JB/T 9167.2-1998 Guidelines for the management of process equipment design Selection rules for process equipment design
Some standard content:
ICS25.010
Machinery Industry Standard of the People's Republic of China
JB/T9167.2
Management guide for tooling designSelection rule of tooling designPublished on 1998-11-20
Published by the State Bureau of Machinery Industry
Implemented on 1998-12-01
JB/T9167.21998
This standard is a revision of JB/Z283.1~283.5-87 "Management guide for tooling design". Only editorial changes were made during the revision, and the main technical content remained unchanged.
This standard replaces JB/Z283.1~283.5-87 from the date of implementation. All appendices to this standard are informative appendices. This standard is proposed and managed by the Mechanical Science Research Institute. The main responsible drafting unit of this standard is the Mechanical Science Research Institute. The main drafters of this standard are Ma Xianzhi, Li Qin, Shi Junwei and Hu Huiqing. I
1 Scope
Mechanical Industry Standard of the People's Republic of China
Management guide for tooling design
Selection rule of tooling design
Management guide for tooling design Selection rule of tooling design This standard applies to the selection of design of mechanical manufacturing process equipment (tooling). Cited standards
JB/T9167.2-1998
Replaces JB/Z283.2—87
The provisions contained in the following standards constitute the provisions of this standard through reference in this standard. When this standard is published, the versions shown are valid. All standards will be revised, and parties using this standard should explore the possibility of using the latest version of the following standards. JB/T9167.3—1998 Guidelines for the management of process equipment design Rules for the preparation of process equipment design task books 3 Rules for the selection of tooling design
3.1 General rules for the selection of tooling design
a) Production program, production type and production organizational structure; b) Product commonality and product life cycle; c) Characteristics of process schemes;
d) Possibility of specialized division of labor;
e) Application degree of standard tooling;
f) Balance of existing equipment load;
g) Application of group technology;
h) Safety technical requirements.
3.2 Economic principles for the selection of tooling design
Under the condition of ensuring product quality, the cost of tooling required to complete the process is used as the basis for selection analysis. a) Select different tooling schemes for comparison; b) Product quantity and production cycle;
c) The degree of improving product quality and efficiency; d) The manufacturing cost of tooling and its use and maintenance costs. 3.3 Determine the tooling complexity coefficient in order to conduct technical and economic evaluation; improve the management of tooling design, manufacturing and use process. 3.4 Analyze the benefits after tooling selection, mainly by comparing the calculated consumption cost with the rated consumption cost, and include it in the technical indicators for enterprise assessment.
Approved by the State Machinery Industry Bureau on November 20, 1998 and implemented on December 1, 1998
4 Tooling design selection procedure
4.1 Research and analysis
a) Product structure characteristics and accuracy requirements;
JB/T9167.2
b) Product production plan, production organization form and process conditions; c) Process classification;
d) Basic requirements for tooling;
e) Feasibility of adopting typical tooling structure; 1998
f) Select basic calculation data that meets the requirements for designing and manufacturing tooling; g) The possibility of incorporating rational suggestions on tooling into the process. 4.2 Determine the best tooling system to use
a) Standard tooling:
b) General tooling;
c) Combined tooling;
d) Adjustable tooling;
e) Grouped tooling;
f) Special tooling.
According to the classification of process steps, consider the reasonable load of the tooling and determine its total workload. 4.3
4.4 Determine the structural principle of the tooling based on the following factorsa) Type of rough parts;
b) Material characteristics;
c) Structural characteristics and accuracy;
d) Positioning reference;
e) Equipment model;
f) Production batch;
g) Production conditions.
4.5 Prepare tooling design task book (according to JB/T9167.3) Technical documents required for tooling design selection
a) This standard;
b) Tooling standard:
c) Tooling manual, sample and instruction manual;d) Typical tooling structure;
e) Special tooling list and atlas.
