ASSIGNMENT

NICMAR / SODE MATERIALS AND EQUIPMENT MANAGEMENT

Name of work: Constructing a new international airport 30 k.m. away from a city. The project is to be implemented in phases.

Phase I: One strip of landing of 100 m width is to be constructed in 100days. The scope of work is as follows:

a) Cutting and Dozing of 100,000 cum of earth. Average height 0.75m. b) Transportation of 20,000 cum of surplus earth from site to dumping place 3 k.m. away from site( including spreading) Filling of 80,000 kms in landing strip. c) Bringing in 3000cum of sand from 20k.m.(including spreading and leveling at site)

d) Procurement of 1, 50,000 litres of Bitumen. Duration of work 30days from 60th day of starting of work. Bitumen to be obtained from refinery at Bongaigaon in Assam. Lead time up to site is 45 days. Storage facility available at site 50,000 litres tank.

There are so many types of earth moving machines are available in the market. Of which we use the equipments that are useful for our scope of work only.

Bulldozers the term bulldozer may be used in a broad sense to include both a bulldozer and angle dozer. These machines may be further divided on the basis of their mountings, in to crawler tractor or wheel tractor mounted. Based on the method of raising and lowering the blade a bulldozer may be classified as cable controlled or as hydraulically controlled. Bull dozers are mounted with blades perpendicular to the direction of shovel while angle dozers are mounted with blades at an angle with the direction of travel. The former push the earth forward while the latter push it forward and to one side. Some blades may be adjusted to permit their use of bulldozers or angle dozers. They may be used from the start to the finish of such operations as: cleaning land timber and stumps operating up pilot roads through mountains and rough terrains moving earth for haul distances up to 100 m helping load tractor pull scrapers spreading earth fill cleaning construction sites to debris maintenance of haul roads cleaning the floors of borrow and quarry pits

Scrapers:
Tractors pulled scrapers have established an important position in the earth moving field. As they are self operating to the extent that they can load, haul and discharge material they are not dependent on other equipment. If one of them experiences a temporary breakdown it is not necessary to stop the job as would be the case of machine which is used exclusively for loading earth into hauling units for if the loader breaks down the entire job must stop until repairs can be made. The self loading scrapers are available with capacities up to 38 cum or more. These machines are the result of a compromise between the best loading and best hauling machines and as must be expected at any composite machines they are not superior to other equipment in both loading and hauling. Power shovels drag lines and belt loaders usually will surpass them in loading only while trucks may surpass them in hauling only especially when long, well maintained haul roads are used. The development of High speed haul tractors has increased the economic haul distance speed. Wheel type tractors have increased the economic haul distance for the type of equipment up to 0.5 to 2.0 km.

Following equipments are used excavate earth and related materials and to lift them frequently in construction operation. The equipment includes the following machines:

Power shovels
Back hoes Draglines Clamshells and cranes Trenching machines Wheel mounted belt loaders Power shovels are used for excavation and loading into hauling units

Back hoes are used in excavation on natural surface. These are more rigid than draglines and advantageously used on close range work Clamshells are used mainly for lifting vertically and handling loose materials such as sand, crushed stones in dams, pier foundation and sheet piling etc. Trenching machines are either wheel or crawler type Wheel excavators can cut weathered or broken rock.

Estimated productivity of 90ck, 0.9cum back hoe bucket

1. Bucket capacity (cum) - 0.9 2. Soil condition Average 3. Bucket fill factor 1.05 4. Actual Bucket Capacity 0.945Cum 5. Swing angle 180degrees 6. Standard cycle time - 15sec 7. Digging condition Deeper 8. Digging depth / Specified maximum digging depth Above 70% 9. Dumping condition Rather difficult 10. Conversion factor 1.5 11. Actual cycle time 22.5 sec 12. Operating conditions Average 13. Job efficiency 0.75 14. Hourly production (cum) 113 15. Number of hours of operation per day 12 16. Total production achieved per day 1362cum 17. Number of days of operation per month -25

