The cost analysis was done based on a 7ft 4ft vessel, with approx. 55 linear meters of weld, time spent and consumables would slightly differ from company to company. The costings for time and labour are based on the Engineer/Operator earning £12 per hour.
Method – Pickling Paste.
Application Time Cost/Labour
Move vessel out side factory 10 £2
Apply paste 15 £3
Wait for paste to activate 30 £0 Assuming operator continues working
Hose off vessel 40 £8
Re work – Tidelines/Acid 30 £6
Dress ready for shipping 10 £2
Operational Total 2 hrs 15 minutes £21
2kg cleans approx. 110 linear meters at a cost of £48 for 2kg tub.
Cost of paste used on vessel £24
Abrasive pads used on vessel £3
Total job cost and time x1 vessel 2hrs 15mins £51
Method – Electro Cleaning WELDBrush 500
Application Time Cost
Clean and passivate vessel 50 £10
Spray and wipe vessel 10 £2
Operational Total 1 hour £12
2kg Cleans approx. 150 linear meters at a cost of £50 for 2kg tub.
1 carbon fibre brush will last approx. 60 hours costing £15.
Cost of solution used on vessel £17
Cost of carbon fibre brush £0.25p
Total job cost and time x1 vessel 1 hour £29.25p
The following annual cost analysis has been based on 6 vessels are being manufactured and shipped a week, based over a period of 52 weeks the total delivered vessels are 312 per annum.
Time per Week Cost per Week
Pickling Paste 13hrs 30 mins £306
WELDBrush 6 hrs £175.50
Time per Month Cost per Month
Pickling Paste 58hrs £1,326
WELDBrush 26hrs £760
Time per Year Cost per Year
Pickling Paste 692hrs £15,912
WELDBrush 312hrs £9,126
By changing current finishing method of pickling paste to using the WELDBrush, not only will the business be saving £6,786 per annum on labour and consumable cost, but it will be gaining over 380 additional working hours, looking at a standard 8 hour working day this will give back an additional 47.5 working day per year.
Average time to complete vessel – 7 hours
Cost per vessel – £8695
Time back from above analysis – 47.5 hours
Potential additional vessels to sell – 7
Additional profit – £60,865
Cost saving – £6,786
Total saving for year 1 – £67,651
The vessel is also passivated to prevent any rust or corrosion, to passivate this externally this would incur further costing that have not been added to the analysis.
Health and safety benefits would be for Engineer/Operator, to the environment and long term the company, washing harmful and corrosive acid and metal particles down the drain into the surrounding environment is an illegal act and carries heavy fines for any company caught doing such.