6 Technical and economic indicators for tooling design selection
6.1 Special tooling standardization coefficient;
Tooling universal coefficient;
Tooling utilization rate;
6.4 Tooling load rate:;
6.5 Tooling cost;
JB/T9167.2
6.6 Tooling complexity coefficient [see Appendix D (suggested appendix)];6.7 Tooling coefficient;
6.8 Tooling verification conclusion.
Economic evaluation when selecting tooling design
For the economic evaluation when selecting tooling design, see Appendix A (suggested appendix) 8 Evaluation of the economic effect of tooling design
8.1 Evaluation principleswww.bzxz.net
8.1.1 On the basis of ensuring product quality, improving production efficiency, reducing costs, accelerating production cycles and increasing economic efficiency, conduct a comprehensive evaluation of all aspects of the selection, design, manufacturing and use of the tooling system. 8.1.2 The evaluation of the economic effect of tooling design must be combined with the actual economic management and accounting system. 8.1.3 The evaluation method should be simple and applicable.
8.2 Evaluation function
8.2.1 Optimize the tooling design selection plan;
8.2.2 Improve the level of tooling design;
8.2.3 Ensure the best economic effect;
8.2.4 Shorten the tooling preparation cycle.
8.3 Evaluation basis
8.3.1 Tool design quota;
Tool manufacturing quota;
Tool maintenance quota:
8.3.4 Raw material cost standard;
8.3.5 Tool management fee standard;
Financial management regulations for tool cost amortization. 8.4 Evaluation indicators
8.4.1 Total annual planned tool cost investment; Total expected economic effects
8.4.3 Savings during the tool selection, design, and manufacturing accounting period. 8.5 Evaluation Content
8.5.1 Savings in tool design costs;
8.5.2 Savings in material costs;
8.5.3 Savings in improving product quality;
8.5.4 Savings in improving production efficiency
Savings in standardization;
Savings in manufacturing costs;
Savings in management costs;
Evaluation of the best tooling solution
Payback period for tooling investment =||tt| |JB/T9167.2
→min
JB/T9167.2
【Prompt】
Economic evaluation method for selecting tooling design Appendix A
A1 Load factor K of single process equipment:
t·Nae
Where: Time to complete the process:
Number of repetitions of the process performed by a single tool per month; T Total effective working time of the tool per month. During the analysis period, the process cost of the special tooling is equal to the cost of the special tooling. A2
A3 During the analysis period, the cost of the process of the adjustable fixture Ck: C=C +C.N+
Where: Ch
Manufacturing cost of replacement parts;
Adjustment fee;
NThe number of units put into production:
Depreciation of fixed parts;
NThe number of tooling processes.
4In the period of analysis, the cost of the combined tooling process Cz: A4
C-Ca·N+Cw
Where: Ca
Assembly cost;
NThe number of units put into production;
Maintenance fee.
5In the period of analysis, the cost of the combined tooling process C. ：A5
Where: C
Cost of replaceable parts;
Assembly cost;
Depreciation of fixed parts;
N. The number of grouped parts.
5In the analysis period, the cost of the general tooling process C,: A6
Where: Cg
Depreciation;
-The number of processes using tooling.
JB/T9167.2
B1Several indicators in tooling economic analysis
JB/T9167.21998
【Prompt Appendix）
Evaluation method of tooling economic effect
Appendix B
B1.1The tooling cost in the trial production stage accounts for 10%~15% of the trial production cost, and the tooling cost in the formal production stage accounts for less than 5% of the product cost.
B1.2The annual consumption cost ratio of purchased tooling, self-made general tooling, and special tooling should generally be 2:1:3. B1.3 Under reasonable inventory reserves, the investment amount of tooling is the consumption of the year. B1.4 Special depreciation method. The calculation cost is generally budgeted on an annual basis. In actual accounting, it can be amortized according to the following methods: a) Special tooling is amortized into the cost of the product once; b) Purchased tooling adopts \5:5\ amortization, that is, 50% of the cost is amortized when it is shipped out of the warehouse, and another 50% is amortized when it is scrapped; c) Self-made general tooling, part of which is amortized by \5:5\ for purchased tooling, and the other part is amortized once according to special tooling, and modular fixtures are also amortized once.
B2 Ways to shorten the tooling investment recovery period
B2.1 Minimize special tooling and change its ratio with standard tooling. B2.2 Increase the service life of tooling.
B2.3 Improve the quality and processing efficiency of tooling and reduce product costs. B3 Calculation of annual tooling costs
B3.1 Annual tooling costs F:
1+K,+Kw).C
Where: K, design cost coefficient (ratio of tooling design and adjustment costs to manufacturing costs), generally taken as 0.5; K maintenance cost coefficient (ratio of tooling maintenance management costs to manufacturing costs), generally taken as 0.2~0.3; T, service life. In years, generally 3~5 years, when the tooling is scrapped during the production change; C—tooling manufacturing costs.
