Car Tycoon Simulator

Group 5
Aside from the qualitative readings and the computational drills and simple equations asignments, Alariao, Christine
this simulator intends to connect different topics and themes in operations. This simulator will be Faustino, Patrick
done piece by piece and it is arranged according to our lessons. The goal of this is for students so see
how dynamic and how interrelated operations works and trains the student to bridge aproject from Li, Long
marketing, to operations, to finance aspects (let's assume we are in the proejct planning stage) all Risos, Pauline Angela M.
the way to the pre mobilization stage. The worksheets in green are cells where the students do Tayag, Irish June
spreadsheet manipulationsand the uncolored ones provide information about the simulator. The
cells in green are arranged as follows

1) Worksheet for Brand and model Selection (Spreadsheet 4)

This spreadsheet shows the various brands and products available as well as key marketing
suggested selling prices, direct costs and manufacturing time inputs for each product.

2) Manufacturing and Market Areas forecast spreadsheet (Spreadsheet 5)

This spreadsheet makes the students decide whch will be the manufacturing base of
operations and which markets they will enter but the detail of the cities and region. This
worksheet aims to let the student connect demographics and target manufacturing. Students
must also find what would be the consumption drivers and consumption patterns of the product.

3) Line Balancing and Manufactuting Forecast (Spreadsheet 8)

This spreadsheet aims to let the student create a balanced production line and to manage
capacities for the plant

4) Plant Capacities Spreadsheet (Spreadsheet 9 and 10)

This gives the students the opportunity for them to tailorfit the plant capacities and to decide on
when to introduce capacity increases. This is also the portion where we can observe where the
Capital Expenses and where the Operating Expenses come into the picture. Plant facility layout will
also be covered in this as the plant size will grow depending on the number of equipment

5) Logistics and Inventory Spreadsheet

This is where students can configure their logistics network they will select several logstics
decisions such as (if applicable)

6) Financial Statements
Angela M.
In this Simulation, we will have a walkthrough of the several themes in Operations Management as the course unfolds. Assignments will be
given on a particular topic and on a staggard basis.

Founded in Munich, Bavaria Germany in 1910 Wunderbar originally manufactured aircraft engines
and propeller systems. Upon the defeat of Germany in WW1 in 1917, the company was not allowed
to engage in the aviation business as part of the peace treaty conditions. Since then, the company has
focused its efforts in developing engines for locomotives, trucks and automobiles. It temporarily
Ceased production in the closing 2 years of WW2 (1944-1945) and resumed in 1947. It entered into
car manufacturing in 1953 and has since become a major player in the Western Europe's car industry
alongside the brands of Citroen, BMW, Volkswagen & Audi Group, the Daimler Group and Volvo.
Wunderbar was quite unique in its strategy is that it decided to only acquire few brands in Europe and
diversified its portfolio in Asia and the Americas. One of its acquired European Brands is Levonciagga
that focuses of mass production sports cars that have a price range quite similar to Porsche. The
company in its last board meeting decided to allocate a maxuimum of 40% of its capital expenditure
in 2020 in introducing its presence in South East Asia.
 ft engines
not allowed
company has
porarily
ntered into
car industry
nd Volvo.
in Europe and
Levonciagga
he. The
expenditure
In This Page we can see all the available Car Brands and the models affiliated with Wunderbar Motors. We
will select the brand and models that we think are the best fit for introduction on the market. Selling
prices still do not include VAT or luxury taxes.

COMPANY AND CAR MODELS MARKETING/S

Car Brand Market Car Model Image Type Designed

Seating

Sakura Budget Speedlight Subcompact 4 or 5

Sakura Budget Festival Economy Car 5

Sakura Affordable Cyberline Compact Car 5

Sakura Midprice Fortuna Sports Activity Vehicle 6
derbar Motors. We
arket. Selling

MARKETING/SALES/DIRECT COSTS PROFILES

Minimum Fully Maximum fully Minimum Selling

User Comments Doors Direct Built Selling Price BuilT Selling price Price to Retail
Materials Cost (as sold to (as sold to Client
retailers) retailers)

2nd row is a bit cramped but pretty ok 2 $ 9,300 $ 10,111 $ 10,225 $ 11,080

better access but seats 4 comfortably. It has amazing fuel mileage and good exterior facelift. 4 $ 9,500 $ 11,300 $ 11,452 $ 12,000
Interiors look the same from the previous model.

seats 4-5 comfortably plus a good trunkroom that’s a bargain for the price. Sleek dark red 4 $ 12,054 $ 13,500 $ 14,500 $ 17,500
colors and energizing blue colors available.
Great for small families. Seats 4 very comfortably. 2 seats at the back are ok for medium frame 4 $ 14,200 $ 17,200 $ 17,754 $ 22,500
individuals
 Techincal Dimensions

Maximum Selling
Price to Retail Vehicle Type Fuel Type Length In Meters Width In meters Height In Meters Volume in Cubic Weight in kg Step A Engine
Client Meters Shop

$ 11,391 Minicompact Gasoline 4.19 1.76 1.41 10.44 1,104.86 3.9

$ 12,700 Subcompact Gasoline and Diesel 4.25 1.78 1.54 11.64 1,299.84 3.9

$ 18,000 Mid-Size Gasoline and Diesel 4.80 1.75 1.55 12.99 1,513.92 4.4
$ 22,900 Large Gasoline and Diesel 5.25 1.82 1.70 16.25 1,619.76 4.8

$ 2,091
18.35%
 Manufacturing Times of Key Compenents

Step B Transaxle Assembly Step C Press Shop Step D Welding/Frame Step E Chassis and Body Step F electronics and Step G Plastic Parts and Total
Assembly Assembly Interior Assembly Wheels

3.1 0.500 0.600 1.500 1.500 1.100 12.20

3.2 0.550 0.660 1.680 1.400 1.166 12.56

3.5 0.600 0.780 1.600 1.600 1.310 13.79

3.5 0.620 0.850 1.720 2.100 1.310 14.90
 In This Page we are to select the Brand and Models of vehcles we would want to manufacture over the next 5 years. Kindl
and select a minimum of 2 car models per brand.
Also select 1 Host country you will manufacture in and Select the Countries you will sell to and client cities where you will
manufactured venicles You can select a minimum of 2 and a maximum of 3 client countries and select a minimum of 2 an
cities.
To help you decide which cities are best, feel free to use this link: http://citypopulation.de/

Kindly explain the reasons for your selection of the brand, models and country. feel free to supplement with available refe

Host Country for

Car Brand Car Model Manufacturing Client country 1
Sakura Speedlight Vietnam Indonesia
Sakura Festival Vietnam Indonesia
Sakura Cyberline Vietnam Indonesia
Sakura Fortuna Vietnam Indonesia
acture over the next 5 years. Kindly select up to 2 bands

to and client cities where you will be distributing your

ries and select a minimum of 2 and a maximum of 5 client

de/

to supplement with available references.

Client city 1 Client city 2 Client city 3 Client Country 2

Jakarta Surabaya Medan Vietnam
Jakarta Surabaya Medan Vietnam
Jakarta Surabaya Medan Vietnam
Jakarta Surabaya Medan Vietnam
Client City 4 Client City 5
Hồ Chí Minh Hà Nội
Hồ Chí Minh Hà Nội
Hồ Chí Minh Hà Nội
Hồ Chí Minh Hà Nội
 In This Page we are to create a forecast of manufactured vehicles over the next 5 Years. To simplify the simulation lets assume that the First
Year is for scoping and site selection and the second Year is for Plant Construction and training. Manufacturing starts on Year 3. This format tries
to show how aggregate forecasting works.

Please specify the destination countries and destination cities. Please justify your selection as a group based on sound marketing principles.
Explain the forecasting method made and justify why this method is most appropriate.

.
Country Indonesia
City Jakarta
Region
Design and Construction
Year 1 Year 2
Brand Model Qtr 1 Qtr 2 Qtr 3 Qtr 4 Qtr 1 Qtr 2 Qtr 3 Qtr 4
Sakura Speedlight
Sakura Festival
Sakura Cyberline
Sakura Fortuna
Totals 0 0 0 0 0 0

Country Indonesia
City Surabaya
Region
Design and Construction
Year 1 Year 2
Brand Model Qtr 1 Qtr 2 Qtr 3 Qtr 4 Qtr 1 Qtr 2 Qtr 3 Qtr 4
Sakura Speedlight
Sakura Festival
Sakura Cyberline
Sakura Fortuna
Totals 0 0 0 0 0 0

Country Indonesia
City Medan
Region
Design and Construction
 Year 1 Year 2
Brand Model Qtr 1 Qtr 2 Qtr 3 Qtr 4 Qtr 1 Qtr 2 Qtr 3 Qtr 4
Sakura Speedlight
Sakura Festival
Sakura Cyberline
Sakura Fortuna
Totals 0 0 0 0 0 0

Total Yearly Demand for Indonesia

Design and Construction

Year 1 Year 2
Brand Model Qtr 1 Qtr 2 Qtr 3 Qtr 4 Qtr 1 Qtr 2 Qtr 3 Qtr 4
Sakura Speedlight 0 0 0 0 0 0 0 0
Sakura Festival 0 0 0 0 0 0 0 0
Sakura Cyberline 0 0 0 0 0 0 0 0
Sakura Fortuna 0 0 0 0 0 0 0 0
Country Total 0 0 0 0 0 0

Appendix:

How the forecasts were derived:

INDONESIA FORECASTING OPTIONS (10 YEARS DATA)

1 Fuel2 3 4
Price Bank Passenger
(USD/ GDP per capita Lending Car Total Vehicle
Year Population Liter) (US$) Interest % Ownership Ownership Year
1 2010 241,834,215 0.51 3,122.363 13.25% 8,891,041 76,907,127 2010
2 2011 245,116,206 0.47 3,643.044 12.40% 9,548,866 85,601,351 2011
3 2012 248,452,413 0.62 3,694.349 11.80% ### 94,373,324 2012
4 2013 251,806,402 0.61 3,623.912 11.66% ### 104,118,969 2013
5 2014 255,129,004 0.81 3,491.625 12.60% ### 114,209,260 2014
 6 2015 258,383,256 0.65 3,331.695 12.66% ### 121,394,185 2015
7 2016 261,556,381 0.60 3,562.846 11.89% ### 129,281,079 2016
8 2017 264,650,963 0.64 3,837.652 11.07% ### 137,211,818 2017
9 2018 267,670,543 0.74 3,893.846 10.54% ### 146,858,759 2018
10 2019 270,625,568 0.73 4,135.569 10.37% ### 155,694,707 2019
2020
r 0.99909 0.67237 0.69682 (0.79820) 0.99871 2021
r2 0.99818 0.45208 0.48556 0.63713 0.99742 2022
intercept (63,611,675) 2023
slope 0.29870 2024
2025
2026
Population growth rate: Market Share of Current Competitors:
2010 1.338% Toyota 32.20%
2011 1.348% Daihatsu 17.20%
2012 1.352% Honda 13.30%
2013 1.341% Mitsubishi 11.60%
2014 1.311% Suzuki 9.70%
2015 1.267% Others 16.00%
2016 1.220%
2017 1.175% Target M.S.:
2018 1.134% Yr 1 0.50% Speedlight
2019 1.101% Yr 2 0.50% Festival
2020 1.095% Yr 3 1.00% Cyberline
2021 1.065% Yr 4 1.25% Fortuna
2022 1.035% Yr 5 1.75%
2023 1.005% Target position: niche entry
2024 0.975%
2025 0.945%
2026 0.916% SEASONALITY
2027 0.886% Model Market Share
Speedlight Festival Cyberline Fortuna Qtr 1
20% 40% 30% 10% Qtr 2
Qtr 3
Qtr 4
 Jakarta 8 67%
Subarabya 2.5 21%
Medan 1.5 13%
12
References
https://www.theglobaleconomy.com/Indonesia/lending_interest_rate/
https://www.ceicdata.com/en/indonesia/number-of-motor-vehicle-registered
https://data.worldbank.org/indicator/NY.GDP.PCAP.CD?end=2019&locations=ID&start=2010
https://data.worldbank.org/indicator/SP.POP.GROW?end=2019&locations=ID&start=2010
hat the First
his format tries

principles.

