8/8 APPENDICES
APPENDIX A - Machine Cost and Work Records
APPENDIX B - Field Production Studies
APPENDIX C - PACE Data Collection Forms
APPENDIX B - Field Production Studies
APPENDIX C - PACE Data Collection Forms
APPENDIX A - Machine Cost and Work Records
Machine rates, unit costs, and machine
utilization, can be compiled on a weekly basis for use in comparison and
control. The weekly machine costs, accummulated over a period of time, provide
estimates of the hourly machine cost or machine rate for planning and
budgeting.
The basis for the weekly report is the daily
report (Figure A.1). This report records the hour meter or odometer reading at
the end of the day, the amounts of materials supplied to the machine, the
number of machine hours worked and any additional hours worked by the operator
which are not machine hours. An estimate of the production is made. Either at
the end of the day, or weekly, the unit costs of the materials consumed are
added to the daily report so that the daily operating costs for the machine are
complete.
The daily machine cost and work record is kept
for all machines. The weekly report can be compiled individually by machine or
collectively for all machines of the same type using a form similar to the
Weekly Machine Cost and Work Record (Figure A.2). Figure A. 2 column (25) is
the weekly estimate of the machine hourly cost. Column (27) is the weekly unit
production cost. Column (29) is the machine utilization for the week.
DAILY MACHINE COST AND WORK RECORDS |
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Machine______________________
|
Machine No. ___________________
|
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Machine Meter Reading (end of day)
_______________________________
|
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Total Km
Traveled_____________________ Date_____________________
|
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ITEM
|
Amount
Used
|
Unit
Cost
|
Total
Cost
|
Gasoline (liters)
|
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Oil, Motor Lube (kg)
|
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Oil, Hydraulic (liters)
|
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Diesel Fuel (liters)
|
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Grease (kg)
|
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Filters (number)
|
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Tires (number)
|
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Cost of Repair Parts
|
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Cost of Repair Labor
|
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TOTAL
|
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Day's
Work
|
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Machine Hours______________
Operator's Other Work __________________________ |
Preventive
Maintenance Done__________________________ |
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Hours_____________
|
Hours_____________
|
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Major Delay: Cause____________
|
Time__________________________
|
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Volume of Wood:
|
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Cut
|
______________________________
|
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Loaded
|
______________________________
|
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Transported
|
______________________________
|
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Km of Road Built
|
______________________________
|
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Km of Road Maintained
|
______________________________
|
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REMARKS
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Table A.1 - Definitions
for Daily Machine Cost and Work Record.
Item 1
|
- Equipment type
|
Item 2
|
- Number of machine, all machines
should have numbers assigned to them, prominently displayed.
|
Item 3
|
- Either the engine hour meter or
the odometer reading at the end of the day.
|
Item 4
|
- Subtract from previous day's
record to get total machine hours worked or kilometers traveled.
|
Item 5
|
- Date
|
Item 6-12
|
- Consummable Items. Unit costs
and total costs can be calculated at the end of each week by office
personnel.
|
Item 13-14
|
- Repair parts and labor. These
costs can be calculated at the end of each week by office personnel.
|
Item 15
|
- Total cost for Items 6-14.
|
Item 16
|
- Machine hours from Item 4.
|
Item 17
|
- Type of other work done by
machine operator off machine.
|
Item 18
|
- Operator hours spent on other
work.
|
Item 19
|
- Type of preventive maintenance
done.
|
Item 20
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- Hours spent on preventive
maintenance
|
Item 21
|
- Cause of any major delays.
|
Item 22
|
- Hours spent in major delay.
|
Item 23-27
|
- Production per day, measured in
volume cut, skidded, loaded or transported by machine, or miles of road built
or maintained by equipment.
|
Item 28
|
- Any comments by the operator on
the day's activities.
|
Table A.2 - Definitions
for Weekly Machine Cost and Work Record.
Column
|
Description
|
1
|
Enter week number.
|
2-3
|
Enter gasoline supplied and total
cost summed up from the daily work sheets from the past week.
|
4-5
|
Enter motor oil supplied and total
cost summed up from the daily work sheets from the past week.
|
6-7
|
Enter diesel fuel supplied and
total cost summed up from the daily work sheets from the past week.
|
8-9
|
Enter grease supplied and total
cost summed up from the daily work sheets from the past week.
|
10-11
|
Enter hydraulic oil supplied and
total cost summed up from the daily work sheets from the past week.
|
12-13
|
Enter the number of filters and
total cost of filters summed up from the daily work sheets from the past
week.
|
14-15
|
Enter the number of tires and the
total cost summed up from the daily work sheets from the past week.
|
16-17
|
Enter amount (if applicable) and
total cost of miscellaneous materials summed up from the daily work sheets
from the past week.
