The machine rate is usually, but not always, divided into fixed costs, operating costs, and labor costs. For certain cash flow analyses only items which represent a cash flow are included. Certain fixed costs, including depreciation and sometimes interest charges, are omitted if they do not represent a cash payment. In this manual, all fixed costs discussed below are included. For some analyses, labor costs are not included in the machine rate. Instead, fixed and operating costs are calculated. Labor costs are then added separately. This is sometimes done in situations where the labor associated with the equipment works a different number of hours from the equipment. In this paper, labor is included in the calculation of the machine rate.
Fixed Costs are those which can be predetermined as accumulating with the passage of time, rather than with the rate of work. They do not stop when the work stops and must be spread over the hours of work during the year. Commonly included in fixed costs are equipment depreciation, interest on investment, taxes, and storage, and insurance.
Operating Costs vary directly with the rate of work. These costs include the costs of fuel, lubricants, tires, equipment maintenance and repairs.
EQUIPMENT RATES – ALL COSTS
EQUIPMENT RATES – INTRO
The unit cost of logging or road construction is essentially derived by dividing cost by production. In its simplest case, if you rented a tractor with operator for $60 per hour – including all fuel and other costs – and you excavated 100 cubic meters per hour, your unit cost for excavation would be $0.60 per cubic meter. The hourly cost of the tractor with operator is called the machine rate. In cases where the machine and the elements of production are not rented, a calculation of the owning and operating costs is necessary to derive the machine rate. The objective in developing a machine rate should be to arrive at a figure that, as nearly as possible, represents the cost of the work done under the operating conditions encountered and the accounting system in use. Most manufacturers of machinery supply data for the cost of owning and operating their equipment that will serve as the basis of machine rates. However, such data usually need modification to meet specific conditions of operation, and many owners of equipment will prefer to prepare their own rates.
Importance of Scheduling
Scheduling is the art of planning your activities so that you can achieve your goals and priorities in the time you have available. When it’s done effectively, it helps you:Understand what you can realistically achieve with your time.Make sure you have enough time for essential tasks.Add contingency time for “the unexpected.”Avoid taking on more than you can handle.Work steadily toward your personal and career goals.Have enough time for family and friends, exercise and hobbies.Achieve a good work-li
Source: Effective Scheduling – Time Management Training From MindTools.com
5 Tips on Machinery Maintenance
1. Stay on top of large machinery operator trainingMany types of large machinery have multiple operators. One of the ongoing inspections on any checklist should be overseeing the correct operation of the equipment.Large machinery should be inspected as soon as it is purchased. Operator training is usually done at that point, but training needs to be kept up. Employees come and go, skills become rusty and poor operation leads to breakdowns.Operator manuals can be revised for the specific work situation. They can be rewritten in simpler language. A short manual can be provided to each operator for easy reference. And, if you operate in a paperless environment, you can rest assured operators use the most current version of each manual.One other note is to identify best practices, which can then be applied to other facilities or geographic locations. The knowledge you learn about how to maintain your equipment can become quite valuable – be sure to best leverage this important knowledge and use it at every applicable location.
5 Tips on Machinery Maintenance
2. Add and test lubricants frequentlyLubricants reduce friction around any moving part. A schedule of good lubrication maintenance extends the life of large machinery equipment and parts.Lubrication is one of the first and most important of maintenance checks. Look for signs of excess oil or grease build-up on pistons. Check for leaks around oil seals.Be sure to use the right lubricant. There are specific kinds of oil and grease for every component. Check the manufacturer’s recommendations.Getting the lubricants checked is a good way to diagnose problems with large machinery. Experts analyze particles in the used oil. The makeup of any contaminants will indicate which part may be suffering from wear or breakdown.