B3.2 Annual consumption cost F of modular fixture:
F=C,+C,/N,+CF
Special parts cost of modular fixture:
Where: C
C—depreciation of fixture parts and auxiliary equipment plus tooling design fee: C=A,C4+A2Cs+Z(1+H)
A——depreciation rate of fixture parts;
C4—estimated cost of fixture parts;
A2depreciation rate of auxiliary equipment;
-estimated cost of auxiliary equipment;
Annual salary of tooling designer;
Management cost coefficient of tooling design
JB/T9167.2
Assembly, adjustment and management fees for each set of tooling: 1998
C,=Zh·t( 1+H. )
Assembly worker’s salary for 1h;
Assembly adjustment time, h;
Management cost coefficient;
Annual assembly quantity:
PAnnual assembly batch;
Average number of assemblies per batch.
B3.3Annual consumption cost of combined tooling F,:
Where: K.
+K.+K.).Ca
Design cost coefficient (ratio of design fee to manufacturing fee); depreciation coefficient;
Maintenance and management cost coefficient;
Service life, years;
Manufacturing and assembly costs.
Annual consumption cost F of adjustable tooling:
Where: K.
Depreciation coefficient;
Maintenance and management cost coefficient
Number of adjustable devices in a tooling set;
Manufacturing cost of fixed part of a tooling set; Design cost coefficient;
Service life, years;
Manufacturing cost of adjustable part;
Maintenance cost coefficient of adjustable part.
B3.5Annual consumption cost E of general tooling:
Where: T
Service life, years;
Maintenance and management cost coefficient (generally 0.1); General tooling cost.
JB/T9167.2
1Special tooling design quota table
Special tooling design quota table is shown in Table C1.
Location shafts, sleeves, washers, pins, etc.
Eccentric sleeves, templates, spindles, tool bars
Tools with more than 10 special parts for turning, milling, planing, grinding, boring, and balancing tools
General drilling jigs
Accuracy of wallboard drilling jigs
Less than 80 holes
Wallboard drilling jigs with more than 81 holes
Tap, reamer, drill, milling cutter, etc.
Forming milling cutter, gear cutter
Smooth gauges
Standard gauges
Thread gauges
Arc, tooth profile templates
Marked hole templates
Marked hole templates
Simple stamping dies|| tt||More than 20 holes
Less than 19 holes
Compound die, progressive die, fine stamping die
Assembly tools, welding tools
Detection tools
Station tools
JB/T9167.2
【Prompt attachment】
Special tool design quota example
Time quota
20~-32
Including general drawing
Excluding non-drilling holes
Using dummy drawing 1), which is 1/2 of the original working time
Excluding positioning holes
Including general drawing
1) Dummy drawing refers to a drawing with only graphics but no design dimensions. When designing, you only need to fill in the dimensions to save design time. 10+CF
Special parts cost of combined fixture:
Where: C
C—depreciation of fixture parts and auxiliary equipment plus tooling design fee: C=A,C4+A2Cs+Z(1+H)
A——depreciation rate of fixture parts;
C4—estimated cost of fixture parts;
A2depreciation rate of auxiliary equipment;
-estimated cost of auxiliary equipment;
Annual salary of tooling designer;
Management cost coefficient of tooling design
JB/T9167.2
Assembly, adjustment and management fees for each set of tooling: 1998
C,=Zh·t( 1+H. )
Assembly worker’s salary for 1h;
Assembly adjustment time, h;
Management cost coefficient;
Annual assembly quantity:
PAnnual assembly batch;
Average number of assemblies per batch.
B3.3Annual consumption cost of combined tooling F,:
Where: K.
+K.+K.).Ca
Design cost coefficient (ratio of design fee to manufacturing fee); depreciation coefficient;
Maintenance and management cost coefficient;
Service life, years;
Manufacturing and assembly costs.
Annual consumption cost F of adjustable tooling:
Where: K.