|
18-19
|
Enter the repair parts cost and
repair labor cost from the daily work sheets from the past week.
|
20-21
|
Enter the equipment meter reading
or odometer reading from the end of the last day of the week and subtract it
from the reading from the last day of the previous week to obtain a total for
the week.
|
22
|
Add columns 3, 5, 1, 9, 11, 13,
15, 17, 18, and 19 to obtain the total operating cost for the machine during the
week.
|
23
|
Add the total wages including
social costs for the operators and helpers using the equipment. Do not add in
the labor for repairs included in Col (19).
|
24
|
Add up the total depreciation,
interest, taxes, license, insurance and any other fixed costs and divide by
52 to establish the weekly ownership cost. Once calculated, it will usually
not change during the year.
|
25
|
To obtain the hourly machine cost
during the week, add up the operating, labor, and ownership costs and divide
by the number of hours worked by the machine.
 |
26
|
Enter the production summed up
from the daily work sheets from the past week.
|
27
|
Divide the total cost by the total
production to determine the unit cost of production for the week.
 |
28
|
Enter the total number of hours
the machine was scheduled to operate for the week.
|
29
|
Divide the total number hours the
machine worked by the number of hours it was scheduled to work and multiply
by 100 to calculate the machine utilization in percent.
 |
The weekly cost and work report is a valuable
record not only for deriving your own machine rates, but for discussions with
the crew and foreman so that they are aware of the costs of machine operation.
An additional column can be added to the form to
show the importance of increased machine utilization. This additional column
could be called the hourly machine cost at 100% utilization. If labor is a
constant cost for the week, the hourly machine rate at 100% utilization is
calculated as
APPENDIX B - Field Production Studies
To estimate cycle time coefficients, the
observer should study the operation until he is familiar with the elements
making up the activity. A flow process chart can then be prepared to describe
the elements and define the beginning and ending points of each element. A data
collection form is prepared, data collected and coefficients calculated.
The observer gathering the time study data must
be able to see the operation he is studying at all times. Often he must
constantly move with the equipment in order to record the element times, while
simultaneously keeping a safe distance from the operation.
For example, let's design a study form to
develop cycle time coefficients for a skidding operation. We would like to
estimate the loaded speed, unloaded speed, load size, hook time and unhook time
for a rubber-tired skidder. The flow process for the skidding activity would be
Element
|
Element
Begin (B) and End (E) Point
|
Skidder travels to logs
|
(B) - Skidder leaves landing.
|
(E) - Skidder arrives at first log
pickup point.
|
|
Position skidder
|
(B) - Skidder arrives at first log
pickup point.
|
(E) - Begin pulling winch line
from skidder.
|
|
Lateral outhaul
|
(B) - Begin pulling winch line
from skidder.
|
(E) - Winch line arrives at log(s)
|
|
Hook Log
|
(B) - Winch line arrives at log(s)
|
(E) - Winch line starts in toward
skidder.
|
|
Lateral Inhaul
|
(B) - Winch line starts in toward
skidder.
|
(E) - Logs arrive at skidder.
|
|
Intermediate Move
|
(B) - Logs arrive at skidder.
|
(E) - Skidder moves to next pickup
point.
|
|
Position skidder
|
(B) - Skidder moves to next log
pickup point.
|
(E) - Begin pulling winch line
from skidder.
|
|
Lateral outhaul
|
(B) - Begin pulling winch line
from skidder.
|
(E) - Winch line arrives at log(s)
|
|
Hook Log
|
(B) - Winch line arrives at log(s)
|
(E) - Winch line starts in toward
skidder.
|
|
Lateral Inhaul
|
(B) - Winch line starts in toward
skidder.
|
(E) - Logs arrive at skidder.
|
|
Loaded Return to Landing
|
(B) - Logs arrive at skidder.
|
(E) -Skidder arrives at landing.
|
|
Unhook and deck logs
|
(B) - Skidder arrives at landing.
|
(E) - Skidder leaves landing.
|
Using the Skidding Cycle Element Time Study Form
(Table B.1), we record a sample of cycles for a rubber-tired skidder.
For example, on cycle no. 1 a small rubber-tired
skidder leaves the landing and travels 200 meters in 1.5 minutes along the skid
trail to the log pickup point. The operator turns and positions the skidder in
0.2 minutes. The helper pulls out the winch line 20 meters in 0.7 minutes. Two
logs are hooked in 1.2 minutes, winched to the skid trail in 1.0 minutes. The
skidder returns to the landing in 3.0 minutes. The logs are unhooked and pushed
into the deck and the skidder is positioned to leave the landing in 1.6
minutes. During cycle no. 3, the logs are picked up at two points during
winching. During cycle no. 4, logs are picked up at two points along the skid
trail.
