COST MODEL SUMMARIES

1-1-1-1-1-1-1-1-1-1-1-1-1-1-1-1-1-1- 1-1-1-1-1-1- 1-1-1-1-1-1- 1-1-1-1-1-1- 1-1-1-1-1-1-1Part #1: Roof Panel

Material:
1 (0-Aluminum; 1-Steel; 2-SMC)
Part Weight:
26.97 lbs
Material Cost
$0.33
0.05
per piece
per year
percent
VARIABLE COST ELEMENTS
----------------- ----------------- ----------------Material Cost
$10.70 $1,605,223
57.47%
Labor Cost
$1.58
$236,900
8.48%
Energy Cost
$0.12
$17,708
0.63%
----------------- ----------------- ----------------Total Variable Cost ===>
$12.40 $1,859,830
66.59%
FIXED COSTS

per piece
per year
percent
investment
----------------- ----------------- ----------------- -------------------Main Machine Cost
$1.12
$168,190
6.02%
$5,876,337
Tooling Cost
$1.23
$184,684
6.61%
$738,738
Fixed Overhead Cost
$1.24
$186,108
6.66%
Building Cost
$0.02
$3,687
0.13%
$280,156
Auxiliary Equipment Cost
$0.22
$33,638
1.20%
$1,175,267
Maintenance Cost
$0.94
$141,538
5.07%
Cost of Capital
$1.44
$215,286
7.71%
----------------- ----------------- ----------------- -------------------Total Fixed Cost ===>
$6.22
$933,131
33.41%

========= ========= =========

Total Part Cost ===>
$18.62 $2,792,961
100%
========= ========= =========
1-1-1-1-1-1-1-1-1-1-1-1-1-1-1-1-1-1- 1-1-1-1-1-1- 1-1-1-1-1-1- 1-1-1-1-1-1- 1-1-1-1-1-1-1============================ ========= ========= ========= ===========
Body Fabrication Line Inputs
(NOTE: Labor assumed NOT dedicated)
Annual Production
Labor Wage
Benefits
Overhead

150,000 bodies/year
$15.00 /hr
100.0% of wage
150.0% of wage & benefits

Opportunity Cost of Capital

15.00% /yr
Amortization Period (product life)
5 years
============================ ========= ========= ========= ===========
MODEL RESULTS
Body-In-White Part Fabrication Estimates

Basis Parts
Material
Weight
Part Cost
-------------------------------------------------- ----------------- ----------------- ----------------- -------------------Part #1: Roof Panel
Steel
26.97
$18.62
Part #2: Quarter Panel Inner
Steel
Err:520
Err:520
Part #3: Quarter Panel Outer
Steel
12.45
$69.56
Part #4: Rear Floor Pan
Aluminum
21.01
$68.95
-------------------------------------------------- ----------------- ----------------- ----------------- -------------------Total B-I-W Material Cost
Err:520
Total B-I-W Fabrication Cost
Err:520
453
Total B-I-W Weight
Err:520 lbs
515
Mass Fractions - Materials
Steel
Aluminum
SMC
Mass Fractions - Part Types
Type 1
Type 2
Type 3
Type 4

Err:520 lbs
81.472 lbs
0.000 lbs

Err:520
Err:520
Err:520

373.410 lbs
Err:520 lbs
76.140 lbs
81.472 lbs

Err:520
Err:520
Err:520
Err:520

-------------------------------------------------- ----------------- ----------------- ----------------- -------------------Body Line Cost Estimates

Labor Cost
$232.90
Capital Cost
$266.35
============================ =========
Total BIW Assembly Cost
$499.25
BIW Part Fabrication Cost
Err:520
BIW Assembly Cost
$499.25
============================ =========
TOTAL
Err:520
============================ ========= ========= ========= ===========

COST MODEL SUMMARIES

2-2-2-2-2-2-2-2-2-2-2-2-2-2-2-2-2-2- 2-2-2-2-2-2- 2-2-2-2-2-2- 2-2-2-2-2-2- 2-2-2-2-2-2-2Part #2: Quarter Panel Inner
Material:
1 (0-Aluminum; 1-Steel; 2-SMC)
Part Weight: Err:520
lbs
Material Cost
$0.33
0.05
per piece
per year
percent
VARIABLE COST ELEMENTS
----------------- ----------------- ----------------Material Cost Err:520
Err:520
Err:520
Labor Cost Err:520
Err:520
Err:520
Energy Cost Err:520
Err:520
Err:520
----------------- ----------------- ----------------Total Variable Cost ===>
Err:520
Err:520
Err:520
FIXED COSTS

per piece
per year
percent
investment
----------------- ----------------- ----------------- -------------------Main Machine Cost Err:520
Err:520
Err:520 Err:520
Tooling Cost Err:520
Err:520
Err:520 Err:520
Fixed Overhead Cost Err:520
Err:520
Err:520
Building Cost Err:520
Err:520
Err:520 Err:520
Auxiliary Equipment Cost Err:520
Err:520
Err:520 Err:520
Maintenance Cost Err:520
Err:520
Err:520
Cost of Capital Err:520
Err:520
Err:520
----------------- ----------------- ----------------- -------------------Total Fixed Cost ===>
Err:520
Err:520
Err:520

========= ========= =========

Total Part Cost ===>
Err:520
Err:520
Err:520
========= ========= =========
2-2-2-2-2-2-2-2-2-2-2-2-2-2-2-2-2-2- 2-2-2-2-2-2- 2-2-2-2-2-2- 2-2-2-2-2-2- 2-2-2-2-2-2-2-

COST MODEL SUMMARIES

3-3-3-3-3-3-3-3-3-3-3-3-3-3-3-3-3-3- 3-3-3-3-3-3- 3-3-3-3-3-3- 3-3-3-3-3-3- 3-3-3-3-3-3-3Part #3: Quarter Panel Outer
Material:
1 (0-Aluminum; 1-Steel; 2-SMC)
Part Weight:
12.45 lbs
Material Cost
$0.33
0.05
per piece
per year
percent
VARIABLE COST ELEMENTS
----------------- ----------------- ----------------Material Cost
$11.16 $1,673,502
16.04%
Labor Cost
$3.85
$576,915
5.53%
Energy Cost
$0.33
$50,099
0.48%
----------------- ----------------- ----------------Total Variable Cost ===>
$15.34 $2,300,516
22.05%
FIXED COSTS

per piece
per year
percent
investment
----------------- ----------------- ----------------- -------------------Main Machine Cost
$2.98
$446,901
4.28% $15,084,669
Tooling Cost
$19.47 $2,920,908
27.99% $11,683,633
Fixed Overhead Cost
$12.09 $1,813,202
17.38%
Building Cost
$0.04
$6,248
0.06%
$448,026
Auxiliary Equipment Cost
$0.60
$89,380
0.86%
$3,016,934
Maintenance Cost
$11.45 $1,717,141
16.46%
Cost of Capital
$7.60 $1,140,081
10.93%
----------------- ----------------- ----------------- -------------------Total Fixed Cost ===>
$54.23 $8,133,862
77.95%