Operational
Year 3 Year 4 Year 5
Qtr 1 Qtr 2 Qtr 3 Qtr 4 Qtr 1 Qtr 2 Qtr 3 Qtr 4 Qtr 1 Qtr 2 Qtr 3 Qtr 4
3,967 1,983 3,306 3,967 4,135 2,067 3,446 4,135 8,598 4,299 7,165 8,598
7,934 3,967 6,612 7,934 8,269 4,135 6,891 8,269 17,196 8,598 14,330 17,196
5,950 2,975 4,959 5,950 6,202 3,101 5,168 6,202 12,897 6,449 10,748 12,897
1,983 992 1,653 1,983 2,067 1,034 1,723 2,067 4,299 2,150 3,583 4,299
19,835 9,917 16,529 19,835 20,673 10,337 17,228 20,673 42,991 21,495 35,825 42,991

Operational
Year 3 Year 4 Year 5
Qtr 1 Qtr 2 Qtr 3 Qtr 4 Qtr 1 Qtr 2 Qtr 3 Qtr 4 Qtr 1 Qtr 2 Qtr 3 Qtr 4
1,240 620 1,033 1,240 1,292 646 1,077 1,292 2,687 1,343 2,239 2,687
2,479 1,240 2,066 2,479 2,584 1,292 2,153 2,584 5,374 2,687 4,478 5,374
1,859 930 1,550 1,859 1,938 969 1,615 1,938 4,030 2,015 3,359 4,030
620 310 517 620 646 323 538 646 1,343 672 1,120 1,343
6,198 3,099 5,165 6,198 6,460 3,230 5,384 6,460 13,435 6,717 11,195 13,435

Operational
 Year 3 Year 4 Year 5
Qtr 1 Qtr 2 Qtr 3 Qtr 4 Qtr 1 Qtr 2 Qtr 3 Qtr 4 Qtr 1 Qtr 2 Qtr 3 Qtr 4
744 372 620 744 775 388 646 775 1,612 806 1,343 1,612
1,488 744 1,240 1,488 1,550 775 1,292 1,550 3,224 1,612 2,687 3,224
1,116 558 930 1,116 1,163 581 969 1,163 2,418 1,209 2,015 2,418
372 186 310 372 388 194 323 388 806 403 672 806
3,719 1,859 3,099 3,719 3,876 1,938 3,230 3,876 8,061 4,030 6,717 8,061

Operational
Year 3 Year 4 Year 5
Qtr 1 Qtr 2 Qtr 3 Qtr 4 Qtr 1 Qtr 2 Qtr 3 Qtr 4 Qtr 1 Qtr 2 Qtr 3 Qtr 4
5,950 2,975 4,959 5,950 6,202 3,101 5,168 6,202 12,897 6,449 10,748 12,897
11,901 5,950 9,917 11,901 12,404 6,202 10,337 12,404 25,794 12,897 21,495 25,794
8,926 4,463 7,438 8,926 9,303 4,651 7,752 9,303 19,346 9,673 16,121 19,346
2,975 1,488 2,479 2,975 3,101 1,550 2,584 3,101 6,449 3,224 5,374 6,449
29,752 14,876 24,793 29,752 31,010 15,505 25,842 31,010 64,486 32,243 53,738 64,486

Y= a + bX
Passenger
Car
Growth Rate Population Ownership Speedlight Festival Cyberline Fortuna
241,834,215 8,891,041
245,116,206 9,548,866
248,452,413 10,432,259
251,806,402 11,484,514
255,129,004 12,599,038
 258,383,256 13,480,973
261,556,381 14,580,666
264,650,963 15,423,968
267,670,543 16,440,987
270,625,568 17,239,800
1.095% 273,587,835 18,109,669
1.065% 276,500,899 18,979,809
1.035% 279,362,482 19,834,570 19,835 39,669 29,752 9,917 99,172.85 0.5%
1.005% 282,170,329 20,673,281 20,673 41,347 31,010 10,337 103,366.40 0.5%
0.975% 284,922,208 21,495,274 42,991 85,981 64,486 21,495 214,952.74 1.0%
0.945% 287,615,915 22,299,890 55,750 111,499 83,625 27,875 278,748.63 1.3%
0.916% 290,249,274 23,086,481 80,803 161,605 121,204 40,401 404,013.42 1.8%

2022 2023 2024 2025 2026

19,835 20,673 42,991 55,750 80,803
39,669 41,347 85,981 111,499 161,605
29,752 31,010 64,486 83,625 121,204
9,917 10,337 21,495 27,875 40,401

99,173 103,366 214,953 278,749 404,013

EASONALITY

30%
15% impact of ramadan
25%
30% december bonus
100%
 Year 6 Year 7
Qtr 1 Qtr 2 Qtr 3 Qtr 4 Qtr 1 Qtr 2 Qtr 3 Qtr 4
11,150 5,575 9,292 11,150 16,161 8,080 13,467 16,161
22,300 11,150 18,583 22,300 32,321 32,321 16,161 26,934
16,725 8,362 13,937 16,725 24,241 24,241 12,120 20,201
5,575 2,787 4,646 5,575 8,080 8,080 4,040 6,734
55,750 27,875 46,458 55,750 80,803 72,722 45,788 70,029

Year 6 Year 7
Qtr 1 Qtr 2 Qtr 3 Qtr 4 Qtr 1 Qtr 2 Qtr 3 Qtr 4
3,484 1,742 2,904 3,484 5,050 2,525 4,208 5,050
6,969 3,484 5,807 6,969 10,100 10,100 5,050 8,417
5,227 2,613 4,355 5,227 7,575 7,575 3,788 6,313
1,742 871 1,452 1,742 2,525 2,525 1,263 2,104
17,422 8,711 14,518 17,422 25,251 22,726 14,309 21,884
 Year 6 Year 7
Qtr 1 Qtr 2 Qtr 3 Qtr 4 Qtr 1 Qtr 2 Qtr 3 Qtr 4
2,091 1,045 1,742 2,091 3,030 1,515 2,525 3,030
4,181 2,091 3,484 4,181 6,060 6,060 3,030 5,050
3,136 1,568 2,613 3,136 4,545 4,545 2,273 3,788
1,045 523 871 1,045 1,515 1,515 758 1,263
10,453 5,227 8,711 10,453 15,151 13,635 8,585 13,130

Year 6 Year 7
Qtr 1 Qtr 2 Qtr 3 Qtr 4 Qtr 1 Qtr 2 Qtr 3 Qtr 4
16,725 8,362 13,937 16,725 24,241 12,120 20,201 24,241
33,450 16,725 27,875 33,450 48,482 48,482 24,241 40,401
25,087 12,544 20,906 25,087 36,361 36,361 18,181 30,301
8,362 4,181 6,969 8,362 12,120 12,120 6,060 10,100
83,625 41,812 69,687 83,625 121,204 109,084 68,682 105,043
 A) 6.3 Hours
Engine
Shop

1.78 Hours 1.6

1.1 Hours Hours

3.5 Hours E) Chassis F) G) Plastic

B) and Body Electro Parts
Transaxle Assemly nics
Start Assembly and
Interior

1.23 Hours

.8 Hours
C) Press D
Shop Welding

Step E Step F Step G

Step A Step B Chassis and electronics Plastic
Ste[s/Brand Engine Transaxle Step C Step D Body and Interior Parts and
s Shop Assembly Press Shop Welding Assembly Assembly Wheels Cycle time This is the timein
0 6.3 3.5 1.230 0.800 1.100 1.780 1.600 10.78 hours Hours to complete 1
unit of Avondale

Takt Time
Demand 100 cars per day
8 hour workday
Takt Time 12.5 cars per hour
0.08 hours per car
4.8 minutes per car
 1.6
Hours

G) Plastic
Parts
End
Appendix: Automobile Manufacturing
Processes
Engine Shop Freshly Minted Engine Blocks.
A-1) Block Casting
This entails the pouring of aluminum magnesium alloy blocks to form
the engine valves as well as forming of the pistons through drop forge
processes. Several Blocks are made at a time per batch. In actual
practice block casting is outsourced to several steel companies that
specialize in alloys. Other engine components are also done by casting
albeit with some machining such as pistons, crankshafts etc.

A-2) Assembly of Engine Parts

The alloy engine blocks are formed and the other engine attachments
are bolted are put into place. Assembly of other components to
engine blocks such as spark plugs,
protective covering and sensor cases.

B The Transaxle Assembly is where the machining gear blanks, shafts Housing of the Gears
and assemble of gear box is done here. The gear box is send to engine ( Gear Box)
shop where it is fitted with engine and the unit is called powertrain.

The Three Main subcomponents here are the following

B-1 Machining of gears, creation of gear box

B-2 Assembly of the Gears and Transmissions

B-3 Assembly of the Powertrain. Where the power of the engine is

Transmission Gears
transformed and transferred into kinetic energy for motion.
B-3 Assembly of the Powertrain. Where the power of the engine is
transformed and transferred into kinetic energy for motion.

Where Metal Panels are formed into different components such as car The Press Shop where
doors, trunk, front trunk and ceiling panel. The Sub components are the metal is pressed to
following: their forms
C-1 Chassis - The chassis is made of a reinforced frame that supports
the weight of the body, the powertrain and the body of the car.

C-2 Body and Reinforcement

The Body of the Car that will be welded and painted on. Provides the
style and form of the vehicle. Reinforcements include strengthening of
the cabin, side bars. The Chassis is the most
durable part of the Vehicle as
C-3 Panels it carries the vehicle and
Pressed Panels for the doors, trunk and front hood. passenger weight and must
pass safety standards on
C-4 Ports and inner electronics holes for machining of the body and rigidly.
punching of holes and tube ways for electronics as well as interior
attachments of the car.
Pressed and assembled
C-5 Electrocoating Process doors, notice the holes
- The chassis, body and panels are submerged into a chemical mixture that are machined to fit
of Nickel, Manganese and Zinc and then baked for 4-5 Hours at 360 electronics
Degrees. This step is for corrosion protection. components as well s
attachments to interior
trimming.

D. Mostly welding of the car body and sub compoennts of the body as Some Robots do the
well as welding of joint posts for the doors, hood and trunks. (mostly welding of the hinges
manually but aided by robotics tools) and then polished for smoothness and some robots do
after. The Sub components are stated herein. the polishng and
cutting of holes where
D -1 Initial Welding and polishing wires and ducting will
be put .
D-2 Assembly of doors and Hood
D. Mostly welding of the car body and sub compoennts of the body as Some Robots do the
well as welding of joint posts for the doors, hood and trunks. (mostly welding of the hinges
manually but aided by robotics tools) and then polished for smoothness and some robots do
after. The Sub components are stated herein. the polishng and
cutting of holes where
D -1 Initial Welding and polishing wires and ducting will
be put .
D-2 Assembly of doors and Hood

D-3 Painting of the Vehicle

A Vehicle has 2 main layers of coat, a primer that directly bonds to the
metal and body and the other a polished coat.

E. Assembling of the engine, powertrain chasis, body and the interiors of the car. The
Subcomponents and stages are made in the following order.

E-1 Installation of the Engine to the Chasis-

E-2 Installation of the gearboks, powertrain to the chasis frame of the car. Parts are ut
together, snapped and bolted together. Inspection is made after to make sure the parts
are snugly fit.
E-3 The Suspension system and steering system is also installed in in this stage. Since the
compinents often have to be inserted t steel angles and manouvers, manpower aided
with hydraulic tools are employed.

F. Electronics and Interior Assembly

In this Part the lights, the interiors of the car and the other electroic systems such as
sensors are installed. The Sub Components re installed as folows

F-1 General Circuitry Installation

General circuitry embedded inside the body of the vehicle

F-2 Lights and engine Circuit Installtion

Lighting system and electronic sensors in the engine.
In this Part the lights, the interiors of the car and the other electroic systems such as
sensors are installed. The Sub Components re installed as folows

F-1 General Circuitry Installation

General circuitry embedded inside the body of the vehicle

F-2 Lights and engine Circuit Installtion

Lighting system and electronic sensors in the engine.

F-3 Instrument Dash Board Installation

F-4 Car Seats and Basic Interiors Installation

F-5 Trimming and accesories Installation.

G. Plastic Parts and Wheels Assembly

Plastic parts, aesthetic components re made in this stage. There are three Sub parts.
These tasks are often done manually conveyor belt style with the aid of semi fixed tools in
the respective workstations. In the project you will notice that plastic parts and wheels
assemble will differ for every model.

G-1 Plastic parts and other exterior accessories installation.

Plastic parts and aesthetic parts such as the bumpers, grille and lighting is installed.

G-2 Window glass, wipers and rubber linings in the windows and trunk for moisture
control are installed in the vehicle.

G-3 The Wheels are also bolted in the vehicle.

ted Engine Blocks.

other components to
s such as spark plugs,
overing and sensor cases.

The Power train system the

radiator is shown here but its
not included in this stage.
 The Body of the vehicle that will give the overall
form of the car. Some parts are pressure
formed and some are pressed. This picture
shows that its already has light assembly. Iw till
be welded on the next step.

Images of the
electroplating process

Some Robots do the

welding of the hinges
and some robots do
the polishng and
cutting of holes where
wires and ducting will
be put .
Some Robots do the
welding of the hinges
and some robots do
the polishng and
cutting of holes where
wires and ducting will
be put .
You are given this Manufacturing Information

Familiarize yourself with the Task Precedence in the previous spreadsheet and
take note that different brands have different times. Take note that some tasks
depend on certain resources more (manpower vs robotics). Replace the cells in
green with the manufacturing profile of the vehicles you have selected
1

8-1 Time to Manufacture in hours Step A Engine Step B Transaxle Step E Chassis and
Steps/Brands Shop Assembly Step C Press Shop Step D Welding Body Assembly
Preceded by None None None C A, B, D
Succedded By C C D E F
Speedlight 3.9 3.1 0.5 0.6 1.5
Festival 3.9 3.2 0.6 0.7 1.7
Cyberline 4.4 3.5 0.6 0.8 1.6
Fortuna 4.8 3.5 0.6 0.9 1.7
Total 17.0 13.3 2.3 2.9 6.5

Now this is where you multiply the hours per task needed
for every vehicle to the quarterly demand per vehicle so we
2 find out the manufacturing hours per quarter needed per
model.
270,000.00

Indonesia

REQUIRED HOURS FOR Speedlight Year 3 Quarter 1 Year 3 Quarter 2 Year 3 Quarter 3 Year 3 Quarter 4 Year 4 Quarter 1
Step A Engine Shop 23,206 11,603 19,339 23,206 24,188
Step B Transaxle Assembly 18,446 9,223 15,372 18,446 19,226
Step C Press Shop 2,975 1,488 2,479 2,975 3,101
Step D Welding 3,570 1,785 2,975 3,570 3,721
Step E Chassis and Body Assembly 8,926 4,463 7,438 8,926 9,303
Step F. Electronics and Interior Assembly 8,926 4,463 7,438 8,926 9,303
Step G Plastic Parts and Wheels 6,545 3,273 5,455 6,545 6,822
 Total 72,595 36,297 60,495 72,595 75,664

REQUIRED HOURS FOR Festival Year 3 Quarter 1 Year 3 Quarter 2 Year 3 Quarter 3 Year 3 Quarter 4 Year 4 Quarter 1
Step A Engine Shop 46,413 23,206 38,677 46,413 48,375
Step B Transaxle Assembly 38,082 19,041 31,735 38,082 39,693
Step C Press Shop 6,545 3,273 5,455 6,545 6,822
Step D Welding 7,854 3,927 6,545 7,854 8,187
Step E Chassis and Body Assembly 19,993 9,997 16,661 19,993 20,839
Step F. Electronics and Interior Assembly 16,661 8,331 13,884 16,661 17,366
Step G Plastic Parts and Wheels 13,876 6,938 11,564 13,876 14,463
Total 149,426 74,713 124,521 149,426 155,744

REQUIRED HOURS FOR Cyberline Year 3 Quarter 1 Year 3 Quarter 2 Year 3 Quarter 3 Year 3 Quarter 4 Year 4 Quarter 1
Step A Engine Shop 39,272 19,636 32,727 39,272 40,933
Step B Transaxle Assembly 31,239 15,620 26,033 31,239 32,560
Step C Press Shop 5,355 2,678 4,463 5,355 5,582
Step D Welding 6,962 3,481 5,802 6,962 7,256
Step E Chassis and Body Assembly 14,281 7,140 11,901 14,281 14,885
Step F. Electronics and Interior Assembly 14,281 7,140 11,901 14,281 14,885
Step G Plastic Parts and Wheels 11,694 5,847 9,745 11,694 12,188
Total 123,084 61,542 102,570 123,084 128,289

