AI HOC A NNG

TRNG AI HOC BACH KHOA

KHOA C KH











TP BAI GIANG
MN HOC
THIT K DY CHUYN SAN XUT
(Danh cho SV nganh C kh)

Giao vin : Th. s., GVC TRN QUC VIT
















A NNG 2007
3
Chng I:

C S THIT K DY CHUYN SN XUT

1. Khi nim v cng tc thit k trong sn xut c kh

1.1 ngha, v tr thit k nh my c kh
Trong sn xut c kh, c c mt sn phm s dng(mt chi tit my, mt b
phn hoc mt my hon chnh) ta cn tri qua 5 giai on c bn sau:
< 1 > Thit k sn phm: l cn c vo yu cu s dng thc t, ngi thit k phi
hnh dung c hnh dng, kch thc v cc yu cu k thut ca sn phm, biu din sn
phm ln bn v.
< 2 > Thit k cng ngh: l da vo bn v thit k sn phm kt hp vi hiu bit
v kh nng thc t sn xut ra sn phm (kh nng v trang thit b, kh nng con ngi)
nh ra ng li, bin php nhm bin sn phm trn bn v thnh sn phm s dng. Giai
on ny cn gi l giai on thit k qui trnh cng ngh.
< 3 > Thit k trang b cng ngh: l cn c vo qui trnh cng ngh c xc lp,
ta phi thit k c mt h thng trang thit b, my mc ph hp sn xut ra sn phm
yu cu.
< 4 > T chc sn xut: l thit k ra mt h thng s dng cc trang b cng ngh
nhm to ra sn phm mt cch hp l nht ( cht lng tt, nng sut cao v gi thnh h).
< 5 > THIT k nh my c kh: tin hnh ch to sn phm.

Nm giai on trn l mt qu trnh c mt mc tiu thng nht l to ra nhng sn
phm c kh ph hp vi yu cu s dng thc t. Mc ph hp th hin 3 phng din:
cht lng, nng sut v kinh t.
hon thnh qu trnh thng nht , mi giai on c nhim v hon thnh mt
phn ca mc tiu cn t, ng thi to tin hon thnh giai on tip theo. Do c
im , nn kt qu ca mc tiu cui cng l phn nh kt qu ca mi giai on.
Trong 5 giai on th thit k nh my c kh l giai on cui cng. Do vy tnh
chnh xc ng n ca n khng ch l yu cu ca bn thn giai on ny, m n cn l i
hi ca 4 giai on trc . Hn na thit k nh my c kh l giai on gn cht gia
nghin cu v thc tin, gia k thut v kinh t, v vy n mang tnh tng hp rt cao.

1.2. Phn loi thit k nh my c kh .
Trong ngnh c kh, da vo nhim v sn xut, da vo u t xy dng v cn c
vo nhng iu kin thc t khc,thit k nh my c kh c phn lm hai loi :
1. Thit k nh my mi, hon chnh.
2. Thit k m rng pht trin nh my c nhng cha ph hp vi nhim v
yu cu
Theo kinh nghim d l thit k mi, hon chnh, hay thit k m rng pht trin nh
my c kh (hoc mt b phn cu thnh ca nh my c kh) th v nguyn tc thit k, ni
dung thit k v trnh t thit k ni chung l thng nht. S khc nhau y chng qua l
mc , phng php thc hin c th m thi
Chnh v l do , ti liu ny ch ch trng nghin cu thit k mt nh my (b
phn nh my) mi hon chnh. Vi nhng hiu bit ta cng c th nghin cu trong
trng hp thit k m rng.

1.3 T chc thit k nh my c kh:
4
Mt t chc thit k nh my c kh phi bo m hon thnh 3 nhim v c bn sau:
< 1 > Qui nh c cc ch tiu ca tng giai on thit k ( trong c bit ch
n cc ch tiu cht lng).
< 2 > Tng hp c cc giai on thit k.
< 3 > Qui nh c k hoch, thi hn thit k.
Mun hon thnh 3 nhim v phc tp , t chc thit k phi l mt tp th cn b
khoa hc k thut hot ng trn nhiu lnh vc khc nhau( nh c kh, in, xy dng, a
cht, kinh t...). Nhng r rng do tnh cht chuyn mn ca nh my thit k, nn ngi ch
tr t chc thit k phi l mt cn b hot ng trn lnh vc c kh.

1.4 Mt s khi nim, nh ngha dng trong thit k nh my c kh
thng nht trong sut qu trnh tnh ton, thit k, ngi ta a ra mt s khi
nim, nh ngha sau:
1/ Cng trnh: l mt n v ca nh my mang tnh c lp v k thut v khng gian. V
d mt to nh, mt kho, mt trm pht in..
2/ C quan u t: l c quan chu trch nhim cung cp vn u t xy dng c bn, mua
sm thit b . . .
3/ C quan thit k ( t chc thit k ) l t chc chu trch nhim thit k, cung cp ti
liu, bn v v nh my v theo di vic thc hin thit k.
4/ C quan xy lp: l t chc thc hin vic xy lp nn nh my theo thit k (thi cng).
C quan ny bt u nhim v t khi nhn ti liu t t chc thit k n khi ton b cng
trnh c bn giao xong.
5/ Ti liu thit k: l nhng vn bn c s dng trong qu trnh thit k, trong thng
a ra gim nh trc v sau thit k.
< 1 > Ti liu trc thit k: dng lm c s hon thnh cng tc thit k, bao gm:
- Bn nhim v thit k.
- Cc bn v v sn phm ( bn v ch to, bn v lp rp . .)
- Cc ti liu, bn v c lin quan n a im xy dng.
- Cc vn bn k kt hp tc vi cc c quan, b phn . .
< 2 > Ti liu sau thit k: l nhng ti liu, s liu nhn c ca cc giai on thit k,
l kt qu ca qu trnh thit k, dng n thi cng v nh gi kt qu thit k.
Ti liu sau thit k thng gm c:
- Ton b tnh ton, thuyt minh trong qu trnh thit k.
- Cc bn v mt bng nh my.
- Cc bn v kin trc nh xng.
- Cc bn v thi cng.
- Cc s liu v kinh t- k thut.

2. Nhng ti liu ban u v vic phn tch cc ti liu ny

2.1 Cc loi ti liu ban u
c c s tin hnh cng tc thit k, t chc thit k cn c cung cp hoc phi
xc nh cho c nhng ti liu v s liu c lin quan n nh my cn thit k. Nhng ti
liu, s liu c bn lm c s ban u goi l ti liu ban u.
Thng thng nhng ti liu ban u cn cho cng tc thit k bao gm:
1/ Bn nhim v thit k l vn bn hp php quan trng nht do c quan cp trn son
tho v cung cp cho t chc thit k.
2/ Bn lun chng kinh t-k thut (cn gi l bn gii trnh) v cng trnh thit k. Do t
chc thit k son tho c cp trn c thm quyn thng qua.
3/ Cc loi bn v lin quan ti sn phm.
5
4/ Cc ti liu, bn v c quan h ti a im xy dng nh my nh th nhng, a cht
cng trnh, bn a th, ti liu v thin nhin, kh hu m, hng gi . .
5/ Cc vn bn k kt vi cc c quan hu quan, nh hp ng cung cp nguyn vt liu,
hp ng hp tc sn xut, hp ng cung cp v b sung nhn lc, hp ng tiu th sn
phm ..
Trong nhng loi ti liu ban u k trn, th ti liu quan trng s mt l bn nhim v
thit k. Bn nhim v thit k cn th hin y nhng ni dung sau :
< 1 > Nu r tn gi, nhim v, mc ch ca nh my cn thit k.
< 2 > Nu r loi sn phm v cc yu cu k thut sn phm.
< 3 > nh r sn lng hng nm ca tng loi sn phm.
< 4 > Ch ra cc nhim v khc (nu c) ca nh my.
< 5 > ra cc yu cu m rng, pht trin trong tng lai.
< 6 > Cho bit r vng v a im xy dng ca nh my.
< 7 > Nu c cc s liu, ch tiu lm phng hng thit k nh:
- c lng tng s vn u t xy dng.
- c lng tng s thit b, cng nhn, din tch.
- c nh gi thnh sn phm.
< 8 > D kin ch lm vic ca nh my nh s ngy lm vic trong thng, s ca lm
vic trong ngy, s gi lm vic trong ca . .
< 9 > nh ra cc ch tiu kinh t - k thut s b nh:
_ Nng sut tnh cho mt thit b.
_ Nng sut tnh cho mt cng nhn.
_ Nng sut tnh trn 1m
2
din tch ca nh my.
< 10 > D kin thi gian a nh my vo sn xut.
< 11 > D kin thi gian hon vn . . .

2.2 Phn tch cc ti liu ban u
Trn c s cc ti liu ban u, c bit l bn nhim v thit k, t chc thit k tin
hnh nghin cu, phn tch cc yu t c bn ca ti liu bt tay vo cng tc thit k.
Thng nhng yu t c bn l: sn phm, sn lng, qui trnh cng ngh, cc hot ng
ph v thi gian, thi hn.

2.2.1 Phn tch sn phm :
Sn phm l i tng, l mc tiu sn xut ca nh my. V vy, nh my thit k
trc ht phi ph hp vi i tng cho. Mun t c s ph hp ny, ngi thit k
phi phn tch mt cch t m v ton din sn phm ch to.
Trong vic phn tch sn phm cn c bit coi trng phn tch tnh cng ngh
trong sn phm. C th cn i su phn tch 3 kha cnh:
< 1 > Nhng yu cu k thut ca sn phm, ca cc chi tit, b phn cu thnh sn
phm. T cho php ta la chn c phng php ch to hp l.
< 2 > Cc chui kch thc to nn cc v tr tng quan ca sn phm. S hiu bit
ny l c s xc nh cch thc ch to, phng php lp rp v kim tra sn phm.
< 3 > Kt cu ca sn phm c hiu bit t m s gip ta la chn hp l cc trang
b cng ngh trong qu trnh thc hin sn xut ra sn phm.

2.2.2 Phn tch sn lng :
Nh ta nghin cu trong cng ngh ch to my v t chc sn xut cng
nghip th phng php t chc sn xut, vic la chn h thng cng ngh tin hnh sn
xut trc ht ph thuc vo qui m sn xut. Sn lng cng ln (tc qui m sn xut cng
6
ln) cho php ta sn xut theo phng php t chc tin tin t hiu qu cao, ng thi cho
php la chn cc trang b cng ngh hin i mang li hiu qu kinh t ln.
Thng thng sn lng sn phm ch to hng nm c cho trong cc dng sau:
- Trng lng sn phm cn ch to hng nm (T/nm)
- S lng sn phm cn sn xut hng nm (chic/nm)
- Gi tr tng sn lng bnh qun hng nm (/nm)
trong ph bin hn c l s lng sn phm nm (chic/nm).
Phn tch sn lng l tnh cho c sn lng hng nm m nh my phi hon
thnh. Trn c s sn lng v mt vi yu t khc xc nh c qui m sn xut (nh dng
sn xut). l c s ht sc quan trng mang tnh ch o trong qu trnh thit k sau ny.
Sau y gii thiu mt cch tnh s lng sn phm ch to t cc ti liu ban u:
Ta gi : Si l s lng loi chi tit th i c trong cc sn phm cn gia cng.
Ni l s lng ca sn phm c chi tit th i.
mi l s lng chi tit th i c trong mi sn phm.

i
l s % d tr b sung cho vic ch i v vn kho tng v vn chuyn (t
l ny c qui nh).

i
l s % d tr b vo lng ph phm.
Nu gi Sik

l s lng loi chi tit th i c trong sn phm th k, ta s c mi quan
h sau :

+ =
100
1
100
1
i i
i i
k
i
m N S

[chic] (1.1)
V :

=
=
h
k
k
i i
S S
1
(1.2)
Vi h l s loi sn phm c chi tit th i. Nu ta gi n l s loi chi tit c trong cc
sn phm th tng s chi tit trong tt c cc sn phm l :

=
=
n
i
i
S S
1
tng
[chic] (1.3)

2.2.3 Phn tch qui trnh cng ngh: l nghin cu t m nm vng cc biu hin c th
sau :
(1) Ton b qu trnh sn xut din ra u, nh th no, bng g.
(2) Trnh t cc cng on, nguyn cng to thnh sn phm.
(3) Qu trnh thay i trng thi t phi liu n thnh phm.
(4) Hnh thc vn chuyn trong qu trnh sn xut (dng vt liu)
Qui trnh cng ngh l c s tnh ton khi lng lao ng, la chn trang b cng
ngh v b tr hp l mt bng nh my.

2.2.4 Phn tch cc yu t thi gian
Cc yu t thi gian trong nhng ti liu ban u l cc mc thi gian - mang tnh thi
hn. Nhng yu t thi gian ny bao gm: thi gian cho php thit k, thi gian bt u thi
cng, thi gian bt u sn xut, thi gian bt u s dng sn phm do nh my xut ra v
thi gian thu hi vn u t.
Nhng yu t thi gian k trn l mt phn c s chn phng php thit k,
nh ra k hoch, tin thit k, thi cng mt cch ph hp.

3. Nhng ni dung ch yu ca cng tc thit k:
Nh my l mt b phn ca nn kinh t quc dn trong mt ch x hi nht nh.
V vy nhim v, phng thc pht trin sn xut ca n phi tun theo qui lut kinh t ca
ch x hi . Mun vy thit k nh my l phi ng thi nghin cu gii quyt nhng
7
vn thuc v kinh t, thuc v k thut v thuc v t chc. Ngi ta gi l 3 ni dung
c bn phi gii quyt khi thit k nh my, phn xng hoc mt b phn ca nh my.
Sau y ta nghin cu c th hn tng ni dung.

3.1 Ni dung kinh t ca cng tc thit k
Ni dung kinh t ca thit k th hin cc vn sau:
1/ T bn nhim v thit k phi xc nh c chng trnh sn xut ca nh my, phn
xng.
2/ Phi d tr c ngun cung cp nguyn liu, nhin liu, nng lng nh my hot
ng lu di.
3/ Phi hp vi cc c quan c thm quyn xc nh tt a im xy dng nh my.
4/ Xc nh qui m, cu to ca nh my.
5/ Lp d kin kh nng m rng pht trin nh my trong tng lai.
6/ Lp phng n hp tc sn xut.
7/ Gii quyt tt vn u t xy dng, y t thit b.
8/ Nghin cu gii quyt nhng vn v i sng, phc li, sinh hot vn ha ca nh
my.

3.2 Ni dung k thut ca cng tc thit k
Ni dung k thut ca thit k bao hm nhng vn cn gii quyt sau:
1/ Thit k qui trnh cng ngh ch to sn phm. y l ni dung k thut quan trng
nht, ng thi cng kh khn v tn nhiu cng sc nht. N c tnh quyt nh i cc bc
thit k tip theo.
2/ Xc nh khi lng lao ng cn thit cho vic sn xut ra sn phm. Khi lng lao
ng c th biu th bng qu thi gian (nh i vi nh my, phn xng c kh, phn
xng lp rp, phn xng dng c, phn xng sa cha...), cng c th biu th bng trng
lng sn phm cn sn xut hng nm (trong thit k phn xng c v phn xng rn
dp).
3/ Xc nh chng loi v s lng cc my mc, thit b.
4/ Xc nh loi, s lng, trnh cng nhn, cn b k thut v nhn vin phc v trong
nh my.
5/ Xc nh cc nhu cu v nguyn liu, nng lng, vn chuyn.
6/ Nghin cu gii quyt vn vn chuyn.
7/ Gii quyt tt vn v sinh cng nghip.
8/ Tnh ton nhu cu din tch v b tr mt bng nh my, phn xng.
9/ Gii quyt vn kin trc nh xng.
10/ Nghin cu gii quyt vn khoa hc lao ng, ci tin iu kin lm vic cho cn
b, cng nhn trong nh my.

3.3 Ni dung t chc ca cng tc thit k.
V phng din t chc, khi thit k cn nghin cu gii quyt tt vn c lin quan
sau :
1/ Xc nh h thng lnh o, qun l nh my. Qui nh quan h cng tc gia cc c
cu t chc.
2/ T chc h thng qun l k thut, qun l sn xut.
3/ Nghin cu gii quyt vn qun l lao ng, bi dng trnh cho cng nhn cn
b.
4/ T chc tt h thng bo v nh my.
5/ Gii quyt tt cc vn sinh hot vn ho, chnh tr, x hi.

8
4. Cc phng php thit k:
Tu thuc vo qui m sn xut, tnh chnh xc v y ca cc ti liu ban u, ni
dung ca lun chng kinh t - k thut v thi gian cho php thit k m ta la chn, s dng
phng php thit k cho ph hp.
Trong thc t c hai phng php thit k (cn gi l 2 phng php lp chng trnh
sn xut):
- Phng php thit k chnh xc.
- Phng php thit k gn ng (cn gi l thit k c nh)
sau y ta nghin cu nhng c trng c tnh bn cht ca hai phng php thit k .

4.1 Phng php thit k chnh xc
Khi cc ti liu ban u y , chnh xc; thi gian tin hnh thit k , c bit
l thit k nh my c qui m sn xut ln, c tm quan trng c bit i vi nn kinh t
quc dn hoc quc phng th cng vic thit k c tin hnh trn phng php chnh xc.
Phng php thit k chnh xc da trn phng php lp chng trnh sn xut chnh
xc. Ct li ca phng php ny l tin hnh lp qui trnh cng ngh t m cho tt c cc chi
tit ca cc loi sn phm m nh my sn xut, c km theo phiu cng ngh y t m.
T ta xc nh c mt cch chnh xc khi lng lao ng ca cc phn xng, b phn
v ton nh my.
R rng vic lp qui trnh cng ngh t m cho tt c cc chi tit ca cc sn phm l
khi lng cng vic ht sc ln. N ch thch ng vi vic thit k cc nh my c qui m
ln, s loi sn phm sn xut khng nhiu, chng loi chi tit trong cc sn phm cng
khng nhiu, nhng s lng ln v tt nhin thi gian thit k cho php rng.
Ni chung phng php thit k ny t c ng dng trong thc t, nht l i vi
nc ta, c bit l i vi nh my c kh a phng.

4.2. Phng php thit k gn ng (c nh).

4.2.1 Cc cch tin hnh
Khi cc iu kin trn khng tho mn th ta chn phng php thit k gn ng.
Phng php thit k gn ng c th c tin hnh theo 2 cch sau :
1/ Da vo sn phm hoc chi tit in hnh.
2/ Da vo cc thit k mu hoc cc ch tiu kinh t - k thut c c kt theo
kinh nghim.
Trong 2 cch trn, cch th nht c ng dng rng ri trong mi bc thit k. Do
ta cng tp trung nghin cu phng php ny. Ring cch th hai, vic thc hin dn
gin, cho chnh xc thp, s gii thiu thm phn thit k c th.

4.2.2 Phng php thit k gn ng da trn sn phm (hoc chi tit) in hnh :
Phng php ny c tin hnh theo cc bc sau y :
1/ Da vo kt cu, trng lng, cng ngh, vt liu ta phn loi v ghp nhm cc
sn phm (hoc chi tit). C th l :
a/ Nu nh my sn xut nhiu loi sn phm, s lng mi loi khng nhiu lm
th ta tin hnh phn loi v ghp nhm sn phm.
b/ Nu nh my sn xut nhiu loi sn phm, s lng mi loi khng nhiu,
nhng s lng chi tit trong mi loi ln, th ta tin hnh phn loi, ghp nhm chi tit
khng k sn phm no.
2/ La chn sn phm (hoc cc chi tit) in hnh ca cc nhm. C th l :
a/ Nu phn loi sn phm th chn mi nhm 1 sn phm in hnh. Nu c th
th tip tc ghp nhm v chn in hnh tip...
9
b/ Nu phn loi chi tit th chn trong mi nhm 3 chi tit in hnh :
- Chi tit in hnh nh.
- Chi tit in hnh va.
- Chi tit in hnh ln.
3/ Qui i s lng sn phm (hoc chi tit) khc trong mi nhm v s lng sn
phm (hoc chi tit) in hnh. Tnh ton s lng sn phm (hoc chi tit) ca tng nhm v
cc nhm qui v in hnh.
Cng thc qui i tng qut l :
N
qx
= N
x
.K
x
(1.4)

Trong : Nqx l s lng sn phm (hoc chi tit) X c qui i v sn phm
(hoc chi tit) in hnh.
Nx

l s lng sn phm (hoc chi tit) X trc qui i.
Kx l h s c nh, ln ca n c trng cho mc khc nhau v
trng lng, v phc tp v v sn lng gia sn phm (hoc chi tit) ang xt (X) so vi
sn phm (hoc chi tit) in hnh trong nhm.
Nh vy :
K
x
= K
x1
.K
x2
.K
x3
(1.5)

K
x1
l h s c nh k n s sai khc v trng lng (hoc din tch b mt gia
cng) ca sn phm (hoc chi tit) ang xt (X) so vi sn phm (hoc chi tit) in hnh
trong nhm. Gi tr ca Kx
1
c th xc nh theo cng thc sau :


h h
F
F
Q
Q
K
x x
x

=
3
2
1
(1.6)

Trong Q
x
v F
x
l trng lng, din tch b mt gia cng ca sn phm (hoc chi
tit) ang xt.
Q
h
v F
h
l trng lng v din tch b mt gia cng ca sn phm (hoc
chi tit) in hnh trong nhm.
K
x2
l h s c nh k n s sai khc v phc tp gia sn phm (hoc chi tit)
ang xt so vi sn phm (hoc chi tit) in hnh trong nhm. Gi tr ca K
x2
c cho theo
kinh nghim ca ngi thit k, thng c gng phn nhm sao cho K
x2
1.
K
x3
l h s c nh k n s sai khc v sn lng gia sn phm (hoc chi tit)
ang xt so vi sn phm (hoc chi tit) in hnh trong nhm. Gi tr ca K
x3
c th tham
kho chn bng 1-1.
Sau khi qui i ton b cc sn phm (hoc chi tit) ca cc nhm v sn phm (hoc
chi tit) in hnh, ta tnh sn lng yu cu sn xut theo phng php c nh theo cng
thc :




=

= = =
+ =
a
i
b
x
a b
x
N N N
1 1 1
hi
1 i
qx
(1.7)

a v a l s nhm (a = a) sn phm (hoc chi tit).
b v b l s sn phm (hoc chi tit) khng in hnh v c chn lm in
hnh trong tng nhm.
10

Bng 1-1 H s c nh Kx
3
(N l sn lng)
N
h
/N
x
0,5 0,75 1,0 1,1 1,2 1,3 1,4 1,5 1,6 1,8 2,0 2,2 2,5 3,0
Kx
3
0,97 0,99 1,0 1,01 1,03 1,05 1,06 1,07 1,08 1,1 1,12 1,13 1,15 1,17
N
h
/N
x
3,5 4,0 4,5 5,0 5,5 6,0 6,5 7,0 7,5 8,0 8,5 9,0 9,5 10
K
x3
1,2 1,22 1,23 1,25 1,27 1,28 1,3 1,31 1,32 1,33 1,34 1,35 1,36 1,37

4/ Tin hnh lp qui trnh cng ngh y , t m i vi cc sn phm (hoc chi tit)
in hnh ph hp vi dng sn xut theo sn lng qui i - c km theo phiu cng ngh t
m.
5/ Xc nh khi lng lao ng ca phn xng, b phn hoc ton nh my.
Trn c s qui trnh cng ngh xc lp v khi lng lao ng tnh ton, hon
thnh cc bc tnh ton thit k tip theo.

5. Cc giai on thit k

5.1 Khi nim v qu trnh thit k nh my c kh .
Thit k nh my c kh l mt qu trnh thu thp, nghin cu phn tch, tng hp
xut phng n v la chn phng php ti u.
hon thnh tng khi lng cng vic c th v to c s cho vic thc hin cc
bc tip theo, ngi ta phn qu trnh thit k ra lm 3 giai on :
- Thit k s b.
- Thit k k thut.
- Thit k thi cng.

5.2 Giai on thit k s b :
Thit k s b l giai on thit k u tin, c nhim v gii quyt cc vn sau :
1/ Nu r kh nng k thut v tnh hp l kinh t ca a im xy dng nh my.
2/ nh ra qui trnh cng ngh sn xut, vn hnh, khai thc sn xut.
3/ Xc nh ngun cung cp vt t, nguyn liu, nng lng, lao ng, vn chuyn cho
nh my.
4/ nh r kt cu kin trc, hng mc cc cng trnh.
5/ Tnh khi lng xy lp, vn u t chia cho cc phn : xy lp, thit b, kin thit
c bn, xy dng chnh, ph.
6/ Xc nh kh nng, iu kin thi gian thi cng v a nh my vo hot ng.
7/ Nu cc ch tiu kinh t k thut.
Bc thit k s b sau khi hon thnh phi c cp trn c thm quyn thng qua
(duyt y) mi c chuyn sang giai on thit k k thut.

5.3 Giai on thit k k thut.
Trong giai on thit k k thut cn i su nghin cu qui trnh cng ngh ; vn
vn chuyn, kho tng ; vn v sinh cng nghip, an ton lao ng ; vn t chc hot
ng kinh t ... hon thnh nhng tnh ton chnh xc cc ni dung nu thit k s b.
C th l :
1/ Thit k qui trnh cng ngh sn xut sn phm ph hp vi qui m sn xut. T
tnh ton c khi lng lao ng ca phn xng, b phn v ton nh my.
2/ Tnh ton chnh xc cc nhu cu v my mc thit b, v nhn lc v din tch cc
phn xng, b phn v ton nh my.
3/ Tnh ton nhu cu v nng lng, vn chuyn.
4/ Tnh ton h thng kho tng, cc cng trnh ph v phc v.
11
5/ Xc nh cc bin php an ton lao ng, v sinh cng nghip.
6/ Xc lp h thng t chc lnh o, qun l nh my.
7/ Tnh ton kinh t.
8/ Xc nh chnh xc cc ch tiu kinh t - k thut.

5.4 Giai on thit k thi cng
Sau khi giai on thit k k thut c c quan cp trn c thm quyn duyt y,
cho php tip tc tin hnh th ta chuyn sang giai on thit k thi cng. y l giai on
thit k cui cng, nhm cung cp ti liu, bn v cho t chc xy lp hon thnh cng vic
xy dng nh my.
Trong giai on thit k thi cng ch yu l hon thnh cc loi bn v phc v cho
cng vic thi cng. Do trong mt s ti liu cn gi l giai on lp cc bn v thi cng.
Cc bn v thi cng cn hon thnh trong giai on ny l :
1/ Cc bn v v mt bng nh my (c nh r cao, kch thc gii hn, cc mc
cho cc cng trnh kin trc, mng li ng s, knh mng, sn bi, in, nc ...)
2/ Bn v mt ct ngang, ct dc ca cc hng mc cng trnh.
mi giai on thit k ta mi ch nu nhng ni dung c bn cn c ch nghin
cu gii quyt. V vy gii quyt trit v ton din, ngi thit k cn nghin cu k
nhng ni dung kinh t, k thut v t chc nu phn trc trnh nhng khim khuyt
trong bn thit k.
Trong thc t nc ta cng nh trn phm vi th gii, c nhiu nh my ging nhau
v nhim v sn xut, v qui m v nhiu yu t khc. gim bt sc lao ng v thi gian
thit k, trong qu trnh thit k, ta c th s dng cc tnh ton ca nhng bn thit k mu
ny. Tt nhin khi s dng cc s liu tnh ton ca nhng thit k mu ta cn nhn thm vi
h s iu chnh k n s pht trin ca khoa hc k thut. Trong nhng trng hp nh
vy, cng vic thit k ca giai on thit k s b v thit k k thut c th nhp li lm
mt. Nh vy cng vic thit k c tin hnh bng 2 giai on :
- Thit k s b m rng.
- Thit k thi cng.

5.5 M hnh tng qut v qu trnh thit k nh my c kh
d dng trong vic theo di, thc hin v kim tra qu trnh thit k, ta c th a
ra s tng qut v qu trnh thit k nh my c kh nh hnh 1.1.

Trong m hnh 1.1 c:
1. Phn tch nhim v thit k
2. Lp chng trnh sn xut .
3. Phn loi- ghp nhm- chn in hnh.
4. Thit k qui trnh cng ngh - Tnh khi lng lao ng
5. Xy dng cc ch tiu s dng vt liu
6. Tnh ton nhu cu vt liu - so snh vi ch tiu
7. Tnh ton nhu cu thit b - so snh vi ch tiu
8. Tnh ton nhu cu nhn lc
9. Xc nh h thng cung cp nng lng
10. Xc nh lng d tr nguyn liu, vt t k thut
11. Lp s cng ngh
12. Xc nh nhu cu vt liu ph
13. Xc nh c cu cc b phn ph
14. Xc nh bc th - chi ph tin lng
15. Tnh din tch cc phn xng b phn
12
16. Tnh tng din tch mt bng - chn kt cu nh xng
17. Xc nh ln cui a im xy dng
18. Thit k h thng ng vn chuyn
19. Xc nh h thng cp thot nc
20. Xy dng qui hoch tng mt bng
21. Tnh nhu cu thit b vn chuyn
22. Tng hp cc chi ph u t vn, chi ph sn xut, chu k vng quay vn.
23. Chn phng n ti u. Bo v phng n v lp h s k thut.

Hnh 1.1 M hnh qu trnh thit k nh my c kh.

1
2
3
4
9 5
7 11 6
8 12 10
14 13
15 16 17
18
19
20 21 22
23
13
Chng II

PHN TCH KINH T TRONG THIT K NH MY C KH

1. Khi nim v phn tch kinh t

Qui lut pht trin ca mi hnh thi x hi l tm mi bin php nng cao hiu qu
kinh t ca nn sn xut. Qui lut kinh t hot ng trong ch x hi ch ngha nhm
mc ch khng ngng tho mn nhu cu ngy cng cao ca mi thnh vin trong x hi.
Cc cng trnh cng nghip l nhng b phn cu thnh ca nn sn xut x hi, l
mt phn c s vt cht - k thut ca ch ngha x hi. Do hiu qu kinh t ca chng
va l mc tiu u tin, li va l ch tiu cui cng xc minh cho l do ra i v s tn ti
ca chng trong nn kinh t quc dn
Thit k mt nh my, mt phn xng l da vo yu cu s dng (yu cu k thut)
ca sn phm tnh ton xut ra nhiu phng php c th sn xut ra sn phm , tip
theo l cn c vo kt qu phn tch kinh t chn ra phng n ti u trong nhng phng
n c th .
Nh vy t quan im kinh t, cng tc thit k phi ln lt gii quyt hai bc
cng vic:
<1> a ra nhng phng n c th sn xut ra sn phm
<2> La chn mt phng n ti u t nhng phng n c th.
hon thnh c 2 bc trn, khi thit k bt k mt cng trnh cng nghip
no, ngi thit k phi lu :
1/ Khng c php dng li mt hoc mt vi phng n a ra vi vng kt
lun. C nh vy mi trnh c s nh gi cc b, phin din.
2/ Phn tch kinh t khng c tch ri vi phn tch k thut. C nh vy bn
thit k mi mang tnh hon chnh c.
T nhng phn tch trn, r rng phn tch kinh t trong thit k dy chuyn sn xut
ni chung v nh my c kh ni ring, c 2 nhim v c bn:
(1) Khng nh phng n thit k c c chp nhn hay khng.
(2) Khng nh c phng n thit k no l ti u trong nhng phng n
thit k c th chp nhn.

2. C s phn tch kinh t
Phn tch kinh t l i su phn tch xem xt hiu qu kinh t ca cc phng n kt
lun nhng phng n c th chp nhn v trn c s so snh hiu qu kinh t rt ra c
nhng phng n ti u. y l cng vic phc tp i hi ngi thit k phi c cch nhn
ton din theo quan im, nguyn tc chung ca ng v nh nc ta trong cng tc qun l
kinh t ni chung v qun l cng nghip ni ring.
Khi xem xt hiu qu kinh t trong cng nghip, t nht cn cp n cc mt ch
yu sau:
1/ H thng cc ch tiu gi tr- hin vt.
2/ Xem xt mi quan h vi cc ngnh lin quan.
3/ Nghin cu k yu t thi gian.
4/ nh gi y hiu qu kinh t - x hi.
Tip theo ta ln lt tham kho nhng vn c th.