18. Total monthly production (Cum) 34020 19. Annual production (Cum) 48240

Estimated productivity of 180ck, 1.6cum back hoe bucket

1. Bucket capacity (cum) - 1.6 2. Soil condition Average 3. Bucket fill factor 1.05 4. Actual Bucket Capacity 1.68Cum 5. Swing angle 180degrees 6. Standard cycle time - 19sec 7. Digging condition Deeper 8. Digging depth / Specified maximum digging depth Above 70% 9. Dumping condition Rather difficult 10. Conversion factor 1.5 11. Actual cycle time 28.5 sec 12. Operating conditions Average 13. Job efficiency 0.75 14. Hourly production (cum) 159 15. Number of hours of operation per day 12 16. Total production achieved per day 1910cum 17. Number of days of operation per month -25 18. Total monthly production (Cum) 47747 19. Annual production (Cum) 572968

Estimated productivity of 180ck, 1.85cum back hoe bucket

1. Bucket capacity (cum) - 1.85 2. Soil condition Average 3. Bucket fill factor 1.05 4. Actual Bucket Capacity 1.9425Cum 5. Swing angle 180degrees 6. Standard cycle time - 19sec 7. Digging condition Deeper 8. Digging depth / Specified maximum digging depth Above 70% 9. Dumping condition Rather difficult 10. Conversion factor 1.5 11. Actual cycle time 28.5 sec 12. Operating conditions Average 13. Job efficiency 0.75 14. Hourly production (cum) 184 15. Number of hours of operation per day 12 16. Total production achieved per day 2208cum 17. Number of days of operation per month -25 18. Total monthly production (Cum) 55208 19. Annual production (Cum) 662495

Estimated productivity of 300ck, 2.7cum back hoe bucket

1. Bucket capacity (cum) - 2.7 2. Soil condition Average 3. Bucket fill factor 1.05

4. Actual Bucket Capacity 2.835Cum 5. Swing angle 180degrees 6. Standard cycle time - 24sec 7. Digging condition Deeper 8. Digging depth / Specified maximum digging depth Above 70% 9. Dumping condition Rather difficult 10. Conversion factor 1.5 11. Actual cycle time 36 sec 12. Operating conditions Average 13. Job efficiency 0.75 14. Hourly production (cum) 213 15. Number of hours of operation per day 12 16. Total production achieved per day 2552cum 17. Number of days of operation per month -25 18. Total monthly production (Cum) 63788 19. Annual production (Cum) 765450

Take two 180ck, 1.6cum backhoe buckets and one 90ck, 0.9cum backhoe buckets. For 100,000cum of earthwork excavation use two 180ck, 1.6cum backhoe buckets. Number of days required to get the output 30 Number of hours required 360 Calculation of owning and operating cost of two 180ck excavators Basic cost 45, 00,000INR Life of equipment - 12000Hrs Life of equipment 12years Maintenance constant 50% Depreciation cost 4500000 x 0.9/12000 = 337.50INR

Fuel charges 18litres@38/- per litre = 684INR Labour charges 25% x 684 = 171INR Repair Charges Depreciation cost x Maintenance constant 337.5 x 50% = 168.25 Operator cost = 20INR Helper cost = 15INR

Foreman cost = 7.5INR Mechanic = 6INR Watchman = 3INR Total crew cost =51.5INR Total usage cost = 51.5+168.25+171+684+337.50 =1412.3INR

Operating cost per hr = 4500000/12000 = 375INR = 1412.3+375 =1787.3 = 1787INR (say) Total cost of operation for excavation = 360 x 1787 = 643428INR

Owning cost

= 4500000 +1412.3x360 = 4500000+508410 = 5008410INR

For two equipments it is equal to 10016820INR

Calculation of owning and operating cost of 90ck excavator

Basic cost 40, 00,000INR

Life of equipment - 10000Hrs Life of equipment 10years Maintenance constant 50% Depreciation cost 4000000 x 0.9/10000 = 360INR Fuel charges 18litres@38/- per litre = 684INR Labour charges 25% x 684 = 171INR Repair Charges Depreciation cost x Maintenance constant 360 x 50% = 180 Operator cost = 20INR Helper cost = 15INR

Foreman cost = 7.5INR Mechanic = 6INR Watchman = 3INR Total crew cost =51.5INR Total usage cost = 51.5+180+171+684+360 =1446.5INR