REQUIRED HOURS FOR Fortuna Year 3 Quarter 1 Year 3 Quarter 2 Year 3 Quarter 3 Year 3 Quarter 4 Year 4 Quarter 1
Step A Engine Shop 14,281 7,140 11,901 14,281 14,885
Step B Transaxle Assembly 10,413 5,207 8,678 10,413 10,853
Step C Press Shop 1,845 922 1,537 1,845 1,923
Step D Welding 2,529 1,264 2,107 2,529 2,636
Step E Chassis and Body Assembly 5,117 2,559 4,264 5,117 5,334
Step F. Electronics and Interior Assembly 6,248 3,124 5,207 6,248 6,512
Step G Plastic Parts and Wheels 3,897 1,949 3,248 3,897 4,062
Total 44,330 22,165 36,942 44,330 46,205

TOTAL REQUIRED HOURS FOR EACH STEP Year 3 Quarter 1 Year 3 Quarter 2 Year 3 Quarter 3 Year 3 Quarter 4 Year 4 Quarter 1
Step A Engine Shop 123,173 61,586 102,644 123,173 128,381
Step B Transaxle Assembly 98,181 49,091 81,818 98,181 102,333
 Step C Press Shop 16,721 8,360 13,934 16,721 17,428
Step D Welding 20,916 10,458 17,430 20,916 21,800
Step E Chassis and Body Assembly 48,317 24,159 40,264 48,317 50,360
Step F. Electronics and Interior Assembly 46,115 23,058 38,429 46,115 48,065
Step G Plastic Parts and Wheels 36,013 18,006 30,011 36,013 37,536
389,435 194,717 324,529 389,435 405,902
Step F. Electronics
and Interior Step G Plastic Parts
Assembly and Wheels Total
E F
G H
1.5 1.1 12.20
1.4 1.2 12.56
1.6 1.3 13.79
2.1 1.3 14.90
6.6 4.9

8 33,750.00 4608

Year 4 Quarter 2 Year 4 Quarter 3 Year 4 Quarter 4 Year 5 Quarter 1 Year 5 Quarter 2 Year 5 Quarter 3 Year 5 Quarter 4
12,094 20,156 24,188 50,299 25,149 41,916 50,299
9,613 16,022 19,226 39,981 19,991 33,318 39,981
1,550 2,584 3,101 6,449 3,224 5,374 6,449
1,861 3,101 3,721 7,738 3,869 6,449 7,738
4,651 7,752 9,303 19,346 9,673 16,121 19,346
4,651 7,752 9,303 19,346 9,673 16,121 19,346
3,411 5,685 6,822 14,187 7,093 11,822 14,187
 37,832 63,054 75,664 157,345 78,673 131,121 157,345

Year 4 Quarter 2 Year 4 Quarter 3 Year 4 Quarter 4 Year 5 Quarter 1 Year 5 Quarter 2 Year 5 Quarter 3 Year 5 Quarter 4
24,188 40,313 48,375 100,598 50,299 83,832 100,598
19,846 33,077 39,693 82,542 41,271 68,785 82,542
3,411 5,685 6,822 14,187 7,093 11,822 14,187
4,093 6,822 8,187 17,024 8,512 14,187 17,024
10,419 17,366 20,839 43,334 21,667 36,112 43,334
8,683 14,471 17,366 36,112 18,056 30,093 36,112
7,232 12,053 14,463 30,076 15,038 25,063 30,076
77,872 129,787 155,744 323,874 161,937 269,895 323,874

Year 4 Quarter 2 Year 4 Quarter 3 Year 4 Quarter 4 Year 5 Quarter 1 Year 5 Quarter 2 Year 5 Quarter 3 Year 5 Quarter 4
20,467 34,111 40,933 85,121 42,561 70,934 85,121
16,280 27,134 32,560 67,710 33,855 56,425 67,710
2,791 4,651 5,582 11,607 5,804 9,673 11,607
3,628 6,047 7,256 15,090 7,545 12,575 15,090
7,442 12,404 14,885 30,953 15,477 25,794 30,953
7,442 12,404 14,885 30,953 15,477 25,794 30,953
6,094 10,157 12,188 25,345 12,673 21,121 25,345
64,145 106,908 128,289 266,780 133,390 222,317 266,780

Year 4 Quarter 2 Year 4 Quarter 3 Year 4 Quarter 4 Year 5 Quarter 1 Year 5 Quarter 2 Year 5 Quarter 3 Year 5 Quarter 4
7,442 12,404 14,885 30,953 15,477 25,794 30,953
5,427 9,045 10,853 22,570 11,285 18,808 22,570
961 1,602 1,923 3,998 1,999 3,332 3,998
1,318 2,197 2,636 5,481 2,741 4,568 5,481
2,667 4,445 5,334 11,092 5,546 9,243 11,092
3,256 5,427 6,512 13,542 6,771 11,285 13,542
2,031 3,385 4,062 8,448 4,224 7,040 8,448
23,102 38,504 46,205 96,084 48,042 80,070 96,084

Year 4 Quarter 2 Year 4 Quarter 3 Year 4 Quarter 4 Year 5 Quarter 1 Year 5 Quarter 2 Year 5 Quarter 3 Year 5 Quarter 4
64,191 106,984 128,381 266,971 133,486 222,476 266,971
51,166 85,277 102,333 212,803 106,402 177,336 212,803
 8,714 14,523 17,428 36,241 18,121 30,201 36,241
10,900 18,167 21,800 45,334 22,667 37,778 45,334
25,180 41,967 50,360 104,725 52,362 87,271 104,725
24,033 40,054 48,065 99,953 49,977 83,294 99,953
18,768 31,280 37,536 78,056 39,028 65,047 78,056
202,951 338,252 405,902 844,083 422,041 703,402 844,083
Year 6 Quarter 1 Year 6 Quarter 2 Year 6 Quarter 3 Year 6 Quarter 4 Year 7 Quarter 1 Year 7 Quarter 2 Year 7 Quarter 3
65,227 32,614 54,356 65,227 94,539 47,270 78,783
51,847 25,924 43,206 51,847 75,146 37,573 62,622
8,362 4,181 6,969 8,362 12,120 6,060 10,100
10,035 5,017 8,362 10,035 14,544 7,272 12,120
25,087 12,544 20,906 25,087 36,361 18,181 30,301
25,087 12,544 20,906 25,087 36,361 18,181 30,301
18,397 9,199 15,331 18,397 26,665 13,332 22,221
 204,044 102,022 170,037 204,044 295,738 147,869 246,448

Year 6 Quarter 1 Year 6 Quarter 2 Year 6 Quarter 3 Year 6 Quarter 4 Year 7 Quarter 1 Year 7 Quarter 2 Year 7 Quarter 3
130,454 65,227 108,712 130,454 189,078 189,078 94,539
107,039 53,520 89,200 107,039 155,141 155,141 77,571
18,397 9,199 15,331 18,397 26,665 26,665 13,332
22,077 11,038 18,397 22,077 31,998 31,998 15,999
56,196 28,098 46,830 56,196 81,449 81,449 40,725
46,830 23,415 39,025 46,830 67,874 67,874 33,937
39,003 19,501 32,502 39,003 56,530 56,530 28,265
419,996 209,998 349,997 419,996 608,735 608,735 304,368

Year 6 Quarter 1 Year 6 Quarter 2 Year 6 Quarter 3 Year 6 Quarter 4 Year 7 Quarter 1 Year 7 Quarter 2 Year 7 Quarter 3
110,384 55,192 91,987 110,384 159,989 159,989 79,995
87,806 43,903 73,172 87,806 127,264 127,264 63,632
15,052 7,526 12,544 15,052 21,817 21,817 10,908
19,568 9,784 16,307 19,568 28,362 28,362 14,181
40,140 20,070 33,450 40,140 58,178 58,178 29,089
40,140 20,070 33,450 40,140 58,178 58,178 29,089
32,867 16,434 27,390 32,867 47,637 47,637 23,819
345,958 172,979 288,298 345,958 501,425 501,425 250,713

Year 6 Quarter 1 Year 6 Quarter 2 Year 6 Quarter 3 Year 6 Quarter 4 Year 7 Quarter 1 Year 7 Quarter 2 Year 7 Quarter 3
40,140 20,070 33,450 40,140 58,178 58,178 29,089
29,269 14,634 24,391 29,269 42,421 42,421 21,211
5,185 2,592 4,321 5,185 7,515 7,515 3,757
7,108 3,554 5,923 7,108 10,302 10,302 5,151
14,383 7,192 11,986 14,383 20,847 20,847 10,424
17,561 8,781 14,634 17,561 25,453 25,453 12,726
10,955 5,477 9,129 10,955 15,878 15,878 7,939
124,601 62,300 103,834 124,601 180,594 180,594 90,297

Year 6 Quarter 1 Year 6 Quarter 2 Year 6 Quarter 3 Year 6 Quarter 4 Year 7 Quarter 1 Year 7 Quarter 2 Year 7 Quarter 3
346,206 173,103 288,505 346,206 501,785 454,515 282,405
275,961 137,981 229,968 275,961 399,973 362,400 225,035
 46,997 23,499 39,164 46,997 68,117 62,056 38,098
58,788 29,394 48,990 58,788 85,206 77,934 47,451
135,806 67,903 113,172 135,806 196,835 178,655 110,538
129,618 64,809 108,015 129,618 187,866 169,686 106,054
101,222 50,611 84,352 101,222 146,710 133,377 82,243
1,094,599 547,299 912,166 1,094,599 1,586,492 1,438,623 891,825
Year 7 Quarter 4 Average
94,539 42,910
75,146 34,108
12,120 5,501
14,544 6,602
36,361 16,504
36,361 16,504
26,665 12,103
 295,738 134,231

Year 7 Quarter 4 Average

157,565 85,820
129,284 70,416
22,221 12,103
26,665 14,523
67,874 36,969
56,562 30,807
47,108 25,658
507,279 276,296

Year 7 Quarter 4 Average

133,324 72,617
106,054 57,763
18,181 9,902
23,635 12,873
48,482 26,406
48,482 26,406
39,698 21,622
417,854 227,589

Year 7 Quarter 4 Average

48,482 26,406
35,351 19,254
6,262 3,411
8,585 4,676
17,373 9,462
21,211 11,553
13,231 7,207
150,495 81,969

Year 7 Quarter 4 Average

433,910 227,753
345,835 181,542
 58,784 30,917
73,429 38,674
170,090 89,341
162,615 85,270
126,702 66,589
1,371,367
 The Different Car Brands have different Manufactuing configurations. The red
cells are locked and we assume that is the configuration for a particular brand.
We will select the correct configuration depending on the brand we carry. These
apply to the Machining section and the Robotics section

1) Machining Section
Step A Engine Shop
Item Description
Machining areas chip and polish blocks of engine metal
Number of Machining Areas and components.
Number of Engines per batch average batch size.
number of machine rooms multipled by average batch
Batch X # Of Machining Area size
Working Hours Daily Standard work hours per day
Extended working hours You may Extend the working hours here.
Average working Hours daily * batch size
Working Days Monthly This is the Base case configuration of your plant
Average Working Hours Monthly * Batch size This is the Available Machine Hours Monthly
Operating Number of Months in Quarter
Available Hours Per Quarter

Step B Transaxle Assembly

Item Description
Workstations of personnel and tools used to manufacture
Number of Workstations the trans axle
Number of Engines per batch average batch size.
number of machine rooms multipled by average batch
Batch X Number of Workstations size
Working Hours Daily Standard work hours per day
Extended working hours You may Extend the working hours here.
Average working Hours daily * batch size
Working Days Monthly This is the Base case configuration of your plant
Working Hours Monthly This is the Available Machine Hours Monthly
Operating Number of Months in Quarter
Available Hours Per Quarter

2) Robotics Production Profile

Step C Press Shop
Item Description
Number of Pressing Machines The Minimum robots for this type of configuration
Number car Parts per batch average batch size.
Average working Hours daily Assuming robots can start up immidiately.
Extended working hours per day You May adjust this
Average working Hours daily * batch size
Working Days Monthly Standard configuration. You may adjust this
Total of Robotics Hours Monthly self computing
Operating Number of Months in Quarter
Available Hours Per Quarter

Step D Welding
Item Description
Number of Robotic Welding Arms The Minimum robots for this type of configuration
Number car Parts per batch average batch size.
Average working Hours daily Assuming robots can start up immidiately.
Extended working hours per day You May adjust this
Working Days Monthly Standard configuration. You may adjust this
Total of Robotics Hours Monthly self computing
Operating Number of Months in Quarter
Available Hours Per Quarter

3) Manpower Production Profile

Step E. Chassis and Body Assembly
Item Description
Number of Workers This
Lookisatthe
thenumber
default of people of
standard in the
the company
plant you are
Average working Hours daily selecting
average overtime per day. Warning do not abuse
Average Overtime Daily this. There are labor rules.
Hours Per day Look at the default standard of the company you are
Average Working Days Monthly selecting
Workhours Per Month
Operating Months in a Quarter
Oparating Hours Per Quarter
Average Required Hours Per Quarter to
Satisfy Demand
Utilization Rate

Step F. Electronics and Interior Assembly

Item Description
Number of Workers This
Lookisatthe
thenumber
default of people of
standard in the
the company
plant you are
Average working Hours daily selecting
average overtime per day. Warning do not abuse
Average Overtime Daily this. There are labor rules.
Hours Per day Look at the default standard of the company you are
Average Working Days Monthly selecting
Workhours Per Month
Operating Months in a Quarter
Oparating Hours Per Quarter
Required Hours Per Quarter to Satisfy
Demand
Utilization Rate

Step G Plastic Parts and Wheels

Item Description
Number of Workers This
Lookisatthe
thenumber
default of people of
standard in the
the company
plant you are
Average working Hours daily selecting
average overtime per day. Warning do not abuse
Average Overtime Daily this. There are labor rules.
Hours Per day Look at the default standard of the company you are
Average Working Days Monthly selecting
Workhours Per Month
Operating Months in a Quarter
Oparating Hours Per Quarter
Required Hours Per Quarter to Satisfy
Demand
Utilization Rate
 . The red
ar brand.
arry. These