2.1 Cc ch tiu gi tr v hin vt ch yu xt hiu qu kinh t
14
Tiu chun tng qut xt hiu qu kinh t l mc tng nng sut lao ng x hi.
qun trit iu , ta cn cn c vo h thng cc ch tiu gi tr - hin vt sau:
1/ Ch tiu nng sut lao ng
Nng sut lao ng trong sn xut c kh l lng sn phm c sn xut ra trong
mt n v thi gian.
R rng y l mt ch tiu thun ty ch cp ti lao ng sng m n khng phn
nh lao ng tiu hao trc tip, cng nh lao ng tiu hao cho vic chun b sn xut (nng
sut lao ng nh vy bao gm c lao ng tiu hao trc tip v lao ng tiu hao cho vic
chun b sn xut). Do vy tiu chun nng sut lao ng cn mang tch cht phin din khi
xt ti vn hiu qu kinh t.
2/ Ch tiu gi thnh sn phm
Khi xt hiu qu kinh t cn s dng ch tiu gi thnh hon ton (tc bao gm c chi
ph vn chuyn sn phm cho n tay ngi tiu dng).
Ch tiu gi thnh mang tch cht hon thin hn so vi ch tiu nng sut lao ng.
Song m bo tnh so snh ca ch tiu ny ta cn gii quyt tt cc vn c lin quan
sau:
(1) Phi m bo tnh thng nht ca h thng gi c.
(2) Phi m bo tnh thng nht v ch tin lng.
(3) Phi m bo cc phng n c tnh ton theo khi lng sn phm ging
nhau.
nc ta hin nay, do cng tc hch ton v thng k cha c lm tt, do
nhng vn trn ni chung l cha c m bo tt. V vy, chnh xc ca ch tiu gi
thnh cn thp.
3/ Ch tiu t sut vn u t c bn
T sut vn u t c bn l s vn u t c bn tnh cho mt n v cng sut c
huy ng, hay tnh cho mt n v thnh phm c tng thm (so vi thit k mu). Ch tiu
ny c biu th bng gi tr hoc bng hin vt.
Vn u t c bn c cu thnh bi nhng chi ph v chi ph mua sm my mc
thit b (k c chi ph vn chuyn, lp rp cc thit b ); chi ph v u t xy dng nh
xng, chi ph v u t ci tin phng php cng ngh, phng php thit k ...
Nh nc c qui nh gi tr t sut vn u t c bn. Phng n thit k c chp
nhn nu c t sut vn u t xy dng c bn ca phng n khng vt qu t sut qui
nh.
4/ Ch tiu thi hn thu hi vn u t c bn b thm
Thi hn thu hi vn u t c bn b thm (T) l t s vn u t c bn (V) v s
li thu v hng nm (L), tc l

L
V
T = (2.1)
Nh nc qui nh gi tr nh mc ch tiu thi hn thu hi vn u t c bn b
thm. ( k hiu l [ T ]). Nh vy iu kin phng n thit k c chp nhn l :
T [T] (2.2)
5/ Ch tiu h s hiu qu kinh t
H s hiu qu kinh t (H) l t s gia s li thu v (L) v vn u t c bn (V), tc
l :

V
L
H = (2.3)

Nh nc c qui nh mc gi tr h s hiu qu kinh t [H], nh vy phng n thit
k c chp nhn nu h s hiu qu kinh t khng nh hn gi tr nh mc.Tc l :
H [H] (2.4)
15

2.2 Xt hiu qu kinh t ca cc ngnh lin quan
Nh my c kh l mt thnh phn trong nn kinh t quc dn. Do hiu qu kinh t
ca nh my c lin quan hu c ti cc ngnh lin quan khc.
T quan im ton din, tit kim v cn i; khi xt hiu qu kinh t ta cn tnh n
mt cch ton din s lao ng x hi tit kim c khng ch ca bn thn ngnh c
phng n thit k, m phi tnh n cc ngnh, cc b phn khc c lin quan.
Vn t ra khi xt hiu qu cc ngnh c lin quan l : nu b mt ng vn u t
c bn vo ngnh A no th cn phi b thm bao nhiu ng vo cc ngnh c lin quan
trc tip n ngnh A ngnh A t hiu qu kinh t theo yu cu.
gii quyt vn trn, ngi ta a ra khi nim h s lin quan (Klq) nh sau :
H s lin quan (K
lq
) l t s gia tng chi ph b vo cc ngnh lin quan (Vlq) v
tng chi ph b vo ngnh sn xut chnh (VA), tc l :

A
lq
lq
V
V
K = (2.5)
Gi tr ca h s lin quan, ph thuc vo loi ngnh u t. Theo ti liu ca Lin x
ta c th tham kho cc gi tr sau :
- i vi ngnh in K
lq
= 1,7
- i vi ngnh luyn kim K
lq
= 2,5
- i vi ngnh sn xut nhm K
lq
= 3,7
- i vi ngnh c kh ch to t K
lq
= 4,0

2.3 Xt hiu qu kinh t v mt thi gian
Khi xc nh hiu qu kinh t so snh cc phng n, khng th ch da vo s c
li v s tin tit kim c ln nht, m cn phi xt n s c li nht v mt thc hin
phng n trong khong thi gian ngn nht.

2.4 Xt hiu qu kinh t v mt cht lng
Cht lng ca phng n thit k theo quan im hiu qu kinh t, biu hiu trn 2
mt.
1/ Phng n thit k c th hin ng ng li, phng chm ca ng v phng
hng xy dng pht trin kinh t hay khng .
2/ Phng n thit k c th hin c cc quan im, nguyn tc qun l, kinh doanh
x hi ch ngha hay khng. V d: c ci thin iu kin lm vic, c bin php m bo an
ton lao ng khng . .
y r rng quan nim v cht lng c ngha l cht lng v kinh t - x hi
(khng phi cht lng k thut) ca phng n thit k.

Cn nhn mnh li rng: khi xt hiu qu kinh t nh gi mt phng n thit k,
trn quan im ton din, khng c tch ri gia mt s lng v mt cht lng - Bi v
xt cho cng 2 mt ny c lin quan mt thit nhau v nm trong mt th thng nht.

3. ng dng phn tch kinh t trong thit k nh my c kh

Phn tch kinh t trong thit k nh my c kh nhm hai mc ch:
1/ la chn phng n ti u trong cc phng n thit k a ra.
2/ Xy dng h s kinh t - k thut cho nh my, phn xng thit k.
phc v cho 2 mc ch , trong qu trnh thit k ta phi gii quyt cc ni dung
ch yu sau y:
<1> Xc nh vn u t c bn xy dng hoc ci to m rng
16
<2> Xc nh chi ph sn xut trong qu trnh sn xut ra sn phm
<3> Tnh gi thnh sn phm.
<4> Xc nh thi gian hon vn u t c bn.
<5> Tnh cc ch tiu kinh t - k thut.
<6> nh gi hiu qu kinh t ca bn thit k trn c s so snh cc ch tiu kinh t
k thut tnh c t bn thit k vi cc ch tiu qui nh (hoc thit k mu).
Tip theo ta ln lt tm hiu tng ni dung c th.

3.1 Xc nh vn u t c bn
Theo qui nh hin hnh ca nh nc, vn u t c bn (V) cho mt cng trnh cng
nghip l tng chi ph nhm ti sn xut ra ti sn c nh cho nn kinh t quc dn.
Vn u t c bn bao gm:
1/ Chi ph xy lp nh xng (V
XL
).
2/ Chi ph v thit b, dng c sn xut v phc v sn xut (V
tb
).
3/ Cc chi ph khc v xy dng c bn (V
Xd
).
Nh vy vn u t c bn s l:

V = V
XL
+ V
tb
+ V
Xd
(2-6)

3.1.1 Chi ph xy lp nh xng
Chi ph xy lp nh xng gm hai thnh phn:
- Chi ph xy dng, m rng hoc ci to cc cng trnh kin trc, chi ph chun b mt
bng sn xut.
- Chi ph lp t thit b sn xut v thit b phc v sn xut.
3.1.1.1 Chi ph xy dng, m rng, ci to v chi ph chun b mt bng sn xut :
Thnh phn chi ph xy lp ny c xc nh trn c s d ton theo gi qui nh ca
nh nc cho mt n v cng trnh xy dng ng vi tng thi gian c th. n v tnh l
/m
2,
, /m, /m
3
. V d :
- Gi thnh xy lp nh xng sn xut chnh, sn xut ph, b phn ph vi kt cu nh
nhiu tng s dng vnh cu l 1200000 /m
2
(tu tng thi k).
- Gi thnh xy lp ng ti in thp sng l (???) /m (tu tng thi k).
- Gi thnh xy lp ng ng dn nc : 30 l (???) /m ; 70 : (???) /m (tu tng
thi k).
- Gi thnh xy lp ng ng dn kh nn : (???) /m (tu tng thi k).
- Gi thnh xy lp ng ng dn hi nng : (???) /m (tu tng thi k).
3.1.1.2 Chi ph lp t thit b
Thnh phn chi ph ny bao gm :
- Chi ph lp t thit b sn xut v phc v sn xut c tnh lu di hoc tm thi .
- Chi ph sn m bo v cc thit b lp t
- Chi ph th my v iu chnh my sau khi lp t
Thng chi ph lp t thit b c ly theo gi tr % kinh nghim so vi gi tr bn
thn thit b (chi ph thit k v ch to thit b) V d thng ly 2 ~ 3 %

3.1.2 Chi ph thit b dng c
Thit b sn xut v phc v sn xut gm c 2 loi : loi cn lp t v loi khng cn
lp t.
Chi ph thit b c xc nh da vo gi tr tng loi, theo kiu, c, c tnh k
thut- thng gm c thnh phn sau :
<1> Gi tr bn thn thit b (chi ph thit k, ch to) : V
ct

< 2 > Chi ph vn chuyn v bo qun chng : V
vc

17
< 3 > Chi ph tho g, lau chi sa cha trc khi lp t : V
s

Cc thnh phn chi ph < 2 > v < 3 > c ly theo t l % ca gi tr bn thn thit
b, dng c . V d :
- Thit b c kh ly 3-5% cho chi ph vn chuyn, ly 5 % cho chi ph sa cha.
- Thit b vn chuyn ly 7-10 % cho chi ph sa cha. Nh vy chi ph thit b s l :

V
tb
= V
ct
+ V
vc
+ V
s
(2.7)

Khi thit k gn ng, tng chi ph v dng c, trang b cng ngh c xc nh theo
t l % ca gi tr bn thn thit b sn xut (Vct). V d ly 2 %, c khi 8-15 %. Vn ti sn
nghip v ( chi ph v thit b phc v qun l kinh doanh v d nh my tnh, my
photocopie, ...) cng c xc nh gn ng theo t l % ca gi tr bn thn thit b sn
xut, v d ly 1-1,5 %.

3.1.3 Cc chi ph khc v xy dng c bn
Nhng chi ph khc v xy dng c bn, thng bao gm :
<1> Chi ph v o to bi dng cn thit cho qu trnh sn xut sau ny (khng tnh
chi ph nng cao tay ngh cc x nghip ang hot ng v c yu cu m rng, chi ph
o to trong cc trng chnh qui).
<2> Chi ph mua t xy dng, n b ti sn do mua t, di chuyn cc cng trnh kin
trc c (khng tnh chi ph cho khu ph v xy dng li cng trnh kin trc c)
<3> Chi ph v thit k (k c khu thm d kho st ln thit k tng phn). Thng
chi ph ny ly theo t l % ca tng chi ph xy dng nh xng. V d ly 8 %.
<4> Chi ph qun l ban kin thit (ban qun tr)
<5> Chi ph hp tc k thut trong qu trnh xy dng.
<6> Cc chi ph khc do qui nh trong qu trnh thit k, thi cng nh : chi ph di
chuyn n v thi cng, chi ph khnh thnh v nghim thu cng trnh, chi ph xy dng nh
cho n v thi cng ...

Vic xc nh vn u t c bn ca phng n thit k c cc mc ch sau y :
1/ Vn u t c bn gip ta nhn bit qui m ca cng trnh thit k.
2/ Bit vn u t c bn c k hoch chun b v chi ph.
3/ Bit vn u t xp cng trnh theo hng ngch. T m nh c quan ch qun
v xt duyt cng trnh.
Cc mc gii hn tnh hng ngch tu thuc vo tng thi k
- Cc cng trnh trn hng ngch do hi ng chnh ph xt duyt khi c cc b
qun l trnh ln.
- Nhng cng trnh di hng ngch do cp b ch qun hoc U ban nhn dn tnh
xt duyt.

3.2 Xc nh chi ph cho sn xut hng nm
Chi ph sn xut hng nm bao gm tt c cc ph tn v vt t k thut v lao dng
nhm sn xut ra sn phm vi cht lng v s lng qui nh trong nhim v thit k.
Chi ph sn xut trong nh my thng gm cc thnh phn sau :
1) Chi ph v vt t cc loi (k c vt t chnh v vt t ph)
2) Chi ph (khu hao) v trang thit b, dng c (k c chnh ln ph)
3) Chi ph v nng lng cc loi
4) Chi ph v lng ( cng nhn chnh, ph, phc v trc tip sn xut)
5) Chi ph v nh xng v cc cng trnh kin trc khc.
18
6) Chi ph v qun l x nghip (ph tn v thit b v chi ph lng cho cn b nhn
vin phc v qun l, iu hnh sn xut)
Nhn chung cc thnh phn chi ph cho qu trnh sn xut rt kh xc nh c
ton din v chnh xc. V vy trong thc t tnh ton, thng ch yu xc nh cc thnh
phn trc tip to thnh chi ph sn xut (nh chi ph vt liu chnh, chi ph lng cng
nhn sn xut, khu hao trang thit b, dng c sn xut, chi ph nng lng), cn nhng
thnh khc ca chi ph sn xut c ly gn ng kinh nghim theo t l % ca thnh
phn chnh. V d :
- Chi ph qun l x nghip ly 150-300 % chi ph lng cng nhn chnh
- Chi ph vt liu ph ly khong 3 % chi ph vt liu chnh ...
Tu thuc vo yu cu c th ca tng giai on thit k m s dng cc phng
php thch hp xc dnh chi ph sn xut. Sau y ta nghin cu cc phng php .

3.2.1 Xc nh s b chi ph sn xut (K
sx
)
Phng php xc nh s b thng dng trong bc thit k s b.
Xc nh s b chi ph sn xut c da vo cc thnh phn c bn sau :
- Chi ph v cc loi vt liu chnh ( tr i ph liu c th dng li) K
vl
.
- Chi ph lng chnh cho cng nhn sn xut : K
L

- Chi ph qun l x nghip : K
Q
. Thng K
Q
c ly theo t l % ca K
L
- tc l : K
Q
=
k
q
. K
L
. Thng kq = 1,5- 0,8 tu thuc vo mc c gii ho, t ng ho ca qu trnh
sn xut.
Nh vy chi ph sn xut s b s l :

K
sx
= K
vl
+ K
L
(1 + k
q
) (2.8)

Sau y ta i vo xc nh tng thnh phn chi ph c th.
3.2.1.1 Xc nh chi ph vt liu chnh K
VL

Nu nh my cn ch to ra j = 1,2,3..., m loi i tng sn phm, th ta cn phi s
dng i= 1,2,3..., n loi vt liu chnh.
Nh vy chi ph cho mt loi vt liu bt k i no sn xut ra 1 loi i tng
sn phm j no s c tnh nh sau :

K
VLij
= [m
f
.g
f
- (m
f
- m
ct
). g
o
] K
vc
.N (2.9)
Trong :
m
f
l khi lng ca phi (kg/ chic)
m
ct
l khi lng cu chi tit (kg/ chic)
g
f
l gi thnh phi liu (/ kg)
g
o
l gi thnh ph liu (/kg)
K
VC
h s vn chuyn vt liu (thng K
VC
= 1,1)
N sn lng hng nm (chic/ nm)
T cng thc (2.9) ta c tng chi ph cho cc loi vt liu ng vi tt c cc i tng
sn phm l :

[ ] N K g m m g m K
vc
n
i
m
j
ct f f f VL
. ) ( .
1 1
0
= =
= (2.10)

3.2.1.2 Xc nh chi ph v lng chnh ca cng nhn sn xut .
Nu ta gi m l s loi i tng sn phm
r l s loi th cn thit gia cng cc i tng sn phm
li l lng chnh ca loi th th i c tnh bnh qun hng gi (/h)
19
Tij l thi gian ngi th th i hon thnh sn xut i tng sn phm j
c tnh bnh qun trong nm (h/nm)
th chi ph lng chnh ca cng nhn sn xut tnh cho tt c cc loi i tng sn
phm v cc loi th l :


ij
m
j
r
i
i L
T l K

= =
=
1 1
, [/nm] (2.11)

3.2.2 Tnh chnh xc chi ph sn xut
Chi ph sn xut c tnh ton chnh xc trn c s cc ph tn c bn ca qu trnh
sn xut ra sn phm.
Nhng ph tn c bn ca qu trnh sn xut gm c :
<1> Chi ph vt liu chnh cc loi c tr i ph liu c th dng li c K
VL
(/nm)
<2> Chi ph tin lng cho cng nhn sn xut cc loi : K
LC
(/nm)
<3> Chi ph tin lng cng nhn iu chnh my cc loi : K
L
(/nm)
<4> Chi ph sa cha my cc loi : K
S
(/nm)
<5> Chi ph v nng lng cc loi : K
n
(/nm)
<6> Chi ph v dung dch trn ngui : K
tn
(/nm)
<7> Chi ph v khu hao my : K
km
(/nm)
<8> Chi ph v khu hao dng c cc loi : K
kd
(/nm)
<9> Chi ph v trang b cng ngh (ch yu l g) : K
g
(/nm)
<10> Chi ph v qun l v iu hnh sn xut : K
Q
(/nm)
<11> Chi ph v vt liu ph cc loi : K
VP
(/nm)
Nh vy chi ph sn xut l tng cc chi ph k trn tc l :

=
=
c
i
i SX
K K
1
, [/nm] (2.12)

Trong Ki l chi ph loi i (/nm)
c l s loi chi ph (i =1,2,3...,c)

3.3. Tnh gi thnh sn phm
Gi thnh sn phm (G) c xc nh trn c s chi ph sn xut.
Tu theo tng giai on thit k m s dng phng php tnh ton cho ph hp.

3.3.1. Cu trc ca gi thnh sn phm
Gi thnh sn phm gm c hai thnh phn chnh :
- Gi thnh cng xng (G
cx
)
- Chi ph ngoi sn xut. Chi ph ny thng c tnh theo t l % ca gi thnh
cng xng ( thng ly 3 %).
Do vn y l xc nh gi thnh cng xng.
1/ Xc nh s b gi thnh cng xng
Phng php ny c ng dng khi thit k s b. N c tin hnh xc nh trn c
s cc chi ph c bn nh : chi ph vt liu chnh (K
VL
), chi ph v lng chnh ca cng
nhn sn xut (K
L
) v chi ph v qun l x nghip (K
Q
).
Gi thnh cng xng c tnh s b theo cng thc :

N
k K K
G
q L VL
CX
) 1 ( + +
= , [/chic] (2.13)

20
Trong N l sn lng hng nm (chic/nm)
k
q
l h s t l, thng k
q
= 1,5 - 0,8
2/ Xc nh chnh xc gi thnh cng xng
Gi thnh cng xng c tnh chnh xc theo ton b chi ph ca qu trnh sn xut
sn phm nu mc.3.2.2.
Cng thc tng qut tnh chnh xc gi thnh cng xng :

=
=
c
i
i CX
K
N
G
1
1
, [/chic] (2.14)
Trong thc t, c mt s thnh phn chi ph rt kh xc nh chnh xc, do vy ngi
ta thng ch tnh gi thnh cng xng theo mt s chi ph ch yu bng cng thc sau :

[ ]
g kd km q L L VL CX
K K K k k K K
N
G + + + + + = ) (
1
, [/chic] (2.15)
Trong kL l h s k n tin thng, ph cp khu vc, bo him x hi. Thng
ly kL =1,14-1,23.
Cc k hiu khc c mc 3.2.2.

3.3.2. Tnh ton gi thnh sn phm
Gi thnh sn phm c xc nh s b hoc chnh xc theo gi thnh cng xng v
chi ph ngoi sn xut. Cng thc tnh nh sau :

G = (1 +k
n
) G
CX
, [/chic] (2.16)

Trong k
n
l h s t l gia chi ph ngoi sn xut so vi gi thnh cng xng.
Thng k
n
= 0,03-0,05 (hin nay, nu k thm chi ph qung co th k
n
c th n 0,1 - 0,2
hoc hn).

3.4. Xc nh thi gian hon vn u t c bn
Thi gian hon vn u t c bn c xc nh trn c s mc chnh lch v vn
u t c bn v mc chnh lch v gi thnh sn phm gia phng n thit k so vi
phng n mu, theo cng thc :

N G G
V V
T
) (
0
0

= , [nm] (2.17)

Trong V
o
, G
o
l vn u t c bn v gi thnh sn phm ca phng n mu.
N l sn lng hng nm
V v G l vn u t c bn v gi thnh sn phm phng n thit k
3.5 Phng php phn tch kinh t la chn phng n ti u
la chn phng n thit k ti u ta cn phn tch, so snh mt cch ton din c
v mt s lng ln v mt cht lng
Kinh nghim cho thy : khi xt v hiu qu kinh t nh gi so snh la chn
phng n thit k th c trng quan trng nht i vi vic sn xut ra sn phm c kh l
h s hiu qu kinh t (H).
H s hiu qu kinh t (H) ph thuc ch yu vo 3 yu t :
<1> Gi tr tng sn lng hng nm S (/nm)
<2> Gi thnh sn phm tnh trung bnh hng nm G (/nm)
<3> Vn u t c bn V()
Trong li sut hng nm (L) c tnh :
21

L = S - G (2.18)

Kt hp cng thc (2.3) v (2.18) ta c :


V
G S
H

= (2.19)
Nh vy, phng n thit k ch c chp nhn khi m h s h qu kinh t ca
phng n khng nh hn h s hiu qu kinh t qui nh (hoc thit k mu) [H]. Tc l :

H [H]

Theo ti liu, ta c [H] =0,2 - 0,3.
T nhng cng thc trn, ta c nhn xt : phng n thit k tt hn l nhng phng
n th hin cc im sau :
1> Phng n c gi tr tng sn lng hng nm cao hn.
2> Phng n phi cho gi thnh sn phm thp hn.
3> Phng n c vn u t c bn nh hn.
n gin cho vic xem xt so snh, thng khi phn tch hiu qu kinh t, ngi ta
tin hnh so snh tng cp phng n v loi phng n xu hn. C tip tc nh th ta nhn
c nhng phng n hp l hn v cui cng nhn c phng n ti u.
V d : thit k mt nh my c kh, ngi thit k xy dng c N phng
n. Qua cc vic phn tch so snh ta thy c n trong N phng n c th c chp nhn.
Nhim v tip theo l t n phng n phi chn c phng n ti u.
Mun hon thnh cng vic ny, ta ln lt so snh tng cp phng n v loi dn
cc phng n xu hn.
Sau y ta tm hiu phng php so snh loi phng n xu hn. Gi th ta ly bt k
hai phng n A v B trong n phng n c th chp nhn. S liu tnh ton ca 2 phng n
nh sau :
- Gi tr tng sn lng nm :S
A
, S
B
.
- Gi thnh sn phm nm : G
A
, G
B
.
- Vn u t c bn : V
A
, V
B
.
Vn dng cng thc (2.19), nu phng n B tt hn phng n A thi:
[ ] H
V V
) G (S ) G (S
H
A B
A A B B
>

= (2.20)


Trong kho st thc t, khi thit k, cc phng n a ra u trn c s c nh gi tr
tng sn lng. Tc l S
A
= S
B
=...S
n
. V vy cng thc (2.20) c dng:

[ ] H
V V
G G
H
A B
B A
>

= (2.21)
Cng thc (2.21) c ngha l : phng n B tt hn phng n A th hin ch : vi 1
ng vn u t b thm th hng nm thu li c bao nhiu ng nh h gi thnh ca
phng n c u t ln hn.
V d : Phng n B c trang b bng cc dy chuyn t ng vi vn u t l
6000 triu ng; phng n A ch c trang b cc my mc vn nng nn vn u t c
bn l 5000 triu ng. Vi trnh k thut nh vy th gi thnh sn phm nm ca phng
n A l 7000 triu ng, cn phng n B ch 6600 triu ng.
22
Ap dng cng thc (2.21) ta c :
4 , 0
5000 6000
6600 7000
=

=
A B
B A
V V
G G
H
Vi [H] = 0,2 - 0,3 th H > [H]
Nh vy nu xt v hiu qu kinh t th phng n B tt hn phng n A.
Ch : ta thy rng trong trng hp so snh nhiu phng n th khi lng v
mc phc tp ca vic tnh ton s tng ln. n gin hn, nu xt theo bi ton ti u,
ta c th p dng 1 trong 2 cng thc sau y :
V
i
+ ([T].G
i
) = min (2.22)
G
i
+ ([H].V
i
) = min (2.23)
Trong : V
i
vn u t ca phng n i
G
i
gi thnh sn phm tnh trung bnh hng nm ca phng n i
[T] thi gian thu hi vn c bn cho php (nh mc)
[H] h s hiu qu kinh t cho php (nh mc)

3.6 Xc nh cc s liu kinh t - k thut ch yu ca nh my thit k
d dng nhn nhn mt cch tng qut kt qu ca phng n thit k (v mt hiu
qu kinh t v cht lng) c ph hp vi cc ch tiu qui nh, ph hp vi trnh pht
trin ca khoa hc k thut hay khng, ta cn xy dng mt h thng cc ch tiu kinh t - k
thut cho bn thit k.
H thng cc ch tiu kinh t - k thut bao gm cc ch tiu tuyt i v cc ch tiu
tng i.

3.6.1. Cc ch tiu tuyt i
Cc ch tiu tuyt i l nhng i lng c trng cho nng lc sn xut ca nh my
- l nhng s liu c tnh ton chnh xc trong qu trnh thit k. Nhng s liu ny c
thng k theo tng loi sau:
1/ S liu v sn phm, sn lng gm c tn, kiu, c, trng lng, s lng tng loi chi
tit, sn lng sn phm hng nm.
2/ S liu v vn u t c bn nh chi ph xy lp, chi ph v thit b, cc chi ph khc v
xy dng c bn.
3/ S liu v cc cng trnh xy lp :
- Din tch sn xut, din tch ph, din tch phc v v sinh hot.
- Tng din tch cc cng trnh c v khng c mi che, din tch ton khu t xy dng.
- Th tch bn trong ca nh my, phn xng.
- Tng s thit b chnh, thit b ph, thit b vn chuyn.
- Tng cng sut thit k cc thit b sn xut, ti trng ca thit b sn xut.
- Tng cng sut v ti trng ca thit b vn chuyn.
4/ S liu v cn b, cng nhn vin nh :
- S lng v bc th cng nhn tng loi.
- Tng s cng nhn sn xut, cng nhn ph v nhn vin phc v.
- Tng s cn b lnh o, cn b k thut, nhn vin hnh chnh s nghip.
5/ Cc s liu v chi ph sn xut nh :
- Tin lng cng nhn sn xut.
- Tin lng ca ton b cn b, nhn vin.
- Tin lng cng nhn ni chung (cng nhn sn xut v cng nhn ph).
- Chi ph sn xut.
- Chi ph phn xng.
- Chi ph qun l sn xut, qun l hnh chnh.
23
6/ Cc s liu v ch lm vic ;
- S ngy lm vic trong nm.
- S gi lm vic trong nm (gi my, gi ngi)
- S gi lm vic trong 1 ca sn xut.
- S ca lm vic trong 1 ngy m.
- H s ti trng trung bnh trong 1 ca sn xut.

3.6.2. Cc ch tiu tng i
Ch tiu tng i l nhng i lng c trng cho hiu qu kinh t ca nh my, l
c s nh gi cht lng ca bn thit k.
Nhng ch tiu tng i c xc nh t cc ch tiu tuyt i v c phn loi
nh sau :
1/ S liu v nng sut lao ng :
S liu v nng sut lao ng c tnh theo gi tr tng sn lng hng nm ca nh
my ng vi tng s cn b cng nhn vin, tng s cng nhn sn xut, tng din tch v
tng s thit b hoc tng s vn u t c bn. C th gm c cc ch tiu sau y :
a) Nng sut lao ng hng nm tnh cho 1 cng nhn sn xut ; 1 cng nhn ni
chung hoc mt cn b cng nhn vin. c xc nh bng cng thc :

=
i
i
R
S
q (2.24)
Trong : S l g tr tng sn lng hng nm.
Ri l tng s nhn lc ca loi cng nhn hoc cn b
i l loi nhn lc (cng nhn sn xut, cng nhn ni chung ...)
b/ Nng sut lao ng hng nm tnh cho 1 n v thit b sn xut..
c xc nh nh sau:

=
C
S
q
t
(2.25)
c l tng s thit b
c/ Nng sut lao ng hng nm tnh cho 1 ng tin lng ca 1 cng nhn sn xut,
1 cng nhn ni chung, 1 cn b cng nhn vin.
Cng thc tng qut l :

=
l
S
q
l
(2.26)
l l qu tin lng cho tng loi nhn lc
d/ Nng sut lao ng hng nm tnh cho 1m
2
din tch sn xut, 1m
2
din tch chung,
cng thc tnh :

=
F
S
q
F
(2.27)

F l tng din tch loi xt
e/ Nng sut lao ng hng nm tnh cho 1 ng vn u t, xc nh theo cng thc:


V
S
q
v
= (2.28)
24
Gi tr tng sn lng hng nm (S) ca nh my bao gm 2 thnh phn :
- Gi tr sn lng hng ho - xc nh bng tng gi tr sn lng thnh phm (n gi
thnh phm)
- Gi tr sn xut t trang t ch.
2/ Cc s liu v din tch bao gm.
a) Din tch sn xut, din tch chung tnh cho 1 n v thit b.
b) Din tch sn xut, din tch chung tnh cho 1 cng nhn sn xut, 1 cng nhn ni
chung, 1 cn b cng nhn vin.
c) H s s dng din tch xy dng (h s mt kin trc, h s s dng t).
3/ S liu v thit b bao gm :
a) Cng sut thit k trung bnh ca 1 thit b sn xut, 1 thit b ni chung, c xc nh
bng t s gia tng cng sut thit k v tng s thit b. n v: Kw/thit b.
b) Cng sut thit k tnh cho 1 cng nhn sn xut, c ly bng t s gia tng cng
sut thit k v tng s cng nhn sn xut, n v tnh Kw/ngi.
c) Gi tr thit b trung bnh l t s gia tng gi tr thit b v tng s thit b. n v
tnh l /thit b.
d) Gi tr thit b tnh cho 1 cng nhn sn xut.
e) H s ti trng trung bnh ca thit b (
Ztb
) (s cp n chng 4)
g/ H s s dng trung bnh theo thi gian c bn (
0tb
) (s cp n chng 4)
h/ S gi my ch to 1 n v sn phm (h/tn, h/chic)
4/ S liu v cn b cng nhn vin gm c :
a) T l gia cng nhn sn xut, cng nhn ni chung, nhn vin, cn b k thut ni
ring so vi tng s cn b nhn vin.
b) Bc th bnh qun ca cng nhn sn xut, cng nhn ni chung.
c) Tin lng tr cho 1 cng nhn sn xut, 1 cng nhn ni chung, 1 cn b nhn vin
(/ngi)
d) T l gia tin lng sn xut v qu tin lng ni chung.
5/ S liu v gi thnh bao gm :
a) Gi thnh cng xng (/chic)
b) Gi thnh sn phm (/chic)
c) T l gia cc thnh phn ca gi thnh cng xng.
d) Vn u t tnh cho 1 cng nhn sn xut, 1 cng nhn ni chung, 1 cn b nhn vin.









25
Chng III
THIT K TNG TH NH MY C KH

1. Khi nim v thit k tng th
Trong nn kinh t quc dn, mt nh my bao gi cng nm trong mt h thng nht
nh. H thng c th l lin hip cc nh my hoc mt cng ty, tng cng ty. V vy s
hot ng ca mi nh my u chu s chi phi ca c h thng. Vi l do , v tr, qui m,
phng thc sn xut, trang b cng ngh . . ca nh my phi ph hp trong mi tng quan
chung ca c h thng, ca c nn kinh t.
Thit k tng th l nhm gii quyt cc vn chung c lin quan n s hnh thnh
nh my nm trong quan h vi ton b h thng.
Thit k tng th khc vi thit k c th (thit k cc phn xng, b phn cu
thnh nh my) ch thit k tng th l gii quyt cc nhim v trong quan h vi ton h
thng, cn thit k c th th b hp trong quan h nh my.

2. Cc ti liu ban u cho thit k tng th
Ti liu ban u l nhng t liu, s liu chung lm c s cho cc giai on thit
k.
D l thit k mt nh my mi, hon chnh hay thit k m rng pht trin mt nh
my c, t chc thit k cng cn phi c cc ti liu ban u sau y:

1/ Bn nhim v thit k do c quan cp trn cung cp.
2/ Vn bn cho php v a im xy dng nh my.
3/ Ngun cung cp nguyn vt liu.
4/ Nhng kh nng v s hp tc vi bn ngoi.
5/ Ngun cung cp nng lng (in, hi t, nc, kh nn...).
6/ Qu trnh cng ngh sn xut sn phm.
7/ Ch lm vic v khi lng lao ng hng nm.

Ring i vi thit k m rng pht trin nh my c cn cn thm cc ti liu
sau:
8/ H thng thit b nh xng ca nh my c.
9/ Hin trng nh my c cn m rng.
10/ Kh nng v yu cu m rng trong tng lai.
Trong nhng ti liu ban u k trn th bn nhim v thit k l quan trng nht.
Khi chun b c y c cc ti liu ban u, t chc thit k phi tin hnh
nghin cu, phn tch cc ti liu y mt cch t m trin khai cng tc thit k.

3. La chn a im xy dng nh my
a im xy dng nh my c nh hng ln n trng thi cn bng v chnh tr, kinh
t, vn ho x hi ca mt vng lnh th. Do , a im xy dng nh my trc ht phi
nm trong qui hoch di hn v phn vng kinh t, phn vng dn c ca trung ng v a
phng.
Vic la chn a im xy dng nh my thng do c quan ch qun nh my thc
hin c s tham gia kin ca c quan thit k c bn v ca t chc thit k nh my. Vic
la chn y phi c c quan cp trn c thm quyn thng qua v quyt nh bng vn bn.

3.1. Nhng cn c la chn a im xy dng nh my.
26
Mun la chn ng a im xy dng nh my, trc tin cn hiu r cc yu t nh
hng n qu trnh xy dng, hot ng ca nh my
Cc yu t nh hng thng c phn thnh 3 nhm:
- Cc yu t thin nhin.
- Cc yu t kinh t - k thut.
- Cc yu t chnh tr - x hi.