Operating cost per hr

= 4000000/10000 = 400INR = 1446.5+400 =1846.5 = 1847INR (say)

Three types of records are maintained at site and they are i) ii) iii) Progress records Work output records of individual machines and team of machines Equipment records

Progress records:

Records of progress may be kept in a variety of forms, but the method adopted should be as simple as possible, and to be of real value, must allow for immediate comparison with planned programme and show at a glance, the actual break up made, often on percentage basis. Suitable methods are i) ii) iii) iv) Work programme as progress records Bar graph progress chart Line graphs Pictorial records

Work output records: Records of actual output of individual machines and if desired, of team of machines, will not only be useful on the projects itself to help in analyzing any causes of delay in progress of work but will prove of great value for further planning and estimating. To enable these records to be compiled, plant supervisors reports will be necessary.

Plant supervisors reports: Each plant supervisor should be required to complete shift report at the end of each shift, showing relevant information about the machines which have been under his control during the shift. The report should not be confused with plant operators daily log which is mainly concerned with servicing and fuel consumption. Typical items to be entered on plant supervisors report for each machine are: i) ii) Task on which employed Total work carried out e.g. number of trips performed, total mileage or number of vehicles loaded , depending on type of task iii) iv) Number of minutes worked per hour Servicing periods

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v)

Remarks on delay and waiting times with reasons.

Basic record of equipment maintained i) ii) iii) Log book: The log book is to utilized for two purposes a) For a technical control to evaluate how the machine is performing, and b) For getting the Plant hours performance classified by works To determine performance, the total plant hours put in by a machine must be known and causes of trouble should be classified. The log book records the consumption of fuels and lubricants, since the performance of the machine can be judged readily from these figures. It records the work on which the machine was employed indicating the officer on whose requisition the machines was utilized. Log book Daily / Monthly working data History book

Daily / monthly working data: Log book also gives record of utilization of machinery. Other data such as sickness, idleness etc. is not readily available in logbook. The data is equally important to indicated performance of machine. For this purpose the data is to be maintained in the form of daily working machinery. Monthly abstract should be prepared.

Maintenance registers: The maintenance register for the following should be maintained: i) ii) iii) iv) Daily maintenance Weekly maintenance 100 to 175 hours maintenance 250 hours maintenance

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v) vi) vii)

500 hours maintenance 1000 hours maintenance 2000 hours maintenance

Supervision: The purpose of supervision is not only to see that work is carried out correctly to specifications laid down and the machines are properly used and output maintained at consistently high level but also to foresee difficulties and likely bottlenecks which may reduce output and to take steps to obstacle them before they occur. Supervisors responsibility to: i) Ensure that all the concerned under his command are clear on their task. ii) See that machines are used to best advantage and operators take their task correctly. iii) iv) Ensure that the work is properly done to the specification laid down. Take early steps to deal with difficulties in order to assist the operators to maintain their output where difficulties develop which he cannot deal with satisfactorily from his own resources, report them without delay to next supervisor, with the recommendation as to how they can best be overcome. v) Always be thinking ahead to foresee likely difficulties and bottlenecks to the progress of work before they occur so that steps can be taken in time to prevent them of failing this to reduce this adverse effect on output.

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Transportation of 20,000 cum of surplus earth from site to dumping place 3 k.m. away from site (including spreading)

Calculation of Disposal of earth for tippers i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv) Lead for 3+3 = 6k.m. Average speed = 25kmph Loading time = 5.00mins Travel time = (6/25)x60 = 14.40mins Unloading time = 4.00mins Idle time = 2.00mins Time per trip = 5+14.40+4+2 = 25.40mins Add for break down 10% = 2.54mins Total time per trip = 25.4+2.54 = 27.94 Working time per day 16hours a day = 16 x 60 = 960mins Number of trips per day per vehicle = 960/27.94 = 34.35 = 35(say) Quantity per vehicle per day = 35 x4 = 140cum Distance travelling per day = 6x35 = 210k.m. Quantity per vehicle per month(assuming 25days per month) = 140x25 =3500cum xv) Distance travelled per month = 210x25 = 5250k.m.