5 Tips on Machinery Maintenance
Vibration, shock, high temperatures, friction and age all contribute to the breakdown of parts in heavy machinery.Vibration can come from gears and belts that are out of alignmentShock can come from accidents and from poor operator techniqueHigh temperatures can come from extended use, friction, poor lubrication and worn parts, among other reasonsAge affects many key components. Over time, belts will warp. Seals will dry and crack. Bolts will loosen and stretch out of shape. Age is a factor to monitor in equipment.Should you discover wear and tear on any moving parts within your heavy equipment, be sure to quickly perform the necessary replacement of any worn parts.
5 Tips on Machinery Maintenance
4. Keep large machinery clean, and maintain a clean environmentThere are many seals and filters in place on heavy machinery to keep working parts clean and free of contamination. Seals should be inspected regularly to make sure they’re in good condition. Filters should be inspected and changed regularly. Breathers should be kept clean to avoid creating a vacuum in the cab which will suck contaminants into the cab. The electronics in the cab are susceptible to breakdown if contaminated. This impacts the clutch, for example.Large machinery should be stored in a shed or other building if at all possible. Exposure to wind and weather can lead to rust and rot. The machinery should be run periodically if it is not in use.
5 Tips on Machinery Maintenance
5. Have a maintenance and repair schedule, and keep good recordsFluids, tires, tracks and electrical systems are among the components that have to be checked regularly for preventive maintenance. Know what needs to be inspected and when. Here are some examples.Power transmissions have many moving parts that need to be maintained in top condition. Gearboxes need to be checked for lubrication, vibration and damage to parts.Friction materials, seals, gaskets and bearings all need to be inspected for wear and replaced. Gears and shafts usually last a long time and don’t need to be replaced often, if at all.Drive train components need constant monitoring. Check pulleys and v-belts on CVT transmissions for alignment and wear. Check sprockets for correct meshing with chains and for breaks.Test the oil to diagnose problems. Change filters frequently.Bearings keep great amounts of force running smoothly and are vital to large machinery performance. Check bearing lubrication often. Maintaining bearings well extends their life.Lubricate gears frequently.Do a seal check to prevent bearing raceway contamination.Run torque checks on the bolts. Bolts can elongate and creep over time.To conclude, following the above 5 steps can significantly extend the useful life of heavy machinery, improving the Return on Investment from these important purchases. In today’s global manufacturing world, even greater value can be extracted if you have a global knowledge capture and distribution system such that this knowledge of machinery maintenance can be effectively shared across your organization – letting you reap even greater benefits on a much wider scale.
5 Maintenance Tips for Heavy Machinery
1. Keep It RoutineJust like the annual check-up with your physician, a regular check-up on the overall functionality and condition of your heavy machinery helps keep the continuity of what is expected and the standard performance of your equipment. Any non-scheduled emergency maintenance and repair jobs done on heavy machinery are typically fraught with human error and performed in a time crunch.The Occupational Safety and Health Administration (OSHA) reports that up to 20 percent of industrial accidents are related to maintenance operations, with 15 percent involving worker fatalities. By taking all the necessary preventative measures, not only are you ensuring the stated lifetime of your heavy machinery, but you’re also keeping operators safe.My grandfather always said, “If everything works on your truck, that’s just an excuse for something to break.” It’s this philosophy of constantly checking and maintaining equipment, catching any minor problems before they evolve into bigger and more costly ones, that further drives the point to have regularly scheduled maintenance checks on your earthmoving machinery.
5 Maintenance Tips for Heavy Machinery
2. Use the Right Tools for the JobMatching your equipment with the exact task that it’s intended to perform requires consideration of a number of variables, including terrain, material composition and elemental effects such as climate, etc. Likewise, it’s important to make certain that all attachments and performance accessories such as buckets and ploughs are made specific to your machine. With the safety of the crew operating this heavy and potentially dangerous equipment in mind, you simply cannot afford any guesswork here.Check and double-check all machinery and attachments before using them in the field. Your workers and your wallet will thank you. When replacing parts, don’t assume the first ones you come across are the right ones for your machinery. Bearings, roller chains, gaskets, seals, etc., must all be the right quality and size and have the correct load-bearing qualities for your machine.