3.1.1 Cc yu t thin nhin nh hng n nh my
Kinh nghim cho thy: cc yu t thin nhin c nh hng ln n qu trnh xy
dng cng nh qu trnh hot ng ca nh my sau ny. Nhng yu t thin nhin thng
bao gm:
- V t ai, th nhng.
- V kh hu, a hnh, a cht nh nhit , m, mch nc ngm.
- V kh nng cung cp nguyn liu, nhin liu ti ch. . .

3.1.2 Cc yu t v kinh t - k thut nh hng ti nh my nh:
- H thng giao thng gm ng st, ng b, ng thu, ng khng.
- Ngun cung cp nng lng ( in, kh t, nc, kh nn . .)
- Ngun cung cp nhn lc, vt t k thut.
- Kh nng phn cng hp tc sn xut.
- Kh nng u t v kh nng tiu th sn phm...

3.1.3 Cc yu t v chnh tr- x hi nh hng ti nh my gm c:
- Vng dn c (thnh th, nng thn, min ni ...)
- Khu vc trng hc, bnh vin, khu ngh mt, khu du lch...
- Khu vc qui hoch pht trin ca trung ng, a phng
Khi la chn a im xy dng nh my phi nghin cu phn tch mt cch tng
hp cc yu t nh hng vi a im la chn, nh my thun tin trong vic xy dng
v pht huy tt hiu qu trong qu trnh sn xut sau ny.

3.2 Nhng nguyn tc la chn a im xy dng nh my
Bn cnh vic nghin cu phn tch mt cch tng hp cc yu t nh hng nhm
loi tr nhng yu t bt li v trit s dng nhng yu t c li, khi la chn a im
xy dng nh my, cn tun theo nhng nguyn tc c bn sau y:
1/ a im xy dng nh my phi gn vi ngun cung cp vt t, nguyn liu nng
lng, lao ng v ngun tiu th sn phm. C nh vy mi gim c chi ph vn chuyn.
2/ a im xy dng nh my phi nm trong qui hoch phn vng kinh t, phn
vng dn c ca trung ng v a phng.
3/ La chn a im xy dng nh my phi ch trnh nhng iu kin thin nhin
trc tip nh hng xu n cht lng sn phm (nh nng, m, kh hu vng bin. . .).
4/ a im xy dng phi m bo an ton nh phng chy, phng khng, phng
gian.
5/ a im xy dng nh my cn phi tho mn nhng yu cu sau:
- din tch xy dng m rng.
- Khng chim nhiu din tch canh tc.
- iu kin a cht n nh (khng c mch nc ngm, khng c hm m,
khng thng xy ra ng t...).
- iu kin san o, xy dng thun tin.
- Khi nh my hot ng khng gy nh hng xu n khu vc ln cn (nh
c hi, bi bm, chn ng...).
27
6/ a im xy dng nh my phi ch ti ngun b sung nhn lc trc mt v
lu di. Ch kh nng hp tc sn xut.

4. Thit k cung cp nguyn vt liu
Thit k cung cp nguyn vt liu bao gm thit k cng ngh v thit k dng vt
liu.

4.1 Thit k cng ngh tng qut
Cng ngh tng qut l qu trnh khi qut mang tnh trnh t ca qu trnh sn xut ra
sn phm ca nh my.
Phn tch sn phm v cc yu t khc c lin quan nh ra cc cng on ca qu
trnh sn xut ra sn phm gi l thit k cng ngh tng qut hay cn goi l thit k cng
on. V d: vt liu cung cp t bn ngoi a vo kho nguyn liu chuyn sang phn
xng c kho trung gian n phn xng gia cng ct gt sang phn xng lp rp
a n b phn sn, m chuyn n b phn tng kim tra, bao gi.
Cng ngh tng qut cho ta thy r cc giai on ln cn thc hin hon thnh qu
trnh sn xut ra sn phm. Thng thng mi mt giai on ca cng ngh tng qut c
thc hin ti mt phn xng hoc b phn c th ca nh my.
Khc vi thit k cng ngh tng qut, cng ngh c th ca tng phn xng l th
t cc nguyn cng thc hin mt cng on no trong cng ngh tng qut. V vy thit
k cng ngh ca phn xng cn gi l thit k nguyn cng.

4.2 Thit k dng vt liu tng qut
Dng vt liu l ng ni lin gia cc cng on (hoc nguyn cng) dng biu
din qui trnh cng ngh sn xut.
Thit k cng ngh tng qut v thit k dng vt liu tng qut gi chung l thit k
cung cp nguyn vt liu tng qut.
Thit k dng vt liu bao gm :
1/ Thit k ng i ca vt liu mt cch hp l.
2/ B tr thch hp v tr ga xut nhp v ng vn chuyn t ngoi vo.
3/ Gii quyt tt vn chuyn nguyn vt liu vo cc to nh, phn xng.
4.2.1 Thit k ng i ca vt liu (dng vt liu)
Tu thuc vo qui m ca nh my; vo v tr, hnh dng ca khu t xy dng v da
vo lng vn chuyn hng nm, ta c th c nhiu cch b tr dng vt liu khc nhau.
d dng theo di, ta thng nht mt s k hiu sau:

Theo kinh nghim thc t, thng s dng cc loi dng vt liu sau:
- Dng vt liu c dng thng
- Dng vn chuyn gp khc
- Dng vn chuyn rng lc
1/ Dng vt liu c dng thng
ng giao thng chnh
Phm vi khu t xy dng
Phm vi ta nh
ng i ca vt liu (dng vt liu)
Ga, trm xut nhp

28
Khi khu t xy dng c dng di v hp, th cc to nh ca nh my c xy k
tip nhau theo tng hng di dc khu t.
Trong nhng trng hp , vn chuyn nguyn vt liu, ngi ta thng xy
dng cc ng song song vi cc dy to nh. Tng ng vi n l dng vt liu c dng
ng thng (hnh 3.1)
Hnh 3.1 Dng vt liu c dng thng.

Loi dng vt liu c dng thng cho kh nng vn chuyn ln. Thng ng dng vo
cc nh my c qui m sn xut ln, lng vn chuyn ng k.
2/ Dng vt liu c dng gp khc

Hnh 3.2 Dng vt liu c dng gp khc.
Dng vt liu c dng gp khc thng c 2 loi:
- Loi gp khc h
- Loi gp khc khp kn
Dng vt liu c dng gp khc h hnh ch L (hnh 3.2 a) c s dng trong trng
hp c khu t xy dng tng ng c dng ch L.
Dng vt liu c dng gp khc khp kn (hnh 3.2 b) thng c ng dng trong cc
trng hp c khu dt xy dng hnh vung hoc gn vung.
Ni chung dng dng vt liu ny c lng vn chuyn nh hn dng thng.
3/ Dng vt liu c dng rng lc
Hnh 3.3 biu din cc trng hp dng vt liu c dng rng lc.
Hnh 3.3 Dng vt liu c dng rng lc
a)
b)
d)
c)
b)
a)
e)
f)
g)
29
Trng hp a, b, c, d l loi dng vt liu c dng rng lc n gin - cc to nh
c xy dng lin tip nhau c dng ch U.
Trng hp e, f, g l loi dng vt liu dng rng lc phc tp. Cc to nh c xy
dng to thnh hnh rng lc, tc l cc phn xng gia cng sn phm c b tr song
song vi nhau v phn xng lp rp c b tr vung gc vi cc phn xng gia cng.
Loi dng vt liu ny thng dng cho cc phn xng, nh my c yu cu cao v
thng gi v chiu sng (v d cc phn xng rn dp).

4.2.2 B tr ga v ng vn chuyn.
Vi nhng nh my ln, m bo vn chuyn nguyn vt liu vo, ra nh my,
ngi ta phi xy dng mt h thng ng st. i vi nhng nh my c qui m nh hn,
lng vn chuyn khng ln lm th xy dng mt h thng ng b.
D l phi xy dng h thng ng st hay ng b, thng phi xy dng mt c
s tp kt vt t v sn phm, chnh l ni giao nhn gia nh my v bn ngoi cn gi
l ga.
Trong thc t, tu thuc vo hnh dng khu vc nh my, tu thuc vo s b tr cc
phn xng trong nh my, tu thuc vo qui m sn xut ca nh my, ta thng gp bn
loi h thng ga - ng :
- H thng ng ct.
- H thng ng song song, c lp, giao nhau.
- H thng ng khp kn.
- H thng ng hn hp.
1/ H thng ng ct
Hnh 3.4 biu din h thng ga - ng ct. Vi h thng ng ny vic a vt
liu vo cc kho, cc phn xng bng mt h thng ng. ng thi vic vn chuyn thnh
phm, bn thnh phm ra ngoi (n ga) li cng chnh bng cc ng .
Loi h thng ga- ng ct c lu lng vn chuyn nh, thng thch ng vi cc
nh my c qui m va v nh.
Hnh 3.4 Hnh 3.5

2/ H thng ng song song, c lp, giao nhau
Loi h thng ny c biu th trn hnh 3.5. Trn h thng, nh ga c xy dng v
mt hoc 2 bn ca nh my, cc ng to thnh mng song song i vo cc to nh v i ra.
Loi h thng ga, ng ny c lu lng vn chuyn ln. Thng p dng vi cc
nh my c qui m va v ln, c nhu cu v vn chuyn ln.
3/ H thng ng vn chuyn khp kn
h thng ny cc tuyn ng dn vo cc phn xng, cc kho c to thnh
nhng vng kn (hnh 3.6).
Ga
xut
Ga
nhp
ng
st
30

Hnh 3.6 Hnh 3.7
Vi h thng ny th ng vn chuyn to thnh mng li khp kn trong nh
my.V c im nn n thng c s dng trong nhng trng hp khu vc nh my
rng v yu cu lng vn chuyn ng k.
4/ H thng ng hn hp
Thc cht ca h thng ny l li dng mt u im ca h thng ng ct v h
thng ng khp kn xy dng thnh h thng ng phi hp (hnh 3.7).
H thng ng phi hp cho kh nng vn chuyn ln, do n thch ng vi cc
nh my c nhu cu vn chuyn ln.

4.2.3. Gii quyt vn vn chuyn vo cc phn xng

Theo kinh nghim thc t, vic vn chuyn t ng vo cc phn xng thng s
dng bng cu trc. Vic b tr v tr v tm hot ng ca cu trc tu thuc vo quy m sn
xut, vo vic b tr cc phn xng trong nhng to nh v vo v tr ca h thng ga -
ng.
Thng thng theo v tr ca h thng ga - ng v b tr cc phn xng, ta hay gp
3 trng hp ph bin sau :
- ng nm bn ngoi nh my, ca vo vung gc vi ng.
- ng xuyn qua nh my.
- ng ch i qua mt phn nh my.
ng y l ng giao thng chnh ni vi ngoi (c th l ng st, ng b).
Sau y l ln lt gii thiu tng trng hp.

1/ Trng hp ng bn ngoi nh my, ca vung gc vi ng
Vi trng hp ny c th c hai cch vn chuyn:

- Cch 1: (hnh 3.8.a) cc gian nh b tr song song nhau v vung gc vi ng.
Cng vic vn chuyn c thc hin bng cc cu trc ring bit.

- Cch 2 : (hnh 3.8.b) c gian nh u xy song song vi ng. Vic vn chuyn
t ng vo cc phn xng c thc hin bng mt cu trc chung. T vic vn
chuyn ti tng gian tip theo li c thc hin bng cc cu trc ring bit.
31

Hnh 3.8 Hnh 3.9

2/ Trng hp i xuyn qua nh my
ng xuyn qua nh my c th l xuyn qua gia gian nh (hnh 3.9), cng c th
i qua st mp tng ca gian nh.
Trong nhng trng hp nh vy th vic vn chuyn t ng vo nh my s thc
hin bng mt cu trc chung. Sau dng cc cu trc ring bit vn chuyn vo cc kho,
phn xng c lp.
3/ Trng hp ng ch i qua mt phn nh my
ng xuyn qua mt phn nh my, thng gp 5 trng hp nh hnh 3.10.

Hnh 3.10

Tu thuc h thng ga - ng xuyn qua nh my, ta c th b tr cc cu trc khc
nhau.
Trn y l mt s dng b tr thng gp trong thc t. Tuy nhin, thc t rt phong
ph, do vy vic la chn phng n cng cn rt linh hot.

5. Xc nh h thng t chc tng qut ca nh my
Nh my c kh l mt tp hp cc phn xng, b phn c cng mt mc ch thng
nht l to ra sn phm theo yu cu. lm c vic , mi phn xng, b phn phi
m nhn hon thnh mt cng on no ca qui trnh cng ngh tng qut. Nh my ni
chung v tng phn xng ni ring mun hon thnh cng vic ca mnh phi c s iu
khin, s tr lc kp thi ca nhng b phn khc. chnh l c im chuyn mn ho v
hip tc ho ca sn xut cng nghip.
Mt khc ta thy rng: sn phm c kh ni chung rt a dng, nn qui trnh cng ngh
sn xut ra chng cng rt khc nhau. thch ng vi khch quan , h thng t chc c
th ca mi nh my cng khng th ging nhau.
Tt nhin mt cch khi qut ta c th thy rng d l nh my no th cng phi t
chc ra lm hai khu vc nhim v :

- Khu vc sn xut
- Khu vc iu khin, h tr cho sn xut
b)
a)
a) b) c) d) e)
32
lm r h thng t chc tng qut ca nh my, ta ln lt tm hiu 2 vn c
lin quan sau y :
+ Thnh phn cu to tng qut ca nh my c kh.
+ Cc dng s biu din h thng t chc tng qut.

5.1. Thnh phn cu to tng qut ca nh my c kh:
Tu theo quy m sn xut, phng php cng ngh v cch t chc sn xut m xy
dng c cu t chc ca nh my cho ph hp.
Cn c vo tnh cht ca tng cng on sn xut din ra trong c qu trnh sn xut
sn phm c kh mt cch tng qut, nh my c kh gm c cc thnh phn cu to sau :
- Cc phn xng sn xut chnh.
- Cc phn xng ph tr sn xut (phn xng ph)
- H thng kho tng.
- Cc t chc nng lng.
- Cc t chc vn chuyn.
- Cc t chc v sinh k thut, an ton lao ng
- Cc b phn phc v.
Sau y ta i vo tm hiu cu to c th ca tng thnh phn cu to mt.

5.1.1. Cc phn xng sn xut chnh :
Nhng phn xng c nhim v trc tip lm thay i hnh dng, kch thc, trng
thi ca phi liu bin n thnh sn phm c gi l nhng phn xng sn xut chnh.
Cn c vo trnh t hnh thnh sn phm, cc phn xng chnh c phn thnh ba
nhm:
1/ Nhm cc phn xng ch to phi :
Tu thuc vo quy m sn xut, kh nng u t xy dng v yu cu sn xut, cc
phn xng ch to phi thng gm c :
- Cc phn xng c ( c gang, c thp, c kim loi mu).
- Cc phn xng gia cng p lc (rn, dp, cn, p, dp ngui...).
- Phn xng chun b phi (nn thng, bc v, khoan tm, ca on...).
2/ Nhm cc phn xng gia cng c : thng l :
- Cc phn xng hn.
- Phn xng sa cha b mt.
- Cc phn xng ct gt (phn xn gia cng chi tit c bit, phn xng gia cng
bnh rng, phn xng gia cng chi tit tiu chun ...).
3/ Nhm cc phn xng giai on kt thc : nh :
- Phn xng lp rp.
- Phn xng nhit luyn.
- Phn xng sn, m, phun kim loi.
- Phn xng bao b, ng gi.
5.1.2 Cc phn xng ph
ph tr cho cc phn xng sn xut chnh lm vic lin tc, ch ng v n
nh, thng trong nh my c kh cn c cc phn xng ph sau:
- Phn xng dng c.
- Phn xng khun, mc mu.
- Cc phn xng sa cha (c in, xy dng).
5.1.3 H thng kho tng trong nh my
cho qu trnh sn xut din ra nhp nhng, ng thi gii quyt tt vn bo
qun vt t, sn phm, trong nh my nht thit phi c h thng kho. H thng kho thng
gm c:
33
- Kho vt liu ca nh my (kho vt liu him, kho vt liu thng thng).
- Kho nhin liu (than, ci, du m, ho cht...),
- Kho trung gian (cha bn thnh phm),
- Kho dng c,
- Kho trang b cng ngh ( g, dng c ct).
- Kho thnh phm.
5.1.4 Cc t chc nng lng: thng bao gm
- Trm pht in, trm bin th, my n.
- Trm kh nn, ni hi, xng du.
- H thng sn xut, phn phi in, kh nn, cp thot nc...
5.1.5 Cc t chc vn chuyn : nh:
- H thng vn chuyn thit b, vt liu (ng s, dy cp, gara, bn bi...) ra vo nh
my
- H thng vn chuyn trong ni b nh my (xch, ng, xe chy in, cu trc, xe
y tay...).
5.1.6 Cc t chc v sinh k thut - an ton lao ng :nh:
- H thng ht bi, thng gi, iu ho nhit .
- H thng lm sch nc bn, trm bm, b lc, b cha...
- Cc trm trang b bo h lao ng.
5.1.7 Cc b phn phc v trong nh my :thng c:
- Ban gim c nh my,
- Vn phng hnh chnh, s nghip.
- Cc phng chc nng.
- C quan t chc, gio dc, o to.
- Trm cp cu, bnh x, nh ngh.
- Trm thng tin lin lc, h thng truyn thanh, in thoi...
- Cc trm gc, trm bo v.
- Nh n tp th.
- Cu lc b...

trn gii thiu mt cch khi qut cc thnh phn cu to ca nh my c kh.
Tuy nhin tu thuc vo mt qui m ca nh my, kh nng u t xy dng v mc yu
cu c th, cc phn xng, b phn v t chc c th chia nh ra hay kt hp li thnh mt
b phn chung cho ph hp.

5.2 Cc dng s biu din h thng t chc tng qut ca nh my
Trong khi tin hnh thit k h thng t chc tng qut ca nh my, d dng khi
qut ho v kim tra theo di cng vic thit k, thng ngi ta tin hnh m hnh ho bng
cc dng s .
Trong thit k nh my (x nghip) c kh thng dng hai dng s :
- S m hnh x nghip
- S m hnh sn xut s khi.

5.2.1 M hnh x nghip c kh
M hnh x nghip nu ln mt cch khi qut cc thnh phn cu to ca mt nh
my c kh c chia theo cc nhm b phn.
Hnh 3.11 biu din m hnh x nghip c kh



34

Hnh 3.11 M hnh x nghip c kh.



Hnh 3.12 M hnh sn xut nh my t
Gia
cng c
Lp
rap
Ch
tao
phi
Ch
tao
dung
Sa
cha c
- in
Kho phi
liu
Kho ban
thanh
phm
Kho thanh
phm
B phn lanh
ao quan ly
B phn
sinh hoat,
phuc li
Nhit
luyn
Khu vc san
xut
Nhom I : Cac phn
xng s. xut chnh
Nhom II : Cac
phn xng
Nhom III : B
phn phu
Nhom IV :
Cac b
phn chung
12
7 8
1 2
3
5
7
4
6 8
1
2
3
4
5
6
1
2 3 4
9
10
11
10
9
1
2
3
35
Hnh 3.13
5.2.2 M hnh sn xut nh my c kh:
M hnh ny nu r quan h gia cc qu trnh sn xut chnh, ph, phc v . . . v c
s phn bit k hiu gia chng. V d hnh 3.12 l mt m hnh sn xut ca mt nh my
sn xut t. Cc k hiu trong hnh 3.12 nh sau :






































Cac phn xng san xut chnh : 1 uc, 2 ren, 3 dp tm, 4 gia cng ct got, 5
nhit luyn,
6 ch tao khung vo, 7 lp rap, 8 sn ma, 9 th tnh nng, 10 bao goi.
Cac phn xng phu : 1 mc, 2 lam mu, 3 dung cu, 4 sa cha
Cac thit b nng lng : 1 tram phat in, 2 lo si trung tm, 3 tram bin th
Cac loai kho : 1 kho g, 2 kho vt liu lam khun, 3 kho kim loai, 4 kho thanh phm
dp,
5 kho nhin liu, cht t, 6 kho san phm uc, 7 kho san phm ren, 8 kho dung cu,
9 kho
36
5.2.3 S d khi tng qut ca nh my c kh :
Hnh 3.13 m t s d khi tng qut ca mt nh my c kh.

6. B tr tng mt bng nh my c kh

6.1. Khi nim

B tr tng mt bng nh my l xp t nh my vo a im xy dng chn, v
xp t v tr cc phn xng, b phn cu thnh nh my vo trong khu vc nh my, ng
thi sp xp v tr cc my mc, thit b vo phn xng v b phn.
S xp t ny mang tnh cht t chc hot ng c biu din trn bn mt bng.
Do mt cch ngn gn c th ni : b tr mt bng nh my l s xp t cc v tr hat
ng ca nh my trong khu vc, ca cc phn xng trong nh my, ca cc b phn, ch
lm vic trong phn xng.
B tr mt bng nh my c xut pht t 2 cch nhn :
1) Theo s hot ng ca nh my
2) Theo quan im xy dng nh my
T 2 cch nhn , c hai phng php tin hnh b tr :
1) B tr theo sn phm, chi tit (theo cng vic : mi phn xng ch ch to v lp
rp cc chi tit ca mt b phn hay mt sn phm nht nh)
2) B tr theo cng ngh : chi tit ca cc b phn sn phm c phn nhm theo
mc tng t v qu trnh cng ngh v kch thc ca chng. Thng s dng trong sn
xut n chic v hng lot. Cc phn xng c kh c chia ra cc gian, cng on theo
kiu chi tit v mc ging nhau v qui trnh cng ngh, v d phn xng gia cng nhm
cc chi tit hp, phn xng gia cng nhm trc . . .

6.2. Nhng nguyn tc chung khi b tr tng mt bng

Theo Egorov, khi b tr mt bng nh my, cn c gng tun th cc nguyn tc c
bn sau y :
1/ Tu theo kh nng, cn b tr v tr tng quan gia cc phn xng b phn theo
trnh t ca qu trnh sn xut ra sn phm sao cho ng vn chuyn l ngn nht
2/ Cn tn lng b tr cc phn xng ph gn vi cc phn xng chnh m n phc
v
3/ Cc to nh trong nh my phi c b tr sao cho m bo kh nng bo v, an
ton lao ng
4/ B tr cc to nh hp l nht, ch m bo kh nng pht trin m rng sau ny
5/ Tn lng b tr mt bng s dng tt nht h thng ng giao thng
6/ Nn b tr phn xng chnh v ph c lin quan nhau trong cng mt to nh.
7/ Cc phn xng, b phn phi c b tr m bo thng gi v chiu sng t
nhin thch hp.
8/ Cc phn xng b phn phi c b tr cc v tr khng gy nh hng xu ti
cc phn xng, b phn khc.
9/ Trn c s cng ngh v an ton nn phn nh my thnh nhng khu vc thch
hp.

6.3 Cc c s ban u b tr tng mt bng

m bo tnh cn i ca nh my v to iu kin cho mi hot ng ca nh my
trong qu trnh sn xut c lin tc, n nh, ng b, c hiu qu ng thi p ng c
37
cc ch tiu kinh t - k thut, trc ht phi b tr tng mt bng nh my mt cch hp l
nht.
Mun cng vic b tr tng mt bng hp l, t chc thit k cn c trong tay ti liu
c s sau y:
1/ Cc vn bn, ti liu c th v a im xy dng nh my, bao gm cc vn bn
hp php cho php ca cp trn v a im, din tch, ranh gii... Km theo l cc ti liu
v a cht cng trnh, v a l kinh t, v vn ho x hi c lin quan ti qu trnh xy dng,
hot ng ca nh my trc mt v lu di.
2/ Chng trnh sn xut ca nh my c nu r loi sn phm, sn lng, thi gian
bt u xy dng, bt u sn xut...
3/ Qui trnh cng ngh v cc ti liu c lin quan n qui trnh cng ngh nh cc s
, cc loi trang thit b.
4/ Qui m ca cc phn xng (c, loi) v nhu cu din tch ca chng.
5/ Cc s biu din t chc ca nh my.
6/ Cc nhu cu v nhn lc theo tng loi : nam, n, vng dn c, ch , ni, ngoi
tr, tp th hay gia nh.
7/ Cc nhu cu v nng lng (in, nc, kh nn, hi t...) ca tng b phn, phn
xng.
8/ Cc nhu cu v vn ho, x hi, y t...
9/ Nu thit k m rng pht trin th phi c cc ti liu v hin trng nh my c
sn (hoc chng trnh sn xut ca nh my tng t)

6.4. Trnh t thit k tng mt bng

Thit k tng mt bng l gii quyt quan h tng qut ca nh my. Theo kinh
nghim thc t, vic thit k tng mt bng c thc hin theo trnh t sau:
1/ H thng ho v phn tch cc ti liu ban u.
2/ Tnh ton thit k cc phn xng v b phn ca nh my.
3/ Thit k dng vt liu.
4/ Phn tch mi quan h gia cc b phn trong nh my.
5/ B tr cc phn xng, b phn vo nhng v tr khng gian thch hp.
6/ Xc nh din tch m rng, khu vc cy xanh v n ci to a hnh
7/ Xy dng s quan h khng gian (bn v mt bng)
8/ So snh la chn cc phng n.
Ton b trnh t trn c th biu din di dng s khi nh hnh 3.14.

6.5 Cc phng php b tr mt bng nh my

Mt bng nh my phi c b tr ph hp vi qui trnh cng ngh v t chc sn
xut, phi m bo tnh lin tc ca qu trnh sn xut, tnh hp l ca qu trnh vn chuyn.
Vic b tr mt bng cn m bo ng vn chuyn ngn nht, khng ct nhau v
cng khng trng nhau.
B tr mt bng nh my thng c tin hnh theo 2 phng php :

- Phng php m hnh ha
- Phng php ton hc.
Nhng phng php ny s c trnh by r hn trong phn thit k c th cc phn
xng.
38
Hnh 3.14



6.6. V d v b tr mt bng tng th

d hnh dung kt qu cui cng ca cng vic thit k mt bng tng th, ta n c
mt v d v s mt bng nh my ch to t ALFA ROMEO. y l nh my c 18000
cng nhn, hng ngy c th sn xut n 1000 t c cht lng. Nh my nm min nam
Italia.
Nhng gii
han
thc
Cac iu kin
bin i
S quan h
v din tch
trong mt bng
S quan
h gia
cac b
phn
Bang quan
h gia
cac b
phn
Dong vt
liu
Cac
hoat
ng
phuc vu
Qui trnh
cng
ngh
Yu cu v
din tch
Din tch
tnh toan
thc t
Thit
b san
xut
Cac
b
phn
phuc
vu
Phng hng lanh ao
X Y Z
So sanh cac phng an
Phng an ti u
39

Nhng k hiu trn mt bng nh my ALPHA ROMEO hnh 3.15:
1/ Nh vn phng
2/ Phn xng dp
3/ Phn xng lp rp v xe v sn
4/ Phn xng c kh
5/ Cc b phn ph v phc v
6/ Nng lng
7/ Kho ph tng thay th
8/ ng th nghim sn phm
9/ Nh thay qun o
10/ Kho thnh phm
11/ B hng
12/ Bn ng thu
13/ Cng vin
14/ Khu th thao, cu lc b
15/ Khu vc m rng nh my.

6.7. Cc ch tiu nh gi tnh hp l khi b tr mt bng

nh gi so snh mc hp l khi b tr mt bng nh my, ngi ta a ra hai
ch tiu so snh (cn gi l 2 h s) :
-Ch tiu nh gi mt kin trc
- Ch tiu nh gi mc s dng din tch

Hnh 3.15 Mt bng nh my ALPHA ROMEO
B
Bn
ng
thu
Kho ph tng
thay th
40
1/ Ch tiu nh gi mt kin trc
Ch tiu nh gi mt kin trc - cn gi l h s mt kin trc Kkt l t s
gia din tch cc to nh v cc cng trnh khc c mi che vi ton b din tch nh my
(tnh t ng ranh gii).
Tc l nu k hiu Fmc l din tch c mi che
Ftg l din tch ton b nh my, th


tg
mc
kt
F
F
K = (3.1)


Vi nhng cng trnh hot ng tt th Kkt= 0,25 - 0,35
2/ Ch tiu nh gi mc s dng din tch
Ch tiu ny cn gi l h s s dng din tch, l t s gia din tch dng vo sn
xut (cc to nh, cc cng trnh c v khng c mi che nh ng vn chuyn ngoi tri,
bi kho) vi ton b din tch ca nh my. Ch tiu ny k hiu l Ks
Nu gi Fs l din tch sn xut th:


tg
s
s
F
F
K = (3.2)

Vi nhng cng trnh hot ng tt th Ks= 0,45 - 0,5

Trong qu trnh thit k, c c mt bng tng th ca nh my, ta cn hon
thnh khi lng cng vic rt ln. Ngoi nhng ni dung c bn trnh by cc mc 1, 2,
3, 4, 5 v 6, ta cn cn phi nghin cu gii quyt cc ni dung lin quan sau:
1/ Phn nh my thnh cc khu vc hp l theo Egorov th phn thnh 5 khu vc :
- Khu vc gia cng nng.
- Khu vc gia cng c v lp rp.
- Khu vc d chy
- Khu vc nng lng, vn chuyn
- Khu vc chung ca ton nh my
2/ Xc nh nhu cu nng lng v vn chuyn cho nh my
3/ Thit k cc b phn khng sn xut ca nh my - thng bc cng vic ny
c song song tin hnh khi thit k cc phn xng.

7. Phn tch kinh t v la chn phng n

Phn tch kinh t gm c 2 ni dung:
1/ Xc nh cho c cc ch tiu kinh t - k thut ca cc phng n thit k.
2/ T quan im hiu qu kinh t, da vo cc ch tiu kinh t- k thut, so snh, la
chn phng n ti u.



41
Chng IV:
THIT K PHN XNG C KH

1. Vai tr phn xng c kh trong nh my c kh

Tn gi phn xng c kh phn no cho ta thy vai tr ch yu ca n trong
nh my, v cng v l ngi ta thng gi cc nh my ch to l nh my c kh . L
phn xng ch yu nht ca nh my ch to bi v:
- S thit b trong phn xng c kh chim t l rt ln trong tng s thit b ca ton
b nh my. Mt khc chng loi thit b trong phn xng c kh cng a dng, vn
u t mua thit b cho phn xng c kh thng ln nht so vi cc phn xng
khc.
- Khi lng lao ng ca phn xng c kh rt ln, thng chim t 40 ~ 60% ton
b khi lng lao ng ch to sn phm ca nh my.
- Hu ht cc chi tit ca sn phm ch to u phi qua gia cng phn xng c kh.
Qu trnh cng ngh phn xng c kh cng rt phc tp v thi gian sn phm
dng li y cng lu nht.
- Phn xng c kh gp phn quyt nh nht ti cht lng ca sn phm gia cng
trong nh my.
V vai tr ca phn xng c kh trong nh my nh vy, nn cng vic thit k phn
xng c kh cn phi t m v cng phu.

2. Phn loi phn xng c kh

Tu theo loi sn phm cn ch to, kt cu v trng lng ca sn phm; tu theo c
im ca qui trnh cng ngh v thit b cn thit ch to sn phm; tu theo dng sn xut
ca nh my m phn xng c kh c nhng c im khc nhau.
tin cho vic nghin cu, thit k phn xng c kh, cn thit phi tin hnh phn
loi chng.
Vic tin hnh phn loi phn xng c kh cng c nhiu c s khc nhau. Trong
thc t thng c cn c trn 3 c s sau y phn loi phn xng c kh.

2.1 Phn loi phn xng c kh theo kt cu v trng lng ca sn phm:

Trn c s ny, phn xng c kh c phn thnh 4 loi: nh, va, nng v rt nng
(tham kho bng 4.1).

2.2 Phn loi phn xng c kh theo s lng my ct kim loi trong :

Theo c s ny, phn xng c kh c phn thnh ba loi: nh, va, ln (tham kho
bng 4.2).
Bng 4.1 Phn loi phn xng c kh theo kt cu v trng lng ca sn phm
Loai phn xng NHE VA NNG RT NNG
Trong lng th cua
chi tit gia cng (KG)
Dn 100 100 2000 2000 15000 > 15000
V du loai san phm
Dung cu cat
Dung cu do
bi
May tinh...
May cat kloai.
t, may keo.
Bom nho, vua...
May cat kim loai nang
May bua
Thit bi vn chuyn nang
...
May cat cuc
nang.
May can,
tuyt bin

42
Bng 4.2 Phn loi phn xng c kh theo s lng my ct kim loi
Loi my
Nh Va Ln Rt ln

Qui m phn xng
S lng my t trong phn xng
NH
VA
LN
n 150
150 300
> 300
n 125
125 250
> 250
n100
100 200
> 200
n 75
75 150
> 150


2.3 Phn loi phn xng c kh theo dng sn xut
Theo dng sn xut, phn xng c kh c phn thnh 5 loi :
- Phn xng c kh sn xut n chic.
- Phn xng c kh sn xut lot nh.
- Phn xng c kh sn xut lot va.
- Phn xng c kh sn xut lot ln.
- Phn xng c kh sn xut hng khi.
Dng sn xut phn loi phn xng c kh c xc nh da vo s lng chi tit
ch yu ca sn phm gia cng hng nm trong phn xng. V d: phn xng sn xut
my tin th ly thn my hoc v hp ng xt.
Vic xc nh dng sn xut cn c th da vo c tnh ca qui trnh cng ngh, thit
b, g, dng c... (bng 4.3)

Bng 4.3 Xc nh dng sn xut
Trng lng chi tit tnh bng KG
> 200 4 200 < 4

Dng sn xut
Sn lng hng nm 1 loi chi tit (chic/nm)
N CHIC
LOT NH
LOT VA
LOT LN
HNG KHI
< 5
5 100
100 300
300 1000
> 1000
< 10
10 200
200 500
500 5000
> 5000
< 100
100 500
500 5000
5000 50000
> 50000


Vic phn loi phn xng c kh c tnh cht quyt nh dn vic phn loi c nh
my c kh, do vy cn phi lm chu o. Ngoi cch xc nh s b dng sn xut nh trn,
ta cn c th xc nh s b dng sn xut bng cch tnh ton h s lot : H s lot K
1
l h
s c trng cho s cc nguyn cng khc nhau thc hin mt ch (my) lm vic v tnh
theo cng thc sau:

N
n
K =
1
(4.1)
trong n : s cc nguyn cng khc nhau ( thc hin cho cc chi tit khc nhau)
N : s thit b cng ngh cng on
Cn c vo gi tr K
1
, ta phn loi phn xng c kh theo bng 4.4.