Summing the times for each element, our
estimates for the skidding coefficients are:
Unloaded Travel Speed = 1350 m/12.8 min = 105
m/min
Loaded Travel Speed = (1325 + 25) m/(18.9 + .3)
min = 70 m/min
Lateral Outhaul Speed = 120 m/5.0 min = 24 m/min
Lateral Inhaul Speed = 120 m/6.2 min = 19 m/min
Position Skidder = 1.0 m/5 cycles = 0.20
min/trip
Hook Time = 13.5 min/5 cycles = 2.7 min/trip
Unhook and Deck = 8.7 min/5 cycles = 1.7
min/trip
Average number of logs per trip = 13 logs/5
cycles = 2.6 logs/trip
If the average log size is 0.5 cubic meters per
log then the average load per trip is 2.6 logs per trip multiplied by 0.5 cubic
meters per log or 1.3 cubic meters per trip.
APPENDIX C - PACE Data Collection Forms
MACHINE RATE
CALCULATIONS
DATA INPUT SHEET 1 of 2
DATA INPUT SHEET 1 of 2
Equipment Description
_______________________________________________
|
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Delivered equipment cost ($)
|
____________
|
|
Lines and rigging ($)
|
____________
|
|
Tires and tracks ($)
|
____________
|
|
Salvage value ($)
|
____________
|
|
Equipment life (years)
|
____________
|
|
Days worked per year
|
____________
|
|
Hours worked per day
|
____________
|
|
Interest expense (%)
|
____________
|
|
Percent of average annual
investment for taxes, licenses, storage, insurance (%)
|
____________
|
|
Percent of equipment depreciation
for service and repairs (%)
|
____________
|
|
Fuel consumption (liters per hour)
|
____________
|
|
Fuel cost ($/liter)
|
____________
|
|
Percent of fuel consumption for
lubricants (%)
|
____________
|
|
Cost of oil and lubricants
($/liter)
|
____________
|
|
Total cost of lines ($)
|
____________
|
|
Average life of lines (hours)
|
____________
|
|
Cost of miscellaneous rigging ($)
|
____________
|
|
Average life of miscellaneous
rigging (hours)
|
____________
|
|
Cost of tracks or tires ($)
|
____________
|
|
Average life of tires or tracks
(hours)
|
____________
|
|
MACHINE RATE
CALCULATIONS
DATA INPUT SHEET 2 of 2
DATA INPUT SHEET 2 of 2
Equipment Description
|
______________________
|
|
Base wage for 1st crew position
($/hour)
|
____________
|
|
Base wage for 2nd crew position
($/hour)
|
____________
|
|
Base wage for 3rd crew position
($/hour)
|
____________
|
|
Base wage for 4th crew position
($/hour)
|
____________
|
|
Base wage for 5th crew position
($/hour)
|
____________
|
|
Base wage for 6th crew position
($/hour)
|
____________
|
|
Fringe Benefits (% of basic wage)
|
____________
|
|
Travel time per day (hours)
|
____________
|
|
Crew operating time per day
(hours)
|
____________
|
|
Supervision cost (% direct labor
cost)
|
____________
|
|
TRUCK RATE CALCULATIONS
DATA INPUT SHEET 1 of 2
DATA INPUT SHEET 1 of 2
Equipment Description
_______________________________________________
|
||
Delivered equipment cost ($)
|
____________
|
|
Tire cost ($)
|
____________
|
|
Salvage value ($)
|
____________
|
|
Equipment life (years)
|
____________
|
|
Days worked per year
|
____________
|
|
Hours worked per day
|
____________
|
|
Interest expense (%)
|
____________
|
|
Percent of average annual
investment for taxes, licenses, storage, insurance (%)
|
____________
|
|
Percent of equipment depreciation
for service and repairs (%)
|
____________
|
|
Fuel consumption (liters per hour)
|
____________
|
|
Fuel cost ($/liter)
|
____________
|
|
Percent of fuel consumption for
lubricants (%)
|
____________
|
|
Cost of oil and lubricants
($/liter)
|
____________
|
|
Cost per tire ($)
|
____________
|
|
Number of tires
|
____________
|
|
Average life per tire (km)
|
____________
|
|
Number of km used per year
|
____________
|
|
TRUCK RATE CALCULATIONS
DATA INPUT SHEET 2 of 2
DATA INPUT SHEET 2 of 2
Equipment Description
|
________________________
|
|
Base wage for 1st crew position
($/hour)
|
____________
|
|
Base wage for 2nd crew position
($/hour)
|
____________
|
|
Base wage for 3rd crew position
($/hour)
|
____________
|
|
Base wage for 4th crew position