========= ========= =========

Total Part Cost ===>
$69.56 $10,434,378
100%
========= ========= =========
3-3-3-3-3-3-3-3-3-3-3-3-3-3-3-3-3-3- 3-3-3-3-3-3- 3-3-3-3-3-3- 3-3-3-3-3-3- 3-3-3-3-3-3-3-

COST MODEL SUMMARIES

4-4-4-4-4-4-4-4-4-4-4-4-4-4-4-4-4-4- 4-4-4-4-4-4- 4-4-4-4-4-4- 4-4-4-4-4-4- 4-4-4-4-4-4-4Part #4: Rear Floor Pan
Material:
0 (0-Aluminum; 1-Steel; 2-SMC)
Part Weight:
21.01 lbs
Material Cost
$1.50
0.3
per piece
per year
percent
VARIABLE COST ELEMENTS
----------------- ----------------- ----------------Material Cost
$44.08 $6,612,210
63.93%
Labor Cost
$2.71
$406,286
3.93%
Energy Cost
$0.21
$30,851
0.30%
----------------- ----------------- ----------------Total Variable Cost ===>
$47.00 $7,049,348
68.16%
FIXED COSTS

per piece
per year
percent
investment
----------------- ----------------- ----------------- -------------------Main Machine Cost
$1.87
$280,946
2.72%
$9,592,565
Tooling Cost
$4.95
$742,726
7.18%
$2,970,905
Fixed Overhead Cost
$4.78
$717,684
6.94%
Building Cost
$0.03
$4,831
0.05%
$356,216
Auxiliary Equipment Cost
$0.37
$56,189
0.54%
$1,918,513
Maintenance Cost
$6.44
$965,833
9.34%
Cost of Capital
$3.50
$525,323
5.08%
----------------- ----------------- ----------------- -------------------Total Fixed Cost ===>
$21.96 $3,293,532
31.84%

========= ========= =========

Total Part Cost ===>
$68.95 $10,342,879
100%
========= ========= =========
4-4-4-4-4-4-4-4-4-4-4-4-4-4-4-4-4-4- 4-4-4-4-4-4- 4-4-4-4-4-4- 4-4-4-4-4-4- 4-4-4-4-4-4-4-

Raw Material Costs

Scrap
Aluminum Sheet $1.50
Steel Sheet
$0.33
SMC
$0.80

0.3
0.05
#N/A

<+A1>============================
=========== =========== ==============<END>
|
SMC MOLDING MODEL
|
|
Materials Systems Laboratory MIT
|
=========================== =========== =========== ======= ===========
Model Revision Date: 10/28/93 Input Revision Date:
05/03/93
COMPONENT SPECIFICATIONS
Part Name/Material Type:
Formulation Number
Weight
Maximum Wall Thickness
Total External Surface Area
Projected Area

ROOF
1
19.00 lbs
0.090 in
3,380 sq in
3,073 sq in

SMC
MAT
(see menu)
WGT
THKM (see menu)
SAREA
PAREA

Number of Cavities
Number of Actions in Tool
Backup Mold
Molding Cy. Time <optional>
Tool Cost/Set <optional>
Press Tonnage <optional>

1
0
0 (1=Y;0=N)
0 sec
$0 ($000/set)
0 tons

CAV
ACT
BACK
CYC
MOLD
TONS

EXOGENOUS COST FACTORS

Annual Production Volume
Product Lifetime
Dedicated Equipment
Process Rejection Rate

150 (000)/yr
4 yrs
0 (1=Y;0=N)
1.0%

NUM
PLIFE
DED
PREJ

Direct Wages (w/ benefits)

Working Days/Yr
Working Hours/Day
Capital Recovery Rate
Capital Recovery Period
Working Capital Period
Price of Building Space
Building Recovery Life
Price of Electricity

$25.00 /hr
250
16
10.0%
10 yrs
3 months
$75.00 /sq ft
20 yrs
$0.080 /KWh

WAGE
DAYS
HRS
CRR
CRP
WCP
PBLD
BLIFE
ELEC

Fixed Overhead
Auxiliary Equipment Cost
Maintenance Cost

35.0%
15.0%
4.0%

OVHD
AUX
MNT

PROCESS RELATED FACTORS

Average Downtime
Material Scrap Rate

15.0%
2.50%

DOWN
SCR

Molding Cycle Time Intercept

50 sec

CYC1

Molding Cycle Time Factor

250 sec/in

CYC2

Machine Cost Coefficient

Machine Cost Scaling Exp.
Direct Laborers Per Machine
Installation Cost

$8,621
0.650
2
20.0%

MCH1
MCH2
NLAB
INST

Internal Molding Pressure

Press Tonnage Safety Factor

1,200 psi
20.0%

PRES1
PRES2

Mold Cost Coefficient

Complexity Deformation Exp.
Complexity Actions Exponent
Weight Factor Exponent
Baseline Physical Mold Life

$48,280
1.08
0.4
0.6
1,200,000 cycles

MOL1
MOL2
MOL3
MOL4
MOLLI

Electrical Heat
Electrical Mechanical Energy
Floor Space Coefficient
Floor Space Scaling Exponent

0.50 kWh/lb
POW1
0.08 kW/press ton POW2
251 sq ft
0.71

FLR1
FLR2

In-Mold Coating Paramters

Coating in Use
Additional Capital Invest.
Added Cycle Time
Coating Thickness
Sides Coated (1 or 2)
Coating Material Price
Coating Transfer Efficiency

1 (1=Y;0=N)
$60,000 /press
30 sec
0.005 in
1
$20.00 /gal
95.0%

COAT

Trimming & Drilling Parameters

Process in use
Machine Cost
Toolind & Fixture Cost
Tool Lifetime
Process Rejection Rate
Number of Additional Laborers
Trimming & Drilling Cy. Time
Simulataneous Trimming

1 (1=Y;0=N)
$252,000
$10,000
150,000 cycles
0.5%
0.5
10 sec
1 parts

CUT
CMACH
CDIE
CDLIFE
TREJ
ADDLAB
CUTIME
SIMTRIM

<END>

<+A1>============================
=========== =========== ==============<END>
|
SMC MOLDING MODEL
|
|
Materials Systems Laboratory MIT
|
=========================== =========== =========== ======= ===========
Model Revision Date: 10/28/93 Input Revision Date:
05/03/93
COMPONENT SPECIFICATIONS
Part Name/Material Type:
Formulation Number
Weight
Maximum Wall Thickness
Total External Surface Area
Projected Area

OUTER
1
11.00 lbs
0.110 in
1,600 sq in
1,455 sq in

SMC
MAT
(see menu)
WGT
THKM (see menu)
SAREA
PAREA

Number of Cavities
Number of Actions in Tool
Backup Mold
Molding Cy. Time <optional>
Tool Cost/Set <optional>
Press Tonnage <optional>

1
0
0 (1=Y;0=N)
0 sec
$0 ($000/set)
0 tons

CAV
ACT
BACK
CYC
MOLD
TONS

EXOGENOUS COST FACTORS

Annual Production Volume
Product Lifetime
Dedicated Equipment
Process Rejection Rate

