Old Main

1
Old Main

• Members
• KaLee Allen
• Mike Berry
• Jen Dronetti
• Greg Hofmann
• Charlie Miracola

2
Redesign
3
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

4
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.

5
Manufacturing Method (cont.)

• Roof
• The bottom plate is 5.5x3.125
• The top plate is 5.25x2.875
• 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

6
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

7
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

8
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).

9
Cost Breakdown (cont.)

• Roof (Sheet)
• Will buy a 4x6x0.375 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 51.24.
• Cost per Old Main is 4.27

10
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

11
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

12
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

13
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

14
Costs of Goods Sold
15
Market Survey
16
Old Main Sensitivity and Break-Even Analysis
17
Retailer Results
18
Questions/Comments