For the disposal of 20,000cum of earth we need 20,000/3500 = 5.71= (6 say)

6no. of tippers are enough to dispose the earth to the dumping yard.

Calculation of Bringing of Sand for tippers i) Lead for 20+20 = 40k.m.

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ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv)

Average speed = 25kmph Loading time = 5.00mins Travel time = (40/25)x60x2 = 192mins Unloading time = 4.00mins Idle time = 2.00mins Time per trip = 5+192+4+2 = 213mins Add for break down 10% = 21.3mins Total time per trip = 213+21.3 = 234.3 Working time per day 16hours a day = 16 x 60 = 960mins Number of trips per day per vehicle = 960/234.3 = 4.09 = 4(say) Quantity per vehicle per day = 4 x4 = 16cum Distance travelling per day = 40x4 = 160k.m. Quantity per vehicle per month(assuming 25days per month) = 16x25 =400cum

xv)

Distance travelled per month = 160x25 = 4000k.m.

For bringing of 3000cum of sand from 20k.m. we need 3000/400 =7.25(8say)

8no. of vehicles are required to get the 3000cum of sand with 20k.m. lead.

Procurement of 150,000 litres of bitumen from refinery which is located Bonagaigaon in Assam. Lead time up to site is 45days. Calculation of Economic order of quantity for Bitumen: Take Wilson Harris square root formula The quantity of order corresponding to the frequency is known as Economic order of quantity. The economic order quantity or lot size can be war analytically. The

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relation between various parameters was developed by RH Wilson and F. Harris and is known as Wilson Harris Square Root Formula.

The relation is worked out below and is based on assumptions. a. The demand over the period of the cycle (normally a year) constant and is known in advance. b. Consumption of material occurs at the uniform rate. c. The price of the material is independent of the order. d. There is no lead time in the replenishment. Let A: be the annual demand in terms of units Q: is the lot size ordered at a time in units P: Price of the material in terms of H: Annual inventory carrying / holding cost expressed in Rs. per Rupee of the inventory S: Ordering cost (i.e. cost of placing one order) in Rs. Since the stock in depleted at uniform rate over the cycle period, inventory carrying cost or holding cost can be the cost over the average stock. As Q increases the number of orders hence ordering costs reduce, but inventory carrying costs increase and vice-a-versa. The economic lot size will have to balance the two costs of opposing nature. If Q is the lot size the average inventory will be Q/2 Inventory carrying cost will be Q/2 x p x h Number of orders over a year = A/ Q Total Ordering costs = A/Q x S Thus the total cost T = Q x p x h/2 + Ax S/Q

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We have to find the most economic order quantity for which T is minimum. dT /dQ should be equated to zero. dT/ dQ = p x h /2 = A x S/Q^2 = 0 A x s / Q^2 = p x h/2 Q^2 / A x S = 2/ p x h Therefore Q = Square root of (2x A x S/p x h) Assume 300 working days in a year Annual consumption 300 x 3333litre a day = 1000000 litres Inventory carrying cost Rs. 4 per litre i.e. 20Rs. Inventory As we need 50000 litres per order because we have only the capacity of 50000litres of storage capacity and the lead time is 45 days from the refinery to site office. We place 3 orders of 15 days duration from the start of the work. By which we can get the bitumen by 45days, 60th day and 75th day the total quantity of bitumen. On 60th day Bitumen work is to be started. Bitumen is planned per day is 3500litres. Within 15 days 50000litres of bitumen can be consumed. The storage capacity will be available for another 50000 litres. As the excavation progresses and the site is available for runway works. Consumption bitumen increases and by that bitumen procurement from the refinery to site storage cann be made. The planned quantity of utilization of bitumen can be done within the stipulated duration of 100days. During storage of bitumen the temperature of 100 degree Celsius is maintained. Maintaining the boiling temperature of bitumen is important site storage tank. So the planned schedule is going to be maintained at the site.

Conclusion:

The equipment and materials management can be achieved with perfect planning and execution. Spare parts for the equipment should be made available for emergency repair works 16

Bibliography: 1. Materials and Equipment management - NICMAR

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