150 (000)/yr
4 yrs
0 (1=Y;0=N)
1.0%

NUM
PLIFE
DED
PREJ

Direct Wages (w/ benefits)

Working Days/Yr
Working Hours/Day
Capital Recovery Rate
Capital Recovery Period
Working Capital Period
Price of Building Space
Building Recovery Life
Price of Electricity

$25.00 /hr
250
16
10.0%
10 yrs
3 months
$75.00 /sq ft
20 yrs
$0.080 /KWh

WAGE
DAYS
HRS
CRR
CRP
WCP
PBLD
BLIFE
ELEC

Fixed Overhead
Auxiliary Equipment Cost
Maintenance Cost

35.0%
15.0%
4.0%

OVHD
AUX
MNT

PROCESS RELATED FACTORS

Average Downtime
Material Scrap Rate

15.0%
2.50%

DOWN
SCR

Molding Cycle Time Intercept

50 sec

CYC1

Molding Cycle Time Factor

250 sec/in

CYC2

Machine Cost Coefficient

Machine Cost Scaling Exp.
Direct Laborers Per Machine
Installation Cost

$8,621
0.650
2
20.0%

MCH1
MCH2
NLAB
INST

Internal Molding Pressure

Press Tonnage Safety Factor

1,200 psi
20.0%

PRES1
PRES2

Mold Cost Coefficient

Complexity Deformation Exp.
Complexity Actions Exponent
Weight Factor Exponent
Baseline Physical Mold Life

$48,280
1.08
0.4
0.6
1,200,000 cycles

MOL1
MOL2
MOL3
MOL4
MOLLI

Electrical Heat
Electrical Mechanical Energy
Floor Space Coefficient
Floor Space Scaling Exponent

0.50 kWh/lb
POW1
0.08 kW/press ton POW2
251 sq ft
0.71

FLR1
FLR2

In-Mold Coating Paramters

Coating in Use
Additional Capital Invest.
Added Cycle Time
Coating Thickness
Sides Coated (1 or 2)
Coating Material Price
Coating Transfer Efficiency

1 (1=Y;0=N)
$60,000 /press
30 sec
0.005 in
1
$20.00 /gal
95.0%

COAT

Trimming & Drilling Parameters

Process in use
Machine Cost
Toolind & Fixture Cost
Tool Lifetime
Process Rejection Rate
Number of Additional Laborers
Trimming & Drilling Cy. Time
Simulataneous Trimming

1 (1=Y;0=N)
$252,000
$10,000
150,000 cycles
0.5%
0.5
10 sec
1 parts

CUT
CMACH
CDIE
CDLIFE
TREJ
ADDLAB
CUTIME
SIMTRIM

<END>

<+A1>============================
=========== =========== ==============<END>
|
SMC MOLDING MODEL
|
|
Materials Systems Laboratory MIT
|
=========================== =========== =========== ======= ===========
Model Revision Date: 10/28/93 Input Revision Date:
05/03/93
COMPONENT SPECIFICATIONS
Part Name/Material Type:
Formulation Number
Weight
Maximum Wall Thickness
Total External Surface Area
Projected Area

FLOOR
1
51.00 lbs
0.180 in
4,500 sq in
4,091 sq in

SMC
MAT
(see menu)
WGT
THKM (see menu)
SAREA
PAREA

Number of Cavities
Number of Actions in Tool
Backup Mold
Molding Cy. Time <optional>
Tool Cost/Set <optional>
Press Tonnage <optional>

1
0
0 (1=Y;0=N)
0 sec
$0 ($000/set)
0 tons

CAV
ACT
BACK
CYC
MOLD
TONS

EXOGENOUS COST FACTORS

Annual Production Volume
Product Lifetime
Dedicated Equipment
Process Rejection Rate

150 (000)/yr
4 yrs
0 (1=Y;0=N)
1.0%

NUM
PLIFE
DED
PREJ

Direct Wages (w/ benefits)

Working Days/Yr
Working Hours/Day
Capital Recovery Rate
Capital Recovery Period
Working Capital Period
Price of Building Space
Building Recovery Life
Price of Electricity

$25.00 /hr
250
16
10.0%
10 yrs
3 months
$75.00 /sq ft
20 yrs
$0.080 /KWh

WAGE
DAYS
HRS
CRR
CRP
WCP
PBLD
BLIFE
ELEC

Fixed Overhead
Auxiliary Equipment Cost
Maintenance Cost

35.0%
15.0%
4.0%

OVHD
AUX
MNT

PROCESS RELATED FACTORS

Average Downtime
Material Scrap Rate

15.0%
2.50%

DOWN
SCR

Molding Cycle Time Intercept

50 sec

CYC1

Molding Cycle Time Factor

250 sec/in

CYC2

Machine Cost Coefficient

Machine Cost Scaling Exp.
Direct Laborers Per Machine
Installation Cost

$8,621
0.650
2
20.0%

MCH1
MCH2
NLAB
INST

Internal Molding Pressure

Press Tonnage Safety Factor

1,200 psi
20.0%

PRES1
PRES2

Mold Cost Coefficient

Complexity Deformation Exp.
Complexity Actions Exponent
Weight Factor Exponent
Baseline Physical Mold Life

$48,280
1.08
0.4
0.6
1,200,000 cycles

MOL1
MOL2
MOL3
MOL4
MOLLI

Electrical Heat
Electrical Mechanical Energy
Floor Space Coefficient
Floor Space Scaling Exponent

0.50 kWh/lb
POW1
0.08 kW/press ton POW2
251 sq ft
0.71

FLR1
FLR2

In-Mold Coating Paramters

Coating in Use
Additional Capital Invest.
Added Cycle Time
Coating Thickness
Sides Coated (1 or 2)
Coating Material Price
Coating Transfer Efficiency

0 (1=Y;0=N)
$60,000 /press
30 sec
0.005 in
1
$20.00 /gal
95.0%

COAT

Trimming & Drilling Parameters

Process in use
Machine Cost
Toolind & Fixture Cost
Tool Lifetime
Process Rejection Rate
Number of Additional Laborers
Trimming & Drilling Cy. Time
Simulataneous Trimming

