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APPENDICES


APPENDIX A - Machine Cost and Work Records
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

Machine______________________

Machine No. ___________________

Machine Meter Reading (end of day) _______________________________

Total Km Traveled_____________________ Date_____________________

ITEM

Amount Used

Unit Cost

Total Cost

Gasoline (liters)




Oil, Motor Lube (kg)




Oil, Hydraulic (liters)




Diesel Fuel (liters)




Grease (kg)




Filters (number)




Tires (number)












Cost of Repair Parts




Cost of Repair Labor





TOTAL



Day's Work

Machine Hours______________
Operator's Other Work
__________________________

Preventive
Maintenance
Done__________________________

Hours_____________

Hours_____________

Major Delay: Cause____________

Time__________________________

Volume of Wood:

Cut

______________________________

Loaded

______________________________

Transported

______________________________

Km of Road Built

______________________________

Km of Road Maintained

______________________________

REMARKS

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

- 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.

Figure A.2. WEEKLY MACHINE COST AND WORK RECORD PART I

Figure A.2. WEEKLY MACHINE COST AND WORK RECORD PART II

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.

Table B.1 Skidding Cycle Element Time Study Form

APPENDIX C - PACE Data Collection Forms

MACHINE RATE CALCULATIONS
DATA INPUT SHEET 1 of 2

Equipment Description _______________________________________________

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

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

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

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

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

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

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

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

a Complete if different from constructed data file


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