Bng 4.4 Phn loi phn xng c kh theo h s lot
K
1
> 20 5 20 3 5 1 3
Dng sn xut n chic v lot nh Lot va Lot ln Hng khi

3. Thnh phn ca phn xng c kh

43
Thng thng, phn xng c kh gm c: gian sn xut, gian ph, b phn phc v
v b phn sinh hot.

3.1 Gian sn xut (b phn sn xut)
Trong gian sn xut c ni t thit b my mc, ch lm vic ca cng nhn, ni t
cc dng c khc phc v cho sn xut (t, gi bn cnh cc my), ng i ca phi liu
gia cc my, khong cch gia cc my, mt s trng hp c ch sn lt chi tit...

3.2 Gian ph (b phn ph)
Trong gian ph gm c ch chun b phi liu, ch mi v pht dng c, ch kim tra,
ch sa cha ca phn xng, ch iu ch v phn phi dung dch bi trn-lm ngui, cc
loi kho ca phn xng...

3.3 B phn phc v: c vn phng phn xng, ch lm vic ca cn b k thut trong
phn xng.

3.4 B phn sinh hot: nh phng tm, phng thay qun o, nh v sinh, trm y t, phng
cho con b, nh n gia ca, cu lc b, hi trng...

Vic phn chia cc b phn trong phn xng c kh mang tnh cht tng i. Cn c
vo iu kin c th m b tr v hnh thnh cc b phn trn. Song vic phn chia ny l cn
thit v n gip chng ta b tr v tnh ton din tch phn xng.

4. Nhng ni dung chnh phi gii quyt khi thit k phn xng c kh

tin hnh thit k phn xng c kh, ngi thit k phi gii quyt mt s nhim
v chnh c tnh cht trnh t sau y:

1/ Chun b cc ti liu cn thit v da vo chng trnh sn xut ca nh my xc
nh nhim v thit k v chng trnh sn xut ca phn xng. Nh vy c ngha l ta cn
c trn c im kt cu ca sn phm ch to v iu kin sn xut, xc nh thnh phn v
ch lm vic ca phn xng thit k.
2/ Chn dng phi liu, tnh s lng phi liu v nguyn liu cn thit hng nm.
Tnh vt liu ph, bn thnh phm. l c s ra yu cu cho cc phn xng ch to
phi v cc b phn c lin quan n vic cung cp phi cho phn xng c kh (cng vic
ny tin hnh khi lp qui trnh cng ngh v trn c s mi xc nh c dng phi, lng
d gia cng tnh trng lng phi)
3/ Lp qui trnh cng ngh ch to cc chi tit ca sn phm: D kin cch t chc
thc hin qui trnh cng ngh. y l cng vic phc tp v quan trng nht.
4/ Tnh s lng thit b, chn loi thit b, xc nh ti trng ca thit b, xc nh ti
trng ca thit b. Lp bng ti trng thit b.
5/ Tnh s lng cc loi dng c, ph tng, g cn thit. Xc nh tnh cht s
dng v c im ca chng.
6/ Xc nh cc yu cu v vn chuyn trong phn xng. Chn loi thit b vn
chuyn v tnh s lng tng loi.
7/ Tnh s lng cng nhn sn xut, cng nhn phc v v cn b cho phn xng.
Xc nh bc cng nhn v bc th bnh qun.
8/ Tnh din tch phn xng. B tr thit b cho gian sn xut.
9/ Xc nh s lng thit b v din tch cc b phn ph, b phn phc v v sinh
hot.
44
10/ Xc nh yu cu nng lng cho phn xng (in, nc, kh p, hi...)
11/ Xc nh cc bin php phng khng, phng ha v sinh k thut v an ton lao
ng. Tnh ton cc thit b cn thit cho khu ny.
12/ B tr t m mt bng chung ton phn xng. Xc nh cc phn thuc v kin
trc phn xng (kch thc, khu , kt cu nh ca...)
13/ Xc nh h thng t chc, lnh o phn xng. Lp s .
14/ Tnh ton phn kinh t ca phn xng
ng nhin cng cn nhn mnh rng : nhng nhim v trn l nhng nhim v tng
qut khi thit k mt phn xng c kh. Song tu thuc vo iu kin v hon cnh c th
cng nh nhng ti liu ban u c, ngi thit k cn gii quyt ni dung trn mt cch
linh hot.

5. Ti liu ban u thit k - chng trnh sn xut ca phn xng c kh

5.1 Ni dung ca ti liu ban u - chng trnh sn xut
Nhng s liu v nhng ti liu cn thit c chun b chu o trc khi bt tay vo
thit k c th gi l chng trnh sn xut v thng c thng k di dng cc bng. V
vy chng trnh sn xut l ti liu c bn nht thit k phn xng c kh.
Trong chng trnh sn xut cn lm r cc vn c bn sau y :
1/ Tn, qui cch v c tnh k thut ca sn phm
2/ Sn lng hng nm ca sn phm k c phn d tr (tnh bng chic bng gi
thnh hoc bng trng lng sn phm / nm) .
3/ S lng tng loi chi tit trong mt sn phm v trong ton b sn phm (tnh ra
chic).
S lng chi tit N trong mt sn phm c tnh theo cng thc :

N = N
0
.H + N
do
+ N
dyc
+ N
pp
(4.2)
trong H : s chi tit cng loi ca sn phm
N
0
: s lng sn phm m nh my giao cho phn xng phi ch to hng nm
N
do
: s chi tit d tr a km theo sn phm
N
dyc
: s chi tit d tr theo yu cu ca khch hnh. i lng ny thng tnh
theo phng php thng k cn c vo s sn phm xut xng v thi hn s dng
co n lc phi thay th chi tit
N
pp
: lng ph phm sinh ra trong qu trnh ch to.
Bng 4.5 cho v d cch tnh N ca cc chi tit ca sn phm my ko vi sn lng
hng nm N
o
= 20.000 chic.

Bng 4.5 V d tnh s lng chi tit ca my ko
Nhim v sn xut
N
dyc
N
pp

S th
t chi
tit

Tn chi tit
S chi
tit cng
loi (H)
N
0
.H N
do

% chic % chic
N
(chic)
01-1
01-2
01-3
...
Blc m t
Np qui lt
Pt tng
...
1
1
4
...
20000
20000
80000
...
-
-
-
...
-
50
200
...
-
10000
160000
...
0,1
0,3
0,3
...
20
90
720
...
20020
30090
240720
...

4/ Trng lng mi sn phm (tnh ra tn), trng lng th v tinh ca cc chi tit
(tnh bng kg hoc tn)
5/ Sn lng, trng lng cc loi sn phm ph (nu c)
6/ Gi thnh sn phm
45
7/ Cc bn v : lp chung, tng b phn, c bit l bn v ch to cc chi tit ca sn
phm vi y iu kin k thut ch to (vt liu, kch thc, dung sai, bng, cc
yu cu k thut khc)
8/ Bn k cc thnh phm mua ngoi
9/ Cc vn bn v kh nng hp tc sn xut, cung cp phi liu, nng lng, phng
hng thay i nhim v sn xut

5.2 Cc loi chng trnh sn xut
Tu thuc vo dng sn xut, mc chnh xc v y ca cc s liu v ti liu,
s mt hng sn phm cn sn xut v thi gian cho php tin hnh cc cng vic thit k,
chng trnh sn xut c th lp mt cch chnh xc hoc c nh
5.2.1 Chng trnh sn xut chnh xc (t m)
Trng hp mt hng sn xut n nh; s lng cn sn xut nhiu nhng t chng
loi; cc bn v lp, bn v ch to y ; thi gian thit k cho php tng i di th cn
lp chng trnh sn xut chnh xc.
Chng trnh sn xut chnh xc thng ng dng khi thit k cc phn xng sn
xut hng khi, hng lot ln, i khi dng cho cc phn xng sn xut lot va v lot nh.
Khi lp chng trnh sn xut chnh xc phi tin hnh lp qui trnh cng ngh ch
to tt c cc chi tit ca sn phm ch to mt cch tht t m (c cc phiu cng ngh km
theo). y l cng vic v cng phc tp v tn nhiu cng sc.
5.2.2 Chng trnh sn xut c nh
Trong trng hp s loi sn phm cn ch to nhiu, nhng s lng mi loi t ; cc
bn v khng tht y cho tt c cc loi sn phm, th cn thit phi lp chng trnh sn
xut c nh.
Phm vi ng dng ca loi chng trnh sn xut c nh ch yu cho cc phn
xng sn xut n chic, lot nh c th, lot va. i khi c th dng cho sn xut lot ln
v hng khi nhng thi gian thit k yu cu ngn.

5.3 Cc cch tin hnh lp chng trnh sn xut c nh
Phn ny nghin cu trong phn 4.2.2 chng I, y ch nhc v tng kt li. Ta
c th tin hnh lp chng trnh sn xut c nh bng 2 cch sau.
5.3.1 Cch 1
Da vo s ging nhau v kt cu, tnh cht cng ngh v cc c trng k thut, ta
chia cc loi sn phm ra tng nhm . Trong mi nhm ta chn 1 sn phm in hnh (tiu
biu cho c nhm v cc mt : s lng nhiu nht, kt cu, vt liu, qu trnh cng ngh ch
to, mc phc tp, trng lng). Tip theo, ta tnh qui i s lng cc loi sn phm cn
li (khng phi sn phm in hnh) trong nhm ra sn phm in hnh bng cch nhn vi h
s c nh Kx theo cng thc (1.4) chng I. Sau ta s tnh c sn lng yu cu sn
xut (ca ton b cc loi sn phm qui v sn phm in hnh ) N theo cng thc (1.7)
chng I.
Lc ny vic cn li l lp chng trnh sn xut da vo sn phm in hnh vi s
lng yu cu sn xut va tnh c trn ging nh khi tin hnh lp chng trnh sn
xut chnh xc.
Nu phn xng phi sn xut nhiu loi sn phm th ta chia lm nhiu nhm v chn
mi nhm 1 sn phm in hnh. n y c th tip tc bng mt trong hai cch nh sau :
- Chn mt s chi tit in hnh ca cc sn phm in hnh v tin hnh lp qui trnh
cng ngh cho cc chi tit in hnh ny ng vi s lng l ton b s lng cc chi tit
trong tng nhm qui i v in hnh.
46
- Chn 1 chi tit in hnh nht trong cc chi tit in hnh c chn t cc sn
phm in hnh, sau y lp qui trnh cng ngh cho sn phm in hnh nht ny tng ng
vi s lng qui i v in hnh ca tt c cc chi tit.

r vn , ta xem xt mt v d minh ho : mt phn xng c kh sn xut 6 loi
sn phm m ta c th chia thnh 2 nhm l A
1
, A
2
, A
3
v B
1
, B
2
, B
3
. Sau khi nghin cu cc
mt, ngi ta chn c 2 loi sn phm in hnh l A
1
cho nhm A v B
2
cho nhm B. Vi
cc iu kin cho v bng cch xc nh h s c nh Kx (theo cc cng thc phn
4.2.2 chng I), ta lp c chng trnh sn xut c nh ca phn xng nh bng 4.6.

Bng 4.6 V d v tnh s lng qui i khi lp chong trnh sn xut c nh
Nhim v thc t cho Chng trnh sn xut c nh
Trng lng
(Tn)
H s c nh


Nhm

Th
t
Tn
sn
phm
Sn
lng
(chic)
1
chic
Tng
Tn sn
phm
in
hnh
K
x1
K
x2
K
x3
K
x

Sn
lng
(chic)
Tng
trng
lng
(Tn)

I
1
2
3
A
1

A
2

A
3

100
80
60
3,5
4
3
350
320
180

A
1

1
1,1
0,85
1
0,8
1,2
1
1,03
1,08
1
0,9
1,1
100
72
66
350
252
231
Cng
nhm I
240 850 238 833
II 1
2
3
B
1

B
2

B
3

50
60
40
10
5
4
500
300
160

B
2

1,6
1
0,87
1,2
1
0,9
1,02
1
1,06
1,94
1
0,83
97
60
33,2
485
300
166
Cng
nhm II
150 960 190,2 951
Tng
cng
390 1810 428,2 1784

T bng 4.6 trn, ta c th rt ra nhng nhn xt sau :
1/ Bng cch lp chng trnh sn xut c nh, t 6 loi sn phm ta rt xung cn
2 loi sn phm in hnh vi sn lng qui i l 238 v 190. Nu tip tc ta c th chn
sn phm in hnh nht v rt xung cn li 1 loi sn phm. Nh vy s mt hng bt phc
tp, to iu kin d dng thit k.
2/ Nh lp chng trnh sn xut c nh, vic thit k mt phn xng ch to 390
chic (hoc 1810 tn) ca 6 loi sn phm tng ng vi vic thit k mt phn xng ch
to 428 chic (hoc 1784 tn) ca 2 loi sn phm. Nh vy cng vic thit k s n gin
hn nhiu
5.3.2 Cch 2
Khi s loi sn phm cng nhiu m s lng mi loi t th vic chia thnh nhm sn
phm cng cha th n gin c nhiu. Trng hp ny ta nn tin hnh chia nhm chi tit
(ngha khng cn chi tit thuc sn phm no, cn c vo kt cu, hnh dng hnh hc v
tnh cng ngh ging nhau. V d nhm trc, nhm hp...). Nh vy mt hng sn phm ca
phn xng c biu th bng nhng nhm chi tit phn chia vi s lng thng k c.
Tin hnh lp qui trnh cng ngh cho 3 chi tit in hnh ca mi nhm (nh, va,
ln) ng vi s lng tnh qui i ra cc chi tit in hnh ny. T tnh c thi gian
cn thit gia cng c nhm.

6. Nhng nguyn tc c bn khi lp qui trnh cng ngh thit k phn xng c kh
47
6.1 Khi nim
Cn thit phi nhn thc rng: thit k cng ngh (bao gm lp qui trnh cng ngh,
la chn thit b, b tr dy chuyn sn xut...) trong bn thit k nh my ch to l phn ch
yu nht, c tnh cht quyt nh nht n nng sut, cht lng sn phm v trnh k
thut ca nh my.
Cng l lp qui trnh cng ngh gia cng cc chi tit, nhng gia ngi k thut
vin trong phn xng c kh v ngi thit k xng c s khc nhau c bn:
- Ngi k thut vin trong phn xng sn xut b rng buc bi iu kin my mc
thit b, dng c, g v trnh cng nhn ang c trong phn xng ca mnh.
- Ngi thit k xng phi bit tn dng nhng thnh tu tin tin v hin i nht
(trong iu kin cho php ca k thut v qui m ca phn xng) lp qui trnh cng ngh
hp l v tin tin nht. Trn c s ra yu cu v chn thit b, dng c, g, bc th
thc hin qui trnh cng ngh .
6.2 Cc nguyn tc c bn khi lp qui trnh cng ngh thit k phn xng c kh
Da vo yu cu : m bo hiu qu kinh t v yu cu k thut tin tin n ti a,
theo qui m nh my m ngi thit k tin hnh lp qui trnh cng ngh. Khi tin hnh c
th, ngi thit k cn nm vng cc nguyn tc c bn sau:
1/ Chn phng php ch to phi tin tin, chnh xc nhm gim lng d gia cng
c, tit kim kim loi, tit kim thi gian gia cng. V d: thay c trong khun ct bng c
di p lc, thay rn t do bng rn khun....
2/ Tn lng s dng cc phng php gia cng tin tin nh gia cng bng tia la
in, gia cng bng siu m. Tng cng s dng cc phng php gia cng tng bn nh
phun bi, ln p.
3/ Trit gim thi gian gia cng c. V d: gim thi gian my nn tp trung
nguyn cng, s dng my t hp, my chuyn dng, dao tin tin... gim thi gian ph
nn s dng g kp nhanh, cp phi t ng, kim tra t ng...
4/ C th ngh thit k my mi, c nng sut cao.
5/ Ap dng phng php gia cng ti ch : thng dng i vi nhng chi tit ln
(>15 tn) gia cng bng my t hp.
6/ Ap dng phng php t chc sn xut theo dy chuyn (c bit i vi dng sn
xut hng khi v hng lot ln)
7/ Phi bm st iu kin thc t ca Vit Nam. Trong nhiu trng hp cn kt hp
gia c kh v th cng. Nhng cn ch c kh ho v hin i ho cc khu nng nhc v
dy chuyn sn xut ch yu.
8/ Khi la chn thit b cn ch :
- iu kin kh hu m nng, cn chn thit b qua nhit i ha.
- Chn thit b cng nc sn xut.
- Trnh chn my mc, thit b ngng sn xut hoc mi sn xut m cha bit r
tnh nng k thut.
- Cn i thit b trong dy chuyn sn xut v thit b d tr.
- Thit b c cng sn xut cng ln cng kinh t.
9/ Khi thit k phn xng c kh theo chng trnh sn xut chnh xc th:
- Vi nhng chi tit chnh, ln v phc tp cn tin hnh lp qui trnh cng ngh t m
km theo phiu cng ngh ghi r: cc nguyn cng, thit b, dng c ct, g, nh mc thi
gian, ch ct gt...
- Vi cc chi tit trung bnh, khng phc tp lm cn lp qui trnh cng ngh y ,
km theo phiu cng ngh.
- Vi nhng chi tit n gin ch cn lp bng k cc nguyn cng c nh mc c thi
gian km theo.
10/ Khi thit k phn xng theo chng trnh sn xut c nh th:
48
- dng sn xut lot ln, lot va v hng khi th qui trnh cng ngh gia cng cc
chi tit c lp t m nh chng trnh sn xut chnh xc.
- Vi dng sn xut n chic, lot nh th cc chi tit ca sn phm in hnh c
chia thnh nhm ging nhau v c tnh cng ngh, sau tin hnh lp qui trnh cng ngh
cho cc chi tit in hnh ca tng nhm ging nh chng trnh sn xut chnh xc.

7. Cc phng php tnh thi gian thit k phn xng c kh
Vn tnh thi gian cn thit cho vic gia cng mt chi tit c c trnh
by k trong gio trnh
<<
cng ngh ch to my
>>
, y theo quan im thit k phn xng
c kh, trn c s nghin cu trong cng ngh ch to my, chng ti ch trnh by mt s
phng php tnh ton thi gian phc v cho cng vic thit k.
Tu thuc vo qui trnh cng ngh gia cng sn phm ; tu thuc vo chng trnh sn
xut (chnh xc hay c nh) ; tu thuc vo nhng s liu v ti liu ban u bit, ta c
th tnh ton thi gian theo cc phng php sau y.

7.1. Phng php tnh chnh xc thi gian
Phng php tnh ny da vo thi gian nh mc trong cc phiu cng ngh c
lp. T cc thi gian nh mc c th phn tch ra hoc tng hp li c c thi gian
cn thit gia cng 1 sn phm v ton b cc sn phm theo chng trnh sn xut trn tng
loi my.
Phng php ny c p dng khi thit k phn xng c kh theo chng trnh sn
xut chnh xc, hoc cho sn phm in hnh v ton b sn phm in hnh khi thit k phn
xng c kh theo chng trnh sn xut c nh.

7.2. Tnh thi gian theo phng php suy rng
Phng php ny c tin hnh cn c vo mt s nh mc thi gian suy ra thi
gian cho cc chi tit v sn phm khc nh h s c nh K hoc nh th.
Phng php suy rng c ng dng trong trng hp thit k phn xng theo
chng trnh sn xut c nh (ch c nh mc thi gian cho cc chi tit v sn phm in
hnh)
Tu thuc vo s liu v ti liu bit, tu thuc vo cch lp chng trnh sn xut
c nh, ta c cc phng php suy rng nh sau :

7.2.1 Da vo thi gian nh mc cho sn phm in hnh v h s c nh K
Trong trng hp chng trnh sn xut c nh cho thi gian nh mc ca sn
phm in hnh v xc nh c h s c nh K, ta c th tnh c thi gian gia cng
cc sn phm khc trong nhm
Nu ta gi : T
1,1
l thi gian gia cng mt sn phm no khc sn phm in hnh
trn mt loi my (ph hoc gi)
T
h
l thi gian nh mc gia cng sn phm in hnh trn loi my
(ph hoc gi)
K l h s c nh
th ta c mi quan h sau:
T
1,1
= T
h
.K [ph hoc gi] (4.3)

7.2.2 Da vo thi gian gia cng nh mc cho 3 chi tit in hnh nh, ln, va
trong nhm chi tit
Trong trng hp chng trnh sn xut c nh khng chia nhm sn phm m
phn nhm chi tit, da vo thi gian nh mc gia cng 3 chi tit in hnh (nh, va, ln)
49
trong nhm suy ra thi gian gia cng cc chi tit khc ca nhm bng gii tch hoc nh
th.
7.2.2.1 Tnh thi gian bng gii tch
Ta gi: T
x
l thi gian gia cng chi tit ang xt ca nhm (ph hoc gi)
T l thi gian gia cng chi tit in hnh (ph hoc gi)
Q
x
l trng lng chi tit ang xt (KG)
Q l trng lng chi tit in hnh (KG)
C mi quan h sau :
T
x
= T
3
2

Q
Q
x
[ph, gi] (4.4)
Ch : Khi s dng cng thc trn, trong 3 chi tit in hnh ca nhm ta chn gi tr
T v Q ca chi tit in hnh no c trng lng gn nht vi trng lng ca chi tit ang
xt.
7.2.2.2 Xc nh thi gian theo th
Trn c s 3 chi tit in hnh bit ca
nhm, ta lp c th quan h gia trng lng
(hoc kch thc) v thi gian gia cng chng. R
rng nu s chi tit in hnh cng nhiu th th
lp cng chnh xc.
Da vo th lp c ( hnh 4.1), vi
chi tit bt k c trng lng Qx ta d dng tm
c thi gian Tx cn thit gia cng chi tit .


Hnh 4.1
7.2.3 Xc nh thi gian da vo c s thc t
Ch yu phng php ny l cn c vo nhng my a vo sn xut trong thc
t hoc nhng bn thit k cc phn xng c kh tng t nh trng hp ca ta c
thng qua hay ang s dng, trong c nhng ch tiu nh mc thi gian.
Tt nhin vi s pht trin khng ngng ca khoa hc k thut, ta cn iu chnh thi
gian nh mc theo hng gim xung.
Trn nhng c s , ta cn gii quyt cc trng hp thc t sau y :

7.2.3.1 Trng hp sn phm ang xt c ch to ti cc nh my thc t
Trong trng hp ny, xc nh thi gian ta cn tin hnh theo cc bc sau y :
- Theo trnh k thut ca phn xng ang thit k lp qui trnh cng ngh gia
cng mt chi tit ch yu ca sn phm.
- nh mc thi gian gia cng chi tit ch yu theo thit k mi ca ta. Thi gian
ny k hiu l T
mcy
hay gi l thi gian thit k.
- Xc nh h s iu chnh (K
c
) bng cch chia thi gian nh mc ca chi tit ch
yu cho thi gian nh mc ca chi tit ang sn xut thc t (T
mtt
). Tt nhin t s ny nh
hn hoc ti a bng 1 .

K
c
= T
mcy
/T
mtt
(4.5)

- T ta tnh c thi gian gia cng ton b sn phm theo thit k (T
sptk
) theo thi
gian nh mc ca sn phm thc t (T
sptt
) nh h s iu chnh (K
c
) theo cng thc sau :

T
sptk
= T
sptt
.K
c
(4.6)
T
ln

T
x
T
va

T
b

Q
b
Q
va
Q
x
Q
ln



T
h

i

g
i
a
n

Trng lng
hoc kch
thc chi tit
50

7.2.3.2 Trng hp thi gian nh mc thc t sau qu trnh so snh, iu chnh c
cho di dng cc ch tiu kinh t - k thut
Cc ch tiu kinh t k - thut thng l :
- Thi gian cn thit gia cng mt chi tit (hoc mt sn phm) trn mt n v
cng sut hoc mt ngi. Thng gp gi - my, gi - ngi.
- Sn lng hng nm ca sn phm gia cng c trn mt my, tnh bng chic, tn
(hoc trn n v cng sut : kw, m lc)
Thng dng cc ch tiu thi gian ny tnh ton s thit b, s cng nhn .

8. Tnh ton s lng thit b cho phn xng c kh

V vic xc nh thi gian gia cng sn phm c tin hnh bng nhiu phng php
do cng c nhiu phng php tnh ton s lng thit b cho phn xng c kh. C
th c nhng phng php sau :

8.1. Tnh s lng my theo qui trnh cng ngh (tc l theo thi gian xc nh mc rt ra
t qui trnh cng ngh)

8.1.1 Cng thc chung tnh s lng my theo qui trnh cng ngh l :

C
tnh
= T
tnh
/F
1,1
. m, [chic] (4.7)

Trong C
tnh
l s lng my cn tnh ( chic)
F
1,1
l thi gian lm vic thc t ca 1 my trong 1 nm vi ch 1 ca c
tnh bng gi
m l s ca lm vic trong 1 ngy m. Thng ly trung bnh m = 2
Trong cng thc trn Ttnh c xc nh nh sau:

=
60
.
i ctloat
tinh
D T
T , [h] (4.8)
Trong Ttnh l tng thi gian tnh ton gia cng cc chi tit ca tt c cc sn
phm trn mt loi my (gi)
Tct
lot
l thi gian gia cng tng chic trong lot (ph)


N
T
T T
cbkt
tc ctloat
+ = , [ph]
T
tc
= T
o
+T
p
+T
p
v+T
tn
, [ph]
T
tc
: thi gian gia cng tng chic (ph)
T
cbkt
l thi gian chun b v kt thc ca lot chi tit (ph)
N l s lng chi tit trong lot (chic)
Di l s sn phm hng nm ca loi chi tit i no (chic /nm)
Xc nh F
1,1
theo cng thc :

F
1,1
= [(365-104) - n]. 8.k, [gi] (4.9)
Mt nm c 365 ngy, trong c 104 ngy ngh th by v ch nht. n l s
ngy ngh l, ngh tt trong nm. Vit nam hin nay n = 8 (tt DL : 1, tt AL : 4,
30/4 : 1, 1/5 : 1, 2/9 : 1)
51
k l h s k n thi gian ngng my sa cha, c xc nh ty thuc
vo c my, phc tp ca cng vic sa cha, tui th ca my v ch lm vic
(bao nhiu ca kp). C th tham kho :
Theo s ca lm vic:
+ Ngy lm vic 1 ca k = 0,98
+ Ngy lm vic 2 ca k = 0,97
+ Ngy lm vic 3 ca k = 0,96
Vi nhng my c bc phc tp sa cha R>30 th :
+ Ngy lm vic 2 ca k = 0,95
+ Ngy lm vic 3 ca k = 0,94
Nu s dng my c, nu thit k m rng nh my th k ly b hn
Ch : Thng thng khi tnh ton ta nhn c C
tnh
l s l, v vy cn qui trn kt qu tnh
ton theo cc nguyn tc sau y :
Nguyn tc1 Nu s l sau du phy ln hn ,5 ta qui trn ln 1 n v .
V d C
tnh
= 2,63 ta ly C
chn
= 3
Nguyn tc 2 Nu s l nh hn ,5 c 3 cch gii quyt :
- B s l v chuyn khi lng cng vic cho my c tnh nng tng t nhng
cha s dng ht kh nng. V d chuyn cng vic phay cho bo.
- Nu khng thc hin c bng phng php trn th ta phi tn lng ti trng ca
my bng cch gim thi gian nh mc nh nng cao ch ct, gim thi gian ph, thc
hin t ng ho. Nh vy c th b s l. Cng c th b s l nhng thay my ang tnh
bng loi my c cng tnh nng nhng nng sut cao hn.
- Nu c hai cch trn u khng th thc hin c th bt buc ta phi lm chn v
pha ln. Cch gii quyt ny thng gp trong sn xut dy chuyn.
Sau khi chn c s lng ca cc loi my cn thit ch to sn phm, ta c tng
s my cho ton phn xng :

C

= C
chn
(4.10)

Cng cn bit thm rng : c mt s trng hp T
tnh
trong cng thc tnh Ctnh l
tng thi gian cn thit gia cng cc chi tit ca tt c cc sn phm trn cc loi my, th
Ctnh

tnh c s l s my tnh ton c cho ton phn xng. Sau da vo t s % cc
loi my theo tng ngnh sn xut (trong cc s tay thit k xng) ta tnh c s lng
tng loi my.

8.1.2 H s ti trng v h s s dng my
nh gi mc hp l ca vic tnh ton my v la chn my, thy r mc
s dng cc my, ta c 1 s h s sau :
1/ H s ti trng
z
(c trng mc s dng thit b v mt thi gian) : l mt i
lng ni ln mc bn rn ca mt my, mt nhm my hay c mt phn xng khi hon
thnh khi lng cng vic c phn phi. Vi nh ngha nh vy ta c :


chon
tinh
chon
tinh
z
C
C
C m F
T
= =
. .
1 , 1
(4.11)
T cng thc trn ta c nh ngha khc v h s ti trng : H s ti trng
z
l t s
gia s my tnh c v s my chn dng. Tt nhin ta tn lng lm sao
z
gn ti 1 v
khi ton b s my chn dng u c s dng hu ht v mt thi gian
Ni chung, h s ti trng ca nhm my hoc c phn xng ch c th nh hn hoc
bng 1. Trong thc t, tr s h s ti trng
z
c th tham kho nh sau :
52
- Trong sn xut n chic
z trung bnh
= 0,9 ~ 0,95
- Trong sn xut hng lot
z trung bnh
0,85
- Trong sn xut hng khi
z trung bnh
0,8
2/ H s s dng my theo thi gian c bn (h s s dng)
H s s dng my l t s gia thi gian c bn v thi gian tng chic, vi nh
ngha ta c:

tc
o
o
T
T
= (4.12)
Ttc hc cng ngh ch to my hoc xem phn 8.1.1 trc.
i vi ton phn xng, h s s dng my trung bnh l

0tb
=

tinh
T
T
0
(4.13)
Trong T
0
l tng thi gian c bn gia cng tt c cc chi tit trn cc my trong
ton phn xng.
T
tnh
l tng thi gian tnh ton cn thit gia cng tt c cc chi tit
trn cc my trong ton phn xng.
Trng hp l tng l
0
= 1, c ngha l c gng lm cho
0
tin ti 1.
C th tham kho cc s liu thc t sau:
- Trong sn xut n chic
0tb
0,6
- Trong sn xut hng lot
0tb
0,65
- Trong sn xut hng khi
0tb


0,75
Thng thng cc h s nh gi
z
,
Ztb
,
0
v
0tb
c biu din di dng th,
nhm gip cho ngi thit k, ngi s dng v ngi lnh o thy r ch hp l v ch bt
hp l trong vic s dng my v tm cch b sung nhng ch bt hp l .
Phng php biu th th r rng nht nh sau:
+ Trc tung ca h trc to cc biu th gi tr ca
Z
(hoc
0
)
+ Trc honh ng thi biu th:
- S lng my (chic)
- Qui cch my
- Tn my
V d :
Hnh 4.2 Biu ti trng my

53
8.2 Tnh s lng my cho sn xut dy chuyn
Trong cng ngh ch to my nu r: yu t cn thit u tin thc hin sn
xut theo dy chuyn l phi phn chia v iu chnh sao cho thi gian thc hin cc nguyn
cng phi bng nhau hoc bng bi s ca nhau, tc l:

T
nc1
= aT
nc2
= bT
nc3
= = zT
ncn
(4.14)

Trong T
nc1
,

T
nc2
,T
nc3
,Tncn l thi gian thc hin cc nguyn cng t 1 n
a, b, c ,z l nhng s nguyn.
Trong sn xut dy chuyn, s lng my c tnh trc ht cho tng nguyn cng.
Da vo thi gian cn thit hon thnh cc nguyn cng ring bit v vo nhp sn xut
ca dy chuyn ta c:
C
n.c tnh
=
n
c t
t
T
.
[chic] (4.15)
Trong C
n.c tnh
l s lng my tnh ton hon thnh mt nguyn cng no
T
t.c
l thi gian gia cng tng chic ca nguyn cng (khng c thi
gian chun b - kt thc), [ph]
t
n
l nhp sn xut ca dy chuyn (ph) c tnh theo cng thc :
tn =
D
m F . . 60
1 , 1
, [ph] (4.16)
F
1,1
l thi gian lm vic thc t ca mt my trong mt nm vi ch
mt ca ca dy chuyn
F
1,1
= (365 104 n).8.k
m l s ca lm vic trong mt ngy m. Khi m = 1 thi k = 0,97; m = 2 th
k = 0,96; m = 3 th k = 0,94.
D sn lng hng nm loi chi tit c gia cng trn dy chuyn
(chic/nm)
Trng hp dy chuyn thay i gia cng nhiu loai chi tit th:

t
n
=
c d
n
K
D D D
m F
.
2 1
1 , 1
.
...
. . 60
+ + +
, [chic] (4.17)

Trong D
1
, D
2
, , Dn l sn lng hng nm ca cc loai chi tit gia cng trn
dy chuyn (chic/nm)
K
.c
l h s iu chnh ng dy, tc l h s k n thi gian ngng
my iu chnh li ng dy chuyn qua gia cng chi tit khc.
Theo kinh nghim K
.c
= 0,95 ~ 0,92.
Thng thng C
n.c tnh
l s l, v vy ta cn qui trn v bao gi cng qui trn theo
chiu tng ln. V d: C
n.c tnh
= 2,15 th C
n.c

chn
= 3.
Sau khi tnh c s my cho tng nguyn cng, ta d dng tnh c s lng my
cn thit cho ton dy chuyn sn xut theo cng thc sau:

C

=
chon c n
C
. .
(4.18)
nh gi mc hp l ca vic tnh ton, la chn, thng ngi ta s dng h
s ti trng v h s s dng kim tra. Cch xc nh 2 h s ny nh trnh by phn
trc.
Theo kinh nghim, nu phng n tnh ton hp l th:

Ztb
0,8 v
0tb
0,75
54

8.3 Tnh ton s lng my ca phn xng c kh theo cc ch tiu kinh t - k thut

8.3.1 c im v phm vi s dng
So vi hai phng php trnh by trn, phng php ny n gin v nhanh hn
nhiu. Nhng nhc im ln ca phng php ny l chnh xc km. Do c im ,
phng php tnh theo cc ch tiu kinh t - k thut thng c p dng trong cc trng
hp sau y :
- Khi lp nhim v thit k cho bc thit k s b tt c cc dng sn xut.
- Khi thit k k thut cho nhng phn xng sn xut n chic v lot nh.
- Khi thit k cc phn xng c nhiu mt hng sn xut m ti liu ban u thiu
chnh xc.
- Khi thit k phn xng dng c v phn xng sa cha c kh.
- c bit khi thit k phn xng m thi gian thit k yu cu ngn, cn phi a
vo sn xut sm.