Forumula/ Treatment Speedlight Festival Cyberline Fortuna

This is the Default number of Machining
Areas 20.00 20.00 20.00 20.00
Number of Engines processed per batch 30.00 30.00 30.00 30.00
Number of machining Areas x Number of
Engines Per Batch 600.00 600.00 600.00 600.00
Enter your Assumed working hours daily 8.00 8.00 8.00 8.00
2.00 2.00 2.00 2.00
Number of work hours multiplied by the
batch size 6,000.00 6,000.00 6,000.00 6,000.00
26.00 26.00 26.00 26.00
156,000.00 156,000.00 156,000.00 156,000.00
3.00 3.00 3.00 3.00
468,000.00 468,000.00 468,000.00 468,000.00

Forumula/ Treatment Speedlight Festival Cyberline Fortuna

Hardcoded 4.00 4.00 4.00 4.00
Assumption 20.00 20.00 20.00 20.00
Number of machining Areas x Number of
Engines Per Batch 80.00 80.00 80.00 80.00
Hardcoded 8.00 8.00 8.00 8.00
Hardcoded 3.00 3.00 3.00 3.00
Number of work hours multiplied by the
batch size 880.00 880.00 880.00 880.00
Hardcoded 26.00 26.00 26.00 26.00
Working Days per Month X working
hours per day 22,880.00 22,880.00 22,880.00 22,880.00
Hardcoded 3.00 3.00 3.00 3.00
68,640.00 68,640.00 68,640.00 68,640.00

Forumula/ Treatment Speedlight Festival Cyberline Fortuna

10.00 10.00 10.00 10.00
dependent on plant configurations 8.00 8.00 8.00 8.00
Hardcoded 8.00 8.00 8.00 8.00
Hardcoded 3.00 3.00 3.00 3.00
Number of work hours multiplied by the
batch size 88.00 88.00 88.00 88.00
(average
Hardcoded working hours daily + 26.00 26.00 26.00 26.00
extended hours ) * months monthly*
batch size 22,880.00 22,880.00 22,880.00 22,880.00
3.00 3.00 3.00 3.00
68,640.00 68,640.00 68,640.00 68,640.00

Forumula/ Treatment Speedlight Festival Cyberline Fortuna

Hardcoded 20.00 20.00 20.00 20.00
Number of parts welded per batch 5.00 5.00 5.00 5.00
Hardcoded 8.00 8.00 8.00 8.00
Hardcoded 3.00 3.00 3.00 3.00
Hardcoded 26.00 26.00 26.00 26.00
(average working hours daily +
extended hours ) * months monthly 4,160.00 4,160.00 4,160.00 4,160.00
Hardcoded 3.00 3.00 3.00 3.00
monthly hours x months per quarter 12,480.00 12,480.00 12,480.00 12,480.00

Forumula/ Treatment Speedlight Festival Cyberline Fortuna

Hardcoded 30 70 50 25
Hardcoded 8 8 8 8
Hardcoded
Average working Hours Daily + 1 1 1 0
Overtime per day 9 9 9 8
Hardcoded 26 26 26 26
Hours per Day x Days per month 7,020.00 16,380.00 11,700.00 5,200.00
Hardcoded
Months in a Quarter x Workhours per 3 3 3 3
Month 21,060.00 49,140.00 35,100.00 15,600.00
16,503.81 36,968.54 26,406.10 9,462.18
Requided Hours per
Quarter/Available Hours Per Quarter 78.37% 75.23% 75.23% 60.66%

Forumula/ Treatment Speedlight Festival Cyberline Fortuna

Hardcoded 60 80 80 50
Hardcoded 8 8 8 8
Hardcoded
Average working Hours Daily + 3 3 3 3
Overtime per day 11 11 11 11
Hardcoded 26 26 26 26
Hours per Day x Days per month 17,160.00 22,880.00 22,880.00 14,300.00

Months in aHardcoded
Quarter x Workhours 3 3 3 3
per Month 51,480.00 68,640.00 68,640.00 42,900.00
from lineRequided
balancing
Hours per
16,503.81 30,807.11 26,406.10 11,552.67
Quarter/Available Hours Per Quarter 32.06% 44.88% 38.47% 26.93%

Forumula/ Treatment Speedlight Festival Cyberline Fortuna

Hardcoded 50 70 70 50
Hardcoded 8 8 8 8
Hardcoded
Average working Hours Daily + 3 3 3 3
Overtime per day 11 11 11 11
Hardcoded 26 26 26 26
Hours per Day x Days per month 14,300.00 20,020.00 20,020.00 14,300.00
Hardcoded
Months in a Quarter x Workhours per 3 3 3 3
Month 42,900.00 60,060.00 60,060.00 42,900.00
from lineRequided
balancing
Hours per
12,102.79 25,657.92 21,621.93 7,206.66
Quarter/Available Hours Per Quarter 28.21% 42.72% 36.00% 16.80%
 Lets go back to our host country where our manufacturing will happen. We shall now configure the plant to be able to to fit
our forecast. We are to match the demand by providing the needed assets and panpower by adding or subtracting assets
or manpower as needed. Cells in green are hardcoded and can be changed

1) Machining Section
Step A Engine Shop Q1
Year 3
Item Description Forumula/ Treatment
Quarter 1
Number of Machining Areas Machining areas chip and polish blocks This is the Default number of 8.00
of engine metal and components. Number of Machining
Engines Areas
processed per
Number of Engines per batch average
number ofbatch size. rooms multipled by
machine batch
Number of machining Areas x 30.00
Batch X # Of Machining Area average batch size Number of Engines
Enter your Assumed Per Batch hours
working 240.00
Working Hours Daily Standard work hours
You may Extend per day hours
the working daily 8.00
Extended working hours here. Number of work hours multiplied by 2.00
Average working Hours daily * batch size This is the Base case configuration of the batch size 2,400.00
Working Days Monthly your plant
This is the Available Machine Hours 26.00
Average Working Hours Monthly *
Monthly 62,400.00
Batch size
Operating Number of Months in Quarter 3.00
Available Hours Per Quarter 187,200.00
Required Hours Per Quarter to Satisfy
Requided Hours per 123,172.68
Demand
Utilization Rate Quarter/Available Hours Per Quarter 65.80%

Step B Transaxle Assembly

Year 3
Item Description
Workstations of personnel and tools Forumula/ Treatment
Quarter 1
Number of Workstations used to manufacture the trans axle Hardcoded 10.00
Number of Engines per batch average of
number batch size. rooms multipled by
machine NumberFrom plant configurations
of machining Areas x 20.00
Batch X Number of Workstations average batch size Number of Engines Per Batch 200.00
Working Hours Daily Standard work hours
You may Extend per day hours
the working Hardcoded 8.00
Extended working hours here. Hardcoded
Number of work hours multiplied by 2.00
Average working Hours daily * batch size This is the Base case configuration of the batch size 2,000.00
Working Days Monthly your plant Hardcoded 26.00
 This is the Available Machine Hours Working Days per Month X
Working Hours Monthly Monthly working hours per day 52,000.00
Operating Number of Months in Quarter Hardcoded 3.00
Available Hours Per Quarter 156,000.00
Required Hours Per Quarter to Satisfy
Requided Hours per 98,181.12
Demand
Utilization Rate Quarter/Available Hours Per Quarter 62.94%

2) Robotics Production Profile

Step C Press Shop
Year 3
Item Description
The Minimum robots for this type of Forumula/ Treatment
Quarter 1
Number of Pressing Machines configuration 4.00
Number car Parts per batch average
Assumingbatch size.
robots can start up from plant configurations 8.00
Average working Hours daily immidiately. Hardcoded 8.00
Extended working hours per day You May adjust this Hardcoded
Number of work hours multiplied by 2.00
Average working Hours daily * batch size Standard configuration. You may the batch size 80.00
Working Days Monthly adjust this Hardcoded 26.00
(average working hours daily +
extended hours ) * months 8,320.00
Total of Robotics Hours Monthly self computing monthly* batch size
Operating Number of Months in Quarter 3.00
Available Hours Per Quarter 24,960.00
Required Hours Per Quarter to Satisfy
from lineRequided
balancing
Hours per 16,720.54
Demand
Utilization Rate Quarter/Available Hours Per Quarter 66.99%

Step D Welding
Year 3
Item Description
The Minimum robots for this type of Forumula/ Treatment
Quarter 1
Number of Robotic Welding Arms configuration Hardcoded 8.00
Number car Parts per batch average batch
Assuming size.
robots can start up Number of parts welded per batch 5.00
Average working Hours daily immidiately. Hardcoded 8.00
Extended working hours per day You May adjust this Hardcoded
Number of work hours multiplied by 2.00
Average working Hours daily * batch size Standard configuration. You may the batch size 50.00
Working Days Monthly adjust this Hardcoded 26.00
(average working hours daily +
extended hours ) * months 10,400.00
Total of Robotics Hours Monthly self computing monthly
Operating Number of Months in Quarter Hardcoded 3.00
Available Hours Per Quarter monthly hours x months per quarte 31,200.00
Required Hours Per Quarter to Satisfy
from lineRequided
balancing
Hours per 20,915.55
Demand
Utilization Rate Quarter/Available Hours Per Quarter 67.04%

3) Manpower Production Profile

Step E. Chassis and Body Assembly
Year 3
Item Description
This is the number of people in the Forumula/ Treatment
Quarter 1
Number of Workers plant
Look at overtime
the defaultper
standard of the Hardcoded 95.00
average day. Warning
Average working Hours daily company you are selecting
do not abuse this. There are labor Hardcoded 8.00
Average Overtime Daily rules. Hardcoded
Average working Hours Daily + 1.00
Hours Per day Look at the default standard of the Overtime per day 9.00
Average Working Days Monthly company you are selecting Hardcoded 26
Workhours Per Month Hours per Day x Days per month 22,230.00
Operating Months in a Quarter Months in aHardcoded
Quarter x Workhours 3
Oparating Hours Per Quarter per Month 66,690.00
Required Hours Per Quarter to Satisfy
Requided Hours per 48,317.01
Demand
Utilization Rate Quarter/Available Hours Per Quarter 72.45%

Step F. Electronics and Interior Assembly

Year 3
Item Description
This is the number of people in the Forumula/ Treatment
Quarter 1
Number of Workers plant
Look at overtime
the defaultper
standard of the Hardcoded 90.00
average day. Warning
Average working Hours daily company
do not abuse you
this.are selecting
There are labor Hardcoded 8.00
Average Overtime Daily rules. Hardcoded
Average working Hours Daily + 2.00
Hours Per day Look at the default standard of the Overtime per day 10.00
Average Working Days Monthly company you are selecting Hardcoded 26
Workhours Per Month Hours per Day x Days per month 23,400.00
Operating Months in a Quarter Months in aHardcoded
Quarter x Workhours 3
Oparating Hours Per Quarter per Month 70,200.00
Required Hours Per Quarter to Satisfy
from lineRequided
balancing
Hours per 46,115.38
Demand
Utilization Rate Quarter/Available Hours Per Quarter 65.69%

Step G Plastic Parts and Wheels

Year 3
Item Description
This is the number of people in the Forumula/ Treatment
Quarter 1
Number of Workers plant
Look at the default standard of the Hardcoded 85.00
Average working Hours daily company you are selecting Hardcoded 8.00
 average overtime per day. Warning
do not abuse this. There are labor
Average Overtime Daily rules. Hardcoded
Average working Hours Daily + -
Hours Per day Look at the default standard of the Overtime per day 8.00
Average Working Days Monthly company you are selecting Hardcoded 26
Workhours Per Month Hours per Day x Days per month 17,680.00
Operating Months in a Quarter Months in aHardcoded
Quarter x Workhours 3
Oparating Hours Per Quarter per Month 53,040.00
Required Hours Per Quarter to Satisfy
from lineRequided
balancing
Hours per 36,012.70
Demand
Utilization Rate Quarter/Available Hours Per Quarter 67.90%
 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1
Year 3 Year 3 Year 3 Year 4 Year 4 Year 4 Year 4 Year 5
Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1
8.00 8.00 8.00 8.00 8.00 8.00 8.00 15.00

30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00

240.00 240.00 240.00 240.00 240.00 240.00 240.00 450.00
8.00 8.00 8.00 8.00 8.00 8.00 8.00 8.00
- - 2.00 2.00 - 2.00 2.00 2.00
1,920.00 1,920.00 2,400.00 2,400.00 1,920.00 2,400.00 2,400.00 4,500.00
20.00 26.00 26.00 26.00 20.00 20.00 26.00 26.00
38,400.00 49,920.00 62,400.00 62,400.00 38,400.00 48,000.00 62,400.00 117,000.00
3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00
115,200.00 149,760.00 187,200.00 187,200.00 115,200.00 144,000.00 187,200.00 351,000.00
61,586.34 102,643.90 123,172.68 128,381.07 64,190.54 106,984.23 128,381.07 266,971.30
53.46% 68.54% 65.80% 68.58% 55.72% 74.29% 68.58% 76.06%

Year 3 Year 3 Year 3 Year 4 Year 4 Year 4 Year 4 Year 5

Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1
10.00 10.00 10.00 10.00 10.00 10.00 10.00 20.00
20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00
200.00 200.00 200.00 200.00 200.00 200.00 200.00 400.00
4.00 8.00 8.00 8.00 4.00 8.00 8.00 8.00
- - 2.00 2.00 - - 2.00 2.00
800.00 1,600.00 2,000.00 2,000.00 800.00 1,600.00 2,000.00 4,000.00
26.00 26.00 26.00 26.00 26.00 26.00 26.00 26.00
 20,800.00 41,600.00 52,000.00 52,000.00 20,800.00 41,600.00 52,000.00 104,000.00
3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00
62,400.00 124,800.00 156,000.00 156,000.00 62,400.00 124,800.00 156,000.00 312,000.00
49,090.56 81,817.60 98,181.12 102,332.74 51,166.37 85,277.28 102,332.74 212,803.21
78.67% 65.56% 62.94% 65.60% 82.00% 68.33% 65.60% 68.21%

