine Operator	Maintenance
	US$ 10.00	US$ 15.00
Factory Work Time	Hours / Day	Days / Week	Weeks / Year
	20	6	50
Hand Labor	Hand Labor Rate	Insertion Rate / Hour
	US$ 6.00	250
OUTPUTS
Production Data
Insertions Needed	4,900,000	Annual Component Insertion
Machine Work Time
Machine Time	613	Hours to MFG
Hours in Year	6000
Machine Utilization	10.22%
Machine Yearly Costs
Depreciation	US$ 41,000	Straight Line Depreciation
Utilities	US$ 155	Electricity for Machine & Air
Maintenance	US$ 900	Parts & Labor for Machine
Operator	US$ 6,132	Operator Time @ machine
Total Yearly Costs	US$ 48,186	Sum of all costs
Hand Labor Equivalents
Labor Hours	19,600
Labor Costs	US$ 117,600
MACHINE DRIVEN SAVINGS
Hand Placement Cost		US$ 117,600	Per Year
Machine Placement Cost		US$ 48,186	Per Year
Annual Savings		US$ 69,414	Per Year

 

	Price	Unit	Notes
Machine Cost	US$ 205,000	$	Machine Costs
Depreciation Time	5	Years	Straight Line Assumed
Yearly Deprciation Expense	US$ 41,000		Result
Work Days per Week	6	Days
Hours Per Day	20	Hours
Weeks per year	50	Weeks
Hours per Year Available	6,000	Hrs/Year	Work Hours per Year
PM  Hours per 100 Hrs	12	Hours	Maintenance
Machine Working Hours	522	Hours	Total Production Hours
Maintenance Intervals	5	Periods	Maintenance Times
Maintenance Time	60	Hours	Maintenance Times
Maintenance Labor Cost	US$ 900	Costs	Labor Hours x Rate
Production Hours Needed	522	Hours	Machine Production Time
Intrinsic Availability	94.00%	Uptime	Downtime (Increased based on Age)
Lost Hours	31	Hours/Yr	Downtime
Machine Hours To Produce	553	Hours	Production Hours
Guide Jaw / Clinch Costs	US$3,000	Cost	Per Unit
Tooling Replacement	6,000,000	Cycles	Cycles per replacement
Tooling Replacements / Yr	0	Replacements	Replacements Needed
Yearly Replacement Costs	US$0.00	Costs	Total Yearly Tooling Costs
Chain Clip Replacments	US$780	Cost	Cost Per Replacement
Tooling Replacement	15,000,000	Cycles	Cycles per replacement
Tooling Replacements / Yr	0	Replacements	Replacements in a Year
Yearly Replacement Costs	US$0.00	Costs	Total Yearly Chain Costs

Continuity Tube Life Expectancy

Applies to tubes used in Generation 8 clinch units.

The expected life span of a Continuity Tube is dependent upon a number of factors including:

• Lead Composition

A Continuity Tube that is subjected to steel leaded components will cause more stress between the cutter, the cutter Bushing, and the continuity Tube. Expect to experience a higher wear rate on a continuity tube that is subjected to stiffer lead material than a continuity tube that is subjected to softer leaded material.

• Lead Diameter

A larger lead diameter will cause more stress between the cutter, the cutter bushing, and the continuity tube. Larger leads being cut will accelerate the wear of a Continuity Tube.

• Tooling Maintenance

Worn Tooling (cutters and cutter bushings) will cause the scrap lead to ‘tear’ instead of cut with a sharp clean cut. This ‘tear’ in the lead will accelerate continuity tube on both the metal tube and the plastic surrounding the metal tube. The tooling should be changed at recommended intervals, sooner if tearing of leads is noticed.

• Working Environment (dust, humidity, temperature, etc.)

The continuity tube should be kept as clean as possible. Dust buildup caused as a result of the cut/form process and clinching process will grind into the metal tube and the plastic surrounding the metal tube possibly causing accelerated wear of the continuity tube.

There are too many variables associated with the performance of a continuity tube to allow Universal to list it as ‘consumable tooling’ and publish an estimated life span. The greatest life span will be generated by keeping the continuity tube as clean as possible, keeping the lead length within the middle of acceptable lead length range, and changing the cutters and cutter bushings on a regular basis.

Continuity Tubes and False Insertion Errors

Proper continuity lead sense is dependent upon the relationship between:

• the continuity tube
• the cutter
• the angle of the lead being cut
• the lead length as the leads are cut.

It is important the lead is bent and touches the continuity tube before the cut takes place, making the position where the lead enters the cut and clinch assembly very important.

As the cutter moves across to the cut position, the lead begins to bend in the direction of the continuity tube.  However, once the lead is pinched between the cutter and the cutter bushing, the scrap portion of the lead will no longer be pushed toward the continuity tube.  At this point the scrap portion of the lead will actually be forced in the opposite direction of the continuity tube as the cutter shears through the lead.

The following scenario describes what happens if the lead length is set too short.  In other words, the lead entrance to the cutter bushing set so the lead is very close the cutter bushing shear point.

By setting the lead length too short, (the lead too close to the cut point of the cutter bushing), the scrap portion of the lead will not be bent far enough to reach the continuity tube as the cutter bends the lead, resulting in a false insertion error.  In other words, if the lead reaches the cut point before it has been bent far enough to touch the continuity tube, a false continuity error may occur.

On the other hand, having the lead length too long may cause accelerated wear and damage to the continuity tubes.  Forcing the lead into the continuity tube with too much force will cause denting of the continuity tube and wear of the plastic insulation, resulting in premature failure and false continuity errors over time. 

Cutter Stroke Speed and false Continuity Errors

The length of time necessary to drive the Cutter from the home position, to the extended ‘cut’ position, can affect continuity sensing.  If the cutter speed is set too slow, the cutter air pressure is insufficient, or a mechanical assembly used in the operation of the cutter stroke binds, the cutter will not reach the component lead in the ‘window’ of time necessary for continuity to be sensed.  This will result in a false continuity error.  Examples of cutter stroke speed problems:

• Pneumatic flow control for the cutters not properly set
• Poor air flow from the valve to the cutter
• Binding in the mechanical linkage from the cutter piston to the cutter
• Lack of sufficient lubrication in the mechanical linkage from the cutter piston to the cutter
• Incorrectly set cutter backstroke (the starting position for the cutter)
• A torn O-ring on the cutter piston which causes a bind in the cylinder
• Lack of sufficient lubrication on the O-ring for the cutter piston

END