3.

4 Mass and Energy Balance

3.4.1 Mass Balance

The mass balance calculation is applied to help in estimating whether the product output would
later meet desired product mass. The result from mass balance will be used later in productivity
metric which indicates how the company effectively utilizes its resources. Furthermore, the
mass balance calculation in Otohassl product is specifically important to predict whether the
product would be light enough to be clamped onto the sun visor during its installation later. For
making the mass balance, a basis has to be made first. Table xx shows the basis for the
calculation.
Table xx. Basis for Mass Balance Calculation
Indicator Value Unit
of measurement
Basis 1 day
Production 350 unit/day
capacity
Operating time 315 days/year
11 hrs/day

The mass balance will be calculated for each component in each processes. For each calculation,
mass losses is also being taken into account. For the mass balance calculation of Otohassl
product, mass loss occurs during cutting process in which assumed mass loss take 5% for shade
cutting and 1% for the other cutting processes. The mass balance is tabulated on Table xx.
 Table xx. Mass Balance Calculation
Process Sub Process Input   Output    
Components Amoun Uni Components Amoun Loss Unit
t t t
Cutting Cutting for Composite Kraft paper+metallized mylar 255 kg Shade fabric 53.2 0 kg
Shade Shade fabric to store 201.8
Cutting for Drive Tube Aluminium 107.9 kg Aluminium Drive 100.4 7.4 kg
Tube
Cutting for Casing PVC Pipe 622.6 kg Pre-Cut PVC Casing 574.2 48 kg
Cutting Casing for PVC Pipe 574.2 kg PVC Casing 571.4 2.9 kg
Clippers Placement
Cutting for Bottom Rail PVC Pipe 193.8 kg PVC Bottom Rail 179.2 14.5 kg
  TOTAL 1753.4   TOTAL 1753.4    
Assembly - Adhesive (3M double tape) 6.9 kg Adhesive (3M double 6.9 0 kg
tape)
Shade 53.7 kg Shade 53.7 0 kg
Clipper 19.7 kg Clipper 19.7 0 kg
Bottom Railing 179.2 kg Bottom Railing 179.2 0 kg
PVC Casing 574.2 kg PVC Casing 574.2 0 kg
Motor with Built in Antenna 105.3 kg Motor with Built in 105.3 0 kg
Antenna
Drive Tube 100.4 kg Drive Tube 100.4 0 kg
Casing End 2.1 kg Casing End 2.1 0 kg
TOTAL 1041.6   Assembled Shade 1041.6 0 kg
Packaging and - Cardboard Box (2x0,3x0,2m) 1 pcs Packaged Product 1 0 pcs
Labelling Styrofoam 1 pcs 1 0 pcs
    TOTAL BULK 1041.6 kg TOTAL BULK 1041.6   kg
TOTAL BULK 73.2   kg
LOSS
TOTAL PER UNIT 3.0   kg
3.4.2 Energy Calculation
The energy calculation is determined to know how much energy is required in every process that
would later summed up into the energy of the whole process. This is an important step especially
to analyse the economics of a plant. The energy balance is made for the estimation of electrical
energy consumption of the whole plant for each hour, excluding other electricity needs such as
office, toilers, etc. The energy consumption is defined as the power required by each process
equipments to help in achieving desired product target. In actual case, the energy being utilized
must be less than the power initial consumed power. Therefore, in here, we assume all of
equipments have the efficiency of 90% or loss of 10%. The energy calculation for Otohassl
product is tabulated on Table xx.
Table xx. Energy Calculation
Power per Working
Equipmen Equipment time per Energy Consumed
Main Process Quantity
t per hour equipmen (kWh)
(kW) t (hr)
Roller
Cutting for Shade
Blind
(3000 m^2 to 1,8 1.6 3 4 17.28
Cutting
m^2)
Table
PVC
Cutting for Drive
Cutting 2.2 0.666667 1.32
Tube
Machine
1
PVC
Cutting for
Cutting 2.2 0.666667 1.32
Bottom Rail
Machine
PVC
Cutting for
Cutting 2.2 1 0.666667 1.32
Casing
Machine
*Additional:
Belt
Material Transfer 1.5 2 0.666667 1.8
Conveyor
Total Energy 23.04
3.5 Plant Scheduling
Plant scheduling is one of most important part to be conducted as it will support to ensure that
processes in a plant run smoothly and could make desired target per day and later per year. In
plant schedule, time for each processes including peparation time needed would be taken into
account. In Otohassl plant, there would be only 1 batch to produce 350 shades/ year. Table xx
will give the whole plant schedule for Otohassl plant in detailed manner.

3.5.1 Cutting Process

As it’s been mentioned before, the cutting processes will be divided into separate sections based
on the desired end use product, which are the shade, the drive tube, the bottom rail and the casing
and all will be done simultaneously. Specifically for the shade cutting process, with three
workers employed on each three cutting tables, the process would take time four hours to finish
cutting for 350 shades. The calculation comes from: with our cutting table speed of 0.9 m/s, the
cut time for shade would only take time around 2.1 minutes with approximate lag time of 1.8
minute for worker before going to work on the next shade. Then, for all of the cutting processes
for drive tube, bottom rail, the casing as well as the casing with the holes for clippers would take
time for 40 minutes each with our PVC automatic cutter machine. Before each cutting processes,
10 minutes are being set for preparation. After all of the cutting processes being done, all of the
materials would be transferred to the assembly section.

3.5.2 Assembly Process

The assembly process would start once all of the cut parts for the shade has been transferred to
the assembly section which takes a total of 20 minutes. First, the assembly will be done to install
the motor kit inside the drive tube and attaching the shade to the drive tube which takes around
90 minutes for a total of 350 drive tubes. This process time is quite lengthy than the other
assembly process since the process requires a lot of spare parts assembling. All of the other
assembly processes which include the attachment of bottom rail and drive tube into the casing
will take 60 minutes each. It is assumed that each assembly process take 3 minutes time with 10
minutes lag time for preparation. For all of these assembly processes, it is assumed that there
would be 30 workers that will work from start to end for all of the assembly process. All of the
assembled products then being transferred to the Quality Control Section.
3.5.2 Quality Control
The quality control will start once first final product from the assembly process has already been
transferred. This process would take 40 minutes for each part which include checking of shade
specifications and remote control testing with 10 minutes lag time for preparation. Once a
product has been checked, it is immediately transferred to the packaging section using a belt
conveyor.

3.5.3 Packaging
All of the finished products along with the pre-made customized packaging box are brought into
the packaging section. For 350 shades, a total of 60 minutes is required for all of the process
including putting the product into the fit-sized sytrofoam, inserting it into the package box and
sealing it shut. There’s no time required for labelling of the box as it’s been requested to the
supplier to make desired box spec with company’s sticker label already being attached. Finally,
30 minutes is being used to move packaged product to the warehouse.
Table xx. Plant Schedule
Table xx. Plant Schedule (cont’d)
Table xx. Plant Schedule (cont’d)
MASUKKIN BFDD