Year 3 Year 3 Year 3 Year 4 Year 4 Year 4 Year 4 Year 5

Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1
4.00 4.00 4.00 4.00 4.00 4.00 4.00 8.00
8.00 8.00 8.00 8.00 8.00 8.00 8.00 8.00
4.00 8.00 8.00 8.00 4.00 8.00 8.00 8.00
- - 2.00 2.00 - - 2.00 2.00
32.00 64.00 80.00 80.00 32.00 64.00 80.00 80.00
26.00 26.00 26.00 26.00 26.00 26.00 26.00 26.00

3,328.00 6,656.00 8,320.00 8,320.00 3,328.00 6,656.00 8,320.00 16,640.00

3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00

9,984.00 19,968.00 24,960.00 24,960.00 9,984.00 19,968.00 24,960.00 49,920.00
8,360.27 13,933.79 16,720.54 17,427.58 8,713.79 14,522.98 17,427.58 36,241.03
83.74% 69.78% 66.99% 69.82% 87.28% 72.73% 69.82% 72.60%

Year 3 Year 3 Year 3 Year 4 Year 4 Year 4 Year 4 Year 5

Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1
8.00 8.00 8.00 8.00 8.00 8.00 8.00 18.00
5.00 5.00 5.00 5.00 5.00 5.00 5.00 5.00
4.00 8.00 8.00 8.00 4.00 8.00 8.00 8.00
- - 2.00 2.00 - - 2.00 2.00
20.00 40.00 50.00 50.00 20.00 40.00 50.00 50.00
26.00 26.00 26.00 26.00 26.00 26.00 26.00 26.00

4,160.00 8,320.00 10,400.00 10,400.00 4,160.00 8,320.00 10,400.00 23,400.00

3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00

12,480.00 24,960.00 31,200.00 31,200.00 12,480.00 24,960.00 31,200.00 70,200.00
 10,457.78 17,429.63 20,915.55 21,799.97 10,899.99 18,166.65 21,799.97 45,333.53
83.80% 69.83% 67.04% 69.87% 87.34% 72.78% 69.87% 64.58%

Year 3 Year 3 Year 3 Year 4 Year 4 Year 4 Year 4 Year 5

Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1
95.00 95.00 95.00 95.00 95.00 95.00 95.00 195.00
4.00 8.00 8.00 8.00 4.00 8.00 8.00 8.00
- - 2.00 2.00 - - 2.00 2.00
4.00 8.00 10.00 10.00 4.00 8.00 10.00 10.00
26 26 26 26 26 26 26 26
9,880.00 19,760.00 24,700.00 24,700.00 9,880.00 19,760.00 24,700.00 50,700.00
3 3 3 3 3 3 3 3
29,640.00 59,280.00 74,100.00 74,100.00 29,640.00 59,280.00 74,100.00 152,100.00
24,158.51 40,264.18 48,317.01 50,360.11 25,180.06 41,966.76 50,360.11 104,724.97
81.51% 67.92% 65.21% 67.96% 84.95% 70.79% 67.96% 68.85%

Year 3 Year 3 Year 3 Year 4 Year 4 Year 4 Year 4 Year 5

Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1
90.00 90.00 90.00 90.00 90.00 90.00 90.00 195.00
4.00 8.00 8.00 8.00 4.00 8.00 8.00 8.00
- - 2.00 2.00 - - 2.00 2.00
4.00 8.00 10.00 10.00 4.00 8.00 10.00 10.00
26 26 26 26 26 26 26 26
9,360.00 18,720.00 23,400.00 23,400.00 9,360.00 18,720.00 23,400.00 50,700.00
3 3 3 3 3 3 3 3
28,080.00 56,160.00 70,200.00 70,200.00 28,080.00 56,160.00 70,200.00 152,100.00
23,057.69 38,429.48 46,115.38 48,065.38 24,032.69 40,054.48 48,065.38 99,953.02
82.11% 68.43% 65.69% 68.47% 85.59% 71.32% 68.47% 65.72%

Year 3 Year 3 Year 3 Year 4 Year 4 Year 4 Year 4 Year 5

Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1
85.00 85.00 85.00 90.00 90.00 90.00 90.00 160.00
4.00 8.00 8.00 8.00 4.00 8.00 8.00 8.00
 - - - - - - -
4.00 8.00 8.00 8.00 4.00 8.00 8.00 8.00
26 26 26 26 26 26 26 26
8,840.00 17,680.00 17,680.00 18,720.00 9,360.00 18,720.00 18,720.00 33,280.00
3 3 3 3 3 3 3 3
26,520.00 53,040.00 53,040.00 56,160.00 28,080.00 56,160.00 56,160.00 99,840.00
18,006.35 30,010.58 36,012.70 37,535.50 18,767.75 31,279.59 37,535.50 78,055.91
67.90% 56.58% 67.90% 66.84% 66.84% 55.70% 66.84% 78.18%
 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1
Year 5 Year 5 Year 5 Year 6 Year 6 Year 6 Year 6 Year 7
Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1
15.00 15.00 15.00 20.00 20.00 20.00 20.00 25.00

30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00

450.00 450.00 450.00 600.00 600.00 600.00 600.00 750.00
8.00 8.00 8.00 8.00 8.00 8.00 8.00 8.00
- 2.00 2.00 2.00 - 2.00 2.00 2.00
3,600.00 4,500.00 4,500.00 6,000.00 4,800.00 6,000.00 6,000.00 7,500.00
20.00 26.00 26.00 26.00 20.00 26.00 26.00 26.00
72,000.00 117,000.00 117,000.00 156,000.00 96,000.00 156,000.00 156,000.00 195,000.00
3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00
216,000.00 351,000.00 351,000.00 468,000.00 288,000.00 468,000.00 468,000.00 585,000.00
133,485.65 222,476.08 266,971.30 346,205.80 173,102.90 288,504.83 346,205.80 501,784.67
61.80% 63.38% 76.06% 73.98% 60.11% 61.65% 73.98% 85.78%

Year 5 Year 5 Year 5 Year 6 Year 6 Year 6 Year 6 Year 7

Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1
20.00 20.00 20.00 30.00 30.00 30.00 30.00 30.00
20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00
400.00 400.00 400.00 600.00 600.00 600.00 600.00 600.00
4.00 8.00 8.00 8.00 4.00 8.00 8.00 8.00
- - 2.00 2.00 - - 2.00 2.00
1,600.00 3,200.00 4,000.00 6,000.00 2,400.00 4,800.00 6,000.00 6,000.00
26.00 26.00 26.00 26.00 26.00 26.00 26.00 26.00
 41,600.00 83,200.00 104,000.00 156,000.00 62,400.00 124,800.00 156,000.00 156,000.00
3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00
124,800.00 249,600.00 312,000.00 468,000.00 187,200.00 374,400.00 468,000.00 468,000.00
106,401.61 177,336.01 212,803.21 275,961.14 137,980.57 229,967.62 275,961.14 399,973.28
85.26% 71.05% 68.21% 58.97% 73.71% 61.42% 58.97% 85.46%

Year 5 Year 5 Year 5 Year 6 Year 6 Year 6 Year 6 Year 7

Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1
8.00 8.00 8.00 12.00 12.00 12.00 12.00 14.00
8.00 8.00 8.00 8.00 8.00 8.00 8.00 8.00
6.00 8.00 8.00 8.00 4.00 8.00 8.00 8.00
- - 2.00 2.00 2.00 - 2.00 2.00
48.00 64.00 80.00 80.00 48.00 64.00 80.00 80.00
26.00 26.00 26.00 26.00 26.00 26.00 26.00 26.00

9,984.00 13,312.00 16,640.00 24,960.00 14,976.00 19,968.00 24,960.00 29,120.00

3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00

29,952.00 39,936.00 49,920.00 74,880.00 44,928.00 59,904.00 74,880.00 87,360.00
18,120.52 30,200.86 36,241.03 46,997.02 23,498.51 39,164.18 46,997.02 68,116.66
60.50% 75.62% 72.60% 62.76% 52.30% 65.38% 62.76% 77.97%

Year 5 Year 5 Year 5 Year 6 Year 6 Year 6 Year 6 Year 7

Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1
18.00 18.00 18.00 24.00 24.00 24.00 24.00 36.00
5.00 5.00 5.00 5.00 5.00 5.00 5.00 5.00
4.00 8.00 8.00 8.00 4.00 8.00 8.00 8.00
- - 2.00 2.00 - - 2.00 2.00
20.00 40.00 50.00 50.00 20.00 40.00 50.00 50.00
26.00 26.00 26.00 26.00 26.00 26.00 26.00 26.00

9,360.00 18,720.00 23,400.00 31,200.00 12,480.00 24,960.00 31,200.00 46,800.00

3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00

28,080.00 56,160.00 70,200.00 93,600.00 37,440.00 74,880.00 93,600.00 140,400.00
 22,666.77 37,777.94 45,333.53 58,788.09 29,394.04 48,990.07 58,788.09 85,206.43
80.72% 67.27% 64.58% 62.81% 78.51% 65.42% 62.81% 60.69%

Year 5 Year 5 Year 5 Year 6 Year 6 Year 6 Year 6 Year 7

Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1
195.00 195.00 195.00 195.00 195.00 195.00 195.00 265.00
4.00 8.00 8.00 8.00 8.00 8.00 8.00 8.00
- - 2.00 2.00 - 2.00 2.00 3.00
4.00 8.00 10.00 10.00 8.00 10.00 10.00 11.00
26 26 26 26 26 26 26 26
20,280.00 40,560.00 50,700.00 50,700.00 40,560.00 50,700.00 50,700.00 75,790.00
3 3 3 3 3 3 3 3
60,840.00 121,680.00 152,100.00 152,100.00 121,680.00 152,100.00 152,100.00 227,370.00
52,362.49 87,270.81 104,724.97 135,806.33 67,903.17 113,171.94 135,806.33 196,835.34
86.07% 71.72% 68.85% 89.29% 55.80% 74.41% 89.29% 86.57%

Year 5 Year 5 Year 5 Year 6 Year 6 Year 6 Year 6 Year 7

Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1
195.00 195.00 195.00 195.00 195.00 195.00 195.00 255.00
4.00 8.00 8.00 8.00 8.00 8.00 8.00 8.00
- - 2.00 2.00 - 1.00 2.00 3.00
4.00 8.00 10.00 10.00 8.00 9.00 10.00 11.00
26 26 26 26 22 26 26 26
20,280.00 40,560.00 50,700.00 50,700.00 34,320.00 45,630.00 50,700.00 72,930.00
3 3 3 3 3 3 3 3
60,840.00 121,680.00 152,100.00 152,100.00 102,960.00 136,890.00 152,100.00 218,790.00
49,976.51 83,294.19 99,953.02 129,618.11 64,809.06 108,015.09 129,618.11 187,866.24
82.14% 68.45% 65.72% 85.22% 62.95% 78.91% 85.22% 85.87%

Year 5 Year 5 Year 5 Year 6 Year 6 Year 6 Year 6 Year 7

Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1
160.00 160.00 160.00 190.00 190.00 190.00 190.00 230.00
4.00 8.00 8.00 8.00 4.00 8.00 8.00 8.00
 - - - 1.00 - 1.00 2.00
4.00 8.00 8.00 9.00 4.00 8.00 9.00 10.00
26 26 26 26 26 26 26 26
16,640.00 33,280.00 33,280.00 44,460.00 19,760.00 39,520.00 44,460.00 59,800.00
3 3 3 3 3 3 3 3
49,920.00 99,840.00 99,840.00 133,380.00 59,280.00 118,560.00 133,380.00 179,400.00
39,027.96 65,046.59 78,055.91 101,222.15 50,611.08 84,351.79 101,222.15 146,709.63
78.18% 65.15% 78.18% 75.89% 85.38% 71.15% 75.89% 81.78%
 Q2 Q3 Q4
Year 7 Year 7 Year 7
Quarter 2 Quarter 3 Quarter 4
25.00 25.00 25.00

30.00 30.00 30.00

750.00 750.00 750.00
8.00 8.00 8.00
2.00 - 2.00
7,500.00 6,000.00 7,500.00
26.00 22.00 26.00
195,000.00 132,000.00 195,000.00
3.00 3.00 3.00
585,000.00 396,000.00 585,000.00
454,515.10 282,405.38 433,910.41
77.69% 71.31% 74.17%

Year 7 Year 7 Year 7

Quarter 2 Quarter 3 Quarter 4
30.00 30.00 30.00
20.00 20.00 20.00
600.00 600.00 600.00
8.00 8.00 8.00
2.00 - 2.00
6,000.00 4,800.00 6,000.00
26.00 26.00 26.00
 156,000.00 124,800.00 156,000.00
3.00 3.00 3.00
468,000.00 374,400.00 468,000.00
362,400.04 225,035.47 345,835.49
77.44% 60.11% 73.90%

Year 7 Year 7 Year 7

Quarter 2 Quarter 3 Quarter 4
14.00 14.00 14.00
8.00 8.00 8.00
8.00 8.00 8.00
2.00 2.00
80.00 64.00 80.00
26.00 26.00 26.00

29,120.00 23,296.00 29,120.00

3.00 3.00 3.00

87,360.00 69,888.00 87,360.00
62,056.46 38,098.47 58,783.95
71.04% 54.51% 67.29%

Year 7 Year 7 Year 7

Quarter 2 Quarter 3 Quarter 4
36.00 36.00 36.00
5.00 5.00 5.00
8.00 4.00 8.00
- -
40.00 20.00 40.00
26.00 26.00 26.00

37,440.00 18,720.00 37,440.00

3.00 3.00 3.00

112,320.00 56,160.00 112,320.00
 77,934.19 47,451.38 73,429.44
69.39% 84.49% 65.38%

Year 7 Year 7 Year 7

Quarter 2 Quarter 3 Quarter 4
265.00 265.00 265.00
8.00 8.00 8.00
2.00 - 2.00
10.00 8.00 10.00
26 26 26
68,900.00 55,120.00 68,900.00
3 3 3
206,700.00 165,360.00 206,700.00
178,654.73 110,538.07 170,089.65
86.43% 66.85% 82.29%

Year 7 Year 7 Year 7

Quarter 2 Quarter 3 Quarter 4
255.00 255.00 255.00
8.00 8.00 8.00
2.00 - 3.00
10.00 8.00 11.00
26 26 26
66,300.00 53,040.00 72,930.00
3 3 3
198,900.00 159,120.00 218,790.00
169,685.64 106,053.52 162,615.40
85.31% 66.65% 74.32%