1 (1=Y;0=N)
$252,000
$10,000
150,000 cycles
0.5%
0.5
10 sec
1 parts

CUT
CMACH
CDIE
CDLIFE
TREJ
ADDLAB
CUTIME
SIMTRIM

<END>

<+F1>
<+G1>
NDEM STAMPING COST MODEL : DESIGN DATA
Materials Systems Laboratory
---------------------------------------------------------- Steel
Al
Piece Weight
26.97
Stock Weight
32.88
PIECE DESIGN RELATED INFORMATION
Part name
Class A finish? (1=Y;0=N)
Maximum piece length
Maximum piece width
Surface area
Projected surface area
Number of parts per hit
Piece weight
Input metal stock weight
Input metal stock surface area
Stretch limited piece?(1=Y;0=N)
Flanged stretch piece?(1=Y;0=N)
No. of re-entrant flanged sides
Number of stretch strikes
Draw limited piece? (1=Y;0=N) (NA)
Flanged draw piece? (1=Y;0=N) (NA)
No. of re-entrant flanged sides(NA)
Maximum draw depth (NA)
Box draw? (1=Y;0=N) (NA)
Box length (NA)
Box width (NA)
Box corner radius (NA)
Draw depth/Box corner radius (NA)
Number of box draw strikes (NA)
Cylindrical draw? (1=Y;0=N) (NA)
Punch diameter (NA)
Draw depth/Punch diameter (NA)
Input metal stock diameter (NA)
Punch diameter/Stock diameter (NA)
Input metal stock thickness (NA)
Stock thickness/Stock diameter (NA)
Poisson regression (NA)
Num. of cylin. draw strikes (1)(NA)
Linear function index (NA)
ZD1 (NA)
ZD2 (NA)
ZD3 (NA)
ZD4 (NA)

roof
1
64.13 in
52.75 in
3,382.59 in
2,757.72 in
1
see above lbs
see above lbs
4119.84 in
1
1
0
2
0
0
0
0 in
0
0 in
0 in
0 in
#N/A
#N/A
0
0 in
#VALUE!
0 in
#N/A
0 in
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A

<+H1>

<+I1>

TANDEM S
-------------------15.6
19

NAME
FINISH
MAXLEN
MAXWID
SAREA
PSAREA
CAV
PWGT
INWGT
INAREA
STRETCH
SFLANGE
SREENT
SSTRIKE
DRAW
DFLANGE
DREENT
MAXDPTH
BOX
BWDTH
BLGTH
BRAD
DB
BSTRIKE
CYLIN
PUNDIA
DD
INDIA
DS
INTHK
TD
PREGR
CSTRIKE1
INDEX
ZD1
ZD2
ZD3
ZD4

Probability(D1) (NA)
Probability(D2) (NA)
Probability(D3) (NA)
Probability(D4) (NA)
Probability(D5) (NA)
Ordered logit estimation (NA)
Num. of cylin. draw strikes (2)(NA)

#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A

PD1
PD2
PD3
PD4
PD5
OLOGIT
CSTRIKE2

Number of draw strikes (NA)

#N/A

DSTRIKE

0
0
0
0

BSTR
CSTR1
CSTR2
DSTR

PRECAUTIONS
Minimum flange corner radius
Max. 1st draw for square box (NA)
Max. 1st draw for rect. box (NA)

#VALUE! in
#N/A in
#N/A in

RMIN
LSDPTH
LRDPTH

OVERRIDE SPECIFICATIONS
Estimated stretch strikes
Estimated draw strikes (NA)
User override (0=NO OVERRIDE)

<END>

2
0
0

OVRIDE

<END> <+F1>
<+G1>
TANDEM STAMPING COST MODEL : DESIGN DATA
Materials Systems Laboratory
-------------------- ---------------------------------------------------------- Steel
Al
Piece Weight
36.33
Stock Weight
53.7
Input metal stock thickness
0.03
PIECE DESIGN RELATED INFORMATION
Part name
Class A finish? (1=Y;0=N)
Maximum piece length
Maximum piece width
Surface area
Projected surface area
Number of parts per hit
Piece weight
Input metal stock weight
Input metal stock surface area
Stretch limited piece?(1=Y;0=N)(NA)
Flanged stretch piece?(1=Y;0=N)(NA)
No. of re-entrant flanged sides(NA)
Number of stretch strikes (NA)
Draw limited piece? (1=Y;0=N)
Flanged draw piece? (1=Y;0=N)
No. of re-entrant flanged sides
Maximum draw depth
Box draw? (1=Y;0=N) (NA)
Box length (NA)
Box width (NA)
Box corner radius (NA)
Draw depth/Box corner radius (NA)
Number of box draw strikes (NA)
Cylindrical draw? (1=Y;0=N)
Punch diameter
Draw depth/Punch diameter
Input metal stock diameter
Punch diameter/Stock diameter
Input metal stock thickness
Stock thickness/Stock diameter
Poisson regression
Num. of cylin. draw strikes (1)
Linear function index
ZD1
ZD2
ZD3

REAR
0
83.72 in
54.41 in
4,555.56 in
3,856.51 in
1
see above lbs
see above lbs
6280.7 in
0
0
0
#N/A
1
1
2
6.78 in
0
0 in
0 in
0 in
#N/A
#N/A
1
28.66 in
0.2365
54.41 in
0.5266
see above
in
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

<+H1>

21.01
31.05
0.05

ZD4
Probability(D1)
Probability(D2)
Probability(D3)
Probability(D4)
Probability(D5)
Ordered logit estimation
Num. of cylin. draw strikes (2)
Number of draw strikes

#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
2
0
#VALUE!
#VALUE!
4

PRECAUTIONS
Minimum flange corner radius
Max. 1st draw for square box (NA)
Max. 1st draw for rect. box (NA)

#VALUE! in
#N/A in
#N/A in

OVERRIDE SPECIFICATIONS
Estimated stretch strikes (NA)
Estimated draw strikes
User override (0=NO OVERRIDE)

<END>

#N/A
#VALUE!
0

<+I1>

<END> <+F1>
<+G1>
TANDEM STAMPING COST MODEL : DESIGN DATA
Materials Systems Laboratory
-------------------- -------------------- ---------------------------------------------------------- Steel
Piece Weight
12.45
Stock Weight
36.8
PIECE DESIGN RELATED INFORMATION

NAME
FINISH
MAXLEN
MAXWID
SAREA
PSAREA
CAV
PWGT
INWGT
INAREA
STRETCH
SFLANGE
SREENT
SSTRIKE
DRAW
DFLANGE
DREENT
MAXDPTH
BOX
BWDTH
BLGTH
BRAD
DB
BSTRIKE
CYLIN
PUNDIA
DD
INDIA
DS
INTHK
TD
PREGR
CSTRIKE1
INDEX
ZD1
ZD2
ZD3

Part name
Class A finish? (1=Y;0=N)
Maximum piece length
Maximum piece width
Surface area
Projected surface area
Number of parts per hit
Piece weight
Input metal stock weight
Input metal stock surface area
Stretch limited piece?(1=Y;0=N)
Flanged stretch piece?(1=Y;0=N)
No. of re-entrant flanged sides
Number of stretch strikes
Draw limited piece? (1=Y;0=N) (NA)
Flanged draw piece? (1=Y;0=N) (NA)
No. of re-entrant flanged sides(NA)
Maximum draw depth (NA)
Box draw? (1=Y;0=N) (NA)
Box length (NA)
Box width (NA)
Box corner radius (NA)
Draw depth/Box corner radius (NA)
Number of box draw strikes (NA)
Cylindrical draw? (1=Y;0=N) (NA)
Punch diameter (NA)
Draw depth/Punch diameter (NA)
Input metal stock diameter (NA)
Punch diameter/Stock diameter (NA)
Input metal stock thickness (NA)
Stock thickness/Stock diameter (NA)
Poisson regression (NA)
Num. of cylin. draw strikes (1)(NA)
Linear function index (NA)
ZD1 (NA)
ZD2 (NA)
ZD3 (NA)
ZD4 (NA)