8.3.2 Cch tnh
C s ca phng php tnh ton ny l da vo ch tiu kinh t - k thut cho sn
trong cc s tay thit k xng. Cc ch tiu cho sn l kt qu thng k theo kinh nghim
t nhng nh my ang sn xut, hoc t nhng bn thit k tt, hp l.
Cng cn thy r rng: chnh xc ca phng php tnh ton theo cc ch tiu kinh
t - k thut mt mt ph thuc vo bn thn cc ch tiu y, mt khc ph thuc rt ln vo
tc pht trin ca khoa hc k thut. Tht vy nu tc pht trin ca khoa hc k thut
cng nhanh th tnh thi s ca cc ch tiu (mt d chnh xc trong thi gian trc ) cng
gim. V vy cn thit c nhng iu chnh cho ph hp.
Tu thuc vo loi ch tiu kinh t - k thut, s my cho phn xng c kh c th
tnh bng cc cng thc sau:
C
tnh
=
m q
Q
.
(4.19)
hoc C
tnh
=
m F
h Q
.
.
1 , 1
(4.20)
Trong C
tnh
s lng my cc loi c tnh chung cho c phn xng (chic)
Q sn lng hng nm cn sn xut trong phn xng (chic/nm).
m s ca lm vic trong mt ngy m.
F
1,1
thi hn lm vic thc t ca mt my trong mt nm vi ch 1
ca tnh bng gi ( tnh phn trc).
q l sn lng hng nm gia cng c trn mt my lm vic vi
ch mt ca (tnh bng tn/nm hoc chic/nm).
h l s gi my cn thit gia cng mt tn hoc mt chic sn
phm (tnh bng gi/tn hoc gi/chic).
q v h l cc ch tiu kinh t - k thut cho trong cc s tay thit k xng hoc c
ti cc c quan thit k.
Sau khi c gi tr C
tnh
(t hai cng thc trn), da vo h s ti trng bit trc
theo dng sn xut (ch khng xc nh theo cng thc
z
= C
tnh
/C
chn
). ta tnh c s my
chn dng:

C
chn
= C
tnh
/
ztb
, [chic] (4.21)
(ly trn theo nguyn tc 0,5)
55
Cn ch rng: C
chn
ta xc nh c l s my chung ca tt c cc loi. V vy phi
cn c vo t l % cc loi my trong phn xng (cho trong cc s tay thit k xng)
tnh s my tng loi. S my tng loi c tnh ra thng l s l, ta cn tin hnh qui trn,
khi qui trn cn ch sao cho tng s cc loi my bng gi tr C
chn
.
Trong khi tnh ton, nu khng bit tht c th, ta c th ly gi tr
ztb
= 0,85.

9. Tnh yu cu v cng nhn v cn b cho phn xng c kh

9.1 Cc loi cng nhn cn b
Cng nhn v cn b ca phn xng c kh c phn ra cc loi sau:
- Cng nhn sn xut : gm cng nhn trc tip ng my v cng nhn ngui.
- Cng nhn ph : nh cng nhn iu chnh my, cng nhn vn chuyn, cng nhn
mi dng c, cng nhn sa cha...
C hai loi cng nhn sn xut v cng nhn ph c gi chung l cng nhn.
- Nhn vin phc v gm nhng ngi qut dn phoi, trc in thoi, thng tin lin
lc...
- Cn b k thut v nhn vin vn phng, k ton.

9.2 Tnh s lng cng nhn sn xut v bc th bnh qun

9.2 1 Tnh s lng cng nhn ng my
S lng cng nhn ng my c tnh theo cc phng php sau:
9.2.1.1 Tnh s cng nhn ng my theo thi gian cn thit ch to sn phm:
Phng php ny c ng dng cho tt c cc phng php thit k nu ta bit c
thi gian cn thit ch to sn phm hoc bit s gi - ngi cn thit ch to mt tn
(hoc mt chic) sn phm
Khi bit thi gian cn thit ch to sn phm: ta s dng cng thc di y
tnh:
R
M
=
C C
tinh
S F
T
.
, [ngi] (4.22)
Trong : R
M
l s cng nhn ng my ca 1 loi my no (ngi)
F
c
l thi gian lm vic thc t ca 1 cng nhn trong 1 nm (gi/nm)

F
c
= (365 104 n f) 8.k
c
(4.23)

n l s ngy ngh l, ngh tt hng nm. ta, hin nay n = 8
f l s ngy ngh php hng nm
k
c
l h s k n thi gian ngh vic bt thng do m au, hp hnh, cng
tc t sut. H s k
c
cn c vo iu kin lm vic, iu kin sc khe ca
cng nhn xc nh. Thng i vi cng nhn lm vic phn xng
c kh, lp rp, dng c, sa cha c th ly k
c
= 0,91.

S
c
l h s ng nhiu my, xt n kh nng ca ngi cng nhn c th mt
lc iu khin c nhiu my. S
c
ph thuc vo trnh t ng ho v c
kh hoa ca nh my
+ Vi cc loi my vn nng ly S
c
=1
+ Vi my tin nhiu dao, my bn t ng, my phay ln, ly S
c
=1,5 ~ 2
+ Vi my bn t ng nhiu trc chnh, ly S
c
= 1,2 ~ 1,5
+ My t ng mt trc, my bo rng cn, ly S
c
= 3 ~ 4
+ My xc rng, my ln rng, ly S
c
= 4 ~ 5
56
T
tnh
l tng thi gian tnh ton cn thit gia cng tt c cc chi tit trn loi
my (gi)
Cn ch rng : trong cng thc tnh R
M
trn nu mun tnh s lng cng nhn
ng mt loi my no vi 1 bc th nht nh (v d cn tnh s th tin bc 3) th Ttnh
phi l thi gian tnh ton gia cng tt c cc chi tit trn my vi trnh th tng
ng
Khi bit thi gian di dng gi - ngi cn thit ch to 1 tn hoc 1 chic sn
phm
Trong trng hp ny, s cng nhn ng my cn thit ca tt c cc loi c tnh
theo cng thc sau :

c c
M
S F
t Q
R
.
.
= , [ngi] (4.24)

Trong R
M
l s cng nhn ng my cn thit ca tt c cc loi
Q l sn lng hng nm sn phm cn phi gia cng (tn/nm, chic/nm)
t l s gi - ngi cn thit gia cng 1 tn hoc mt chic sn phm, t cho
trong s tay thit k xng.
Fc v Sc nh trn
9.2.1.2 Tnh s cng nhn ng my theo s my cn thit chn
Theo phng php ny, s cng nhn ng my c tnh bng cng thc sau :


c c
z chon
M
S F
C m F
R
.
. . .
1 , 1

= , [ngi] (4.25)
Trong R
M
l s cng nhn ng mt loi my no
F
1,1
l thi gian lm vic thc t ca mt my trong 1 nm vi ch 1 ca
m l s ca lm vic trong 1 ngy m

z
l h s ti trng ca my . Trong trng hp khng bit chnh xc c th
ly
z
= 0,85
C
chn
, F
c
v S
c
nh trn
Trong c ba phng php tnh trn, R
M
c th l s l, ta phi qui trn thnh s
nguyn theo nguyn tc 0,5. Nu s l < 0,5 ta b i v tng bc cho ngi th cui cng, nu
s l > 0,5 th tng ln 1 n v v c th gim bc ca ngi th cui cng.

9.2.2 Tnh s lng cng nhn ngui
Thng thng s cng nhn ngui c tnh theo t l phn trm (%) ca s lng
cng nhn ng my v ph thuc vo dng sn xut ca phn xng. V d :
- Dng sn xut n chic, lot nh, cng nhn ngui trong phn xng c kh ly
khong 3-5 % s cng nhn ng my
- Dng sn xut lot ln v hng khi s cng nhn ngui ly khong 1- 3 % s cng
nhn ng my
Cn ch rng, s cng nhn ngui c ly nh trn l cng nhn sn xut trc tip
tham gia vo qu trnh gia cng cc chi tit (lm nhng cng vic m my khng lm c).

9.2.3 Tnh bc th bnh qun
9.2.3.1 Khi nim
Trong vic tnh ton s lng cng nhn sn xut, ta cn cn phi tnh bc th bnh
qun trong phn xng. Bc th bnh qun l bc th tng trng dng nh gi trnh
lnh ngh ca mt loi th hoc tt c cc loi th trong phn xng. Bc th bnh qun c
th l s chn hoc s l. Tnh c bc th bnh qun khng nhng c th nh gi c
57
trnh chuyn mn ca cng nhn trong phn xng, c th bit c mc t ng ho
v c gii ho ca phn xng ; m cn bit c lng cng nhn sn xut trung bnh trong
mi gi, mi thng m nh my phi tr.
9.2.3.2 Nguyn tc tnh bc th bnh qun
Qui i tt c cc bc ra bc 1 bng cch nhn s lng cng nhn bc qui i vi
h s quan h tin lng (h s cp bc tin lng). Sau em chia s cng nhn qui i
ra bc 1 cho tng s lng cng nhn thc t tt c cc bc hin c ta s c h s quan h
tin lng bnh qun. Da vo h s quan h lng bit hoc da vo th suy ngc
li bc th bnh qun
9.2.3.3 Trnh t tnh ton bc th bnh qun
xc nh bc th bnh qun cho ton phn xng, ta cn tin hnh cc bc theo
trnh t sau y
1/ Xc nh h s quan h lng (q
i
)
H s quan h lng l s liu so snh mc chnh lch gia lng mt bc th bt k
vi lng bc th 1. V mi ngnh sn xut c thang lng khc nhau, nn h s quan h
lng gia cc ngnh cng khc nhau.
thy r cch xc nh h s quan h lng ta xt v d sau:
Mt ngnh ngh c lng th bc 1 l 250.000 ng, lng th bc 2 l 290.000 ng,
lng th bc 3 l 340.000 ng, lng th bc 4 l 400.000 ng, lng th bc 5 l 470.000
ng, lng th bc 6 l 550.000 ng, lng th bc 7 l 630.000 ng. Ta lp c bng h
s quan h tin lng nh bng 4.7

Bng 4.7 V d v h s quan h lng
Bc th 1 2 3 4 5 6 7
H s quan h lng q
i
1 1,16 1,36 1,6 1, 88 2,2 2,52

T bng 4.7 ta d dng xy dng c th quan h gia bc th v h s quan h
lng (hnh 4.3). Bng th nu xc nh c h s quan h lng trung bnh q
tb
ta s tm
c bc th trung bnh. (v d ta tnh c q
tb
= 1,75 th nh th hnh 4.3, ta s tm c
bc th bnh qun l 4,5)

2/ Qui i s lng th cc bc v s th bc 1:
0
0.5
1
1.5
2
2.5
3
1 2 3 4 5 6 7
Series1
1,
75
4
,
5

Bc th
H

q
u
a
n

h

n
g

Hnh 4.3
1,7
5
58
Bng cch nhn s cng nhn bc bt k no vi h s quan h lng tng ng ta
s nhn c s lng cng nhn ca bc c qui i v bc 1.


i
i
M
i
M
q R R .
q
=

(4.26)
trong
i
M
R
q
l s th bc i qui i v bc 1

i
M
R l s th bc i
qi l h s quan h lng bc i
Tin hnh nh th cho tt c cc bc th v cc loi th (tin, phay, bo...) v cng li
ta s nhn c s th qui i v bc 1 ca ton phn xng :

=

q M
R
i
M
R
q
(4.27)

3/ Tnh h s quan h lng trung bnh ca tng loi v ton phn xng
H s quan h lng trung bnh (qtb) c xc nh bng cng thc sau:

q
tb
=

M
Mqd
R
R
(4.28)

q
tb
l h s quan h lng trung bnh tng loi th hoc ton phn xng
R
Mq
l s lng th qui i v bc 1 ca tng loi th hoc ton phn xng
R
M
l s lng th tt c cc bc ca tng loi th hoc ton phn xng.
4/ Xc nh bc th trung bnh
Sau khi xc nh oc h s quan h lng trung bnh, da vo th quan h bc th
- h s quan h lng, ta d dng suy c bc th trung bnh ca tng loi hoc ton phn
xng
9.2.3.4 V d tnh ton c th:
Mt phn xng c kh c 125 cng nhn sn xut gm c 75 th tin (10 th bc 2,
30 th bc 3, 25 th bc 4, 10 th bc 5) v 50 th phay (5 th bc 2, 10 th bc 3, 20 th bc
4, 15 th bc 5). Hy xc nh bc th trung bnh ca th tin, th phay v ton b phn
xng vi gi s l mc lng ca th theo v d phn 9.2.3.3 (1/) trn
Ta tin hnh theo cc bc sau:
- Lp bng h s quan h lng
Tin hnh nh v d phn 9.2.3.3 (1/) trn v lp c bng h s quan
h lng nh bng 4.7
- Qui i v th bc 1
R
Mq
(tin) = 10.1,16 + 30.1,36 + 25.1,6 + 10.1,88 = 111,2
R
Mq
(phay) = 5.1,16 + 10.1,36+ 20.1,6 + 15.1,88 = 79,6
R

Mq
= 111,2 + 79,6 = 190,8
- Tnh h s quan h lng trung bnh
q
tb
(tin) = 111,2/75 = 1,48
q
tb
(phay) = 79,6 / 50 = 1,59
q
tbpx
= 190,8 / 125 = 1,53
- Xc nh bc th bnh qun: da vo th hnh 4.3 trn ta c
Bc th tin trung bnh 3,49
Bc th phay trung bnh 3,95
Bc th trung bnh ca c phn xng 3,52.

9.3 Tnh s cng nhn ph, nhn vin phc vu, cn b k thut v nhn vin hnh chnh
59

Trong thit k nh my c kh, s cng nhn ph, nhn vin phc v, cn b k thut
v nhn vin hnh chnh c xc nh theo t l % ca s cng nhn sn xut. Ta c th
tham kho cc s liu sau y:

9.3.1 S cng nhn ph:
Ty thuc vo dng sn xut, trnh chuyn mn ho, t ng ho ca phn xng
m t l cng nhn ph so vi cng nhn sn xut c khc nhau
+ dng sn xut hng lot: 18 - 20%
+ Dng sn xut hng khi: 35 - 50%
+ Sn xut dy chuyn: 40 - 50%
+ Sn xut t ng: 60%

9.3.2 S nhn vin phc v :
Trong phn xng c kh, nhn vin phc v chim khong 2 - 3% cng nhn ni
chung (c cng nhn sn xut v cng nhn ph)

9.3.3 S lng k s v cn b k thut
Trong phn xng c kh s k s v cn b k thut chim khong 10-13% tng s
cng nhn ni chung (k c cng nhn sn xut ln cng nhn ph).

9.3.4 S nhn vin hnh chnh, vn phng chim khong 4-5% tng s cng nhn ni
chung ca phn xng c kh.
Cn phi nhn mnh rng, trong thc t nc ta c nhiu ni nhng t l trn khng
m bo hoc vt qu. Tt nhin m bo hot ng ca cc b phn c ng b, ta
cn c gng gii quyt nhng trng hp bt hp l gy ra nhng lng ph nhn lc, lng ph
thi gian. Tuy vy khng th thot ly khi hon cnh thc t, do ngi thit k phi suy
ngh cn i mt cch tt nht trong iu kin cho php.

10. Tnh ton din tch v b tr mt bng phn xng c kh

10.1. Tnh ton din tch phn xng c kh

Nh ta bit: phn xng c kh thng c 4 b phn: b phn sn xut, b phn
ph, b phn phc v v b phn sinh hot. Mi b phn c xc nh theo nhng phng
php khc nhau.
Thng thng trong thit k phn xng c kh, ngi ta ch tnh ton din tch ca b
phn sn xut v b phn ph - gi l din tch chung, cn din tch phc v v b phn sinh
hot c xc nh theo t l % ca din tch sn xut hoc tham kho phn thit k cng
trnh sinh hot ca ngnh xy dng.
Tip theo chng ta nghin cu hai phng php xc nh din tch phn xng thng
c ng dng trong thc t.

10.1.1 Xc nh chnh xc din tch phn xng c kh
Phng php ny da trn c s b tr mt bng phn xng (tc l sp t v tr
ca cc my mc, thit b, ch lm vic, ng i ca thit b vn chuyn...) xc nh kch
thc ca phn xng, t tnh c din tch ca phn xng. Nh vy vic xc nh din
tch ca phn xng phi i t xc nh kch thc v din tch ca tng phn, tng khu vc
nh trong phn xng.

60
10.1.2 Xc nh din tch phn xng theo din tch n v
Phng php ny c tin hnh trn c s bit s lng my t trong phn
xng v din tch n v ta c th tnh ton c din tch ca phn xng. Sau khi xc nh
c din tch phn xng ta mi tin hnh b tr mt bng phn xng.
Nu ta gi A l din tch phn xng cn phi tnh ton (m
2
)
Cchn l s my cn thit cho phn xng (chic)
a l din tch n v (m
2
/chic)
Ta c mi quan h sau :
A = C
chn
. a, [m
2
] (4.29)

Trong cng thc trn din tch n v a l phn din tch trung bnh ca phn xng
tnh cho mt my t trong phn xng. Din tch n v l mt ch tiu kinh t - k thut
dng nh gi vic s dng din tch ca phn xng. Gi tr ca din tch n v a c
cho theo kinh nghim trong cc s tay thit k xng tu theo c my hoc ngnh sn xut.
Ta c th tham kho mt s trch dn bng 4.8 v 4.9

Bng 4.8 Din tch sn xut n v cho theo c my.

C MY

Kch thc (di x rng) hoc trng lng (Tn) ca
my
Din tch sn
xut n v
(m
2
)
B
Trung bnh
Ln
Rt ln
n 1500mm x 700mm
T 1500 x 700 n 3500 x 2000 hoc n 5 tn
T3500 x 2000 n 5000 x 3000 hoc 5 - 15 tn
T 5000 x 3000 n 10000 x 5000 hoc 15 - 40 tn
10 - 12
15 - 25
30 -45
50 -150


Bang 4.9 Din tch n v cho theo nganh san xut

Ngnh sn xut
Din tch sn
xut n v
(m
2
)
Din tch chung
n v (m
2
)
Ch to t ti trng 2,5- 4 tn :
Phn xng ng c
Phn xng khung
Phn xng hp s
Ch to my tin loi va
Ch to my phay ln
Ch to my mi trn
Ch to bi ln

12 - 14
10 -12
10 -12
17 - 19
20 -22
16 - 20
13 - 15

20 - 21
19 - 20
16
24 - 28
30 - 35
25 - 30
20 - 24

Cn ch rng: Nu din tch n v l din tch sn xut n v th din tch tnh
c mi ch l din tch sn xut ca phn xng. Nu din tch n v l din tch n v
chung th din tch tnh c tnh c l din tch chung (tc gm din tch sn xut v din
tch ph)

10.2 Cc kch thc ch yu ca phn xng
Kch thc phn xng thng c xc nh bng b rng (L), bc ct (t) v chiu
cao (H) (xem hnh 4.4).

10.2.1 B rng gian (nhp) L
61
l khong cch gia hai hng ct cu trc. Ni mt cch khc: b rng gian l
khong cch gia cc ct theo chiu ngang ca gian nh.
B rng gian c xc nh trn c s b tr cc thit b, ph thuc vo:
- Kch thc chi tit cn gia cng.
- Kch thc cc my v thit b vn chuyn trong phn xng.
Thng b rng gian c ly bng bi s ca 6 (12, 18, 24, 36m...) i vi phn
xng sn xut sn phm nh th c th ly l bi s ca 3. V d: L = 12, 15, 18 ...
B rng gian c qui chun theo loi phn xng :
- Phn xng sn xut sn phm loi nh : L = 12m
- Phn xng sn xut sn phm loi va : L = 12, 15, 18.
- Phn xng sn xut loi nng : L = 18, 21, 27, 30

Hnh 4.4 Kch thc phn xng

10.2.2 Bc ct t
Bc ct t l khong cch gia cc ct theo chiu dc gian nh.
L
K
h
5

h
4

h
3

h
2


h
1

62
Bc ct t ph thuc vo vt liu xy dng, kt cu ca nh, ti trng ca nh v ca
cu trc m xc nh gi tr. Thng thng t = 6m. Vi kt cu thp hoc trng hp khng
c cu trc c th t = 9m hoc t = 12m. Ngoi ra cn c th ly t = 3,9m. Khong cch gia
cc ct theo chiu ngang v dc to thnh mng li ct. (L x t).

10.2.2 Chiu cao ca phn xng H
Chiu cao phn xng l khong cch t nn nh n mp di thp nht ca kt cu
chu lc ca nh.
Chiu cao H ph thuc vo kch thc ca sn phm, vo chiu cao thit b t trong
xng, kt cu ca cu trc v cc iu kin v sinh, k thut. Gi tr chiu cao H qui nh l
bi s ca 200 mm.
T hnh 4.4 ta c :
H = H
1
+ h
1
+ h
2
(4.30)

H
1
l chiu cao t nn nh n mt ng ray ca cu trc, ph thuc vo kch thc
sn phm v chiu cao ca thit b, ta c th tnh H
1
nh sau:

H
1
= h
1
+ h
2
+ h
3
+ h
4
+ h
5
(4.31)

h
1
l chiu cao my, nu my qu thp th ly h
1
= 2 m (cao hn ngi).
h
2
l khong cch t mp di ca sn phm v im cao nht ca my (0,5 - 1m).
h
3
l chiu cao ln nht ca sn phm cn vn chuyn.
h
4
l chiu cao cp gi chi tit, ph thuc sn phm cn vn chuyn (thng >1m).
h
5
l khong cch t tm mc cu ( v tr cao nht) n mt ng ray, c gi tr
t 0,5 - 1,6 m tu thuc kt cu ca cu trc.
h
1
l cao ca cu trc, ph thuc vo ti trng ca cu trc. V d :
Q = 5 tn th h
1
=1650 mm
Q = 10 tn th h
1
=1800 mm
Q = 15 tn th h
1
= 2300 mm
h
2
l khong cch t mp trn cu trc n mp di thp nht ca kt cu chu lc
(dm mi), gi tr ca h
2
100 mm
Cc kch thc phn xng ni chung phi m bo sao cho 1 cng nhn lm vic
trong phn xng ti thiu c c 14m
3
khng gian hoc 45 m
2
din tch.

10.3. Cc phng php b tr v tr tng i gia phn xng c kh v lp rp trong to nh.
Mc ch vic b tr v tr tng i gia phn xng c kh v phn xng lp rp
trong to nh nhm :
- To iu kin thun li cho qu trnh ch to v lp rp sn phm .
- Rt ngn c dy chuyn sn xut.
- Tit kim din tch mt bng.
Sau y ta nghin cu mt s phng php b tr c th

10.3.1 Phng php b tr song song (hnh 4.5)

10.3.1.1 c im phng php b tr song song
- Hng i vo ca phi liu v hng ra ca sn phm trng nhau. Do kh nng
lu thng km (thng l chung mt cng), phi liu v sn phm thng b n li.
- Cc chi tit t phn xng c kh qua phn xng lp rp phi vn chuyn bng tay,
hoc bng xe m khng dng c cu trc
- ng vn chuyn thng di v quanh co.
63
Kho phi liu
Phn xng C kh
Kho trung gian
ng vo ca phi liu
Phn xng lp rp
Kho phi liu
Phn xng C kh
Kho trung gian
Phn
xng
lp rp
ng vo ca phi liu
Cu trc
10.3.1.2 Phm vi s dng : phng php b tr song song c s dng khi lng sn
phm sn xut t v trng lng ca cc chi tit, sn phm nh.

10.3.2 Phng php b tr ni tip (hnh 4.6)

10.3.2.1 c im ca phng php ny :
- Cc chi tit vn chuyn t phn xng c kh sang lp rp c th c tin hnh
bng cu trc. Nhng vn chuyn sn phm dc theo phn xng lp rp th li khng s
dng c cu trc.
- ng vn chuyn tng i ngn.
- Do cu trc nh ca ging nhau, b tr ni tip nhau nn d m rng.

10.3.2.2 Phm vi s dng
Phng php ny c ng dng khi trng lng ca sn phm khng ln, qui m
phn xng nh, trung bnh. c bit khi chng trnh sn xut cha n nh cn phi m
rng thm phn xng.

10.3.3 Phng php b tr vung gc nhau (hnh 4.7)

10.3.3.1 c im phng php b tr vung gc
- Cc chi tit c chuyn t c kh sang lp rp bng nhng cu trc quay hoc nh
cu trc ca phn xng c kh chy sang phn xng lp rp. Bn thn phn xng lp rp
c cu trc ring vn chuyn dc theo phn xng .
- C 2 phn xng u dng cu trc vn chuyn nn tn lng vn chuyn trn
khng, tit kim din tch mt bng xng sn xut.
- Nh ca 2 phn xng b tr vung gc vi nhau, c kt cu v kch thc khc
nhau. Do cu trc nh ca phc tp, kh m rng.

10.3.3.2 Phm vi ng dng ca phng php :
V v mt dy chuyn sn xut l tt nht, nhng chi ph v xy dng tn hn hai
phng php trn, do thng c s dng cho nhng phn xng c qui m ln v trung
bnh, chng trnh sn xut n nh, trng lng sn phm ln.

















Hnh 4.5 Px. c kh v lp rp b tr song song Hnh 4.6 Px c kh v lp rp b tr ni tip
64

Hnh 4.7 Phn xng c kh v lp rp b tr vung gc

10.4 B tr mt bng phn xng c kh

10.4.1 Phn chia phn xng c kh
Tu thuc vo c tnh sn phm, qui trnh cng ngh, dng sn xut v phng php
t chc sn xut phn xng c kh c chia thnh tng gian, b phn hoc ng dy.
Thng thng c 2 trng hp sau :
- Trong dng sn xut hng khi thng chia phn xng c kh ra tng gian gia
cng tng b phn. Mi gian li chia ra cc ng dy gia cng cc chi tit khc nhau
ca b phn. V d phn xng ng c t c gian blc - xilanh, gian trc khy - trc cam.
Trong gian trc khu - trc cam c ng dy gia cng trc khu, ng dy gia cng trc
cam...
- Trong cc dng sn xut hng lot, phn xng c kh c th c chia ra tng gian
hoc tng b phn gia cng cc kiu chi tit khc nhau hoc nhng loi chi tit c kch
thc khc nhau. V d trong phn xng c kh sn xut my tin c cc gian gia cng trc,
gian gia cng bc, gian gia cng hp ... hoc c b phn gia cng chi tit ln, b phn gia
cng chi tit nh ...

10.4.2 Cc phng php b tr my trong phn xng c kh
C hai phng php b tr my trong phn xng :

10.4.2.1 B tr theo loi my
Trong phng php ny, my c t theo tng loi c cng tnh cht gia cng. C
ni cn gi phng php ny ny l t theo nhm my. Khi b tr theo nhm my cn ch
cc im sau :
- Cc nhm my cn sp t theo trnh t tng qut gia cng a s cc chi tit in
hnh. V d : chi tit in hnh c dng tm th my nn t theo th t : bn ly du, my
phay ging, my bo ging, my khoan, my mi phng...
- Mi nhm my nn chia thnh nhng nhm nh c tnh nng gn nhau v t thnh
cm.
- t my sao cho tn lng s dng ht kh nng ca cu trc. Cc my ln v cc
my gia cng cc chi tit ln nn t di tm hot ng ca cu trc.

Kho phi liu
Phn xng C kh
Kho trung gian
Phn xng lp rp
65
10.4.2.2 B tr my theo th t cc nguyn cng
Da vo qui trnh cng ngh, t my gia cng lin tc cc chi tit theo mt ng
i sut.
Phng php ny ng dng trong sn xut hng khi v hng lot ln, trong t chc
sn xut theo dy chuyn.

10.4.3 Nhng im cn ch khi t my vo mt bng phn xng trong bn thit
k

+ Cc my c k hiu bng nhng hnh hnh hc theo t l nht nh, thng ly t
l 1:100, 1:200. Nhng hnh hnh hc ny c ch n kch thc ln nht ca my, gii hn
chuyn ng xa nht ca my, phn nh ra xa nht ca phi. Cc k hiu c th tham kho
trong s tay thit k xng.

+ V tr ng lm vic ca cng nhn c biu din bng 1 vng trn 500 mm v
theo t l, phn trng biu th mt, phn gch biu th lng ca ngi cng nhn (xem
hnh 4.8)


Hnh 4.8 Biu din v tr ng lm vic ca cng nhn

+ Phi m bo nhng khong cch cn thit cng nhn lm vic, thao tc thun
li, an ton, c ch a chi tit vo v ly chi tit ra.

+ Khng nn b tr cng nhn ng lm vic nhn ra ng ci, vn hoa ni ng
ngi i li.

+ Cc my chnh xc cn b tr xa ch c va p, rung ng, bi bm. Nn b tr thnh
khu vc hoc phng ring.

10.4.4 Nhng kch thc c th khi b tr my

Tu thuc vo c my m khong cch gia cc my, gia my vi tng, gia my
vi ct c khc nhau. C th tham kho cc trng hp hnh 4.9 v bng 4.10


ng i
8
0
0

5
0
0

T620
66

Hnh 4.9 Kch thc b tr my

Bng 4.10 Khong cch gia cc my, gia my v tng, gia my v ct

Gi tr khong cch theo c
my (mm)


Khong cch

n

1
8
0
0
x
8
0
0

n

4
0
0
0
x
2
0
0
0

n


8
0
0
0
x
4
0
0
0

n


1
6
0
0
0
x
6
0
0
0

Kch thc gia cc my khi b tr i din nhau : a
(theo chiu ngang)
700 900 1500 2000
Kch thc gia cc my khi b tr i din nhau : b
(theo chiu dc)
700 800 1200 1500
Khi b tr lin tip cng chiu c

1300 1500 2000 -
1 cng nhn ng 1
my d

2000 2500 3000 -
Khong
cch gia
cc my khi
b tr my
vung gc
vi ng
i (hoc b
tr nghing)

Khi cc my c b
tr ging nhau tng
i 1 cng nhn ng 2
my e
1300 1500 - -
Cng nhn ng i din ( hoc vung gc) vi
tng, ct
g
700 800 900 1000 Khong
cch gia
my vi
tng v ct Cng nhn ng quay lng vo tng v ct
h

1300 1500 2000 -

d
e
e
d
a
a
a
b b
b
1
3 ng i
ng i
h
h
h h
g
g
g
g
c
c c
c
c
2 ng i

n
g

n
g

i

Ct
Ct
Tng
4
Ct Ct
Tng
5
67

Nu ng i mt chiu, vn chuyn bng xe chy in ti trng 1 - 2 tn c b rng
i gia cho xe l 1, 2m th kch thc t my theo hnh 4.10
Hnh 4.10 Kch thc t my khi c ng i cho xe

Nu ng i 2 chiu th vic b tr my hoc theo trng hp a) hoc theo trng
hp d) hnh 4.10 v khong cch B = 3000 mm
Nu vn chuyn bng t th B = 3500 mm trng hp a) v d) hnh 4.10

10.4.5 Cch xp t my trong tng gian
Trong tng gian my c th c t nm dc, ngang hoc xin. Thng thng th
my c t theo chiu dc ca gian.
Khi din tch t my hp th my c th t ngang li i gia.









