Rabu, 26 November 2014

INFLUENCE OF ADDITIONAL MAN POWER TO COST SAVING WHEN 5% EFFICIENCY IS IMPROVING

INFLUENCE OF ADDITIONAL MAN POWER TO COST SAVING
WHEN 5% LOOM EFFICIENCY  IS IMPROVING

Oleh: H. Khaeruddin Khasbullah.




Consider:
Actual Cost = USD 523.000;
Weft density/ inch = 40 ends
Rpm = 600
Machine (looms) = 269 unit
Actual efficiency = 75% (Efficiency I)
Target efficiency with additional 20 man power = 80% (Efficiency II).
Operator salary = Rp 3.000.000/ month = USD 250./ month. (E.R = Rp.12.000/USD).
Additional man power according the down time happened = 20 persons.
Additional salary = USD 250 x 20 (6-7 persons/ shift) persons = USD 5.000;
Assumed fix cost increase according to efficiency improvement 
(energy and spare part cost increasing) = 2% = USD 523.000 x 2% = USD 10'460
Actual cost II = Actual cost + additional salary = USD 523.000 + USD 5.000 + USD 10'460 = USD 538.460;/ month.

Problem: We at present get low loom efficiency (75%) caused by so many down time due to bad weft yarn we have used with reasonable price.  Is it logic if we take some more man power if we may  possible to improve the loom efficiency by 5% ( 75% ==> 80%)
 
Calculation:

I. Efficiency (1) = 269 x 600 x 40 x 0,914 x 30 x 0,75
                                             40
= 3'319'191 meter/ month.

Efficiency (2) = 269 x 600 x 40 x 0,914 x 30 x 0,80 (5% up)
                                          40

= 3'540'470 meter/ month.

II. Cost/ meter (1) = 523.000; USD
                                3'319'191 m

= 0,1575 USD/m

Cost/ meter (2) = 538.460; USD
                             3'540'470 m

= 0,1520 USD/m

  1. Diff. Cost/ meter = USD 0,1575 – USD 0,1520 USD

                                = USD 0,0055/ meter.

Total Diff/ gain/ month = USD 0,0055x USD 3'540'470;

                                     = USD 19'472.58

                                     = Rp 233'671.020/month = Rp.2'804'052'240/ years

==> We still have big gain with additional man power if the efficiency can reach to 80% from 75%

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