Year 7 Year 7 Year 7

Quarter 2 Quarter 3 Quarter 4
230.00 230.00 230.00
8.00 8.00 8.00
 2.00 - 3.00
10.00 8.00 11.00
26 26 26
59,800.00 47,840.00 65,780.00
3 3 3
179,400.00 143,520.00 197,340.00
133,377.19 82,243.11 126,702.17
74.35% 57.30% 64.21%
1) Machining Section
Step A Engine Shop
Year 3 Year 3 Year 3
Item Size Unit Quarter 1 Quarter 2 Quarter 3
Space Required per Machining Area 30 Square Meters 240.00 240.00 240.00
Standard Buffer Space 15 Square Meters 120.00 120.00 120.00
Total Facility Space requirements for Engine Shop 360.00 360.00 360.00

Step B Transaxle Assembly

Year 3 Year 3 Year 3
Item Size Unit Quarter 1 Quarter 2 Quarter 3
Space required per Machining Assembly 40 Square meters 400.00 400.00 400.00
Standard buffer Space 20 Square meters 200.00 200.00 200.00
Total Facility Space requirements for Transaxle Assembly Square meters 600.00 600.00 600.00

2) Robotics Production Profile

Step C Press Shop
Year 3 Year 3 Year 3
Item Size Unit Quarter 1 Quarter 2 Quarter 3
Space needed in Pressing Machines 25 Square meters 100.00 100.00 100.00
Standard buffer Space 12.5 Square meters 50.00 50.00 50.00
Total Facility Space for Press Shop Square meters 150.00 150.00 150.00

Step D Welding
Year 3 Year 3 Year 3
Item Size Unit Quarter 1 Quarter 2 Quarter 3
Space needed in Welding 2.5 Square meters 20.00 20.00 20.00
Standard buffer Space 1.25 Square meters 10.00 10.00 10.00
Total Facility Space for Welding Square meters 30.00 30.00 30.00

3) Manpower Production Profile

Step E. Chassis and Body Assembly
Year 3 Year 3 Year 3
Item Size Unit Quarter 1 Quarter 2 Quarter 3
Space needed in Chassis and Body Assembly. 4 workers per station 18 Square meters 427.5 427.5 427.5
Standard buffer Space 9 Square meters 213.75 213.75 213.75
Total Facility Space Chassis and Body Assembly Square meters 641.25 641.25 641.25
Step F. Electronics and Interior Assembly
Year 3 Year 3 Year 3
Item Size Unit Quarter 1 Quarter 2 Quarter 3
Space needed in Electronics and Interior Assembly. 2 workers per station 9 Square meters 405 405 405
Standard buffer Space 4.5 Square meters 202.5 202.5 202.5
Total Facility Space for Electronics and Interior Assembly Square meters 607.50 607.50 607.50

Step G Plastic Parts and Wheels

Year 3 Year 3 Year 3
Item Size Unit Quarter 1 Quarter 2 Quarter 3
Space needed in Electronics and Interior Assembly. 2 workers per station 9 Square meters 382.5 382.5 382.5
Standard buffer Space 4.5 Square meters 191.25 191.25 191.25
Total Facility Space for Electronics and Interior Assembly Square meters 573.75 573.75 573.75

Allocation for Raw Materials and WIP Inventories

Year 3 Year 3 Year 3
Facility Space for WIP Quarter 1 Quarter 2 Quarter 3
Allocated space of 4 square meters 11,900.74 5,950.37 9,917.29
for every 10% of demand

Year 3 Year 3 Year 3

Quarter 1 Quarter 2 Quarter 3
Total Facility Size Needed 14,863.24 8,912.87 12,879.79
Add Open Space for Logistics and Utilities 35% of facility size 5,202.13 3,119.50 4,507.92
Total Lot Size to be Acquired Square meters 20,065.38 12,032.38 17,387.71
 Year 3 Year 4 Year 4 Year 4 Year 4 Year 5 Year 5 Year 5 Year 5 Year 6
Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1
240.00 240.00 240.00 240.00 240.00 450.00 450.00 450.00 450.00 600.00
120.00 120.00 120.00 120.00 120.00 225.00 225.00 225.00 225.00 300.00
360.00 360.00 360.00 360.00 360.00 675.00 675.00 675.00 675.00 900.00

Year 3 Year 4 Year 4 Year 4 Year 4 Year 5 Year 5 Year 5 Year 5 Year 6
Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1
400.00 400.00 400.00 400.00 400.00 800.00 800.00 800.00 800.00 1,200.00
200.00 200.00 200.00 200.00 200.00 400.00 400.00 400.00 400.00 600.00
600.00 600.00 600.00 600.00 600.00 1,200.00 1,200.00 1,200.00 1,200.00 1,800.00

Year 3 Year 4 Year 4 Year 4 Year 4 Year 5 Year 5 Year 5 Year 5 Year 6
Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1
100.00 100.00 100.00 100.00 100.00 200.00 200.00 200.00 200.00 300.00
50.00 50.00 50.00 50.00 50.00 100.00 100.00 100.00 100.00 150.00
150.00 150.00 150.00 150.00 150.00 300.00 300.00 300.00 300.00 450.00

Year 3 Year 4 Year 4 Year 4 Year 4 Year 5 Year 5 Year 5 Year 5 Year 6
Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1
20.00 20.00 20.00 20.00 20.00 45.00 45.00 45.00 45.00 60.00
10.00 10.00 10.00 10.00 10.00 22.50 22.50 22.50 22.50 30.00
30.00 30.00 30.00 30.00 30.00 67.50 67.50 67.50 67.50 90.00

Year 3 Year 4 Year 4 Year 4 Year 4 Year 5 Year 5 Year 5 Year 5 Year 6
Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1
427.5 427.5 427.5 427.5 427.5 877.5 877.5 877.5 877.5 877.5
213.75 213.75 213.75 213.75 213.75 438.75 438.75 438.75 438.75 438.75
641.25 641.25 641.25 641.25 641.25 1,316.25 1,316.25 1,316.25 1,316.25 1,316.25
 Year 3 Year 4 Year 4 Year 4 Year 4 Year 5 Year 5 Year 5 Year 5 Year 6
Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1
405 405 405 405 405 877.5 877.5 877.5 877.5 877.5
202.5 202.5 202.5 202.5 202.5 438.75 438.75 438.75 438.75 438.75
607.50 607.50 607.50 607.50 607.50 1,316.25 1,316.25 1,316.25 1,316.25 1,316.25

Year 3 Year 4 Year 4 Year 4 Year 4 Year 5 Year 5 Year 5 Year 5 Year 6
Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1
382.5 405 405 405 405 720 720 720 720 855
191.25 202.5 202.5 202.5 202.5 360 360 360 360 427.5
573.75 607.50 607.50 607.50 607.50 1,080.00 1,080.00 1,080.00 1,080.00 1,282.50

Year 3 Year 4 Year 4 Year 4 Year 4 Year 5 Year 5 Year 5 Year 5 Year 6
Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1
11,900.74 12,403.97 6,201.98 10,336.64 12,403.97 25,794.33 12,897.16 21,495.27 25,794.33 33,449.84

Year 3 Year 4 Year 4 Year 4 Year 4 Year 5 Year 5 Year 5 Year 5 Year 6
Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4 Quarter 1
14,863.24 15,400.22 9,198.23 13,332.89 15,400.22 31,749.33 18,852.16 27,450.27 31,749.33 40,604.84
5,202.13 5,390.08 3,219.38 4,666.51 5,390.08 11,112.27 6,598.26 9,607.60 11,112.27 14,211.69
20,065.38 20,790.30 12,417.62 17,999.40 20,790.30 42,861.59 25,450.42 37,057.87 42,861.59 54,816.53
 Year 6 Year 6 Year 6 Year 7 Year 7 Year 7 Year 7
Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4
600.00 600.00 600.00 750.00 750.00 750.00 750.00
300.00 300.00 300.00 375.00 375.00 375.00 375.00
900.00 900.00 900.00 1,125.00 1,125.00 1,125.00 1,125.00

Year 6 Year 6 Year 6 Year 7 Year 7 Year 7 Year 7

Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4
1,200.00 1,200.00 1,200.00 1,200.00 1,200.00 1,200.00 1,200.00
600.00 600.00 600.00 600.00 600.00 600.00 600.00
1,800.00 1,800.00 1,800.00 1,800.00 1,800.00 1,800.00 1,800.00

Year 6 Year 6 Year 6 Year 7 Year 7 Year 7 Year 7

Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4
300.00 300.00 300.00 350.00 350.00 350.00 350.00
150.00 150.00 150.00 175.00 175.00 175.00 175.00
450.00 450.00 450.00 525.00 525.00 525.00 525.00

Year 6 Year 6 Year 6 Year 7 Year 7 Year 7 Year 7

Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4
60.00 60.00 60.00 90.00 90.00 90.00 90.00
30.00 30.00 30.00 45.00 45.00 45.00 45.00
90.00 90.00 90.00 135.00 135.00 135.00 135.00

Year 6 Year 6 Year 6 Year 7 Year 7 Year 7 Year 7

Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4
877.5 877.5 877.5 1192.5 1192.5 1192.5 1192.5
438.75 438.75 438.75 596.25 596.25 596.25 596.25
1,316.25 1,316.25 1,316.25 1,788.75 1,788.75 1,788.75 1,788.75
 Year 6 Year 6 Year 6 Year 7 Year 7 Year 7 Year 7
Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4
877.5 877.5 877.5 1147.5 1147.5 1147.5 1147.5
438.75 438.75 438.75 573.75 573.75 573.75 573.75
1,316.25 1,316.25 1,316.25 1,721.25 1,721.25 1,721.25 1,721.25

Year 6 Year 6 Year 6 Year 7 Year 7 Year 7 Year 7

Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4
855 855 855 1035 1035 1035 1035
427.5 427.5 427.5 517.5 517.5 517.5 517.5
1,282.50 1,282.50 1,282.50 1,552.50 1,552.50 1,552.50 1,552.50

Year 6 Year 6 Year 6 Year 7 Year 7 Year 7 Year 7

Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4
16,724.92 27,874.86 33,449.84 48,481.61 43,633.45 27,472.91 42,017.40

Year 6 Year 6 Year 6 Year 7 Year 7 Year 7 Year 7

Quarter 2 Quarter 3 Quarter 4 Quarter 1 Quarter 2 Quarter 3 Quarter 4
23,879.92 35,029.86 40,604.84 57,129.11 52,280.95 36,120.41 50,664.90
8,357.97 12,260.45 14,211.69 19,995.19 18,298.33 12,642.14 17,732.71
32,237.89 47,290.32 54,816.53 77,124.30 70,579.28 48,762.56 68,397.61
 CAPITAL EXPENSE AND OPERATING EXPENSES
This Portion is where we decide on the actual facility size and incur the operating expenses. This portion contains 3 main

12A- Facility Capital Expenditures - the capex of the factory itself

12A-1 facility size considered
12A-2 summation of capex for infrastructure (building)
12B- Equipment Capital Expenditures - the capex of buying the machineries. equipment inside those factory
12B-1
12B-2
12C The cost of running the facility per hour. (costs of electricity)

Based on the demand forecast and the recommended number of facilities we decide when the facility and when the equi
The default here is to construct the needed equipment and facility based on the time where the forecast is highest. You m
additional equipment and facility construction but assume it takes 2 Quarters to complete. the Peso US Dollar conversion
pesos to 1 US Dollar. We also use a top down estimate method using the general area of the facility then multiplying it wi
Ease of use, the Standard Facility Capex per square meter is put right below this textbox.
Computation of the Costs of Facilities. This is
12 A how
The Costings for Industrial Facilities may be much the factory
downloaded structure and the
here: https://www.arcadis.com/en/asia/our-perspectives/rese
necessary improvements will cost. the cost
publications/arcadis-construction-cost-handbook/
However you may use your own validated stillsources.
does not include land acquisition costs.

Conversion Rate IDR per USD 1 15,180.00 15,180.00

Value in IDR 5,388,900.00 466.00
Construction cost per Mechanical Cost In USD
Standard costs Incurred sqm In USD per sqm
Cost in USD Per Square meter $ 355.00 $ 0.03

1) Machining Section
Step A Engine Shop Construction cost per Mechanical Cost In USD
Item sqm In USD per sqm
REQUIRED OR NOT? yes yes
Space Required per Machining Area $ 355.00 $ 0.03
Standard Buffer Space $ 355.00 $ 0.03
Total Facility Space requirements for Engine Shop

Step B Transaxle Assembly Construction cost per Mechanical Cost In USD

Item sqm In USD per sqm
REQUIRED OR NOT? yes yes
Space required per Machining Assembly $ 355.00 $ 0.03
Standard buffer Space $ 355.00 $ 0.03

2) Robotics Production Profile

Step C Press Shop Construction cost per Mechanical Cost In USD
Item sqm In USD per sqm
REQUIRED OR NOT? yes yes
Space needed in Pressing Machines $ 355.00 $ 0.03
Standard buffer Space $ 355.00 $ 0.03
Step D Welding Construction cost per Mechanical Cost In USD
Item sqm In USD per sqm
REQUIRED OR NOT? yes yes
Space needed in Welding $ 355.00 $ 0.03
Standard buffer Space $ 355.00 $ 0.03

3) Manpower Production Profile

Step E. Chassis and Body Assembly Construction cost per Mechanical Cost In USD
Item sqm In USD per sqm
REQUIRED OR NOT? yes yes
Space needed in Chassis and Body Assembly. 4 wor$ 355.00 $ 0.03
Standard buffer Space $ 355.00 $ 0.03

Step F. Electronics and Interior Assembly Construction cost per Mechanical Cost In USD
Item sqm In USD per sqm
REQUIRED OR NOT? yes yes
Space needed in Electronics and Interior Assembly. $ 355.00 $ 0.03
Standard buffer Space $ 355.00 $ 0.03

Step G Plastic Parts and Wheels Construction cost per Mechanical Cost In USD
Item sqm In USD per sqm
REQUIRED OR NOT? yes yes
Space needed in Electronics and Interior Assembly $ 355.00 $ 0.03
Standard buffer Space $ 355.00 $ 0.03

Allocation for WIP Inventories Construction cost per Mechanical Cost In USD
Item sqm In USD per sqm
REQUIRED OR NOT? yes no
Total Space in sqm $ 355.00 $ -

40% of Factory
Allocation of Space for Logistics and Utility Area Construction cost per Mechanical Cost In USD
Item sqm In USD per sqm
REQUIRED OR NOT? yes no
Total Space in sqm $ 142.00 $ -
 This is for Capital Expenditures for tools,
equipment, machineries and furniture.