OUTER
1
91.37
52.1
1,561.97
1,138.95
1
see above
see above
4165.25
1
1
4
6
0
0
0
0
0
0
0
0
#N/A
#N/A
0
0
#VALUE!
0
#N/A
0
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A

ZD4
PD1
PD2
PD3
PD4
PD5
OLOGIT
CSTRIKE2

Probability(D1) (NA)
Probability(D2) (NA)
Probability(D3) (NA)
Probability(D4) (NA)
Probability(D5) (NA)
Ordered logit estimation (NA)
Num. of cylin. draw strikes (2)(NA)

#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A

Number of draw strikes (NA)

#N/A

DSTRIKE
0
0
0
0

BSTR
CSTR1
CSTR2
DSTR
PRECAUTIONS

RMIN
LSDPTH
LRDPTH

Minimum flange corner radius

Max. 1st draw for square box (NA)
Max. 1st draw for rect. box (NA)

#VALUE!
#N/A
#N/A

OVERRIDE SPECIFICATIONS
Estimated stretch strikes
Estimated draw strikes (NA)
User override (0=NO OVERRIDE)
OVRIDE
<END>

6
0
0

<+H1>

Al

in
in
in
in
lbs
lbs
in

in
in
in
in

in
in
in

<+I1>

<END> <+F1>
TANDEM STAMPING COST MODEL : DESIGN DATA
Materials Systems Laboratory
-------------------- -------------------- ---------------------------------------------------------7.2
Piece Weight
21.24
Stock Weight
PIECE DESIGN RELATED INFORMATION
NAME
FINISH
MAXLEN
MAXWID
SAREA
PSAREA
CAV
PWGT
INWGT
INAREA
STRETCH
SFLANGE
SREENT
SSTRIKE
DRAW
DFLANGE
DREENT
MAXDPTH
BOX
BWDTH
BLGTH
BRAD
DB
BSTRIKE
CYLIN
PUNDIA
DD
INDIA
DS
INTHK
TD
PREGR
CSTRIKE1
INDEX
ZD1
ZD2
ZD3
ZD4

Part name
Class A finish? (1=Y;0=N)
Maximum piece length
Maximum piece width
Surface area
Projected surface area
Number of parts per hit
Piece weight
Input metal stock weight
Input metal stock surface area
Stretch limited piece?(1=Y;0=N)
Flanged stretch piece?(1=Y;0=N)
No. of re-entrant flanged sides
Number of stretch strikes
Draw limited piece? (1=Y;0=N) (NA)
Flanged draw piece? (1=Y;0=N) (NA)
No. of re-entrant flanged sides(NA)
Maximum draw depth (NA)
Box draw? (1=Y;0=N) (NA)
Box length (NA)
Box width (NA)
Box corner radius (NA)
Draw depth/Box corner radius (NA)
Number of box draw strikes (NA)
Cylindrical draw? (1=Y;0=N) (NA)
Punch diameter (NA)
Draw depth/Punch diameter (NA)
Input metal stock diameter (NA)
Punch diameter/Stock diameter (NA)
Input metal stock thickness (NA)
Stock thickness/Stock diameter (NA)
Poisson regression (NA)
Num. of cylin. draw strikes (1)(NA)
Linear function index (NA)
ZD1 (NA)
ZD2 (NA)
ZD3 (NA)
ZD4 (NA)

PD1
PD2
PD3
PD4
PD5
OLOGIT
CSTRIKE2

Probability(D1) (NA)
Probability(D2) (NA)
Probability(D3) (NA)
Probability(D4) (NA)
Probability(D5) (NA)
Ordered logit estimation (NA)
Num. of cylin. draw strikes (2)(NA)

DSTRIKE

Number of draw strikes (NA)

BSTR
CSTR1
CSTR2
DSTR
PRECAUTIONS
in
in
in

RMIN
LSDPTH
LRDPTH

Minimum flange corner radius

Max. 1st draw for square box (NA)
Max. 1st draw for rect. box (NA)
OVERRIDE SPECIFICATIONS

OVRIDE

Estimated stretch strikes

Estimated draw strikes (NA)
User override (0=NO OVERRIDE)

<END>

<+G1>

<+H1>

<+I1>

<END>

atory
Steel

Al
9.57
20.85

INNER
0
63.1 in
63 in
1,199.77 in
785.88 in
1
see above lbs
see above lbs
2359.93 in
1
1
3
5
0
0
0
0 in
0
0 in
0 in
0 in
#N/A
#N/A
0
0 in
#VALUE!
0 in
#N/A
0 in
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A

-------------------- -------------------5.53
12.03

NAME
FINISH
MAXLEN
MAXWID
SAREA
PSAREA
CAV
PWGT
INWGT
INAREA
STRETCH
SFLANGE
SREENT
SSTRIKE
DRAW
DFLANGE
DREENT
MAXDPTH
BOX
BWDTH
BLGTH
BRAD
DB
BSTRIKE
CYLIN
PUNDIA
DD
INDIA
DS
INTHK
TD
PREGR
CSTRIKE1
INDEX
ZD1
ZD2
ZD3
ZD4

#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A

PD1
PD2
PD3
PD4
PD5
OLOGIT
CSTRIKE2

#N/A

DSTRIKE

0
0
0
0

#VALUE! in
#N/A in
#N/A in

5
0
0

BSTR
CSTR1
CSTR2
DSTR

RMIN
LSDPTH
LRDPTH

OVRIDE

<+A1>
<+B1>
<+C1>
<+D1>
EM STAMPING COST MODEL : MATERIAL DATA
Materials Systems Laboratory
---------------------------------------------------------- ------------------------- --------------- -------------------Target Material From BIW Model Sheet
1 Revised: 2-27-94

MATERIAL RELATED INFORMATION

Material (1=aluminum;0=steel)
Density
Modulus, E
Initial yield strength
Strain hardening exponent, n
Strain rate hardening exponent, m
Uniform elongation, Eu
Total elongation, Etot
Reduction in area
Anisotropy, r
Poission's ratio
Stiffness (Oil canning resistance)
Dent resistance
Buckling resistance
Dom. req. (1=stiff;2=dent;3=buck)
Piece metal gauge
Price/lb
Scrap price/lb

0
0.2850 lbs/in
29,007,600.00 lbs/in
24,681.16 lbs/in
0.21
0.0330
25.00%
43.00%
50.00%
1.57
0.26
22,706.8400 lbs
0.0164 lbs
56.7800 ft-lbs
1
0.0280 in
0.3300 $/lb
0.0500 $/lb

CALCULATED VALUES
Stiffness (Oil canning resistance)
Dent resistance
Buckling resistance

<END>

22,706.8400 lbs
0.0164 lbs
56.7800 ft-lbs

MAT
DEN
MOD
YSTREN
STRNHD
STRNRTHD
UELONG
TELONG
REDAREA
ANISOTR
PRATIO
STIFF
DENTRES
BUCKRES
DOMREQ
PTHK
PRICE
SCRPRICE

TANDEM STA

<END> <+F1>
<+G1>
<+H1>
<+I1>
TANDEM STAMPING COST MODEL : DESIGN DATA
Materials Systems Laboratory
--------------- ---------------------------------------------------------- --------------- --------------- --------------------