($/hour)
|
____________
|
|
Base wage for 5th crew position ($/hour)
|
____________
|
|
Base wage for 6th crew position
($/hour)
|
____________
|
|
Fringe Benefits (% of basic wage)
|
____________
|
|
Travel time per day (hours)
|
____________
|
|
Crew operating time per day
(hours)
|
____________
|
|
Supervision cost (% direct labor
cost)
|
____________
|
|
ANIMAL RATE CALCULATIONS
DATA INPUT SHEET 1 of 2
DATA INPUT SHEET 1 of 2
Description
______________________________________________________
|
||
Delivered animal cost ($)
|
____________
|
|
Salvage value ($)
|
____________
|
|
Working life (years)
|
____________
|
|
Delivered harness cost ($)
|
____________
|
|
Salvage value ($)
|
____________
|
|
Life of harness (years)
|
____________
|
|
Delivered miscellaneous equipment
($)
|
____________
|
|
Salvage value ($)
|
____________
|
|
Life of miscellaneous equipment
(yr)
|
____________
|
|
Number of days worked per year
|
____________
|
|
Hours worked per day
|
____________
|
|
Interest Expense (%)
|
____________
|
|
Percent of average annual
investment for taxes, licenses, storage, insurance (%)
|
____________
|
|
Percent of harness depreciation
for service and repairs (%)
|
____________
|
|
Percent of misc equip depreciation
for service and repairs (%)
|
____________
|
|
Pasture rental ($/month)
|
____________
|
|
Cost of grain ($/month)
|
____________
|
|
Cost of hay ($/month)
|
____________
|
|
Cost of supplemental vitamins
($/mth)
|
____________
|
|
Veterinarian expenses ($/month)
|
____________
|
|
Cost of shoes ($/month)
|
____________
|
|
After hours care ($/month)
|
____________
|
|
ANIMAL RATE CALCULATIONS
DATA INPUT SHEET 2 of 2
DATA INPUT SHEET 2 of 2
Equipment Description
|
______________________
|
|
Base wage for 1st crew position ($/hour)
|
_________
|
|
Base wage for 2nd crew position
($/hour)
|
_________
|
|
Base wage for 3rd crew position
($/hour)
|
_________
|
|
Base wage for 4th crew position
($/hour)
|
_________
|
|
Base wage for 5th crew position
($/hour)
|
_________
|
|
Base wage for 6th crew position
($/hour)
|
_________
|
|
Fringe Benefits (% of basic wage)
|
_________
|
|
Travel time per day (hours)
|
_________
|
|
Crew operating time per day
(hours)
|
_________
|
|
Supervision cost (% direct labor
cost)
|
_________
|
|
STUMP TO TRUCK UNIT
COSTS INCLUDING LOCAL ROADS
DATA INPUT SHEET 1 OF 2
DATA INPUT SHEET 1 OF 2
Activity
|
Element
|
Quantity
|
Units
|
Fall and buck
|
Machine costa
|
_________
|
$/hr
|
Time to fall/buck
|
_________
|
min/tree
|
|
Volume per tree
|
_________
|
m3
|
|
Delay time
|
_________
|
min/hr
|
|
Skidding or Yarding
|
Machine costa
|
_________
|
$/hr
|
Move-in time
|
_________
|
hr
|
|
Volume per cycle
|
_________
|
m3
|
|
Outhaul speed
|
_________
|
m/min
|
|
Lateral outhaul
|
_________
|
m/min
|
|
speed Hook time
|
_________
|
min
|
|
Lateral inhaul
|
_________
|
m/min
|
|
speed Inhaul speed
|
_________
|
m/min
|
|
Unhook time
|
_________
|
min
|
|
Delay time
|
_________
|
min/hr
|
|
Loading
|
Machine costa
|
_________
|
$/hr
|
Cycle time
|
_________
|
min/trip
|
|
Load size
|
_________
|
m3/trip
|
|
Delay time
|
_________
|
min/hr
|
a Complete if
different from constructed data file
STUMP TO TRUCK UNIT
COSTS INCLUDING LOCAL ROADS
DATA INPUT SHEET 2 OF 2
DATA INPUT SHEET 2 OF 2
Activity
|
Element
|
Quantity
|
Units
|
Transport
|
Machine costa
|
_________
|
$/hr
|
Distance (one-way)
|
_________
|
km
|
|
Volume per load
|
_________
|
m3
|
|
Speed (unloaded)
|
_________
|
km/hr
|
|
Loading time
|
_________
|
min
|
|
Speed (loaded)
|
_________
|
km/hr
|
|
Unloading time
|
_________
|
min
|
|
Roads and Landings
|
Road costa
|
_________
|
$/km
|
Road spacing
|
_________
|
m
|
|
Landing spacing
|
_________
|
m
|
|
Removal per ha
|
_________
|
m3
|
|
Skidding weave
|
_________
|
>
1
|
|
Skidding direction (one or two
way)
|
_________
|
1
or 2
|
|
Cost per landinga
|
_________
|
$
|
|
Removal per ha
|
_________
|
m3
|
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