We will have to purchase the necessary

mentioned items. the cost of equipment
are constants.

It is an option to have more than 1 round

of equipment purchase
12 B

Machining Section
Step A Engine Shop Equipment Bought Cost of Equipment
Boring Machine $ 54,901.96
Engine Cranes $ 3,529.41

Step B Transaxle Assembly Equipment Bought Cost of Equipment

Assembly Sets $ 2,941.18
Computer Equipment $ 1,960.78
Diagnostic tools $ 1,568.63

2) Robotics Production Profile

Step C Press Shop Equipment Bought Cost of Equipment
Car Panel Press Large $ 11,500.00
components
Car Panel Press Small $ 25,000.00
components
Time and Motion capture $ 1,176.47
Equipment

Step D Welding Equipment Bought Cost of Equipment

Spot Welding robotic arm $ 32,000.00

3) Manpower Production Profile

Step E. Chassis and Body Assembly Equipment Bought Cost of Equipment
Overhead Cranes and $ 3,529.41
Pully
Toolsets $ 823.53

Step F. Electronics and Interior Assembly Equipment Bought Cost of Equipment

Toolsets $ 823.53
 Testing Kits $ 850.00

Step G Plastic Parts and Wheels Equipment Bought Cost of Equipment

Toolsets $ 823.53
Alignment computer $ 1,200.00

Allocation for WIP Inventories Equipment Bought Cost of Equipment

Electric forklift $ 30,000.00

Allocation of Space for Logistics and Utility

Area Equipment Bought Cost of Equipment
Street sweeper Truck $ 130,000.00
Assorted Maintenance tools 2500

Grand Total for Tools, Equ

 xpenses. This portion contains 3 main parts

ment inside those factory

de when the facility and when the equipment gets purchased.

me where the forecast is highest. You may opt to schedule
omplete. the Peso US Dollar conversion rate based here is 51
rea of the facility then multiplying it with the specific This
costs. For
Photo by Unknown
xtbox. Author is licensed under
CC BY-SA

is.com/en/asia/our-perspectives/research-and-

15,180.00 15,180.00 15,180.00

589.00 7,590.00 139.00
Electrical Cost IN USD Plumbing Cost in USD Hydraulic Costs in USD
per sqm per sqm per sqm.
$ 0.04 $ 0.50 $ 0.01

Electrical Cost IN USD Plumbing Cost in USD Hydraulic Costs in USD

per sqm per sqm per sqm.
yes no no
$ 0.04 $ - $ -
$ 0.04 $ - $ -

Electrical Cost IN USD Plumbing Cost in USD Hydraulic Costs in USD

per sqm per sqm per sqm.
yes no no
$ 0.04 $ - $ -
$ 0.04 $ - $ -

Electrical Cost IN USD Plumbing Cost in USD Hydraulic Costs in USD

per sqm per sqm per sqm.
yes no Yes
$ 0.04 $ - $ 0.01
$ 0.04 $ - $ 0.01
Electrical Cost IN USD Plumbing Cost in USD Hydraulic Costs in USD
per sqm per sqm per sqm.
yes no Yes
$ 0.04 $ - $ 0.01
$ 0.04 $ - $ 0.01

Electrical Cost IN USD Plumbing Cost in USD Hydraulic Costs in USD

per sqm per sqm per sqm.
yes no no
$ 0.04 $ - $ -
$ 0.04 $ - $ -

Electrical Cost IN USD Plumbing Cost in USD Hydraulic Costs in USD

per sqm per sqm per sqm.
yes no no
$ 0.04 $ - $ -
$ 0.04 $ - $ -

Electrical Cost IN USD Plumbing Cost in USD Hydraulic Costs in USD

per sqm per sqm per sqm.
yes no Yes
$ 0.04 $ - $ 0.01
$ 0.04 $ - $ 0.01

Electrical Cost IN USD Plumbing Cost in USD Hydraulic Costs in USD

per sqm per sqm per sqm.
yes no Yes
$ 0.04 $ - $ 0.01

Electrical Cost IN USD Plumbing Cost in USD Hydraulic Costs in USD

per sqm per sqm per sqm.
yes yes no
$ 0.04 $ 0.50 $ -
 The number of stations comes from the manufacturing schedules
ease of simplicity, the default is selecting the maximum number o
stations or manpower that is seen during the forecast horizon.
12 B-1 In Reality, the materials planning schedule is more complicated
especially in robotics and machinery that need customization and
times are variable. however its simplified in this exercise.
You may opt to have more than one purchasing rounds.

Number of Equipment
Number of Stations per station Unit Total costs
25.00 4 machines $ 5,490,196.08
25.00 4 pcs $ 352,941.18
Subtotal $ 5,843,137.26

Number of Stations Number of Equipment Unit Total costs

per station
30.00 10 lots $ 882,352.94
30.00 1 units $ 58,823.53
30.00 1 lots $ 47,058.82
Subtotal $ 988,235.29
Total Tools and Equipment Capex for Machining Section $ 6,831,372.55

Number of Equipment
Number of Stations per station Unit Total costs
30.00 1 Pc $ 345,000.00
30.00 1 Pc $ 750,000.00
30.00 1 lot $ 35,294.12
Subtotal $ 1,130,294.12

Number of Equipment
Number of Stations per station Unit Total costs
36.00 1 Unit $ 1,152,000.00
Subtotal $ 1,152,000.00
Total Tools and Equipment Capex for Robotics Section $ 2,282,294.12

Number of Number of Equipment

Unit Total costs
Stations/personnel per Station
265.00 44.167 pcs $ 41,308,823.54
265.00 265.00 pcs $ 57,832,352.94
Subtotal $ 99,141,176.47

Number of Number of Equipment

Unit Total costs
Stations/personnel per Station
255.00 255.00 pcs $ 53,550,000.00
 255.00 63.75 pcs $ 13,817,812.50
Subtotal $ 67,367,812.50

Number of Number of Equipment

Unit Total costs
Stations/personnel per station
230.00 230.00 pcs $ 43,564,705.88
230.00 19.17 pcs $ 5,290,000.00
Subtotal $ 48,854,705.88
Total Equipment and Tools for use of Manpower intensive Production $ 215,363,694.90

Area Size (from facility Number of Equipment

Unit Total costs
size) per station
48,481.61 24.24 Units 727,224.15
Subtotal $ 727,224.15

Area Size (from facility Number of Equipment

Unit Total costs
size) per station
19,995.19 1 Units 130,000.00
19,995.19 1 Units 2,500.00
Subtotal $ 132,500.00

Grand Total for Tools, Equipment and Furnitures $ 225,337,085.70

The number of stations comes from the

12 B-2 manufacturing schedules. for ease of simplicity,
the default is selecting the maximum number of
stations or manpower that is seen during the
forecast horizon.

In Reality, the materials planning schedule is

more complicated especially in robotics and
machinery that need customization and lead
times are variable. however its simplified in this
exercise.
You may opt to have more than one purchasing
rounds.
 We take the facility size that we went to c
Step multiply it with the total cost. Where tota
cost + mechanical cost+ electrical cost+ p
12A-1 hydraulic costs

Scheduled construction
Engine Shop Area built Total Cost /Installation

750.00 $ 266,302.12 Year 1 Q1

375.00 $ 133,151.06 Year 1 Q1
1,125.00 $ 399,453.19 Year 1 Q1

Scheduled construction
Transaxle Assembly Area built Total Cost /Installation

1,200.00 $ 426,083.40 Year 1 Q1

600.00 $ 213,041.70 Year 1 Q1
1,800.00 $ 639,125.10 Year 1 Q1

Scheduled construction
Pres Ship Area Built Total Cost /Installation

350.00 $ 124,277.53 Year 1 Q1

175.00 $ 62,138.76 Year 1 Q1
525.00 $ 186,416.29 Year 1 Q1
 Scheduled construction
Welding Area Built Total Cost /Installation

90.00 $ 31,957.08 Year 1 Q1

45.00 $ 15,978.54 Year 1 Q1
135.00 $ 47,935.62 Year 1 Q1

Scheduled construction
Chassis and Body Assembly Area Built Total Cost /Installation

1,192.50 $ 423,420.38 Year 1 Q1

596.25 $ 211,710.19 Year 1 Q1
1,788.75 $ 635,130.57 Year 1 Q1

Electronics and Interior Assembly Area Scheduled construction

Built Total Cost /Installation

1,147.50 $ 407,442.25 Year 1 Q1

573.75 $ 203,721.13 Year 1 Q1
1,721.25 $ 611,163.38 Year 1 Q1

Scheduled construction
Plastic Parts and Wheels Area Built Total Cost /Installation

1,035.00 $ 367,506.41 Year 1 Q1

517.50 $ 183,753.20 Year 1 Q1
1,552.50 $ 551,259.61 Year 1 Q1

Scheduled construction
WIP Inventories area built Total Cost /Installation

48,481.61 $ 17,213,296.71 Year 1 Q1

48,481.61 $ 17,213,296.71 Year 1 Q1

Scheduled construction
Space for Logistics and Utility Area Built Total Cost /Installation

19,995.19 $ 2,850,090.21 Year 1 Q1

19,995.19 $ 2,850,090.21 Year 1 Q1

Scheduled construction
Total Area Area to be constructed Total Cost /Installation
77,124.30 $ 23,133,870.67 Year 1 Q1
omes from the manufacturing schedules. for
ault is selecting the maximum number of
t is seen during the forecast horizon.
12 C
lanning schedule is more complicated
machinery that need customization and lead
er its simplified in this exercise.
e than one purchasing rounds.

Machining Section
Remarks/ Time Purchased Step
Several boring machines for different piston Step A Engine S
and valves done simultaneously. Purchased
Engine cranes carry Engine Blocks. Step B Transaxle As
Purchased in Year 2 Q4.
for equipments in the machining 2) Robotics Production Profile
stations
Step
Step C Press Sh
Purchased in Year 2 Q4. Step D Weldin
Purchased in Year 2 Q4. 3) Manpower Production Profile
Purchased in Year 2 Q4. Step
Step E. Chassis and Bod
Step F. Electronics and Inte
Step G Plastic Parts an

Remarks Area
Purchased in Year 2 Q4. Allocation for WIP Inv
Purchased in Year 2 Q4. Allocation of Space for Logistic
Purchased in Year 2 Q4.

Remarks
Purchased in Year 2 Q4.

Remarks/ time of purchase

1 crane for every 6 persons. Purchased in
Year 2 Q4.
1 toolset per person. Purchased in Year 2
Q4.

Remarks/ time of purchase

1 toolset per person. Purchased in Year 2
Q4.
 1 testing kit to 4 Persons. Purchased in
Year 2 Q4.

Remarks/ time of purchase

1 toolset per person. Purchased in Year 2
Q4.
1 alignment computer and device to 4
persons. Purchased in Year 2 Q4.

Remarks/ time of purchase

1 unit covers 2000 square meters of WIP
area. Purchased in Year 2 Q4.

Remarks/ time of purchase

hard coded 1 street sweeper can clean up
to 100,000 sqm. Purchased in Year 2 Q4.
Hardcoded. Purchased in Year 2 Q4.

ations comes from the

hedules. for ease of simplicity,
ecting the maximum number of
ower that is seen during the

terials planning schedule is

d especially in robotics and
eed customization and lead
e. however its simplified in this

ave more than one purchasing

 the facility size that we went to construct then we
it with the total cost. Where total cost = construction
echanical cost+ electrical cost+ plumbing cost +
c costs

in this case, I used the final size needed given the finaly year forecast

in this case, I used the final size needed given the finaly year forecast
 This Portion is for the direct production costs (Put under the operating expenses in the
Income statement). Machining section tasks and robotics section are quoted per hour
while manpower tasks are quoted per manpower hours used, these are the costs in
addition to the salaries but are only incurred when manpower hours are utilized for
production.

on
Step Cost per Hour
Step A Engine Shop $ 240.385
Step B Transaxle Assembly $ 168.269
duction Profile
Step Cost per Hour
Step C Press Shop $ 168.269
Step D Welding $ 432.692
oduction Profile
Step Cost per Hour
Step E. Chassis and Body Assembly $ 6.300
Step F. Electronics and Interior Assembly $ 6.300
Step G Plastic Parts and Wheels $ 6.300

Area Cost per Square meter per

Quarter
Allocation for WIP Inventories $ 7.50
Allocation of Space for Logistics and Utility Area $ 4.50
 ating expenses in the
are quoted per hour
ese are the costs in
urs are utilized for

Remarks
Using Standard Costing Methods.
Using Standard Costing Methods.

Remarks
Using Standard Costing Methods.
Using Standard Costing Methods.