Hnh 4.11 Ba hng my dc, mt li i dc v cc li i ngang











Hnh 4.12 Va t dc, t ngang Hnh 4.13 Xin v dc xen k
B
B
B
B
a) b) c) d)
B = 1800 mm B = 2000 mm B = 3000 mm B = 1800 mm

n
g

i


n
g
a
n
g

ng i dc
68
Nhng loi my di (nht l my gia cng vt liu thanh), my doa, my bo ging,
phay ging, trut th c th t xin so vi trc dc gian mt gc t 15 - 20
0

Ta c th tham kho mt vi cch b tr hnh 4.11, 4.12, 4.13.

11. Thit k cc b phn ph ca phn xng c kh

11.1 Cc b phn ph ca phn xng c kh
Mt cch tng qut, cc b phn ph ca phn xng c kh gm c :
- Gian chun b phi liu.
- Gian mi dng c.
- Gian sa cha c kh.
- Gian kim tra.
- B phn sa cha g v dng c.
- Giao pha ch v phn phi dung dch trn ngui.
- B phn gia cng li phoi ct.
- Kho nguyn vt liu, phi liu.
- Kho gia cc nguyn cng.
- Kho trung gian.
- Kho dng c v ch phn phi dng c.
- Kho g.
- Kho vt liu ph.
- Kho du m .
- Kho mi ...
Tu thuc vo dng sn xut v qui m ca phn xng m cc b phn ph ca phn
xng c khc nhau. Cc b phn ph c th b tr lin hp vi nhau hoc gp chung trong
mt vi phn xng. V d :
Kho trung gian nhp chung vi kho gia cc nguyn cng.
Kho dng c nhp chung vi kho g.
Kho mi nhp chung vi kho vt liu ph.
B phn sa cha g chung vi b phn sa cha c kh ...
Khi thit k phn xng, ch mt vi b phn ph c tnh ton t m, cn a s cc
b phn khc thng chn theo kinh nghim.Sau y ta xt cch tnh ton thit b v din tch
vi b phn ph.

11.2 Tnh ton mt s b phn ph

11.2.1 Tnh ton cho gian chun b phi liu
Nhim v ca gian chun b phi liu l : lm cc cng vic chun b phi trc khi
a vo gia cng phn xng c kh nh ct t, xn mt, khoan tm, nn thng, bc v...
Thit b ca gian ny thng c my ca, my khoan tm, my nn thng, my tin
bc v...
Din tch n v ca b phn ny khong 25 - 30 m
2
/ chic. Sau khi chn c s
my ta s tnh c din tch cn thit cho b phn ny (A = a. Cchn).

11.2.2 Tnh ton kho nguyn vt liu v phi liu
Trong kho ny cn c :
- Cc gi, t
- Cc ng i chnh, ph
- Bi cht phi liu trc khi a vo gi.
Din tch chung ca kho c tnh theo cng thc sau:
69


. .
.
q F
t Q
S
F
= , [m
2
] (4.32)

Q : trng lng tng cng nguyn vt liu v phi liu cn cht trong kho hng nm
(tn/nm)
t : s ngy tn kho trung bnh, ty thuc dng sn xut v c phi m t c gi tr khc
nhau (bng 4.11)

Bng 4.11 S ngy tn kho trung bnh
Dng sn xut Ngy Phi nh Phi ln
n chic t 12 5
Lot nh t 8 3,5
Lot va t 6 2,5
Lot ln t 4 1,5
Hng khi t 2 0,5

F : s ngy lm vic trong 1 nm
q : ti trng din tch trung bnh ca kho, ph thuc vo v tr ca kho m q khc
nhau, q tnh bng tn/m
2


+ Nh 1 tng, phi c t trng ln hn 4 th :
Vt liu thanh : q = 2,5
Vt c, rn b v trung bnh q = 1,5
Phi c rn ln q = 2
+ Nh nhiu tng, kho trn gc q=0,75
: h s s dng din tch kho
Thng = 0,4 - 0,5

Ngoi tnh ton theo cng thc trn, ta c th tnh din tch kho theo t l phn trm
(%) ca din tch sn xut :

- Din tch kho chim khong 10 -15 % din tch sn xut.
- Din tch kho k c chun b phi liu chim 15 -20 % din tch sn xut

11.2.3. Tnh ton kho trung gian
Kho trung gian l kho cha bn thnh phm ch a vo lp rp.
Din tch kho trung gian c th tnh theo cng thc sau :




=
. .
.
q F
t Q
S
tg
(4.33)

Q l trng lng tng cng ca chi tit a vo kho hng nm (tn/nm)
F l s ngy lm vic trong 1 nm
l h s s dng din tch kho
Thng = 0,4.
t l thi gian chi tit tn kho (ngy), theo bng 4.12.

70
Bng 4.12 Thi gian chi tit tn kho
Gi tr t ty thuc loi sn phm Dng sn xut
Chi tit c nh, va Chi tit c ln Bn thnh phm
n chic
Lot nh
Lot va
Lot ln
Hng khi
15
10
7
4
2
6
4
2
1
0,5
6
5
4
2 - 2,5
1 - 1,5

q l ti trng din tch kho trung gian (q < q) v y chi tit cn c gi , gi gn
cn thn hn.
+ Chi tit nh, trung bnh q = 1 tn/m
2
+ Chi tit ln q = 1,5 tn/m
2


11.2.4 Tnh ton kho pht dng c, g
Vi phn xng nh, va th tt c dng c, g chung trong 1 kho, c th b tr
t 2 - 3 ch pht. Nu phn xng th nn t chc thnh cc kho ring (kho dng c ct, kho
dng c o, kho g...). Din tch ca kho c tnh theo s my trong phn xng v tu
thuc vo dng sn xut. n v tnh l m
2
/my
(phn xng sn xut)

Kho dng c
- Sn xut n chic 0,7 m
2
/my ca phn xng sn xut
- Sn xut lot nh 0,6 -
- Sn xut lot va 0,5 -
- Sn xut lot ln 0,4 -
- Sn xut hng khi 0,3 -

Kho g
- Sn xut n chic 0,5 -
- Sn xut lot nh 0,4 -
- Sn xut lot va 0,3 -
- Sn xut lot ln 0,2 -
- Sn xut hng khi 0,1 -

11.2.5 Tnh ton cho b phn mi dng c
i vi cc phn xng ln (s my nhiu hn 200) th t chc hai b phn mi. i
vi phn xng sn xut nh th t chc mt b phn mi.
B phn mi c th t gia hoc bn cnh phn xng.
S my ca b phn mi dng c c th tnh chnh xc theo thi gian cn thit mi
cc loi dng c, cng c th tnh theo t l % s my trong phn xng c kh (thng ly 4
- 6 %), sau da vo s tay thit k xng phn s my thnh cc loi.
Din tch b phn mi ly 7 - 8 m
2
cho mt my mi. Nu tnh c din tch ph th ly
8 - 10 m
2
cho mt my mi.
Din tch cho cng nhn ngui ly 5m
2
cho 1 ngi.
S lng cng nhn mi c th tnh chnh xc theo thi gian mi; cng c th tnh vo
s lng my tnh. Trong trng hp ny ly 1,7 - 2 cng nhn cho mt my mi.
Cng nhn ngui ca b phn mi ly 20% cng nhn mi.
Nhn vin phc v b phn mi ly 2 - 3 % cng nhn ni chung
Cn b k thut trong b phn mi ly 6 - 10 % cng nhn ni chung.

71
11.2.6 Thit k b phn kim tra
- Trong phn xng sn xut hng lot: s kim tra vin ly 5 - 7 % cng nhn ng
my.
- Trong phn xng sn xut hng khi: s cng nhn kim tra ly 20 - 25% cng
nhn ng my.
Din tch b phn kim tra ly 5 - 6m
2
cho mt nhn vin kim tra. Nu k c din tch
t thit b, t, bn gh th tng din tch ln 1,5 ln.
Ch kim tra trung gian gia cc my thng mt din tch vung c cnh 2 hoc
2,5m.

11.2.7 Din tch b phn gia cng li phoi ct
- Phn xng c kh c 100 - 300 my ly 0,5 - 1m
2
cho 1 my ca phn xng.
- Phn xng c kh c 300 - 700 my ly 0,3 - 0,5m
2
cho 1 my.
- Phn xng c kh c trn 700 my ly 0,25 - 0,3m
2
cho 1 my

11.2.8 Din tch kho du m
C mi my trong phn xng ly khong 0,07m
2

12. Thit k b phn phc v v sinh hot
B phn phc v v sinh hot c gii thiu k trong lnh vc thit k nh cng
nghip. y ch nu ln mt vi cch tnh ton cc b phn ch yu.

12.1 Vn phng phn xng
Vn phng phn xng c th b tr u (hoc cui) phn xng; cng c th b tr
nm trong to nh hnh chnh chung ca nh my.
Din tch ca vn phng:
- Cho nhn vin v, can ly 5m
2
cho 1 ngi
- Cho cn b lnh o phn xng ly 8 - 20m
2
cho 1 ngi
- Cho nhn vin vn phng khc ly 3 - 4m
2
cho 1 ngi.

12.2 Cc b phn sinh hot
Cc b phn sinh hot nh phng n, nh tm, trm cp cu, nh v sinh...c th b tr
ring trong mt nh sinh hot t trong hoc ngoi phn xng. Din tch nh sinh hot c th
ly bng 1/10 din tch phn xng. C th mt s b phn nh sau:

12.2.1 Nh n gia ca: tnh 0,8m
2
cho 1 cng nhn (ly theo s cng nhn ng nht
trong mt ca lm vic).

12.2.2 Trm cp cu:
- Phn xng di 2000 cng nhn th din tch chung 12 - 40m
2
.
- Phn xng 2000 - 7000 cng nhn, din tch ly 60 - 80m
2
.
- Phn xng trn 7000 cng nhn, din tch ly 175m
2
.

12.2.3 Nh tm: Cn c vo s lng cng nhn lm vic trong 1 ca lm vic, c 15
cng nhn c 1 bung tm. Cc phn xng nng nhc (c, rn, nhit luyn)
c 8 ngi c mt bung tm.

12.2.4 H x: Cn c s cng nhn lm vic ng nht trong 1 ca tnh theo bng
4.13

72
Bng 4.13 S lng h x
S lng h x
S ngi s dng N Nam
< 20
21 - 50
51 - 75
76 - 100
> 100
1
2
3
4
4 + c thm 40 cng nhn
thm 1 h x
1
2
3
4
4 + c thm 40 cng nhn
thm 1 h x


13. Cc ch tiu kinh t - k thut

13.1 Mc ch s dng
Cc ch tiu kinh t - k thut ca phn xng dng :
- nh gi hiu qu kinh t - k thut ca bn thit k.
- So snh vi cc thit k khc rt ra kt lun v n ca mnh.
- Kim tra qu trnh sn xut sau ny.
- Tham kho thit k cc phn xng khc.

13.2 Cc loi ch tiu kinh t - k thut
C hai loi ch tiu kinh t.

13.2.1 Cc ch tiu tuyt i
L nhng ch tiu c rt ra trc tip t bn thit k, c trng cho nng lc sn xut,
qui m phn xng. Bao gm cc ch tiu c th sau:
- Sn lng hng nm ca phn xng (tnh bng tn v bng tin).
- S kp lm vic mt ngy, s ngi lm vic trong mt kp.
- Tng s thit b chung ca phn xng (trong c bao nhiu my ct kim loi).
- Tng s cng nhn sn xut, cng nhn ph, cn b k thut.
- Din tch sn xut v din tch chung.
- Gi tin ca trang b c bn.
- Tng tin lng sn xut v tin lng ni chung hng nm.
- Tng cng sut in thit k.

13.2.2 Cc chi tit tng i
Rt ra trn c s cc ch tiu tuyt i ta c cc ch tiu tng i. N c trng cho
hiu qu kinh t - k thut ca phn xng. Bao gm:
- Sn lng hng nm ca phn xng tnh cho mt cng nhn sn xut, mt cng
nhn ni chung, mt n v thit b, 1m
2
din tch.
- Din tch sn xut v din tch chung tnh cho mt thit b sn xut (m
2
/chic).
- Cng sut thit k trung bnh tnh cho mt my ct kim loi (Kw).
- H s ti trng v h s s dng my trung bnh.
- S gi - my v gi - ngi cn thit gia cng 1 chic, 1 tn hoc 1Kw sn phm.
- H s s dng vt liu.



82
Chng V

THIT K PHN XNG SA CHA C KH
(PHN XNG C - IN)

1. Nhim vu phn xuong sua chua tvong nha may co kh

Phn xng sa cha c kh la mt phn xng phu trong nha may c kh, nhng co
vai tro rt quan trong nham dam bao cho nha mav san xut lien tuc va at nng sut cao.
Ngoai ra phn xng con gop phn cai tin, hin ai hoa cac thit b.
Nhim vu cua phn xng sa cha c kh la:
1/ Quan lv, theo aoi, kiem tra, phat hien cac sai hong cua cac thit b trong toan nha
may nhm ngan ngua va sua chua cac hu hong co th xay ra.
2/ Sua chua cac thiet bi chnh va phu theo ke hoach au phong.
3/ Cai tien cac trang thiet bi mav moc, gop phn tu trang tu che thm cac may mi
cho nha may.
4/ Nhiu trng hp con lam nhim vu che thu san phm moi.
5/ nhng nha may c kh c nho va va phn xng con am nhn tt ca khu sua
chua co dien cua nha may - do o goi la phn xng c din.

2. Cac dang va cac hinh thuc sua chua thit bj
2.1 K hcach sua chua du phcng
O nhung nha may co khl, cng vic sua chua thit b thuong duoc tin hanh thec k
hcach vach san gci la k hcach sua chua du phcng. c la k hcach sua chua tn tin nht,
khca hcc va chu dng nht. Sua chua thec k hcach du phcng cc nhung uu dim co ban sau:
Tranh tinh trang thit b b mai mcn qua muc, kec dai duoc tui thc thit b.
- Vic sua chua tin hanh nhanh, chcng giai phcng thit b d san xut.
2.2 Cac dang sua chua, chu ky sua chua va bc phuc tap sua chua
2.2.1 Dang sua chua:
Sua chua thec k hcach du phcng bac gm cac dang sau:
Lau chui thay du mo,
Kim tra d chlnh xac,
Xem xet,
Tiu tu (sua chua nhc),
Trung tu (sua chua vua),
ai tu (sua chua lon).
2.2.2 Chu kv sua chua (xem giac trinh may cat kim lcai)
,,,1 [et cu cua chu kv sua chua
83
Sua chua thec k hcach du phcng duoc tin hanh thec chu ky sua chua nht dnh. Chu
kv sua chua la thoi gian giua hai ln sua chua o aang dai tu ccn gci la thoi han giua cac dot
sua chua.
Tuong tu nhu trn, thoi han giua cac dot xem xet la thoi gian lam vic cua thit b giua
hai ln xem xet dnh ky.
Can cu vac dac tlnh, trcng luong, d phuc tap, ch d lam vic (s ca trcng ngay, diu
kin su dung thit b va dang san xut d qui dnh chu kv sua chua va thoi han giua cac dot
xem xet.
Nu ta ky hiu: la dai tu. ai tu ln 1: 1
T la trung tu, chl s sau la ln trung tu thu my, vl du T2

t la tiu tu, chl s sau chl thu tu ln tiu tu
x la xem xet.
[oi voi mav cat kim loai be va trung binh (G 10 tn) lam vic hai ca thi cc dang
sua chua va chu ky sua chua nhu sau (hinh 5.1) :
Hinh 5.1 Kt cu chu ky sua chua cua may cat kim lcai be va trung binh
(t
S
la thoi han giua 2 ln sua chua, t
X
la thoi han giua 2 ln xem xet)

Chu ky sua chua cua lcai may nay duoc vit duoi dang:
x / t / T / 9 / 6 / 2 / 1
Tuc la trcng mt chu ky sua chua cc 9 ln xem xet, 6 ln tiu tu, 2 ln trung tu va mt
ln dai tu.
[oi voi mav lon va hang nang (G 10 - 100 tn) cc chu ky sua chua nhu sau:
1 3x t1 3x t2 3x T1 3x t3 3x t4 3x T2 3x t5 3x t6 3x 2
(trcng dc 3x tuc la 3 ln xem xet).
Chu ky sua chua cua cac lcai may duoc vit duoi dang:
x / t / T / 27 / 6 /2 / 1.

[oi voi mav gia cong go: 18 / 6 / 2 / 1
[oi voi mav ren, mav ren ep tu dong, mav bua, mav ep ma sat: 12 / 3 / 2 / 1
[oi voi mav ep co kh, mav ep thuv luc, mav cat dot, mav loc uon: 27 / 6 / 2 / 1.
[oi voi thiet bi nng chuven: 36 / 6 / 2 / 1.
,,,, ]nh thoi gian chu kv va cac thoi han xem xet, sua chua
Sau khi cc duoc kt cu cua chu ky sua chua, ta can cu vac thoi han su dung cua cac
chi tit co ban, kt cu chu yu trcng thit b, tlnh cht va diu kin san xut, s bc phuc tap
78 thang
35 thang
t
X

t
S
5 6 nam
24 thang
1 x t1 x t 2 x T1 x t3 x t4 x T2 x t5 x t6 x 2
84
sua chua d xac dnh thoi gian chu ky va thoi gian sua chua. Cac thoi gian nay ta cc th tra
bang hcac tlnh tcan nhu sau:

26000.K
1
.K
2
.K
3
.K
4
.K
5
+ 8.R.m (P
L
+P
V
.X
P
+P
N
. Y
P
), [gio ] (5.1)
Thoi han xem xet :

1 + + +
=
p P P
X
Z Y X
t

, [gio ] (5.2)
Thoi han sua chua :

1 + +
=
P P
S
Y X
t

, [gio ] (5.3)
Trcng cac cng thuc trn:
K
1
: h s xet dn su anh huong cua dang san : lcat lon va khi K
1
1, lcat vua K
1

1,3, san xut lcat nhc va don chic K
1
1,5
K
2
: h s xet dn su anh huong cua vt liu gia cng: Thep K
2
0,9 1, gang va
kim lcai mau K
2
0,8 0,9.
K
3
: h s xet dn su anh huong v diu kin su dung thit b : binh thuong K
3
1,
mai kh K
3
0,7, thit b dat trcng phcng cach ly dac bit K
3
1,4, cc than
bui m uot K
3
0,8.
K
4
: h s xet dn su anh huong cua trcng luong thit b: thit b trcng luong 10T,
K
4
1, 10T 100T, K
4
1,35 , > 100T, K
4
1,7
K
5
: h s xet dn su anh huong v cht luong ch tac thit b: cht luong xu K
5

0,9, tt K
5
1, rt tt K
5
1,2
P
L
: s ngay ngung may d sua chua lon tlnh chc1 don v bc phuc tap sua chua, khi
cc bc phuc tap sua chua R 5, P
L
1, R > 5, P
L
1,25
P
V
: s ngay ngung may d sua chua vua tlnh chc 1 don v bc phuc tap P
V
0,6
P
N
: s ngay ngung may d sua chua nhc tlnh chc 1 don v bc phuc tap P
N
0,25
m : s ca lam vic cua mt thit b trcng mt ngay dm
R : s don v bc phuc tap sua chua cua thit b (xem phn sau)
X
P
: s ln sua chua vua (trung tu) trcng mt chu ky sua chua
Y
P
: s ln sua chua nhc (tiu tu) trcng mt chu ky sua chua
Z
P
: s ln xem xet trcng mt chu ky sua chua.
Cng thuc xac dnh thoi gian chu ky (5.1) chl ap dung chc nhung thit b lam vic duoi
20 nam, nu thit b lam vic trn 20 nam thi thay hang s 26000 bang 23000
Tlnh tcan nhu vy cc th phuc tap va mt thoi gian nn cc th tra bang d chcn thoi
gian chu ky thec may.
2.2.3 Bc phuc tap sua chua
,,31 [hai niem
Mi thit b du cc klch thuoc, trcng luong, tlnh nang va kt cu ky thut ring, nn
vic sua chua mi lcai thit b cung cc su phuc tap khac nhau. dac trung chc su phuc tap
dc. Nguoi ta su dung
<<
don vi bc phuc tap sua chua
>>
thuong ky hiu la R. R cang lon thi
cng vic sua chua va khi luong lac dng tiu tn chc vic sua chua cang lon.
,,3, \ac dinh bc phuc tap sua chua
85
Cc th su dung cac phuong phap sau d xac dnh s bc phuc tap sua chua R
1/ Phuong phap tlnh tcan : mi lcai thit b su dung mt cng thuc thuc nghim ring
d xac dnh R cua thit b dc, vl du di voi may tin ren vlt, ta cc :

R (0,025h + 0,001L + 0,2n) + C (5.4)
Trcng dc :
: h s xet dn su anh huong cua vic su dung thit b (su dung binh thuong 1,
gia cng vt nang 1,15)
h : chiu cac tm may dn ban may
L : khcang cach lon nht giua hai du mui tm (L 5000 dung hang s 0,001 trcng
cng thuc (5.4), ccn khi L > 5000 thi thay bang hang s 0,002)
n : s cp tc dc cua truc chlnh (may cc hp tc d dung hang s 0,2 trcng cng thuc,
may dung banh dai bc thay bang hang s 0,1)
C : dac dim cu tac cua may C 0,5X + C
1
+ C
2

X : s luong ban dac.
C
1
: s don v bc phuc tap sua chua co cu diu chlnh v cp cua truc chlnh (khi dc
se khng cc s han 0,2 n trcng cng thuc 5.4 nua), di voi may cc h 200 thi
C
1
2, ccn khi h > 200 thi C
1
4
C
2
: s don v bc phuc tap sua chua ban dac chep hinh bang thuy luc C
2
2
2/ Phuong phap sc sanh
a)
thoi gian tiu hac thuc t d sua chua trcng 1 chu ky
R
dnh muc thoi gian sua chua chc 1 don v bc phuc tap trcng 1 chu ky

b) Sc sanh mt may nac dc voi mt may chun, di voi thit b cng ngh thi
thuong dung may chun la may tin ren vlt 1K62 (duong klnh vt gia cng lon nht la
400mm, khcang cach 2 mui tm 1000mm). May nay cc R 11.
3/ Tra bang : Trcng cac s tay v sua chua co khl thuong cc cac bang d tra tr s bc
phuc tap chc cac lcai may. Cc th xem bang 5.1.

Bang 5.1 Bc phuc tap cua mt s may cat kim lcai
Lcai may Ky hiu Bc phuc tap
May tin
May tin
May tin
May tin
May tin
May khcan
May bac
May phay
T616
1A62
T630
165
153R
K125
B665
P82
R 7
R 11
R 14
R 23
R 50
R 6
R 9
R 12

2.3 Cac hinh thuc t chuc sua chua
86
Tuy thuc vac qui mo va aang san xut cua nha may, cc th t chuc sua chua thec cac
hinh thuc sau:
T chuc sua chua tp trung,
T chuc sua chua phn tan,
T chuc sua chua tng hop.
2.3.1 [inh thuc to chuc sua chua tp trung
O hinh thuc t chuc sua chua nay, tt ca cac dang sua chua tu xem xet dn dai tu du
dc phn xuong sua chua co kh dam nhn.
Hinh thuc t chuc sua chua tp trung duoc ap dang chc cac nha mav co nho va trung
binh, san xut hang loat nho hav don chiec (khng cc b phn sua chua co din o cac
phn xuong)
2.3.2 [inh thuc sua chua phn tan
Trcng hinh thuc nay tt ca cac cng vic sua chua tu xem xet dn dai tu du dc cac bo
phn co - dien cua cac phn xuong dam nhn. Phn xuong co dien chung cua nha may
ch co nhiem vu san xut cac chi tit phu tung thay th, du tru, phuc hi cac chi tit
hcng, mcn va dai tu mt s lcai may dac bit.
Dang t chuc sua chua nay phu hop voi cac nha may co lon san xut loat lon va hang
khoi
2.3.3 Dang to chuc sua chua hon hop
ac trung cua dang t chuc sua chua hn hop la:
[ai tu cac may mcc, thit b dc phn xuong sua chua co khl dam nhn
Cac dang sua chua tu xem xet den trung tu dc cac bo phn co - dien o cac phn
xuong khac dam nhn
Dang t chuc sua chua nay thuong ap dung chc cac nha mav hang nang va cac nha
may cc qui mo san xut trung binh.

3. Thanh phn cua phn xuong sua chua co kh
Phn xuong sua chua co khl thuong cc cac b phn sau:

3.1 B phn san xut bac gm:
Cac bo phn thao rua chn bi phoi,
- Bo phn gia cong co kh nguoi lap rap,
- Bo phn ren, han, nhiet luven,
- Bo phn sua chua duong ong, noi hoi
- Bo phn phuc hoi cac chi tiet (nhu ma, phun dat kim loai)
- Bo phn thu, son, sua chua thiet bi dien
Tuy thec qui m san xut va dang t chuc sua chua ma cac b phn trn cc th sap
nhp lai, hcac tach rieng ra. Vl du:
+ O cac nha may co khl co lon thi cac b phn han, ni hoi, sua chua din, sua
chua nha cua duoc tach thanh cac phn xuong ring.
+ O cac phn xuong co din lon cc th cc ring b phn han, nhit luyn hcac
2 phn xuong co din.
87
+ O cac phn xuong co din nhc cac cng vic nhit luyn, han dc cac phn
xuong nhit luyn va ren cua nha may dam nhim.
3.2 B phn phu
B phn phu bac gm he thong kho (khc nguyn vt liu, khc ban than phm, khc chi
tit du tru, khc dung cu), cho de mai aao va mt s bo phn khac.
3.3 B phn phuc vu va sinh hcat
B phn nay tuong tu nhu o phn xuong co khl va phn xuong lap rap

4. Chuong tvinh sua chua cua phn xuong

4.1 Nhung tai liu ban du d lp chuong trinh sua chua
Chuong trinh sua chua cua phn xuong co din duoc xac lp trn nhung co so sau:
+ Khi luong cng vic ma phn xuong phuc vu sua chua chc cac phn xuong
cua nha may.
+ Khi luong du tru cng vic ch thu, thl nghim,
Mun lp chuong trinh sua chua cn co nhung tai lieu ban du sau:
1/ Tn cac phn xuong, cac b phn trcng nha may ma phn xuong co din phai phuc
vu sua chua.
2/ Ban thng k tcan b cac thit b trcng tcan nha may. Trcng ban thng k cn ghi rc
va dy du: kiu, s luong, tlnh nang ky thut, cac klch thuoc cc ban, cng sut, bc phuc tap
sua chua, d chlnh xac...

4.2 Chuong trinh sua chua cua phn xuong

4.2.1 Noi aung cua chuong trinh sua chua

Trn co so 2 tai liu k trn ta se lp duoc chuong trinh sua chua cua phn xuong biu
th bang khoi luong cong viec sua chua (gio may va gio cng cua cng nhn)
]uong lao dong cn thit d sua chua tt ca cac thit b la tai liu quan trcng va chu
yu nht trcng chuong trinh sua chua cua phn xuong nc duoc biu th bang :
1/ So gio cn thiet de gia cong co trn cac may cat, gia cng ngui, lap rap va cac
cng vic khac d hcan thanh tcan b cng vic sua chua, hcac:
2/ [on vi do phuc tap sua chua chc mt thit b
Bc phuc tap sua chua R phu thuc vac klch thuoc dac dim d phuc tap v kt cu
tlnh cht cua thit b. Thit b cc kt cu cang phuc tap R cang lon. Chlnh vi vy mi lcai may
cc bc phuc tap khac nhau, ta cc th tham khac bang 5.1

4.2.2 ]uong lao dong cua cong viec gia cong co, nguoi, lap rap va cac cong viec
khac:
Luong lac dng cua cng vic gia cng co, ngui, lap rap va cac cng vic khac:cua
mt don v bc phuc tap sua chua di voi mi dang sua chua khac nhau cc th tham khac o
bang 5.2
88
Bang 5.2 Luong lac dng cua cng vic gia cng co, ngui, lap rap va cac cng vic khac:
luong lao dng cua 1 don vi phuc
iap sua chua
1h
u iu



(1)


Dang cng vic sua chua



(2)
S
ln
sua
chua
irong
1 chu
ky
(3)
1hoi
gian
cua
chu ky
sua
chua
(nm)
(1)
H
s
chu
ky
K
c



(5)
Gio
may
phuc
vu sua
chua
(6)
Gio
cng
ngui


(7)
Gio
cng
cac
vic
khac
(8)
1ng
ihoi gian
phuc vu
cho sua
chua
(9)
1
2
3
4
5
6
7

Kim tra d chlnh xac
Rua may
Xem xet
Xem xet truoc khi dai tu
Tiu tu
Trung tu
ai tu


8
1
6
2
1


5
5
5
5
5


1,6
0,2
1,2
0,4
0,2


0,5
0,5
4
10
20
0,4
0,75
1
2
5
18
30




1
2
4
0,4
0,75
1,5
2,5
10
30
54

5. Tnh toan thoi gian sua chua
Thoi gian d tin hanh mt dang sua chua nac dc, trcng 1 nam chc tt ca cac thit b
cac kiu cc th tlnh thec cng thuc:

=
m
C S
K l M R T
1
. . .
(5.5)
(m: s luong kiu thit b cn sua chua)
T: thoi gian thuc hin mt dang sua chua nac dc chc tt ca cac loai mav trong 1 nam
R: s bc phuc tap sua chua cua 1 lcai may nac dc cn sua chua dang tlnh
M
S
: s luong may cua 1 lcai may cn sua chua dang tlnh.
l : luong lac dng d sua chua 1 don v bc phuc tap tlnh chc dang sua chua nac
dc.(ly o bang 5.2) on v cua l la ( gio may/1 don v d phuc tap, 1nam )
Kc : h s chu ky sua chua o dang sua chua tuong ung dang tlnh, cc th tra o bang 5.2
hcac tlnh thec cng thuc sau :

C
C
C
T
n
K = (5.6)
n
c
: s ln sua chua cua dang sua chua dang tlnh duoc thuc hin trcng 1 chu ky sua chua
T
c
: khcang thoi gian cua mt chu ky sua chua (nam)
J au :
Mt kiu may cc chu ky sua chua la 5 nam, trcng thoi gian dc phai tin hanh mt ln
dai tu, 2 ln trung tu, 6 ln tiu tu va 9 ln xem xet. Nhu vy ta cc :
T
c
5
ai tu K
c
1/5
89
Trung tu K
c
2/5
Tiu tu K
c
6/5
Xem xet K
c
9/5

]hoi gian thuc hien tt ca cac aang sua chua cho tt ca cac kieu thiet bi trong 1 nam
duoc tlnh thec cng thuc sau :

n
T T
1
(5.7)
( n: s dang sua chua)
Chu v :
1/ T

cc th la thoi gian sua chua chung (bac gm thoi gian may, ngui, lap rap va cac
cng vic khac) cung cc th chl la thoi gian cn thit phuc vu chc sua xhua ring cua tung lcai
cng vic. iu dc tuy thec gia tr cua l trcng cng thuc (5.5) duoc ly c ct nac (cac ct
6,7,8,9 ) trcng bang 5.2
2/ Ngcai cng vic sua chua thit b, phn xuong sua chua ccn phai dam nhn sua chua
lc, duong ng... Thoi gian cua cac cng vic nay ta cc th ly thm 15 20 tng thoi gian
sua chua thit b.