PIECE DESIGN RELATED INFORMATION

Part name
1 Class A finish? (1=Y;0=N)
0.0975 Maximum piece length
10,152,660 Maximum piece width
30,275.36 Surface area
0.25 Projected surface area
-0.0060 Number of parts per hit
20.00% Piece weight
25.00% Input metal stock weight
10.00% Input metal stock surface area
0.6 Stretch limited piece?(1=Y;0=N)
0.32 Flanged stretch piece?(1=Y;0=N)
No. of re-entrant flanged sides
Number of stretch strikes
Draw limited piece? (1=Y;0=N) (NA)
Flanged draw piece? (1=Y;0=N) (NA)
0.0473 No. of re-entrant flanged sides(NA)
1.8000 Maximum draw depth (NA)
0.3000 Box draw? (1=Y;0=N) (NA)
Box length (NA)
Box width (NA)
Box corner radius (NA)
Draw depth/Box corner radius (NA)
Number of box draw strikes (NA)
Cylindrical draw? (1=Y;0=N) (NA)
Punch diameter (NA)
Draw depth/Punch diameter (NA)
Input metal stock diameter (NA)
Punch diameter/Stock diameter (NA)
Input metal stock thickness (NA)
Stock thickness/Stock diameter (NA)
Poisson regression (NA)
Num. of cylin. draw strikes (1)(NA)
Linear function index (NA)
ZD1 (NA)
ZD2 (NA)
ZD3 (NA)
ZD4 (NA)

roof
1
64.13 in
52.75 in
3382.59 in
2757.72 in
1
26.9722 lbs
32.88 lbs
4119.84 in
1
1
0
2
0
0
0
0 in
0
0 in
0 in
0 in
#N/A
#N/A
0
0 in
#DIV/0!
0 in
#N/A
0 in
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A

NAME
FINISH
MAXLEN
MAXWID
SAREA
PSAREA
CAV
PWGT
INWGT
INAREA
STRETCH
SFLANGE
SREENT
SSTRIKE
DRAW
DFLANGE
DREENT
MAXDPTH
BOX
BWDTH
BLGTH
BRAD
DB
BSTRIKE
CYLIN
PUNDIA
DD
INDIA
DS
INTHK
TD
PREGR
CSTRIKE1
INDEX
ZD1
ZD2
ZD3
ZD4

Probability(D1) (NA)
Probability(D2) (NA)
Probability(D3) (NA)
Probability(D4) (NA)
Probability(D5) (NA)
Ordered logit estimation (NA)
Num. of cylin. draw strikes (2)(NA)

#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A

PD1
PD2
PD3
PD4
PD5
OLOGIT
CSTRIKE2

Number of draw strikes (NA)

#N/A

DSTRIKE

0
0
0
0

BSTR
CSTR1
CSTR2
DSTR

PRECAUTIONS
Minimum flange corner radius
Max. 1st draw for square box (NA)
Max. 1st draw for rect. box (NA)

0.0185 in
#N/A in
#N/A in

RMIN
LSDPTH
LRDPTH

OVERRIDE SPECIFICATIONS
Estimated stretch strikes
Estimated draw strikes (NA)
User override (0=NO OVERRIDE)

<END>

2
0
0

OVRIDE

<END> <+K1>
<+L1>
<+M1>
<+N1>
TANDEM STAMPING COST MODEL
TANDEM STA
Materials Systems Laboratory
--------------- ---------------------------------------------------------- ----------------------- --------------- ------------

OVERRIDE SPECIFICATIONS
Blank Prod. Rate <optional>
Line Prod. Rate <optional>
Blank Cost <optional>
Die Set Cost <optional>
Blank Press Cost <optional>
Line Press Cost <optional>
QC Equipment Cost <optional>

0 strokes/hr BPR
250 strokes/hr LPR
0 $/blank
0 $(000)/set
0 $(000)/set
0 $(000)/set
0 $(000)/line

BLANK
DIEC
BPC
LPC
QCC

EXOGENOUS COST FACTORS

Annual Production Volume
Cumulative Rejection Rate
Effective Production Volume
Product Lifetime
Dedicated Equipment (1=Y;0=N)

150 (000)/yr
1.00%
151,515 /yr
4 yrs
0

NUM
REJ
ENUM
PLIFE
DED

Direct Wages (w/ benefits)

Working Days/Yr
Working Hours/Day
Capital Recovery Rate
Capital Recovery Period
Working Capital Period
Price of Building Space
Building Recovery Life
Price of Electricity

35 $/hr
250
16
12.00%
10 yrs
3 months
75 $/ft
20 yrs
0.08 $/KWh

WAGE
DAYS
HRS
CRR
CRP
WCP
PBLD
BLIFE
ELEC

Fixed Overhead
Auxilary Equipment Cost
Maintenance Cost

35.00%
20.00%
5.00%

OVHD
AUX
MNT

50.00%
0
6 $/gal

DOWN
CUP
LUB

PROCESS RELATED FACTORS

Average Down Time
Blanking Coupled to Line (1=Y;0=N)
Lubricant

Power Requirement Coefficient

Power Requirement Exponent
Building Space Coefficient
Building Space Exponent
Total Space Requirement

12.08 KWh/lb
35.13
21 ft/ton
0.35
3,735.42 ft/line

POW1
POW2
FLR1
FLR2

1
0.00%
0 $/part
2

BLK
BSCR
BSA
BLAB

BLANKING
Blanking Operation (1=Y;0=N)
Blanking Scrap Rate
Process Scrap Allowance
Direct Laborers per Machine
Process Rate Coefficient
Process Rate Exponent
Blanking Rate
Effective Line Rate
Run-Time for One Machine
Number of Parallel Streams
Press Capacity Intercept
Press Capacity Coefficient
Blanking Press Capacity
Press Cost Intercept
Press Cost Coefficient
Power Requirement
Building Space Requirement
Installation Cost

923.01 parts/hr/lb
-0.22
428.04 strokes/hr
428.04 strokes/hr
17.70%
0.18
85.71 tons
11.29 tons/lb
456.93 tons
5.77 $
1.55 $/ton
0.1588 kWh/part
1,179.13 ft/line
20.00%

BRTE1
BRTE2
BRTE
ELRB
BRT
#BL
BPCA1
BPCA2
BCA
BPCO1
BPCO2
BPOW
BSR
BINST

Blank Weight

32.8800 lbs/part

BWGT

Number of Forming Stations

Number of Extra Piercing Stations
Number of Trimming Stations
Number of Idle Stations
Inspection Stations
Trimming Scrap Rate
Process Scrap Allowance
Direct Laborers at Line
Direct Laborers at Inspec.

