Problem 1. Dave runs a die casting operation with a 300 ton cold chamber die casting machine which has a downtime of 10%. The machine requires 3 hours of setup prior to making parts and 2 hours of post-processing time. About 5% of the parts that are produced must be scrapped (usually at the beginning and ends of runs), but all of this material can be remelted. The set-up and postprocess laborers are paid $20/hr. The die creates a single part that is approximately 10"x10x1" with a runner that is about 30% of the part size. The tool steel die was $22,000 and has a die life of 100,000 cycles. During processing, the cycle time is 120 s/part and the alloy being processed is A380 (a die casting aluminum alloy). Die operators are paid $22/hr. Dave's friend Nancy runs a sand casting operation. She makes the same part as Dave using the aluminum alloy 356 but with runners and sprue that is 40% of the part size and a melting price of $0.10/lb. Her defect rate is 13% and she loses 10% of her melt to oxidation and residual in the mold. The pattern that she uses to make the dies is $2000 and lasts for 5000 parts and her team makes 4 molds per hour. Each mold uses 30 lbs of sand at $0.70/lb. She pays her mold makers and cleaners $20/hr and her casting pourers $22/hr. a.) Tabulate and plot the total cost per part for 1, 10, 100, 1000, 10,000, and 100,000 parts made by both techniques using the manufacturing cost estimator' on www.custompart.com. (State assumptions for all information not explicitly provided above). b.) About how many parts will both processing techniques have the same cost? c.) What is the limiting factor (i.e. labor, materials, equipment, etc.) for price reduction in each case? Problem 1. Dave runs a die casting operation with a 300 ton cold chamber die casting machine which has a downtime of 10%. The machine requires 3 hours of setup prior to making parts and 2 hours of post-processing time. About 5% of the parts that are produced must be scrapped (usually at the beginning and ends of runs), but all of this material can be remelted. The set-up and postprocess laborers are paid $20/hr. The die creates a single part that is approximately 10"x10x1" with a runner that is about 30% of the part size. The tool steel die was $22,000 and has a die life of 100,000 cycles. During processing, the cycle time is 120 s/part and the alloy being processed is A380 (a die casting aluminum alloy). Die operators are paid $22/hr. Dave's friend Nancy runs a sand casting operation. She makes the same part as Dave using the aluminum alloy 356 but with runners and sprue that is 40% of the part size and a melting price of $0.10/lb. Her defect rate is 13% and she loses 10% of her melt to oxidation and residual in the mold. The pattern that she uses to make the dies is $2000 and lasts for 5000 parts and her team makes 4 molds per hour. Each mold uses 30 lbs of sand at $0.70/lb. She pays her mold makers and cleaners $20/hr and her casting pourers $22/hr. a.) Tabulate and plot the total cost per part for 1, 10, 100, 1000, 10,000, and 100,000 parts made by both techniques using the manufacturing cost estimator' on www.custompart.com. (State assumptions for all information not explicitly provided above). b.) About how many parts will both processing techniques have the same cost? c.) What is the limiting factor (i.e. labor, materials, equipment, etc.) for price reduction in each case