6. Tnh toan s luong thit bj cua phn xuong sua chua co kh

S luong thit b cua phn xuong sua chua co khl cc th duoc tlnh tcan thec thoi gian
cn thit d sua chua mi don v thit b hcac thec ty l tng s may duoc phn xuong phuc
vu.
6.1. Tlnh s thit b thec s gio cn thit d sua chua mi don v thit b
Nho cng thuc (5.5) va (5.7) ta xac dnh duoc T

... Tu gia tr tlnh duoc (T

), s may
cat gct chc phn xuong sua chua co khl cc th xac dnh thec cng thuc sau:


F.m
may) (

=
T
C
sc
tinh
(5. 8)
C
sc
tnh
: s may cat gct cn chc phn xuong sua chua co khl (thec tlnh tcan)
T

(may)
: tng thoi gian may cn tht phuc vu cac dang sua chua tcan b thit b trcng 1
nam ( l l
(may)
o ct 6 cua bang 5.2).
F : s gio lam vic thuc t hang nam cua mt may voi ch d lam vic 1 ca
m : s ca lam vic trcng 1 ngay dm.
Sau khi tlnh tcan duoc s may yu cu C
sc
tnh
, ta cn d y dn h s tai trcng
Z
cua
phn xuong sua chua d xac dnh s may thuc t chcn dung. Nu ta gci C
sc
chon
la s may thuc
t chcn dung, thi :

Z
sc
tinh sc
chon
C
C

= (5. 9)
(
Z
0,85)
90
Khi da bit duoc s may chcn dung (C
sc
chon
), dua thec ty l phn tram qui dnh thec
kinh nghim d tlnh s luong may chc tung lcai. Tl l dc chc trcng s tay Thit k xuong
hcac cc th tham khac bang 5. 3.
Bang 5.3 Ty l cua cac lcai may
Thu
tu
Tn may Ty l cua
T

(may)

Thu tu Tn may Ty l cua
T

(may)

1
2
3
4
5
6
May tin, may Rovcnve
May tin dung, tin cut
May dca
May phay
May gia cng banh rang
May mai
4550
23
34
79
67
1012
7
8
9
10
11
May bac
May xcc
May khcan dung
May khcan cn
Cac may khac
78
23
78
23
4
6.2 Tlnh s may thec ty l tng s may duoc phn xuong sua chua phuc vu
Ta cc th tham khac bang 5.4 ( dung trcng nha may cc bc phuc tap sua chua trung
binh la 10 va chu ky sua chua la 6 nam)
Bang 5.4 S may thec ty l tng s may duoc phn xuong sua chua phuc vu
Ty l giua may cua phn xuong va s may cn duoc sua chua S luong thit b cn
sua chua cua cac
phn xuong (chic)
Phn xuong
sua chua
B phn sua chua o
cac phn xuong
Tng cng
300
500
800
1000
1500
2000
3000
4000
5000
6000
7000
10000
5,4
5,1
4,4
3,9
3,5
3,0
2,7
2,3
1,9
1,8
1,6
1,5
2,0
2,1
2,1
2,2
2,2
2,3
2,4
2,5
2,6
2,6
2,6
2,6
7,4
7,2
6,5
6,1
5,7
5,3
5,1
4,8
4,5
4,4
4,2
4,1
Trn dy la cach xac dnh s luong thit b chlnh, so luong thiet bi phu lv khoang ,0
so luong thiet bi chnh
91
Thuong thit b phu trcng phn xuong sua chua gm cc : may khcan ban, may khcan
l tm, may cat, may cua, may han, may ep bang tay (hay bang thuy luc). Ring s luong mav
mai lv khoang 4- 6 so mav chnh
Ngcai ra thit b phu ccn gm nhung mav trang bi them phuc vu cho nguoi, sua chua,
lap rap, han noi hoi, han thiec, sua chua duong ong..., di khi ca chc ren va nhiet luven. Vl du
phuc vu chc ngui, sua chua lap rap gm cc ban ngui, t, ban ly du, ban ra, phuc vu chc
han ni hoi, duong ng cc may han din, may han h quang, may han din tro, may can, may
un, may cat dt...
Khi phn xuong sua chua nhn phn sua chua din thi cn thm cac thit b phu nhu
may cun dy, cac thit b dung cu dc din. Ngcai ra thit b phu ccn bac gm nhung thit b
vn chuyn nhu xe dy bang tay, xe chay bang din ac qui, cu truc din, palang, cu truc
quay ...

7. Tnh s luong cng nhn, can b cho phn xuong sua chua
7.1. Thanh phn cng nhn va can b trcng phn xuong sua chua
V nhn su, trcng phn xuong sua chua cc :
1/ Cac loai cong nhn :cng nhn san xut, cng nhn phu
2/ Cac can bo lanh dao va can bo kv thut
3/ Nhn vien phuc vu, nhn vin thng k ky thut, cng nhn nghip vu khac
7.2. Tlnh tcan s luong cac lcai
7.2.1. ]nh so luong cong nhn san xut
Cng nhn san xut cua phn xuong sua chua gm cc :
Cng nhn dung may cat gct
Cng nhn ngui, sua chua
- Cng nhn han sua ni hoi, duong ng
Cng nhn san xut cc th duoc tlnh chlnh xac hcac tlnh gn dung
7,11 ]nh chnh xac so luong cong nhn dung mav va cong nhn nguoi sua chua
Cng nhn dung may va cng nhn ngui sua chua gci chung la cng nhn san xut,
nhung cach tlnh tcan khng ging nhau, cu th nhu sau
1> Tlnh s luong cng nhn dung may (R
sc
may
)
Tuong tu nhu o phn xuong co khl, s luong cng nhn dung may cua phn xuong sua
chua duoc xac dnh thec cng thuc :

c
m
c
may
sc
may
S F
T
R
.
) (

= (5.10)
T

(may)
la tng s gio may trcng 1 nam cn d phuc vu sua tt ca cac lcai thit b trcng
nha may
F
c
m
la thoi gian lam vic thuc t cua1 cng nhn dung may trcng 1nam
S
c
la h s dung nhiu may. Vi o phn xuong sua chua, chu yu chl trang b may van
nang , nn mt cng nhn chl dung mt may , dc dc S
c
1
2> Tlnh s luong cng nhn ngui sua chua (R
sc
ngui
)
S cng nhn ngui duo ctlnh thec cng thuc
92

.
) (
n
c
nguoi
sc
nguoi
F
T
R

= (5.11)
T

(ngui)
: tng s gio sua chua ngui trcng 1 nam
F
c
n
: thoi gian lam vic thuc t cua 1 cng nhn ngui trcng 1 nam
7,1, ]nh gn dung so luong cong nhn san xut
1> Tlnh gn dung s cng nhn dung may
S cng nhn dung may duoc tlnh gn dung thec cng thuc sau :


sc
chon
c
Z ca
sc
may
C K R . . = (5.12)
K
ca
: h s tlnh dn s ca lam vic cua may

c
z
: h s tai trcng cua may
thuong K
ca
.
c
z
1,75
C
sc
chon
: s may chcn dung cua phn xuong sua chua
2> Tlnh gn dung s tho ngui sua chua
Ta cc th ly
R
sc
ngui
(130 150) R
sc
may
(5.13)
7.2.2. ]nh so cong nhn phu va cac loai can bo nhn vien khac
Thuong cng nhn phu, can b ky thut va nhn vin khac duoc tlnh thec ty l cua
cng nhn san xut. Cu th la :
a/ Cong nhn phu :
) (
100
) 20 15 (
sc
nguoi
sc
may
sc
phu
R R R +

= (5.14)
b/ Cong nhn phuc vu :
) (
100
) 3 2 (
sc
nguoi
sc
may
sc
pv
R R R +

= (5.15)
c/ [v su va can bo kv thut.
) (
100
) 9 7 (
sc
nguoi
sc
may
sc
kythuat
R R R +

= (5.16)
d/ Cac loai nhn vien va can bo khac.
) (
100
) 5 3 (
sc
nguoi
sc
may
sc
khac
R R R +

= (5.17)

8. Tnh toan din tch va b tv mt bng phn xuong sua chua
8.1 Tlnh din tlch phn xuong sua chua:
Cung tuong tu nhu cac phn xuong khac, din tlch phn xuong sua chua cc th tlnh
chlnh xac hcac xac dnh gn dung thec din tlch don v.
8.1.1 \ac dinh chnh xac aien tch phn xuong sua chua.
Trn co so da b trl trang thit b, ch lam vic, duong di cua cac b phn trcng phn
xuong, ta tin hanh xac dnh klch thuoc tung b phn d xac dnh din tlch tung b phn va
tcan b phn xuong.
8.1.2 \ac dinh gn dung aien tch phn xuong sua chua:
93
Xac dnh din tlch gn dung phn xuong sua chua dua trn co so din tlch don v. Din
tlch don v la din tlch trung binh qui di chc mt may hcac mt cng nhn san xut hcac chc
mt may cn dai tu. Cu th la:
+ Din tlch trung binh chc mt may ly bang 15 20m
2
+ Din tlch trung binh chc mt cng nhn ngui sua chua (gm din tlch dat ban
ngui, ch sua chua, lap rap va duong di...) ly 15 20m
2

+ Din tlch trung binh chc mt may cn dai tu ly 20 25m
2

Khi bit s may, s cng nhn ngui sua chua, hcac s may cn dai tu, ta se tlnh duoc
din tlch cn thit.
Sau khi xac dnh din tlch dat may, din tlch ngui nci chung, din tlch cac b phn
khac duoc ly thec ty l cua chung, thec kinh nghim ta cc:
Din tlch chung b phn ngui lap rap sua chua bac gm ca b phn thu va son
chim 65 85 din tlch dat may.
Din tlch b phn thac may chim 20 25 din tlch ngui hcac chim 12 15
din tlch dat may.
Din tlch chung chc mt don v thit b chlnh (khng k nhit luyn, ren, sua chua
din, sua chua duong ng, van phcng sinh hcat...) cc th ly trung binh 32 40m
2
/1may
Ta gci S
m
la din tlch dat may cua phn xuong sua chua
S
ng
la din tlch ngui sua chua cua phn xuong
S
chung
S
m
+ S
ng
thi ta cc th xac dnh :
Din tlch b phn han hoi ly khcang (5 7) S
chung

Din tlch b phn sua chua duong ng ly ( 4 5) S
chung

Din tlch b phn ren (3,5 5) S
chung

Din tlch b phn ma kim lcai (2,5 3) S
chung

Din tlch b phn han thit, han dng (1 1,5) S
chung

Din tlch gian chun b va khc phi liu (6 7) S
m

Din tlch khc ban thanh phm (7 9) S
m

Khc chi tit va vt liu phu (6 7) S
m

Din tlch ch mai dac va khc dung cu (5 6) S
m

Din tlch lap rap b phn (20 25) S
ng

Din tlch lap rap chung (60 70) S
ng

Din tlch b phn kim tra (4 6) S
ng

Din tlch b phn son va phn phi (6 9) S
ng

8.2. B trl mat bang phn xuong sua chua
8.2.1. Bo tr mav trong phn xuong sua chua
Trcng phn xuong sua chua nci chung may duoc b trl thec nhcm. Nhung cn d y 2
dim sau :
Chu y dn trinh tu gia cng cac chi tit din hinh
B trl sac d trit d su dung cu truc
8.2.2. Bo tr bo phn nguoi sua chua cc 2 cach
1/ Bo phn nguoi bo tr song song voi bo phn dat mav d dung chung cu truc
94
2/ Bo phn nguoi bo tr vuong goc voi bo phn dat mav truong hop nay b phn
ngui phai cc cu truc ring
8.2.3. Bo tr cac bo phn khac cua phn xuong
+ Bo phn thao rua mav : dat o du phn xuong cung nhp voi b phn dat may lon (d
dung chung cu truc)
+ Canh bo phn thao rua mav bo tr cac kho chua chi tit cn phuc hi, khc phi liu
va b phn ch tac phi.
+ [ho ban thanh phm chua cac chi tit du tru dat o cuoi gian dat mav va gn b phn
ngui sua chua lap rap.
+ Cac kho aung cu va bo phn mai aao tuy thuc vac diu kin nc phuc vu ma b trl
chc thun tin, nn dat o trung tm nhung noi cn phuc vu.

9. Mt s ch tiu kinh t ky thut cua phn xuong sua chua
Nhung chl tiu kinh t ky thut co ban dac trung chc phn xuong sua chua la :
1/ [e hoach sua chua hang nam cua phn xuong duoc tlnh bang s don v bc phuc
tap sua chua
2/ So luong mav cat kim loai cua phn xuong
3/ Jon co dinh cua phn xuong (tin mua thit b, xy dung nha cua cng trinh)
4/ San luong san phm san xut hang nam cua 1 cong nhn san xut (tlnh bang tin,
tn san phm hcac s don v bc phla tap sua chua)
5/ ]v le giua so mav cua phn xuong sua chua voi s thit b cn sua chua cua tcan
nha may
6/ Dien tch san xut, aien tch chung cua phn xuong va din tlch tlnh chc 1 thit b
chlnh
7/ Cong sut dien trung binh tlnh chc 1 may chlnh trcng phn xuong .

86
CHNG 6
THIT K PHN XNG LP RP

1. Vai tr phn xng lp rp trong nh my c kh

Mc tiu ca nh my c kh l sn xut ra nhng sn phm hon chnh. V vy, phn
xng lp rp cng vi phn xng c kh chim vai tr ht sc quan trng trong vic hnh
thnh cc sn phm . Tm quan trng ca phn xng lp rp th hin trn cc mt sau :

1/ Thi gian tiu tn cho qu trnh lp rp rt ln.
Tu theo dng sn xut, thi gian lp rp sn phm c th bng 20-60 % thi gian gia
cng c cc sn phm . Trong mt s trng hp (v d lp rp my ct kim loi hng
nng) thi gian lp rp bng 65-80 % thi gian gia cng c.

2/ Gp phn quan trng m bo cht lng ca sn phm
D cc chi tit c gia cng vi cht lng cao, nhng lp rp khng ng th cht
lng sn phm vn khng tt.

3/ Cng vic lp rp phc tp, tinh vi, nhiu khi i hi trnh k thut cao
Thng trnh bc th phn xng lp rp cao hn phn xng c kh.

4/ Lp rp l giai on kt thc ca qu trnh hnh thnh sn phm
Giai on ny chu trch nhim hon chnh, sa cha tt c nhng sai st cn li ca
gia cng c.

2. Nhng ti liu ban u thit k phn xng lp rp
Mun thit k c phn xng lp rp, ta cn chun b cc ti liu v s liu cn thit
sau :

1/ Chng trnh sn xut ca phn xng lp rp bao gm : tn, s lng, trng lng cc
sn phm v cc b phn cn phi lp rp hng nm; tn, s hiu, s lng ca nhng chi tit
lp thnh b phn v sn phm; tn cc phn xng m t cc chi tit, b phn c
a n phn xng lp rp.

2/ Cc bn v lp tng b phn v ton b sn phm vi y cc iu kin k thut v
lp ghp.

3/ Cc iu kin k thut yu cu khi th my v khi nghim thu my

3. Cc phng php lp chng trnh sn xut cho phn xng lp rp
Tng t nh phn xng c kh, chng trnh sn xut cho phn xng lp rp cng
c hai phng php lp :

- Cch lp chng trnh sn xut chnh xc.
- Cch lp chng trnh sn xut c nh.

3.1. Chng trnh sn xut chnh xc ca phn xng lp rp
Da trn chng trnh sn xut ca nh my, thng k li tt c cc s liu di dng
cc bng. Cn c vo nghin cu qui trnh cng ngh lp rp mt cch t m, chnh xc
cho tt c cc sn phm v b phn cn lp rp.
87
Khi lp qui trnh lp phi nghin cu t m tng bc, nguyn cng v xc nh chnh
xc thi gian cn thit lp rp.
Cng vic ny tn nhiu cng sc, v vy ch thch ng i vi dng sn xut hng
khi v lot ln.

3.2. Chng trnh sn xut c tnh cho phn xng lp rp
i vi nhng phn xng lp rp sn xut lot nh, n chic v lot va, s loi sn
phm nhiu m s lng mi loi t, ti liu k thut khng y nn khng th lp chng
trnh sn xut chnh xc c.

Trong nhng trng hp ny, cn c vo :
- kt cu,
- cng ngh,
- iu kin lp rp
ta tin hnh phn loi sn phm thnh tng nhm gn ging nhau.
mi nhm li chn mt sn phm in hnh v tin hnh nghin cu t m qui trnh
cng ngh lp rp sn phm in hnh rt ra thi gian cn thit lp rp n. Thi gian lp
rp cc sn phm khc c tnh theo sn phm in hnh nhn vi h s c nh K
Tng t nh phn xng c kh :

K = K
1
.K
2
.K
3
(6.1)
Trong K
1
l h s k n s khc nhau v trng lng gia sn phm ang xt vi
sn phm in hnh.
K
2
l h s k n s khc nhau v mc phc tp lp rp ca sn phm
ang xt so vi sn phm in hnh. K
2
c da vo kinh nghim v
bn v lp rp ; ngi thit k t xc nh.
K
3
l h s k n s khc nhau v lot sn phm sn xut.
(K
1
v K
3
c xc nh nh phn xng c kh).
.
4. Thnh phn ca phn xng lp rp
Ni chung phn xng lp rp cng c 4 b phn chnh : gian sn xut, gian ph, b
phn phc v v b phn sinh hot.

1/ Gian sn xut bao gm

- Ch gia cng ngui cc chi tit trc khi lp.
- Ch lp b phn, lp chung
- Ch nh bng, th, sn, sy.
- Ch bao gi ...

2/ Gian ph gm c h thng kho (kho trung gian, kho dng c, kho vt liu ph, kho
thnh phm...), ch kim tra, ch pht dng c...

3/ B phn phc v bao gm phng k thut, vn phng, ch lm vic ca qun c...

4/ B phn sinh hot c phng tm, nh v sinh, phng thay qun o, nh n, trm
x....
Tu theo dng sn xut, c im ca sn phm v v tr ca phn xng trong nh
my m cc b phn c th thm, bt. V d trong sn xut n chic, lot nh v lot va th
ch lp rp b phn v ch lp chung nm trong phn xng lp rp. Trong sn xut lot ln
88
v hng khi th ch lp b phn thng nm trong phn xng c kh cui dy chuyn gia
cng, cn ch lp chung th nm trong phn xng lp rp.

5. Cc giai on ca qu trnh lp rp
lp qui trnh cng ngh lp rp, trc ht ngi cn b k thut phi nghin cu
phn sn phm thnh cc n v lp rp (nh t hp b phn ; nhm hoc nhm nh). (xem
trong gio trnh cng ngh ch to my).
Trn c s cc n v lp rp lp nhng s lp rp biu th trnh t ca qu trnh
lp rp.
Ni chung, qu trnh lp rp ca bt k sn phm no cng c th chia ra cc giai on
chnh sau :

1/ Gia cng ngui bng tay cc chi tit trc khi a vo lp rp
Giai on ny tin hnh nhiu trong sn xut n chic v lot nh.

2/ Lp b phn (lp s b) tc l lp cc chi tit thnh cc t hp, nhm hoc nhm
nh.

3/ Lp chung l giai on lp cui cng hon chnh sn phm.

4/ Kim tra, iu chnh nhm sa cc sai st cn li m bo v tr tng quan ng
gia cc b phn ca sn phm.

6. Nhng im cn ch khi lp qui trnh cng ngh lp rp
Lp qui trnh cng ngh lp rp v chn thit b phc v cho qu trnh lp rp c nh
hng rt ln n nng sut ca phn xng lp rp
c trng cho nng sut ca phn xng lp rp l kh nng lu thng ca phn
xng.
Kh nng lu thng ca phn xng lp rp c biu th bng thi gian m sn phm
phi nm li ch lp. Thi gian cng ngn th th kh nng lu thng cng ln nng sut
cng cao.

Nhim v ca ngi cn b k thut lp qui trnh cng ngh lp rp thit k phn
xng lp rp l lm tng kh nng lu thng ca phn xng. Mun vy, khi lp qui trnh
cng ngh lp rp cn ch cc im sau y :

1/ ra yu cu cc phn xng gia cng cc chi tit m bo tnh lp ln
C nh vy mi loi tr c nhng cng vic ngui, sa cc chi tit trc khi lp.

2/ Tn lng lp s b cc chi tit thnh nhng b phn ngoi ch lp chung.

3/ S dng cc g lp v dng c chuyn dng nhm gim bt thi gian thc hin cc
nguyn cng lp.

4/ Tn lng t chc lp rp theo dy chuyn nu iu kin cho php.

5/ Tn lng s dng cc trang b, dng c tin tin phc v cho lp rp.

6/ Ch khu vn chuyn. Vch s vn chuyn cc chi tit, dng c, b phn n
ch lp rp hp l v ngn nht.
89
7/ nh mc chnh xc thi gian cc nguyn cng lp rp.

Qu trnh cng ngh lp rp c lp di dng nhng phiu cng ngh c km theo
cc s lp.
Trong sn xut n chic, lp phiu cng ngh cho tng b phn trong c s lp
v bn k th t cc nguyn cng.
Trong sn xut hng lot v hng khi lp qui trnh cng ngh lp rt t m, trong phiu
cng ngh c ghi y cc bc, nguyn cng lp, ch r nhng g, dng c v ph tng
cn thit ca mi lp ...
y s lp cng c thnh lp rt t m c km theo hnh v ca tng nguyn
cng.

7. Cc dng v cc phng php t chc lp rp

7.1. Cc dng lp rp
D l phng php t chc lp rp th no cng nm trong hai dng lp rp sau :
- Lp c nh.
- Lp di ng.

7.1.1 Lp c nh
y l dng lp m trong qu trnh lp rp sn phm cng nh cng nhn u mt
ch c nh, cc b phn v chi tit lp rp c a ti . Dng lp c nh c s dng
trong sn xut n chic, hng lot v khi lp rp cc b phn ring l trong sn xut hng
khi .

7.1.2 Lp di ng
y l dng lp m trong qu trnh lp rp, sn phm c chuyn t ch lm vic ny
n ch lm vic khc, cn cng nhn (hoc 1 nhm cng nhn) ng mt ch lm vic c
nh hon thnh mt nguyn cng nht nh c tnh cht lp i lp li. Cng c th cng
nhn dch chuyn cng vi sn phm. Dng lp di ng c ng dng trong sn xut hng
khi v hng lot.

7.2. Cc phng php t chc lp rp
Tu thuc dng sn xut v dng lp rp ta c th t chc lp rp theo cc phng
php sau :
- Phng php ring l
- Phng php chia thnh b phn
- Phng php chia thnh nguyn cng
- Phng php lp rp theo dy chuyn

7.2.1 Phng php ring l
phng php ny sn phm c to thnh t cc chi tit v b phn ring l do mt
nhm cng nhn lp rp t u cho n cui. Lp b phn v lp chung khng c chia ra r
rng v cng do nhm cng nhn lm tt c.
c im ca phng php ring l l :
- Cc chi tit thng phi qua sa cha, co trc khi lp, do thi gian lp rp di,
khng nh mc c chnh xc.
- Trnh t lp rp ch c nghin cu c tnh cht s n gin, thm ch c trng
hp do cng nhn t t ra.
90
Phng php ny c nhiu nhc im ch thng dng trong sn xut n chic vi
dng lp c nh m thi.

7.2.2 Phng php chia thnh b phn
Trong phng php ny qu trnh lp rp c phn tng b phn ring bit. Cng
vic lp b phn v lp chung sn phm c tin hnh bi cc nhm cng nhn khc nhau
nhng ch lm vic khc nhau.

c im phng php chia thnh b phn l :
- Cc b phn c lp trc ngoi ch lp chung nn kh nng lu thng ca
phn xng ln, nng sut lp cao.
- Do c chuyn mn ha cng vic nn s dng tt v hp l cc loi cng nhn, c
iu kin nng cao trnh ngh nghip ca cng nhn.
Phng php phn tng b phn thng dng trong sn xut hng lot dng lp c
nh.

7.2.3 Phng php chia thnh nguyn cng
L phng php m qu trnh lp rp c chia thnh cc nguyn cng ring bit. Mi
nguyn cng c hon thnh mt ch lm vic nht nh, bi mt (hoc mt nhm) cng
nhn thc hin trong mt thi gian nht nh ph hp vi nhp lp rp.

c im ca phng php ny l :
- Qu trnh lp rp c thc hin lin tc
- Mc chuyn mn ho kh cao.
- Nng sut cao

Phng php ny c ng dng trong sn xut hng lot (nht l loi ln) v hng
khi.

7.2.4 Phng php lp rp theo dy chuyn
Lp rp theo dy chuyn l phng php lp rp tin tin nht, c nng sut cao. Theo
phng php ny cng vic lp rp c tin hnh lin tc v sn phm lp xong c a
ra khi dy chuyn mt cch c chu k.

iu kin t chc lp rp theo dy chuyn l :
- m bo tnh lp ln ca cc chi tit loi tr cng vic co sa trc khi lp.
- Thi gian cc nguyn cng lp bng nhau hoc bng bi s ca nhau.
- S lng, trnh cng nhn; s lng g, dng c cn cho lp rp c xc nh
chnh xc.
- Bo m vic cung cp vt liu, chi tit, dng c n ch lp rp lin tc v kp thi.
- Phi nghin cu t m, chnh xc v y tt c cc cng vic cn thit t chc
lp rp dy chuyn.

Lp rp theo dy chuyn tuy phc tp, tn km nhng c nhng u im sau :
+ V chuyn mn ho cao nn trnh cng nhn khng i hi cao v c iu kin
nng cao trnh .
+ Tc lp rp nhanh, nng sut cao.
+ Din tch ca phn xng c th gim
+ Sn phm xut xng u n v lin tc.

91
Cc dng lp rp theo dy chuyn
Lp rp theo dy chuyn c 2 dng:

1/ Lp dy chuyn sn phm di ng
dng ny, qu trnh lp rp uc phn thnh cc nguyn cng n gin c thi gian
bng nhau hoc bng bi s ca nhau.
c trng ca dng lp rp ny l : mi nguyn cng hon thnh ti mt ni lm vic
nht nh bi mt hoc mt nhm cng nhn. Sn phm c di chuyn t ch lm vic ny
n ch lm vic khc nh cc c cu vn chuyn. Cc loi c cu vn chuyn thng l:
- ng ln
- Xe y chy trn ray hoc trn t,
- Xe c ng c chy trn ray
- Cc loi bng ti,
- Cc loi bn quay...

Vic di chuyn sn phm c th lin tc hoc theo chu k :

a) Di chuyn sn phm lin tc:
Cng nhn dng ti mt ch hon thnh nguyn cng lp xc nh, sn phm
c chuyn n mt cch lin tc. Trng hp ny cn xc nh tc di chuyn sn phm
sao cho ngi cng nhn kp hon thnh nguyn cng .
Cch di chuyn sn phm lin tc thng ng dng khi chng trnh sn xut ln,
nhp sn xut ngn m cc nguyn cng lp rp n gin.

b) Di chuyn sn phm theo chu k :
cch di chuyn ny, sn phm di chuyn n ch lm vic ca cng nhn v dng
li mt cch c chu k. Thi gian dng ca sn phm phi c xc nh sao cho ngi
cng nhn c th hon thnh c nguyn cng lp rp .
Cch di chuyn ny c ng dng khi nhp sn xut di, cc nguyn cng lp rp
phc tp. V d lp rp trong ngnh ch to my.

2/ Lp rp dy chuyn dng sn phm c nh :
Trong dng lp rp ny, qu trnh lp rp ny cng c chia thnh cc nguyn cng
c thi gian bng nhau. c trng ca dng ny l : cc chi tit lp rp c t c nh thnh
hng di, cn cc nhm cng nhn di chuyn t ch lm vic ny sang ch lm vic tip
hon thnh ch mt nguyn cng ca nhm mnh trong thi gian nht nh ph hp vi nhp
lp rp. dng ny, cc dng c, g lp cn cho lp rp c t trn cc bn di ng dch
chuyn theo cng nhn.

Khi lp dy chuyn c dng sn phm c nh, cn ch cc im sau:
- Thi gian cc nguyn cng c phn bng hoc bng bi s thi gian lm vic
trong mt kp, c nh vy th khi i kp cng l i ch lm vic, nh vy c th tn dng
khong thi gian i kp ly sn phm ra v t cc chi tit vo.
- S lng mi nhm cng nhn c xc nh tu thuc vo phc tp ca nguyn
cng, xut pht t thi gian hon thnh nguyn cng .
- Cn c s chun b chu o trnh s ch i gia cc nhm cng nhn.
Thng cch lp rp ny ng dng khi lp sn phm c trng lng ln, kh di
chuyn.

8. Cch xc nh thi gian thit k phn xng lp rp
92
Thi gian lp rp c xc nh theo 3 cch sau :

- Theo qui trnh cng ngh lp.
- Theo t l thi gian gia cng c.
- Theo cc ch tiu kinh t - k thut.

8.1. Xc nh thi gian theo qui trnh cng ngh lp
y l phng php tnh chnh xc, da vo thi gian nh mc ca tng nguyn
cng lp rp trong phiu cng ngh :

t
chic
= t
o
+ t
f
+ t
fv
+ t
tn
(6.2)

t
chic
: l thi gian lp rp ca tng nguyn cng
t
o
: l thi gian gia cng lp rp c bn
t
f
: l thi gian ph
t
fv
: l thi gian phc v ch lm vic
t
tn
: l thi gian yu cu t nhin ca cng nhn

Nu ta gi : t
of
= t
o
+ t
f
l thi gian cng tc, mt khc thng thi gian phc v (t
fv
)
v thi gian yu cu t nhin (t
tn
) c tnh theo t l phn trm (%) ca thi gian cng tc,
lc cng thc (6.2) c vit di dng :

+
+ =
100
1

of
t t
chic
(6.3)

l s % thi gian phc v so vi thi gian cng tc. Lp dy chuyn = 2 3.
l s % thi gian yu cu t nhin so vi thi gian cng tc. Lp dy chuyn = 3-4

Nu gi T
chic
l thi gian lp xong 1 b phn (hoc mt sn phm) cha k thi
gian chun b - kt thc, th :

=
=
n
i
t T
1
chic chic
(6.4)
(n l s nguyn cng lp rp)

Tip tc nu ta gi :
- T
tnh
l thi gian tnh ton lp xong 1 b phn (hoc 1 sn phm),
- T
ck
l thi gian chun b kt thc cho c lot b phn (hoc sn phm),
- N s b phn (hoc sn phm) ca lot, th ta c :


N
T
T T
ck
+ =
chic tnh
(6.5)

8.2. Tnh thi gian lp rp theo thi gian gia cng c

Tu theo dng sn xut v dng cng vic lp, theo kinh nghim ngi ta nh t l
phn trm (%) ca thi gian lp rp so vi thi gian gia cng c, c th tham kho bng 6.1.


93
Bng 6.1 T l phn trm (%) ca thi gian lp rp so vi thi gian gia cng c
T l phn trm (%)
Dng sn xut

Dng cng vic
lp rp
n chic Lot nh Lot va Lot ln Hng khi
Cng vic ngui
Lp b phn
Lp chung
25-30
5-10
60-70
20-25
10-15
60-70
15-20
20-30
50-65
10-15
30-40
45-60

45-60
40-55

8.3. Tnh thi gian lp theo cc ch tiu kinh t - k thut
Trong phng php ny, thi gian lp rp ton b sn phm c tnh ton da vo
nhng ch tiu v thi gian cn lp rp 1 tn, 1 chic hoc 1 n v cng sut ca sn
phm. Nhng ch tiu ny c rt ra t nhng bn thit k mu hoc nhng nh my thc t.
Thng nhng ch tiu ny c cho trong s tay thit k xng.

9. Tnh ton thit b phn xng lp rp
Thit b ca phn xng lp rp gm c :
- Cc thit b, g phc v cho qu trnh lp rp.
- Cc thit b, g dng t cc b phn ca sn phm lp rp
- Cc thit b vn chuyn.

9.1. Cc thit b g phc v cho qu trnh lp rp
Loi ny gm c :

- Nhng dng c, g thc hin cc nguyn cng lp rp nh :
+ Cc loi tuc n vt
+ Cc loi c l, m lch
+ Cc c, co
+ Cc loi t...

- Cc loi g lp bnh rng, lt bn dao, g lp ng c vo my, ra cc b
phn...

- Nhng my ct kim loi thc hin cc cng vic gia cng c cn li nh my
khoan bn, my khoan cn, my mi bng my...

- Nhng g kim tra, th cc sn phm sau khi lp.

9.2. Cc thit b g t cc sn phm khi lp rp
Cc thit b ny c th rt n gin nh nn t, sn nh, mt bn; c th l nhng loi
phc tp g cc sn phm c th thc hin chuyn ng tnh tin v quay theo cc phng,
chiu. Nhng loi thit b ny tu thuc vo s ch lm vic, thng mi ch lm vic c 1
thit b g t sn phm.

9.3. Nhng loi thit b vn chuyn
Thng dng chuyn dng cho phng php lp theo dy chuyn, dng vn chuyn
chi tit, cm chi tit hoc sn phm nh bng truyn, bn trt, mng nghing, cc loi xe
chy bng in hoc bng tay; cc loi xe chy trn ng ray.
Ngoi ra c cc loi thit b chuyn ch sn phm, chi tit, cc b phn sn phm
nh cu trc quay, cu trc nng h, thang my...
94
S lng my mc thit b cho phn xng lp rp c xc nh tu thuc vo s ch
lp rp.

10. Tnh ton s ch lp rp
S ch lp rp c xc nh theo dng lp rp v phng php t chc lp rp.

10.1. i vi dng lp rp c nh theo phng php lp rp ring l v chia thnh b phn
Trong trng hp ny, tnh s ch lp rp cng chnh l tnh ton s bn lp hoc s
nn dng t sn phm khi lp
Cng thc tnh ton l :


m
T N
E
.
.
1,1
tnh
tnh
F
= (6.6)

E
tnh
: s ch lp sn phm (hoc b phn) theo tnh ton
N : s sn phm (hoc b phn) cn lp hng nm
T
tnh
: thi gian cn thit lp 1 sn phm (hoc 1 b phn) theo tnh ton
F
1,1
: Thi gian lm vic ca 1 ch lp trong 1 nm vi ch lm vic 1 kp

F
1,1
= (365 - 104 - n).8.K (6.7)

n : s ngy ngh l, tt trong 1 nm

K : h s k n thi gian ngh vic sa cha ch lp
+ Ch lm vic l nn nh, khng c thit b : K = 1
+ Ch lm vic c thit b : K = 0,98 (lm 1 kp)
K = 0,97 (lm 2 - 3 kp)

m : s kp lm vic trong 1 ngy m. Thng ly m=2

Ch
(1) Cng thc (6.6) ng dng khi lm 1 ch lp, ch t c 1 b phn hoc 1 sn phm
m thi.

(2) Nu gi M l s sn phm (hoc b phn) c th lp ti mt ch lm vic trong 1 nm
th :

tnh
T
m F
M
.
1 , 1

= (6.8)
Thay vo cng thc (6.6) ta c :

M
N
E =
tnh
(6.9)

Nh vy r rng s ch lp bng s b phn (hoc sn phm) cn lp trong 1 nm
chia cho s b phn (hoc sn phm) lp c ti ch trong 1 nm.