Remarks
This cost is in addition to salaries
This cost is in addition to salaries
This cost is in addition to salaries

Remarks
this is multiplied to the square meter area of WIP
Inventories. This represents the utilities and maintenance
this is multiplied to the square meter area of WIP
Inventories. This represents the utilities and maintenance
 Income Statement Assumptions
Item Amount Unit Remarks
Depreciation of Infrastructure 30.00 Years
Depreciation of Equipment 5.00 Years
Inflation Rate Yoy 2.50% Percent for utilities
Straight Line Depreciation 30% Salvage Value 70.00% Percent
Quarters 4.00

Income Statement

Minimum Fully Maximum fully

Built Selling Price BuilT Selling price Minimum Selling
Revenues Comments/ formulas (as sold to (as sold to
Price to Retail
Client
Speedlight units sold x selling price $ retailers)10,111 $ retailers) 10,225 $ 11,080
Festival units sold x selling price $ 11,300 $ 11,452 $ 12,000
Cyberline units sold x selling price $ 13,500 $ 14,500 $ 17,500
Fortuna units sold x selling price $ 17,200 $ 17,754 $ 22,500
Total Revenues
Cost of Goods Sold
Cost of Direct Materials
Speedlight Units sold x cost of Materials
Festival Units sold x cost of Materials
Cyberline Units sold x cost of Materials
Fortuna Units sold x cost of Materials
Total Cost of Materials

Conversion Costs ( Cost of Direct Labor and Overhead (Equipments)

Machining Costs
Step A Engine Shop Opex per hour x hours needed
Step B Transaxle Assembly Opex per hour x hours needed
Robotics cost
Step C Press Shop Opex per hour x hours needed
 Step D Welding Opex per hour x hours needed
Manpower costs
Step E Opex per hour x hours needed
Step F Opex per hour x hours needed
Step G Opex per hour x hours needed
Cost per WIP Inventories (Total Capex area to be
constructed x (1- Salvage value
Cost of Logistics area in %)/Depreciation in
Depreciation of Infrastructure yrs/Quarters
Depreciation of Equipment Total Equipment Capex/ Depreciable Life
Total Conversion Costs
Total Cost of Goods Sold
Gross Profit
Gross Profit %

Operating and Other Expenses

Headquarters Overhead (@ 10% of total expenses) Sum of cells 29:43 X 10%

Selling and Marketing Expense 5% of HQ Overhead 2%

Total Expenses

Net Income Before Tax

Corporate Tax Rate (research host country tax rate) 25%
Net Income After Tax NIBT- Tax
Remarks

Year 3 Year
Maximum Selling SELLING30% 70%PRICE Qtr 1 Qtr 2 Qtr 3 Qtr 4 Qtr 1
SELLING
PRICE FOR
FOR
Price to Retail RESELLER
RETAIL
Client (50%)
$ 11,391 $ 10,219 $ (50%)11,349 65,513,585.85 32,756,792.92 54,594,654.87 65,513,585.85 68,283,847.04
$ 12,700 $ 11,449 $ 12,649 146,248,221.00 73,124,110.49 121,873,517.50 146,248,221.00 152,432,369.90
$ 18,000 $ 14,499 $ 17,949 150,966,865.30 75,483,432.63 125,805,721.10 150,966,865.30 157,350,543.40
$ 22,900 $ 17,699 $ 22,849 63,383,352.99 31,691,676.50 52,819,460.83 63,383,352.99 66,063,536.67
426,112,025.14 213,056,012.54 355,093,354.30 426,112,025.14 444,130,297.01
Direct Materials
Cost

$ 9,300 55,338,451.26 27,669,225.63 46,115,376.05 55,338,451.26 57,678,453.91

$ 9,500 113,057,051.00 56,528,525.48 94,214,209.14 113,057,051.00 117,837,701.50
$ 12,054 107,588,659.90 53,794,329.96 89,657,216.60 107,588,659.90 112,138,078.00
$ 14,200 42,247,634.83 21,123,817.42 35,206,362.36 42,247,634.83 44,034,088.47
318,231,796.99 159,115,898.49 265,193,164.15 318,231,796.99 331,688,321.88

29,608,817.75 14,804,408.88 24,674,014.79 29,608,817.75 30,860,835.29

16,520,862.08 8,260,431.04 13,767,385.07 16,520,862.08 17,219,451.58

2,813,552.88 1,406,776.44 2,344,627.40 2,813,552.88 2,932,524.78

 9,049,999.51 4,524,999.76 7,541,666.26 9,049,999.51 9,432,681.40

304,397.18 152,198.59 253,664.32 304,397.18 317,268.71

290,526.87 145,263.43 242,105.72 290,526.87 302,811.88
226,879.98 113,439.99 189,066.65 226,879.98 236,473.67

134,947.58 134,947.58 134,947.58 134,947.58 134,947.58

11,266,854.28 11,266,854.28 11,266,854.28 11,266,854.28 11,266,854.28
70,216,838.11 40,809,319.99 60,414,332.07 70,216,838.11 72,703,849.17
388,448,635.10 199,925,218.48 325,607,496.22 388,448,635.10 404,392,171.05
37,663,390.04 13,130,794.06 29,485,858.08 37,663,390.04 39,738,125.96
8.84% 6.16% 8.30% 8.84% 8.95%
117,943,432.10

7,021,683.81 4,080,932.00 6,041,433.21 7,021,683.81 7,270,384.92

140,433.68 81,618.64 120,828.66 140,433.68 145,407.70

7,162,117.49 4,162,550.64 6,162,261.87 7,162,117.49 7,415,792.62

30,501,272.55 8,968,243.42 23,323,596.21 30,501,272.55 32,322,333.35

7,625,318.14 2,242,060.86 5,830,899.05 7,625,318.14 8,080,583.34
22,875,954.41 6,726,182.57 17,492,697.16 22,875,954.41 24,241,750.01

Sales 1,420,373,417.00 100.00%

COGS 1,302,429,985.00 91.70%
GP 117,943,432.10 8.30%
Expense 24,649,047.49 1.74%
NIBT 93,294,384.58 6.57%
T 23,323,596.14 1.64%
NAT 69,970,788.43 4.93%
 Operational
Year 4 Year 5
Qtr 2 Qtr 3 Qtr 4 Qtr 1 Qtr 2 Qtr 3 Qtr 4 Qtr 1

34,141,923.52 56,903,205.87 68,283,847.04 141,997,778.90 70,998,889.47 118,331,482.40 141,997,778.90 184,141,345.00

76,216,184.95 127,026,974.90 152,432,369.90 316,986,504.20 158,493,252.10 264,155,420.10 316,986,504.20 411,065,029.70
78,675,271.72 131,125,452.90 157,350,543.40 327,213,955.40 163,606,977.70 272,678,296.20 327,213,955.40 424,327,889.50
33,031,768.33 55,052,947.22 66,063,536.67 137,380,594.10 68,690,297.06 114,483,828.40 137,380,594.10 178,153,824.40
222,065,148.52 370,108,580.89 444,130,297.01 923,578,832.60 461,789,416.33 769,649,027.10 923,578,832.60 1,197,688,088.60

28,839,226.95 48,065,378.25 57,678,453.91 119,943,628.00 59,971,813.99 99,953,023.32 119,943,628.00 155,541,735.50

58,918,850.76 98,198,084.61 117,837,701.50 245,046,121.70 122,523,060.80 204,205,101.40 245,046,121.70 317,773,438.20
56,069,038.98 93,448,398.30 112,138,078.00 233,193,627.70 116,596,813.90 194,328,023.10 233,193,627.70 302,403,238.70
22,017,044.23 36,695,073.72 44,034,088.47 91,569,866.53 45,784,933.26 76,308,222.11 91,569,866.53 118,746,916.40
165,844,160.92 276,406,934.88 331,688,321.88 689,753,243.93 344,876,621.95 574,794,369.93 689,753,243.93 894,465,328.80

15,430,417.65 25,717,362.74 30,860,835.29 64,175,793.51 32,087,896.76 53,479,827.93 64,175,793.51 83,222,547.71

8,609,725.79 14,349,542.98 17,219,451.58 35,808,232.61 17,904,116.31 29,840,193.84 35,808,232.61 46,435,769.37

1,466,262.39 2,443,770.65 2,932,524.78 6,098,250.52 3,049,125.26 5,081,875.44 6,098,250.52 7,908,152.24

 4,716,340.70 7,860,567.83 9,432,681.40 19,615,470.80 9,807,735.40 16,346,225.67 19,615,470.80 25,437,152.63

158,634.35 264,390.59 317,268.71 659,767.34 329,883.67 549,806.11 659,767.34 855,579.90

151,405.94 252,343.24 302,811.88 629,704.05 314,852.02 524,753.37 629,704.05 816,594.11
118,236.83 197,061.39 236,473.67 491,752.25 245,876.13 409,793.55 491,752.25 637,699.56

134,947.58 134,947.58 134,947.58 134,947.58 134,947.58 134,947.58 134,947.58 134,947.58

11,266,854.28 11,266,854.28 11,266,854.28 11,266,854.28 11,266,854.28 11,266,854.28 11,266,854.28 11,266,854.28
42,052,825.52 62,486,841.28 72,703,849.17 138,880,772.94 75,141,287.41 117,634,277.77 138,880,772.94 176,715,297.38
207,896,986.44 338,893,776.16 404,392,171.05 828,634,016.87 420,017,909.36 692,428,647.70 828,634,016.87 1,071,180,626.18
14,168,162.08 31,214,804.73 39,738,125.96 94,944,815.73 41,771,506.97 77,220,379.40 94,944,815.73 126,507,462.42
6.38% 8.43% 8.95% 10.28% 9.05% 10.03% 10.28% 10.56%
124,859,218.80 308,881,518.10

4,205,282.55 6,248,684.13 7,270,384.92 13,888,077.29 7,514,128.74 11,763,427.78 13,888,077.29 17,671,529.74

84,105.65 124,973.68 145,407.70 277,761.55 150,282.57 235,268.56 277,761.55 353,430.59

4,289,388.20 6,373,657.81 7,415,792.62 14,165,838.84 7,664,411.32 11,998,696.33 14,165,838.84 18,024,960.33

9,878,773.88 24,841,146.92 32,322,333.35 80,778,976.89 34,107,095.65 65,221,683.07 80,778,976.89 108,482,502.09

2,469,693.47 6,210,286.73 8,080,583.34 20,194,744.22 8,526,773.91 16,305,420.77 20,194,744.22 27,120,625.52
7,409,080.41 18,630,860.19 24,241,750.01 60,584,232.67 25,580,321.74 48,916,262.30 60,584,232.67 81,361,876.57

Sales 1,480,434,324.00 100.00% Sales 3,078,596,109.00 100.00%

COGS 1,355,575,105.00 91.57% COGS 2,769,714,591.00 89.97%
GP 124,859,218.80 8.43% GP 308,881,518.10 10.03%
Expense 25,494,631.25 1.72% Expense 47,994,785.33 1.56%
NIBT 99,364,587.58 6.71% NIBT 260,886,732.80 8.47%
T 24,841,146.90 1.68% T 65,221,683.20 2.12%
NAT 74,523,440.69 5.03% NAT 195,665,049.60 6.36%
 Year 6 Year 7
Qtr 2 Qtr 3 Qtr 4 Qtr 1 Qtr 2 Qtr 3 Qtr 4

92,070,672.49 153,451,120.80 184,141,345.00 266,891,264.40 133,445,632.20 222,409,387.00 266,891,264.40

205,532,514.80 342,554,191.40 411,065,029.70 595,790,508.40 595,790,508.40 297,895,254.20 496,492,090.30
212,163,944.80 353,606,574.60 424,327,889.50 615,013,466.80 615,013,466.80 307,506,733.40 512,511,222.40
89,076,912.20 148,461,520.30 178,153,824.40 258,213,056.20 258,213,056.20 129,106,528.10 215,177,546.80
598,844,044.29 998,073,407.10 1,197,688,088.60 1,735,908,295.80 1,602,462,663.60 956,917,902.70 1,491,072,123.90

77,770,867.77 129,618,113.00 155,541,735.50 225,439,487.70 112,719,743.80 187,866,239.70 225,439,487.70

158,886,719.10 264,811,198.50 317,773,438.20 460,575,297.40 460,575,297.40 230,287,648.70 383,812,747.80
151,201,619.40 252,002,699.00 302,403,238.70 438,297,997.50 438,297,997.50 219,148,998.70 365,248,331.20
59,373,458.19 98,955,763.65 118,746,916.40 172,109,716.40 172,109,716.40 86,054,858.19 143,424,763.70
447,232,664.46 745,387,774.15 894,465,328.80 1,296,422,499.00 1,183,702,755.10 723,357,745.29 1,117,925,330.40

41,611,273.85 69,352,123.09 83,222,547.71 120,621,314.00 109,258,436.60 67,885,908.58 104,305,387.40

23,217,884.69 38,696,474.48 46,435,769.37 67,303,196.92 60,980,775.39 37,866,546.15 58,193,471.28

3,954,076.12 6,590,126.87 7,908,152.24 11,461,938.38 10,442,192.98 6,410,799.46 9,891,530.46

 12,718,576.31 21,197,627.19 25,437,152.63 36,868,166.83 33,721,523.86 20,531,845.40 31,772,353.35

427,789.95 712,983.25 855,579.90 1,240,062.63 1,125,524.82 696,389.85 1,071,564.79

408,297.06 680,495.09 816,594.11 1,183,557.31 1,069,019.51 668,137.19 1,024,477.03
318,849.78 531,416.30 637,699.56 924,270.66 840,276.27 518,131.59 798,223.68

134,947.58 134,947.58 134,947.58 134,947.58 134,947.58 134,947.58 134,947.58

11,266,854.28 11,266,854.28 11,266,854.28 11,266,854.28 11,266,854.28 11,266,854.28 11,266,854.28
94,058,549.61 149,163,048.13 176,715,297.38 251,004,308.59 228,839,551.29 145,979,560.08 218,458,809.84
541,291,214.07 894,550,822.28 1,071,180,626.18 1,547,426,807.59 1,412,542,306.39 869,337,305.37 1,336,384,140.24
57,552,830.22 103,522,584.82 126,507,462.42 188,481,488.21 189,920,357.21 87,580,597.33 154,687,983.66
9.61% 10.37% 10.56% 10.86% 11.85% 9.15% 10.37%
414,090,339.90 620,670,426.60

9,405,854.96 14,916,304.81 17,671,529.74 25,100,430.86 22,883,955.13 14,597,956.01 21,845,880.98

188,117.10 298,326.10 353,430.59 502,008.62 457,679.10 291,959.12 436,917.62

9,593,972.06 15,214,630.91 18,024,960.33 25,602,439.48 23,341,634.23 14,889,915.13 22,282,798.60

47,958,858.16 88,307,953.92 108,482,502.09 162,879,048.74 166,578,722.98 72,690,682.20 132,405,185.05

11,989,714.54 22,076,988.48 27,120,625.52 40,719,762.18 41,644,680.74 18,172,670.55 33,101,296.26
35,969,143.62 66,230,965.44 81,361,876.57 122,159,286.55 124,934,042.23 54,518,011.65 99,303,888.79

Sales 3,992,293,629.00 100.00% Sales 5,786,360,986.00 100.00%

COGS 3,578,203,289.00 89.63% COGS 5,165,690,559.00 89.27%
GP 414,090,339.90 10.37% GP 620,670,426.60 10.73%
Expense 60,858,523.63 1.52% Expense 86,116,787.44 1.49%
NIBT 353,231,816.30 8.85% NIBT 534,553,639.20 9.24%
T 88,307,954.06 2.21% T 133,638,409.80 2.31%
NAT 264,923,862.20 6.64% NAT 400,915,229.40 6.93%