Depreciation coefficient;
Maintenance and management cost coefficient
Number of adjustable devices in a tooling set;
Manufacturing cost of fixed part of a tooling set; Design cost coefficient;
Service life, years;
Manufacturing cost of adjustable part;
Maintenance cost coefficient of adjustable part.
B3.5Annual consumption cost E of general tooling:
Where: T
Service life, years;
Maintenance and management cost coefficient (generally 0.1); General tooling cost.
JB/T9167.2
1Special tooling design quota table
Special tooling design quota table is shown in Table C1.
Location shafts, sleeves, washers, pins, etc.
Eccentric sleeves, templates, spindles, tool bars
Tools with more than 10 special parts for turning, milling, planing, grinding, boring, and balancing tools
General drilling jigs
Accuracy of wallboard drilling jigs
Less than 80 holes
Wallboard drilling jigs with more than 81 holes
Tap, reamer, drill, milling cutter, etc.
Forming milling cutter, gear cutter
Smooth gauges
Standard gauges
Thread gauges
Arc, tooth profile templates
Marked hole templates
Marked hole templates
Simple stamping dies|| tt||More than 20 holes
Less than 19 holes
Compound die, progressive die, fine stamping die
Assembly tools, welding tools
Detection tools
Station tools
JB/T9167.2
【Prompt attachment】
Special tool design quota example
Time quota
20~-32
Including general drawing
Excluding non-drilling holes
Using dummy drawing 1), which is 1/2 of the original working time
Excluding positioning holes
Including general drawing
1) Dummy drawing refers to a drawing with only graphics but no design dimensions. When designing, you only need to fill in the dimensions to save design time. 10+CF
Special parts cost of combined fixture:
Where: C
C—depreciation of fixture parts and auxiliary equipment plus tooling design fee: C=A,C4+A2Cs+Z(1+H)
A——depreciation rate of fixture parts;
C4—estimated cost of fixture parts;
A2depreciation rate of auxiliary equipment;
-estimated cost of auxiliary equipment;
Annual salary of tooling designer;
Management cost coefficient of tooling design
JB/T9167.2
Assembly, adjustment and management fees for each set of tooling: 1998
C,=Zh·t( 1+H. )
Assembly worker’s salary for 1h;
Assembly adjustment time, h;
Management cost coefficient;
Annual assembly quantity:
PAnnual assembly batch;
Average number of assemblies per batch.
B3.3Annual consumption cost of combined tooling F,:
Where: K.
+K.+K.).Ca
Design cost coefficient (ratio of design fee to manufacturing fee); depreciation coefficient;
Maintenance and management cost coefficient;
Service life, years;
Manufacturing and assembly costs.
Annual consumption cost F of adjustable tooling:
Where: K.
Depreciation coefficient;
Maintenance and management cost coefficient
Number of adjustable devices in a tooling set;
Manufacturing cost of fixed part of a tooling set; Design cost coefficient;
Service life, years;
Manufacturing cost of adjustable part;
Maintenance cost coefficient of adjustable part.
B3.5Annual consumption cost E of general tooling:
Where: T
Service life, years;
Maintenance and management cost coefficient (generally 0.1); General tooling cost.
JB/T9167.2
1Special tooling design quota table
Special tooling design quota table is shown in Table C1.
Location shafts, sleeves, washers, pins, etc.
Eccentric sleeves, templates, spindles, tool bars
Tools with more than 10 special parts for turning, milling, planing, grinding, boring, and balancing tools
General drilling jigs
Accuracy of wallboard drilling jigs
Less than 80 holes
Wallboard drilling jigs with more than 81 holes
Tap, reamer, drill, milling cutter, etc.
Forming milling cutter, gear cutter
Smooth gauges
Standard gauges
Thread gauges
Arc, tooth profile templates
Marked hole templates
Marked hole templates
Simple stamping dies|| tt||More than 20 holes
Less than 19 holes
Compound die, progressive die, fine stamping die
Assembly tools, welding tools
Detection tools
Station tools
JB/T9167.2
【Prompt attachment】
Special tool design quota example
Time quota
20~-32
Including general drawing
Excluding non-drilling holes
Using dummy drawing 1), which is 1/2 of the original working time
Excluding positioning holes
Including general drawing
1) Dummy drawing refers to a drawing with only graphics but no design dimensions. When designing, you only need to fill in the dimensions to save design time. 10
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