10.2. i vi dng lp rp theo dy chuyn

10.2.1 Lp rp dy chuyn khi sn phm di ng
95
Mun tnh ton c ch lp khi lp theo dy chuyn, iu u tin l phi tnh nhp
sn xut ca dy chuyn
Nhp sn xut sn phm ca dy chuyn lp rp l thi gian m c sau khong thi
gian sn phm lp xong c i ra khi dy chuyn lp rp.
Nhp sn xut c xc nh xut pht t yu cu s lng sn phm cn lp hng
nm v c tnh theo cng thc sau


N
m F
t
d
n
. . 60
= (6.10)

t
n
: nhp sn xut sn phm ca dy chuyn

F
d
: thi gian lm vic thc t lp dy chuyn trong 1 nm vi ch lm vic 1
kp, tnh bng gi

F
d
= (365 - 104 - n).8.K
1
.K
2
(6.11)

K
1
: h s k n thi gian ngh vic ca bng chuyn sa cha
+ Lm vic 1 kp K
1
= 0,98
+ Lm vic 2 kp K
1
= 0,97

K
2
: h s k n thi gian ngh vic ca bng chuyn phc v ch lm vic v
nhng yu cu t nhin ca cng nhn .
+ Nu c cng nhn ph phc v cho cng nhn trong dy chuyn, c ngi
thay th khi cng nhn trong dy chuyn ngh do nhng yu cu t nhin
(ung nc, i v sinh...) th ly K
2
= 1
+ Nu 2 iu kin trn khng m bo th ly K
2
= 0,95- 0,97

Cng thc (6.10) c th vit :


g
d
d
n
N
m F
N
N
m F
t
60
.
60 . . 60
= = = (6.12)
N
g
: s sn phm lp c trong 1 gi.

T cng thc (6.10) , ta c nhn xt : nu N cng ln th tn cng nh c ngha l nu
s lng sn phm phi lp hng nm ln th nhp sn xut phi nh, nhng mt khc thi
gian thc hin nguyn cng tng ch lm vic trong dy chuyn khng th gim tu m
phi c gii hn tu thuc vo c tnh v phc tp ca tng nguyn cng.
Trong trng hp ny mun m bo chng trnh sn xut, lp rp c ton b sn
phm ta cn tin hnh t chc nhng dy chuyn lp rp song song, mi dy chuyn s lp
rp 1 s lng sn phm nht nh.
S lng ng dy lp rp song song P c xc nh theo cng thc:


n
P
t
t
P = (6.13)

t
P
: nhp cng vic ca mi ng dy chuyn - l thi gian thc hin nguyn cng ti
mt ch lm vic (nhp sn xut ca dy chuyn).
96


t
n
: nhp sn xut sn phm chung theo chng trnh sn xut (nhp sn xut ca phn
xng lp rp), tnh theo (6.10)

Nu lp rp dy chuyn sn phm dch chuyn theo lin tc th :
t
P
= t
tcmax

Nu dy chuyn sn phm dch chuyn theo chu k th :
t
P
= t
tcmax
+ t
d

t
tcmax
: thi gian lp rp ca nguyn cng di nht trong dy chuyn
t
d
l thi gian dch chuyn sn phm t ch lm vic ny n ch lm vic tip theo
Trn c s , s ch lp rp song song ti mt ch lp rp cho nhng nguyn cng c
thi gian lp rp lu hn nhp sn xut ca dy chuyn tP c xc nh nh sau :


P
ss
t
t
E
chic
= (6.14)

t
chic
: l thi gian lp rp ca nguyn cng lu hn nhp sn xut ca dy chuyn.
Ch l nu ch t chc mt dy chuyn lp rp, th gi tr t
P
trong cng thc (6.14) s
l t
n
.
n y, s ch lp rp ca ton b dy chuyn (c th c 1 hoc nhiu dy chuyn
lp rp song song) c th xc nh bng cng thc :


tb
R
T
E
.
. 60
n
tnh
t
=

(6.15)

E

: s ch lp rp trn ton b dy chuyn

R
tb
: s lng cng nhn trung bnh mt ch lm vic, cn gi l mt cng nhn
trung bnh mt ch lm vic. Thng R
tb
=1-1,8

10.2.2 Lp rp dy chuyn khi sn phm c nh

Nh ta bit : lp dy chuyn khi sn phm c nh th cc sn phm lp c t
thnh hng di to thnh mt ng chuyn c nh. Ti mi ch, sau khi hon thnh qu
trnh lp ta nhn c 1 sn phm hon chnh, v th :

- S sn phm ng thi c lp mt lc bng s ch lp.
- S ch lp bng s nguyn cng
- S sn phm lp rp c ti mt ch lm vic trong 1 nm c xc nh theo cng
thc sau :

tnh
T
m F
N
d
.
1
= (6.16)
- S ng dy chuyn cng lm vic song song lp rp ht ton b sn phm theo
chng trnh sn xut cho l :


1 1
.E N
N
P = (6.17)
P : s ng dy cng lm vic song song
N : s lng sn phm cn lp trong c nm
N
1
: s lng sn phm lp rp c ti 1 ch lm vic trong nm
97
E
1
: s ch lp rp trn 1 ng dy

11. Tnh s lng cng nhn phn xng lp rp
Cng nhn, cn b ca phn xng lp rp gm c :
- Cng nhn sn xut gm cng nhn ngui, cng nhn lp b phn v cng nhn lp
chung
- Cng nhn ph : cng nhn li cu trc, cng nhn gi kho, cng nhn vn chuyn ...
- K s, cn b k thut v nhn vin hnh chnh

11.1. Tnh cng nhn sn xut

11.1.1 S cng nhn ngui c xc nh theo cng thc sau :


c
m
i
i
ng
F
D T
R
. 60
.
1

=
=
ng
tnh(1)
(6.18)
m : s loi chi tit cn g/c ngui
R
ng
: cng nhn ngui ni chung
ng
tinh
T
) 1 (
: thi gian cn thit gia cng ngui 1 chi tit (pht)
D
i
: s lng chi tit phi gia cng ngui trong 1 nm ca loi i
F
c
: thi gian lm vic thc t ca 1 cng nhn trong 1 nm (gi)

F
c
= (365 - 104 - n - f) .8. K
c
(6.19)

n : s ngy ngh l, ngh tt trong 1 nm
f : s ngy ngh php trong nm
K
c
: h s k n thi gian ngh vic ca cng nhn do nhng nguyn nhn bt
thng. Thng ly K
c
= 0,91.

11.1.2 Tnh s cng nhn lp rp
Cng thc tng qut tnh cng nhn lp rp (c lp b phn v lp chung) l :


c
q
i
i
l
F
N T
R
. 60
.
1

=
=
l
tnh(1)
(6.20)

R
l
: s cng nhn lp rp (b phn hoc chung).
T
l
tnh (1)
: thi gian cn thit lp mt b phn (hoc lp chung 1 sn phm) (gi).
N
i
: s lng b phn (hoc sn phm) ca loi b phn (hoc sn phm) th i
cn lp.
q : s loi b phn (hoc sn phm) cn lp.

Ring vi dng lp theo dy chuyn th cng nhn lp rp trong sn xut dy chuyn
c tnh cho tng ch lm vic hon thnh nhng nguyn cng ring bit ph thuc vo
thi gian thc hin nguyn cng v nhp cng vic. S cng nhn lp rp ny c tnh ton
theo cng thc sau :

98

P
chic
t
t
R
ld
=
1
(6.21)
R
1
ld
: s cng nhn lp rp tnh cho mt ch lm vic trong dng lp theo dy chuyn.
t
chic
: thi gian thc hin nguyn cng lp ti ch lm vic .
t
p
: nhp cng vic ca dy chuyn

S cng nhn lp c tnh t cc cng thc (6.18) (6.20); (6.21) nu l s l th cn
qui trn thnh s nguyn v gi l s cng nhn chn dng.

Trong trng hp s cng nhn chn dng R
chn
2 th c 2 cch gii quyt :
1) B tr cho tt c cc cng nhn vo cng mt ch lm vic nu nh iu kin cng
ngh ca nguyn cng cho php.
2) Khi cch 1 khng gii quyt c th cn b tr thm ch lm vic song song v
phn s cng nhn ra cc ch song song.

11.1.3 Tnh bc th bnh qun ca phn xng lp rp
Tng t nh tnh ton trong phn xng c kh

11.2. Tnh cng nhn ph, nhn vin v cn b ca phn xng lp rp
Thng loi ny c tnh theo t l % s cng nhn sn xut :

11.2.1 Cng nhn ph :
Tu theo dng sn xut ta ly cc t l sau :
- Sn xut n chic, hng lot ly 20-25 % cng nhn sn xut.
- Sn xut hng khi ly 15-20 % cng nhn sn xut.

11.2.2 Nhn vin phc v :
Chim khong 2-3 % cng nhn ni chung (cng nhn sn xut v cng nhn ph).

11.2.3 K s , cn b k thut :
Chim 8-10 % cng nhn ni chung.

11.2.4 Nhn vin, hnh chnh vn phng :
Chim 4-5 % cng nhn ni chung.

12. Tnh din tch v b tr mt bng phn xng lp rp

12.1. Tnh din tch phn xng lp rp
Tng t nh phn xng c kh, din tch phn xng lp rp c th c xc nh
bng 3 phng php :
- Tnh chnh xc da vo b tr thit b, ch lm vic, ng i...
- Xc nh din tch theo din tch n v
- Xc nh theo t l % ca din tch phn xng c kh
Ring phng php th nht vic tnh ton nh phn xng c kh

12.1.1 Tnh din tch phn xng lp rp theo din tch n v
Din tch phn xng lp rp bng din tch n v nhn vi s ngi lm vic ng
nht ca ca c trong phn xng

S
LR
= s.R
max
(6.22)
99

S
LR
: din tch phn xng lp rp.
s : din tch n v tnh cho mt cng nhn.
R
max
: s ngi lm vic ng nht ca ca c trong phn xng.

Din tch n v ca phn xng lp rp l phn din tch tnh cho mt cng nhn
trong ca lm vic ng nht ca phn xng. s l mt ch tiu kinh t - k thut nh gi vic
s dng din tch ca phn xng .

Tu thuc c tnh sn phm, phng php t chc lp rp m din tch n v c khc
nhau (cho trong cc s tay thit k xng). V d :
- Trong sn xut hng lot, sn phm c kch thc trung bnh (my ct kim loi,
ng c, bm, my dt...) th s = 18 - 25 m
2
/ cng nhn
- Din tch n v ca cng vic ngui ly s = 5 - 6 m
2
/ cng nhn ngui

12.1.2. Tnh din tch phn xng lp rp theo din tch phn xng c kh
Gi S
LR
l din tch phn xng lp rp
S
CK
l din tch phn xng c kh, th :
- Dng sn xut n chic, lot nh S
LR
= (50 - 60 %) S
CK

- Sn xut lot va, lot ln S
LR
= (30 - 40 %) S
CK

- Sn xut hng khi S
LR
= (20 - 30 %) S
CK

- Sn xut dy chuyn S
LR
= (15 - 20 %) S
CK


12.2. B tr mt bng phn xng lp rp
B tr mt bng phn xng lp rp phi m bo trong qu trnh lp cc chi tit v
cc b phn di chuyn theo mt ng hp l nht, ngn nht, khng ct nhau v khng i
ngc chiu nhau.
Mun vy, trc tin phi da vo cc giai on ca qu trnh lp b tr cc b
phn ca phn xng theo th t tng qut sau : ch gia cng ngui ch lp rp b phn
ch lp chung ch th sn phm ch sn...

12.2.1 Ch gia cng ngui
gia cng ngui, ch yu y l t cc bn ngui c t v mt t bn ngui
khng c t. Trn cc bn ngui c cc ngn ko bo qun dng c. Bn phi chc chn,
cng vng
Khong cch gia cc t; gia t vi ng i, vi tng phi m bo khong
cch an ton v tit kim (c th tham kho hnh 6.1)
Hnh 6.1 V tr ca t



8
0
0



1
0
0
0

1250-1500
Tng
ng i
Bn ngui
100
Ngoi nhng bn ngui cn cc ch trng trn nn nh t cc thn my tin
hnh co sa v c thm mt vi my khoan bn, khoan cn, my ct ren, my mi phng...
12.2.2 Ch lp b phn my
ch lp b phn cng t mt s bn ngui thng thng khng c hoc ch c vi
t, ch yu t cc bng ln, bng truyn. Ngoi ra trong b phn ny tu theo mc cn
thit c th c vi my khoan, my p ( lp cht), my ra chi tit
phn xng lp b phn cn lu b tr theo th t lp v sn phm a n ni
lp chung ngn nht, kp thi nht.

12.2.3 Ch lp chung ton sn phm

12.2.3.1 Lp c nh
dng lp c nh cn b tr cc bn lp, nhng bi trng trn nn nh t sn
phm .
Trong gian t cc my lp rp g t cc sn phm ln m tin hnh cc
nguyn cng lp.

12.2.3.2 Lp di ng
Dng lp di ng phi b tr cc c cu vn chuyn di chuyn sn phm trong qu
trnh lp.
Cc c cu vn chuyn c th l :
- Dy chuyn xe y trn mt t khp kn
- Dy chuyn bng, ai
- Dy chuyn chy trn ray treo
- Cc ng ln, ng trt
- Cc toa xe ni
- Cc bn quay ...

12.2.4 Ch th cc sn phm
nh gi cht lng sn phm, sau khi lp xong a ra ch th. Ch th sn phm
gm c th khng ti v th c ti
1/ Th khng ti : kim tra v tr tng quan gia cc b phn sn phm
2/ Th c ti : kim tra cng sut, chnh xc, cng vng ca sn phm.

Th khng ti v c ti thng tin hnh v tr khc nhau, cng c th tin hnh
chung 1 ch
S lng b th c th tnh theo cng thc :


m F
T N T N
C
.
. .
1 , 1
1 1
+
= (6.23)

N : s lng sn phm cn th hng nm.
N
1
: s lng sn phm cn th li hng nm (th sau khi iu chnh).
T : thi gian cn thit th 1 sn phm (gi).
T
1
: thi gian cn thit th li 1 sn phm (gi).
F
1,1
: thi gian lm vic thc t ca 1 b th trong 1 nm vi ch lm vic 1 kp.

F
1,1.
= (365 - 104 - n).8.K (6.24)

101
K : h s k n thi gian ngh sa b th.

12.2.5 Ch sn v kh sn
Mc ch sn l bo v b mt bn ngoi ca sn phm, ng thi trang tr mt hng.
Tu thuc qui m ca phn xng v loi sn phm c th tin hnh sn bng nhng phng
php khc nhau nh : sn khi sn phm dch chuyn, sn ti mt ch c nh.
Sn phm sau khi sn phi sy kh bng cch kh t nhin, bng sy nhn to.

12.2.6 Tnh ton v b tr cc b phn ph, sinh hot ca phn xng lp rp
Phn ny tng t nh phn xng c kh

13. Cc ch tiu kinh t - k thut ca phn xng lp rp

13.1. Cc ch tiu tuyt i
- Sn lng sn phm cn lp hng nm (chic, tn, tin).
- Tng s thit b sn xut.
- Tng s cng nhn sn xut v cng nhn, cn b nhn vin khc.
- Ch lm vic ca phn xng.
- Qu tin lng hng nm ca phn xng.
- Tng cng sut in (KW).

13.2. Cc ch tiu tng i
- Sn lng sn phm lp hng nm tnh cho 1 cng nhn sn xut; 1m
2
din tch.
- Sn lng sn phm lp hng nm tnh cho 1 n v gi tin trang thit b chnh v
cho 1 n v tin lng.
- Din tch n v cho 1 cng nhn sn xut ca ng nht.
- Din tch phn xng lp rp theo % din tch phn xng c kh.
- Khi lng lao ng cn thit lp 1 b phn hoc 1 tn sn phm.
- T l % thi gian lp sn phm so vi gia cng c.
- Gi thnh phn xng cho 1 sn phm hoc 1 tn sn phm.
- T l % gia kinh ph phn xng so vi lng cng nhn sn xut.


102
Chng VII

THIT K H THNG CUNG CP
NNG LNG V H THNG VN CHUYN

1. i cng
Nng lng l mt yu t rt quan trng nh my c th hot ng c. Vic thit
k h thng nng lng trong nh my c kh ch yu do nhm cn b k thut chuyn mn
v nng lng m nhn.
Nhu cu vn chuyn (vt liu, sn phm, nhin liu ...) cng l mt yu t khng km
quan trng nhm m bo cho qu trnh sn xut ca nh my c kh c lin tc. S nhn
lc phc v cho khu vn chuyn trong nh my c kh chim t l 10 18% s cng nhn sn
xut. V vy thit k h thng vn chuyn hp l cng l mt nhim v cn thit trong qu
trnh thit k nh my c kh m bo hiu qu kinh t.
2. Thit k h thng cung cp nng lng
Trong phn ny ch cp n vic xc nh nhu cu nng lng khi thit k h thng
cung cp nng lng
2.1 Khi nim
Trong nh my c kh, cc dng nng lng thng s dng l nhit, lc, nh sng v.v...
Nhng dng nng lng ny c sn ra t cc ngun sau:
- Nhin liu rn (than , than cc v.v...),
- Dng in,
- Kh t (nhin liu th kh),
- Du t (nhin liu th lng),
- Hi nc nng,
- Kh nn,
- Ct nc b nn.
2.2 Tnh ton h thng cung cp in nng
2.2.1 i cng
Nng lng do dng in sinh ra rt quan trng i vi vic sn xut trong nh my c
kh. in nng dng chy my v cc thit b sn xut, to ra nhit nng v nh sng
phc v sn xut. Khi thit k xng phi d tnh v nhu cu in nng ca nh my. Cng
vic tnh ton do chuyn vin ngnh in trong t chc thit k m nhim.
2.2.2 Xc nh nhu cu cn thit v in nng
C hai cch tnh:
Cch tnh chnh xc:
Da trn c s tng cng sut thit k ca ton b thit b dng in trong nh
my. u tin phi thng k s lng cc loi thit b dng in nng, phn theo hai loi: loi
in pht ng (dng in nng lm hot ng cc my mc thit b) v loi in thp
103
sng. Sau y tng hp cng sut thit k ca cc loi thit b theo tng phn xng v b
phn, ch l phi xc nh ring nhu cu v loi in xoay chiu v mt chiu.
Tng nhu cu in nng ca cc loi thit b trong phn xng, b phn c xc
nh theo cng sut thit k N
e
v thi gian tiu th in nng ca mi loi hng nm T:
k i j
1 1
W . . .
m n
e i j zi j j
j i
N T g
= =
=
[Kw.h/nm] (7.1)
trong :
i - ch thit b th i,
j - ch loi (nhm) thit b th j,
k - ch phn xng, b phn th k,
m - s loi (nhm) thit b dng in,
n - s lng thit b dng in thuc nhm j,
g
j
- h s nhu cu ca cc loi thit b thuc nhm j (h s ny k n s tiu
th in khng ng thi hoc lm vic non ti,g
j
cho bit t l in nng tiu th thc t
ng thi ca mt loi thit b c th so vi cng sut thit k. Gi tr g
j
c th xem bng 7.1).
Nh vy, nhu cu in nng ca ton b nh my l:

h
k
k = 1
W = W
[Kw.h/nm] (7.2)
Bng 7.1 H s nhu cu ca cc loi thit b.
Loi in Thit b hoc ni dng in H s nhu cu g
j

ng c in ca my ct vn nng 0,20
ng c in ca my ct t ng, my phay rng 0,25
ng c in ca cu trc 0,15
ng c in ca my ba, my p, my nghin 0,45
L in, l sy 0,60
My hn h quang 0,35
Cc thit b cao tn 0,30
My bm, bng ti, my nn 0,75




in pht ng
Qut gi 0,70
Gian sn xut ln 0,70 0,80
Gian sn xut va 0,80 0,90
Vn phng phn xng 0,70 0,90

in thp sng
Kho cha, hm cha 0,50 0,60

Cch tnh gn ng:
104
Cch ny dng xc nh s b nhu cu v in nng ca nh my thit k. Ta c
th da vo cc ch tiu kinh nghim c th v nhu cu in nng tnh theo mt n v sn
phm (Kwh/chic, Kwh/ng, Kwh/tn) ( v d bng 7.2), theo mt n v din tch sn
xut (Kwk/m
2
) (xem bng 7.3) hoc theo mt n v thit b sn xut (Kwh/thit b).
Bng 7.2 Nhu cu in nng theo mt n v sn phm.
Sn phm Nhu cu in nng ch
to 1 sn phm (Kwh/chic)
Sn phm khi
nhit luyn
Nhu cu in nng tnh cho
1 tn sn phm (Kwh/tn)
Nung 200 280
Thng ha 160 250
Ti 100 250
130 140

t

Vt c


5000 8000

300
Thm than 510 600

Bng 7.3 Nhu cu in nng theo mt n v din tch sn xut m
2
.

Loi hng sn xut
Nhu cu
in nng
(Kwh/m
2
)

Loi hng sn xut
Nhu cu
in nng
(Kwh/m
2
)
Ch to my nng 395 Ch to my cng c 143
Ch to ng c diesel 163 Sn xut thp 152
Ch to my bm, my nn 163 Ch to dng bng kim loi 201
Ch to t 282 Ch to my in 197

Nhu cu v in nng ca ton nh my s c xc nh theo tng s thit b
dng in v mc tiu th in thc t ca cc thit b . C th ta c th xc nh nhu cu
v in nng theo 2 dng: in pht ng v in thp sng.
- in pht ng:

1
W . . .
et b tb tb z tb
N C g T

=
(Kwh/nm) (7.3)
trong :
N
etb
cng sut qui nh trung bnh cho mt thit b sn xut (Kw), v d bng 7.4.
C

- tng s thit b sn xut dng in,

g
tb
- h s nhu cu trung bnh (nh my thng: g
tb
= 0,250,32, nh my c nhiu l
in h quang: g
tb
= 0,400,45).
T
tb
- thi gian tiu th in trung bnh hng nm ca mt thit b sn xut (gi/nm).

ztb
- h s ti trng trung bnh ca thit b sn xut, c th ly
ztb
= 0,75.
- in thp sng:
105

2
1
. .
h
Ak k k
k
W N A T

=
=

(Kwh/nm) (7.4)
trong :
A
k
- din tch phn xng, b phn cn thp sng (m
2
),
N
Ak
cng sut cn thit thp sng 1 m
2
din tch (Kw/m
2
), xem bng 7.5,
T
k
- tng s gi cn thp sng hng nm ca phn xng, b phn k (gi/nm)
h - s phn xng, b phn cn thp sng.
Bng 7.4 Cng sut quy nh trung bnh cho 1 thit b sn
xut (N
etb
) thuc phn xng C kh ch to my ct kim loi.
Chi tit sn xut Chi tit ln Chi tit va v nh Chi tit tiu chun
N
etb
(Kw) 15 19 6 8 4,5 6,5

Bng 7.5 Nhu cu v in thp sng cho 1 m
2
din tch (N
A
).
Phn xng, b phn N
A
(W/m
2
)
Phn xng c kh, lp rp,dng c, rn dp; phng th nghim, thit k 20 22
Phn xng c, sa cha c kh, mc 16 18
Kho cha 8 10
Phng lnh o 15
Phng sinh hot 10
B phn nng lng 12 15

2.3 Tnh ton h thng cung cp kh nn
2.3.1 i cng
Kh nn c dng trong cc phn xng sn xut ca nh my c kh thc hin
cc cng vic c th nh sau:
- Vn hnh thit b v dng c (v d dng c sit bu lng),
- To lc kp cht cc g,
- Lm ngui,
- y sn phm n cc v tr cn thit,
- Lm sch phoi, ...
2.3.2 Tnh ton nhu cu v kh nn
C hai cch tnh:
Tnh gn ng:
Da theo ch tiu tnh cho mt thit b hoc mt tn sn phm. S lng thit b
dng kh nn c tnh theo t l phn trm ca tng s thit b c trong cc phn xng v
106
b phn, c th khong 5 10 %. Nhu cu v kh nn ca ton b thit b trong nh my c
tnh nh sau:

0
1
. . . .
n
tbi i i tb ztb
i
Q Q C g T

=
=
(m
3
/nm) (7.5)
trong :
n - s loi trang thit b dng kh nn,
Q
0tbi
- lng kh nn cn thit trung bnh cho loi trang thit b i, xem bng 7.6,
C
i
- s trang thit b loi i dng kh nn,
g
i
- h s nhu cu ca cc trang thit b loi i (h s k n s tiu th kh nn
khng ng thi hoc lm vic non ti),
T
tb
- thi gian tiu th kh nn trung bnh hng nm ca cc thit b (gi/nm),

ztb
- h s ti trng trung bnh; thng
ztb
= 0,75
Bng 7.6 Lng kh nn cn thit trung bnh Q
0tb
cho cc loi thit b
Loi thit b Q
0tb
(m
3
/h) p sut (atm)
Trang b g lp, kp cht trn my ct kim loi 0,1 6 7
Dng c kh nn (khoan, ba tn, my ct, my mi bng
lin tc)
2,5 4,5 5 6
Thit b ra sch 0,7 1 3
Thit b nng h (ti trng 0,17 1,7 Tn) 0,07 0,4 -
Vi phun sn x sn phm 2 3 6

Tnh chnh xc:
Da vo cng sut thit k cho tng thit b dng kh nn, ta xc nh chnh xc
lng kh nn cn thit theo cc bc sau:
- Tng hp cc thit b trong cng mt h thng cung cp kh nn, phn chia
nhm theo p sut v yu cu cht lng,
- Xc nh lng kh nn cn thit cho tng nhm thit b da vo h s nhu cu
v tng thi gian lm vic ca thit b trong nm,
- Xc nh lng kh nn mt mt do ng ng vn chuyn b h, do chnh lch
gia cng sut thit k v cng sut hiu dng ca mi thit b dng kh nn.
Lng kh nn cn thit cho nhm thit b j l:

0 i j
1
. . .
n
j ij j zij
i
Q Q g T
=
=

(m
3
/nm) (7.6)
trong :
n - s lng trang thit b dng kh nn thuc nhm j,
Q
0ij
- lng kh nn cn thit cho trang thit b i thuc nhm j,
107
g
j
- h s nhu cu ca cc trang thit b thuc nhm j,
Tij - thi gian tiu th kh nn hng nm ca thit b i thuc nhm j (gi/nm),

zij
- h s ti trng ca thit b i thuc nhm j.
Lng kh nn tng cng cho tt c cc nhm thit b ca mt phn xng, b
phn l:
0 ij
1 1
. . . .
m n
k ij j zij
j i
Q K Q g T
= =
=
(m
3
/nm) (7.7)
vi:
K - h s k n s hao ht kh nn do ng ng b h (K =1,02 1,5)
m - s nhm thit b dng kh nn.
Nh vy, nhu cu v kh nn ca ton nh my l:

1
h
k
k
Q Q

=
=
(m
3
/nm) (7.8)
h l s phn xng, b phn ca nh my.
3. Thit k h thng vn chuyn
3.1 Khi nim
Hot ng vn chuyn vt liu, sn phm, dng c g lp, v...v ng vai tr rt quan
trng trong vic m bo qu trnh sn xut trong nh my c lin tc. S cng nhn phc
v khu vn chuyn thng chim 10 18 % s cng nhn sn xut. Cc dng vn chuyn
ch yu trong nh my c kh thng l:
- Vn chuyn gia nh my vi bn ngoi.
- Vn chuyn trong ni b nh my (gia cc b phn, phn xng).
- Vn chuyn trong ni b phn xng.
Thit k h thng vn chuyn trong mt nh my c kh bao gm: xc nh quan h
vn chuyn hp l gia cc phn xng, b phn, ch lm vic; tnh v chn s lng thit b
vn chuyn v gii quyt khu xp d ph hp vi kch c, trng lng v tnh cht ca cc
i tng c vn chuyn.
3.2 Cc loi thit b vn chuyn
Thit b vn chuyn trong nh my c phn loi theo phng thc hot ng (bng
tay, c kh, t ng), theo tnh cht cng vic (lin tc, gin on), theo phng vn chuyn
(ng, ngang), v...v.
Theo nhim v vn chuyn, ta phn 2 loi nh sau:
a/ Phng tin vn chuyn gia nh my vi bn ngoi: t, xe la, tu thy v...v.
b/ Phng tin vn chuyn trong phm vi nh my: thng dng cc phng tin sau:
- Phng tin vn chuyn lin tc: ch yu l cc bng ti ai cao su, bng ti xch
c mc treo, bng ti xch c mc xe con, bng ti c con ln dch chuyn v con ln
khng dch chuyn.
108
- Phng tin vn chuyn gin on: mng trt, thang my, xe y tay, xe chy
in acqui (xe ra), cn trc quay, cu trc in.
3.3 Tnh s lng thit b vn chuyn
S lng thit b ca phn xng vn chuyn nguyn vt liu, phi liu, chi tit v
b phn ca sn phm c xc nh trn c s s lng hng cn vn chuyn, s ln vn
chuyn, thi gian vn chuyn, thi gian xp d hng v...v.
a/ Xc nh s lng cc xe vn chuyn (xe ra, xe y, ...)
Vi h thng vn chuyn 2 chiu (i, li):
S lng xe y X
1
c tnh nh sau:

1
1
0 2
. .
2. . . . .60
c
x
Q k T
X
q k F m
=
(7.9)
trong :
Q - khi lng vn chuyn hng nm [tn],
k
1
- h s xt n nhng h hng bt thng (xe lm vic khng lin tc),
k
2
- h s s dng xe vn chuyn (k
2
= 0,8),
q
0
- trng ti ca mt xe vn chuyn [tn],
F
x
- s gi lm vic thc t ca 1 xe vn chuyn trong 1 nm theo ch lm vic
1 ca/ngy [gi] (tnh nh F
1-1
cc chng thit k phn xng),
m - s ca lm vic trong mt ngy m,
T
c
- thi gian vn chuyn [pht]. T
c
c tnh nh sau:
T
c
= T
tb
+ T
ch
+ T
d
+ T
n
(7.10)
vi:
T
tb
- thi gian trung bnh ca mt ln xe i v,
T
ch
- thi gian trung bnh ca mt ln cht hng,
T
d
- thi gian trung bnh ca mt ln d hng,
T
n
- thi gian ngh v nhng l do ngu nhin (khong 10% T
c
mi hnh trnh).
Vi h thng vn chuyn 1 chiu:
S lng xe y X
2
c tnh nh sau:

1
2 1
0 2
. .
2.
. . . .60
c
x
Q k T
X X
q k F m
= =
(7.11)
b/ Xc nh s lng cu trc
Tnh gn ng:
S lng cu trc c th xc nh s b theo cch gn ng nh sau:
- phn xng c kh: 1 cu trc cho 40 80 m chiu di nhp nh,
- phn xng lp rp: 1 cu trc cho 30 50 m chiu di nhp nh.
109
Tnh theo s lng hng cn vn chuyn:
S lng cu trc C c tnh:

1
. .
.
c
c
n i T
C
n F
=
(7.12)
trong :
n - s lng chi tit cn vn chuyn trong 1 ca,
i - s lng trung bnh cc nguyn cng cn vn chuyn ca mt chi tit,
n
1
- s cc chi tit trong 1 ln vn chuyn,
F
c
- thi gian lm vic thc t ca 1 cu trc trong 1 ca sn xut [pht].
F
c
= F.k (7.13)
vi:
F - thi gian lm vic danh ngha ca cu trc trong 1 ca, F = 420 480 pht,
k - h s xt n thi gian ngng vn chuyn sa cha (k = 0,90).
T
c
- thi gian vn chuyn [pht]. T
c
c tnh nh sau:
T
c
= T
tb
+ T
ch
+ T
d
+ T
n
(7.14)
vi:
T
tb
- thi gian mt ln vn chuyn, T
tb
c tnh nh sau:

t b
t b
L
T
v
=
[pht] (7.15)
vi:
L
tb
qung ng vn chuyn trung bnh, [m],
v - vn tc di chuyn trung bnh ca cu trc (30 80 m/ph).
T
ch
- thi gian cht, mc hng vn chuyn,
T
d
- thi gian d, tho hng,
T
n
- thi gian ngh v nhng l do ngu nhin (khong 10% T
c
mi hnh trnh).
Ring s lng cu trc phn xng lp rp c th xc nh trn c s tin
lp rp, thi gian lm vic ca cu trc mi nguyn cng lp rp, v...v.
c/ Xc nh s lng bng ti
C s xc nh l tc di chuyn v nng sut ca bng ti.
Tc ca bng ti c tnh bi cng thc:

.
60.
Q l
v
n
=
[m/pht] (7.16)
hoc:
.
l
v
n
=
[m/pht] (7.17)
110
trong :
Q nng sut ca bng ti [chi tit/gi],
l - bc treo ti hay bc c t hng [m],
n - s lng chi tit mi bc treo [chi tit],
- nhp lm vic [pht].
Tc ca bng ti thng l 1 6 m/ph. Vi sn phm nng 30 50 kg, v = 3
m/ph. Trong cng thc tnh ton ngi ta thng a thm phn d tr trn bng ti qua h s
tng nng sut (ly n 5).
Vi cc bng ti phc v cho b phn ra sch, sn, sy th tc ca bng ti
c ly theo chiu di on lm vic ca bung cng tc L [m] (bung ra, bung sn hoc
bung sy) v thi gian cng ngh T
0
[pht] (ph thuc cng vic):

0
L
v
T
= [m/pht] (7.18)
Trong mt s trng hp, vic tnh ton s lng bng ti c th da vo nng
sut ca chng (Q), vi tc (v), bc treo ti (l) v s chi tit mi bc treo (n) chn
trc:

. .60 v n
Q
l
=
(7.19)
Nu nng sut cn vn chuyn l Q
vc
th s lng bng ti s l:

vc
Q
B
Q
=
(7.20)