2
FRM
0
PRC
2
TRM
1
IDLE
1
INS
17.97%
TSCR
0.2954 $/part
TSA
2 men/press LLAB
2 men/station ILAB

STAMPING

Process Rate Coefficient

Process Rate Exponent

923.01 parts/hr/lb LRTE1

-0.22
LRTE2

Press Line Rate

Effective Line Rate
Run-Time for One Machine
Number of Parallel Streams
Press Capacity Intercept
Press Capacity Coefficient
Press Capacity
Power Requirement
Lubricant
Press Cost Intercept
Press Cost Exponent
Installation Cost
Tooling Cost Coefficient
Complexity Contour Exp.
Complexity Deformation Exp.
Multi-Cavity Exp.
Baseline Tool Life
Productive Tool Life
Num. of Tool Sets per Line
Estimated Tool Set Cost
Building Space Requirement

<END>

250 parts/hr
250 parts/hr
30.30%
0.30
85.71 tons
39.52 tons/lb
1,384.97 tons
1.3021 kWh/part
0.0066 gal/part
5.77 $
0.69
20.00%
4,600.00 $
1.39
0.81
0.34
2,500,000 cycles
4.00 yrs
1.00
703,559.57 $
2,556.29 ft/line

LRTE
ELRP
LRT
#PL
LPCA1
LPCA2
PCA
LPOW
GAL
LPCO1
LPCO2
LINST
TC1
TC2
TC3
TC4
CYC
TLIFE
#TOOL
TC0
LSR

<END> <+P1>
<+Q1>
<+R1>
<+S1>
<END>
TANDEM STAMPING COST MODEL : BLANKING
TANDEM STAMPING COST MODEL : PRE
Materials Systems Laboratory
--------------- ------------------------------------------------ --------------- --------------- ------------ --------------per piece
per year percent
VARIABLE COST ELEMENTS
--------------- --------------- -----------Material Cost
$10.96 $1,644,000 94.33%
Labor Cost
$0.17
$24,778 1.42%
Energy Cost
$0.01
$1,925 0.11%
--------------- --------------- -----------Total Variable Cost ===>
$11.14 $1,670,704 95.86%
per piece
per year percent investment
FIXED COST ELEMENTS
--------------- --------------- ------------ --------------Main Machine Cost
$0.09
$13,875 0.80% $783,963
Fixed Overhead Cost
$0.06
$9,289 0.53%
Building Cost
$0.01
$783 0.04%
$88,435
Auxiliary Equipment Cost
$0.02
$2,775 0.16% $156,793
Maintenance Cost
$0.06
$9,108 0.52%
Cost of Capital
$0.24
$36,287 2.08%
--------------- --------------- ------------ --------------Total Fixed Cost ===>
$0.48
$72,117 4.14%
======== ======== =======
Total Fabrication Cost ===>
$11.62 $1,742,821
100%
======== ======== =======

CAPITAL COSTS

<END>

CRP yrs
CRF
$/yr
--------------- --------------- ------------ --------------Equipment
10.00
0.0671
$11,180
Building
20.00
0.0764
$1,196
Working Capital
0.25
0.0569
$23,911
--------------- --------------- ------------ --------------Total ===>
$36,287

<+U1)
<+V1>
<+W1>
<+X1>
<END>
COST MODEL : PRESS LINE OPERATIONS
TANDEM STAMPING COST MOD
Materials Systems Laboratory
-------------------------------------------------- ------------------------- --------------- --------------- --------------per piece
per year
percent
VARIABLE COST ELEMENTS
------------------------- --------------- --------------Material Cost
-$0.26 -$38,777
-3.69%
Labor Cost
$1.41 $212,121
20.20%
Energy Cost
$0.11
$15,783
1.50%
------------------------- --------------- --------------Total Variable Cost ===>
$1.26 $189,126
18.01%
per piece
per year
percent investment
FIXED COST ELEMENTS
------------------------- --------------- --------------- --------------Main Machine Cost
$1.03 $154,314
14.69% $5,092,375
Tooling Cost
$1.23 $184,684
17.59% $738,738
Fixed Overhead Cost
$1.18 $176,819
16.84%
Building Cost
$0.02
$2,905
0.28% $191,722
Auxiliary Equipment Cost
$0.21
$30,863
2.94% $1,018,475
Maintenance Cost
$0.88 $132,430
12.61%
Cost of Capital
$1.19 $178,998
17.05%
------------------------- --------------- --------------- --------------Total Fixed Cost ===>
$5.74 $861,014
81.99%
============== ======== ========
$7.00 $1,050,140
100%
============== ======== ========

CAPITAL COSTS

<END>

CRP yrs
CRF
$/yr
------------------------- --------------- --------------- --------------Equipment
10.00
0.0671
$124,337
Tooling
4.00
0.0609
$45,012
Building
20.00
0.0764
$4,441
Working Capital
0.25
0.0569
$5,208
------------------------- --------------- --------------- --------------Total ===>
$178,998

<+Z1>
<+AA1>
<+AB1>
<+AC1>
<END>
TAMPING COST MODEL : COST SUMMARY
Materials Systems Laboratory
-------------------------------------------------- --------------- --------------- --------------- --------------per piece
per year
percent
VARIABLE COST ELEMENTS
--------------- --------------- --------------Material Cost
$10.70 $1,605,223
57.47%
Labor Cost
$1.58 $236,900
8.48%
Energy Cost
$0.12
$17,708
0.63%
--------------- --------------- --------------Total Variable Cost ===>
$12.40 $1,859,830
66.59%
FIXED COSTS

per piece
per year
percent investment
--------------- --------------- --------------- --------------Main Machine Cost
$1.12 $168,190
6.02% $5,876,337
Tooling Cost
$1.23 $184,684
6.61% $738,738
Fixed Overhead Cost
$1.24 $186,108
6.66%
Building Cost
$0.02
$3,687
0.13% $280,156
Auxiliary Equipment Cost
$0.22
$33,638
1.20% $1,175,267
Maintenance Cost
$0.94 $141,538
5.07%
Cost of Capital
$1.44 $215,286
7.71%
--------------- --------------- --------------- --------------Total Fixed Cost ===>
$6.22 $933,131
33.41%
======== ======== ========
Total Part Cost ===>
$18.62 $2,792,961
100%
======== ======== ========

CAPITAL COSTS

CRP yrs
CRF
$/yr
--------------- --------------- --------------- --------------Equipment
10.00
0.0671
$135,517
Tooling
4.00
0.0609
$45,012
Building
20.00
0.0764
$5,637
Working Capital
0.25
0.0569
$29,120
--------------- --------------- --------------- --------------Total ===>
$215,286

EQUIPMENT REQUIREMENTS

capacity
count
lines
(tons)
/ line investment
--------------- --------------- --------------- --------------Blanking Press
0.18
456.93
1 $138,752
Line Press
0.30 1,384.97
5 $1,543,144
Tooling
1.00
--1 $703,560
QC Equipment
1.00
--1
$35,178
--------------- --------------- --------------- ---------------

Total $2,420,634

<END>

<+A1>
<+B1>
<+C1>
<+D1>
EM STAMPING COST MODEL : MATERIAL DATA
Materials Systems Laboratory
---------------------------------------------------------- ------------------------- --------------- -------------------Target Material From BIW Model Sheet
0 Revised: 2-27-94

