| system | initial cost ($ + hrs) / unit | annualized cost ($ + hrs) / unit | sqft building | acre land | revenue | market cost | benefits | | --------------- | ----------------------------- | -------------------------------- | ------------- | --------- | ------- | ----------- | ------------------------------------------------------------------------ | | shoe production | $685k + 3200 hrs | $214k + 12,760 hrs | 5000 | 0.5 | $95k | $450k | Sustainable footwear, custom fitting, repair services, leather recycling | #### Assumptions - Community size: 1000 people - Production targets (pairs/year): - Regular shoes/boots: 800 - Athletic shoes: 400 - Sandals/casual: 600 - Cowboy boots: 200 - Children's shoes: 400 - Repair services: 1500 repairs/year - Leather reclamation: 40% recovery rate - Average lifespan before repair/replacement: - Adult shoes: 2-3 years - Children's shoes: 1 year - Athletic shoes: 1-2 years - Vegetable tanning cycle: 6 weeks - Internal resource utilization: - Water: 50,000 gallons/year - Power: 180,000 kWh/year - Tanning materials (bark, etc.): Local harvest - Storage space for aging leather #### Market Solutions $450k/year Average market costs if purchased: - Regular shoes/boots (800 × $150) = $120,000 - Athletic shoes (400 × $120) = $48,000 - Sandals/casual (600 × $80) = $48,000 - Cowboy boots (200 × $400) = $80,000 - Children's shoes (400 × $60) = $24,000 - Repairs (1500 × $80) = $120,000 Total if purchased at market rates: $450,000/year #### Labor 12,480 Hours/year | Task | Hours/Year | Notes | |------|------------|-------| | Leather tanning/processing | 2,080 | Daily maintenance of tanning pits | | Pattern making/cutting | 1,560 | Including digital pattern development | | Assembly operations | 3,120 | Primary shoe construction | | Custom fitting | 1,040 | Individual measurements and adjustments | | Repair services | 2,600 | Including evaluation and documentation | | Leather reclamation | 1,040 | Processing and sorting recovered materials | | Quality control | 520 | Testing and verification | | Equipment maintenance | 520 | Regular maintenance and calibration | | Total labor | 12,480 | ~6 FTE equivalent | #### Operating Costs $153k/year | Component | External Cost ($) | Notes | | --------------------- | ----------------- | -------------------------------- | | Raw materials | $60k | Non-leather materials, adhesives | | Tanning supplies | $25k | Bark extracts, natural agents | | Equipment maintenance | $30k | Regular service, parts | | Utilities | $20k | Power, water, HVAC | | Tools/consumables | $18k | Small tools, needles, etc. | | Total annual cost | $153k | | #### Initial Costs $685k + 3200 hrs -> $61k + 280 hrs/year | Component | Initial Cost ($ + hrs) | Lifespan (Years) | Annual Cost | Notes | |-----------|------------------------|------------------|--------------|-------| | Tanning facility | $150k + 800 hrs | 20 | $7.5k + 40 hrs | Pits, ventilation, treatment | | Cutting equipment | $120k + 400 hrs | 10 | $12k + 40 hrs | CNC cutting, patterning | | Assembly machinery | $200k + 800 hrs | 10 | $20k + 80 hrs | Stitching, lasting machines | | Custom fit station | $50k + 200 hrs | 10 | $5k + 20 hrs | 3D scanning, measurement | | Repair equipment | $80k + 400 hrs | 10 | $8k + 40 hrs | Repair-specific tools | | Reclamation system | $85k + 600 hrs | 10 | $8.5k + 60 hrs | Processing equipment | | Total | $685k + 3200 hrs | - | $61k + 280 hrs | | #### Production Capacity Daily production capacity (one shift): - Regular shoes/boots: 4 pairs - Athletic shoes: 2 pairs - Sandals/casual: 3 pairs - Cowboy boots: 1 pair - Children's shoes: 2 pairs - Repairs: 6 pairs #### Revenue Generation $95k/year | Service Category | Revenue | Notes | |-----------------|---------|--------| | External repairs | $60k | Limited repair services for non-members | | Custom fitting | $20k | Measurement services for external orders | | Leather goods | $15k | Small leather goods from reclaimed material | | Total | $95k | Supplemental income | ### Key Equipment Details #### Tanning Equipment - 6 Vegetable tanning pits (4'x4'x6') - Drum for pre-tanning processing - Water filtration/treatment system - Temperature control system - Ventilation system - Testing equipment for tanning process #### Cutting/Pattern Equipment - CNC leather cutting machine - Digital pattern design station - Material storage systems - Splitting machine - Skiving machine - Band knife splitting machine #### Assembly Equipment - Industrial sewing machines (flat bed, post bed, cylinder arm) - Lasting machines - Heat setting equipment - Sole press - Heel attach machine - Edge finishing equipment #### Custom Fitting Station - 3D foot scanner - Pressure mapping system - Last modification equipment - Measurement tools - Custom insert manufacturing #### Repair Equipment - Shoe repair workstations - Sole stitching machine - Finishing machines - Heat press - Patching equipment - Material removal tools #### Reclamation Equipment - Material separation station - Cleaning system - Testing equipment - Processing machinery - Storage organization system ### Environmental Considerations - Closed-loop water system for tanning - Natural tanning agents from local sources - Energy-efficient machinery - Material reclamation emphasis - Non-toxic adhesives when possible - Waste material composting - Heat recovery systems