MATERIAL RELATED INFORMATION

Material (1=aluminum;0=steel)
Density
Modulus, E
Initial yield strength
Strain hardening exponent, n
Strain rate hardening exponent, m
Uniform elongation, Eu
Total elongation, Etot
Reduction in area
Anisotropy, r
Poission's ratio
Stiffness (Oil canning resistance)
Dent resistance
Buckling resistance
Dom. req. (1=stiff;2=dent;3=buck)
Piece metal gauge
Price/lb
Scrap price/lb

1
0.0975 lbs/in
10,152,660.00 lbs/in
30,275.36 lbs/in
0.25
-0.0060
20.00%
25.00%
10.00%
0.6
0.32
22,706.8400 lbs
0.0164 lbs
56.7800 ft-lbs
1
0.0473 in
1.5000 $/lb
0.3000 $/lb

CALCULATED VALUES
Stiffness (Oil canning resistance)
Dent resistance
Buckling resistance

<END>

22,706.8400 lbs
0.2019 lbs
99.6968 ft-lbs

MAT
DEN
MOD
YSTREN
STRNHD
STRNRTHD
UELONG
TELONG
REDAREA
ANISOTR
PRATIO
STIFF
DENTRES
BUCKRES
DOMREQ
PTHK
PRICE
SCRPRICE

TANDEM STA

<END> <+F1>
<+G1>
<+H1>
<+I1>
TANDEM STAMPING COST MODEL : DESIGN DATA
Materials Systems Laboratory
--------------- ---------------------------------------------------------- --------------- --------------- --------------------

PIECE DESIGN RELATED INFORMATION

Part name
1 Class A finish? (1=Y;0=N)
0.0975 Maximum piece length
10,152,660 Maximum piece width
30,275.36 Surface area
0.25 Projected surface area
-0.0060 Number of parts per hit
20.00% Piece weight
25.00% Input metal stock weight
10.00% Input metal stock surface area
0.6 Stretch limited piece?(1=Y;0=N)(NA)
0.32 Flanged stretch piece?(1=Y;0=N)(NA)
No. of re-entrant flanged sides(NA)
Number of stretch strikes (NA)
Draw limited piece? (1=Y;0=N)
Flanged draw piece? (1=Y;0=N)
0.0799 No. of re-entrant flanged sides
1.8000 Maximum draw depth
0.3000 Box draw? (1=Y;0=N) (NA)
Box length (NA)
Box width (NA)
Box corner radius (NA)
Draw depth/Box corner radius (NA)
Number of box draw strikes (NA)
Cylindrical draw? (1=Y;0=N)
Punch diameter
Draw depth/Punch diameter
Input metal stock diameter
Punch diameter/Stock diameter
Input metal stock thickness
Stock thickness/Stock diameter
Poisson regression
Num. of cylin. draw strikes (1)
Linear function index
ZD1
ZD2
ZD3
ZD4

REAR
0
83.72 in
54.41 in
4555.56 in
3856.51 in
1
21.0056 lbs
31.05 lbs
4119.84 in
0
0
0
#N/A
1
1
2
6.78 in
0
0 in
0 in
0 in
#N/A
#N/A
1
28.66 in
0.2365
54.41 in
0.5266
0.05 in
0.0009
2.0090
2
57.2176
1.4323E-11
1.0353E-14
1.0969E-16
7.1492E-19

NAME
FINISH
MAXLEN
MAXWID
SAREA
PSAREA
CAV
PWGT
INWGT
INAREA
STRETCH
SFLANGE
SREENT
SSTRIKE
DRAW
DFLANGE
DREENT
MAXDPTH
BOX
BWDTH
BLGTH
BRAD
DB
BSTRIKE
CYLIN
PUNDIA
DD
INDIA
DS
INTHK
TD
PREGR
CSTRIKE1
INDEX
ZD1
ZD2
ZD3
ZD4

Probability(D1)
Probability(D2)
Probability(D3)
Probability(D4)
Probability(D5)
Ordered logit estimation
Num. of cylin. draw strikes (2)
Number of draw strikes

1.0000
0.0000
0.0000
0.0000
0.0000
1
2

PD1
PD2
PD3
PD4
PD5
OLOGIT
CSTRIKE2

DSTRIKE

0
4
4
4

BSTR
CSTR1
CSTR2
DSTR

PRECAUTIONS
Minimum flange corner radius
Max. 1st draw for square box (NA)
Max. 1st draw for rect. box (NA)

0.1892 in
#N/A in
#N/A in

RMIN
LSDPTH
LRDPTH

#N/A
4
0

OVRIDE

OVERRIDE SPECIFICATIONS
Estimated stretch strikes (NA)
Estimated draw strikes
User override (0=NO OVERRIDE)

<END>

<END> <+K1>
<+L1>
<+M1>
<+N1>
TANDEM STAMPING COST MODEL
TANDEM STA
Materials Systems Laboratory
--------------- ---------------------------------------------------------- ----------------------- --------------- ------------

OVERRIDE SPECIFICATIONS
Blank Prod. Rate <optional>
Line Prod. Rate <optional>
Blank Cost <optional>
Die Set Cost <optional>
Blank Press Cost <optional>
Line Press Cost <optional>
QC Equipment Cost <optional>

0 strokes/hr BPR
250 strokes/hr LPR
0 $/blank
0 $(000)/set
0 $(000)/set
0 $(000)/set
0 $(000)/line

BLANK
DIEC
BPC
LPC
QCC

EXOGENOUS COST FACTORS

Annual Production Volume
Cumulative Rejection Rate
Effective Production Volume
Product Lifetime
Dedicated Equipment (1=Y;0=N)

150 (000)/yr
1.00%
151,515 /yr
4 yrs
0

NUM
REJ
ENUM
PLIFE
DED

Direct Wages (w/ benefits)

Working Days/Yr
Working Hours/Day
Capital Recovery Rate
Capital Recovery Period
Working Capital Period
Price of Building Space
Building Recovery Life
Price of Electricity

35 $/hr
250
16
12.00%
10 yrs
3 months
75 $/ft
20 yrs
0.08 $/KWh

WAGE
DAYS
HRS
CRR
CRP
WCP
PBLD
BLIFE
ELEC

Fixed Overhead
Auxilary Equipment Cost
Maintenance Cost

35.00%
20.00%
15.00%

OVHD
AUX
MNT

50.00%
0
6 $/gal

DOWN
CUP
LUB

PROCESS RELATED FACTORS

Average Down Time
Blanking Coupled to Line (1=Y;0=N)
Lubricant

Power Requirement Coefficient

Power Requirement Exponent
Building Space Coefficient
Building Space Exponent
Total Space Requirement

12.08 KWh/lb
35.13
21 ft/ton
0.35
4,749.55 ft/line

POW1
POW2
FLR1
FLR2

1
0.00%
0 $/part
2

BLK
BSCR
BSA
BLAB

BLANKING
Blanking Operation (1=Y;0=N)
Blanking Scrap Rate
Process Scrap Allowance
Direct Laborers per Machine
Process Rate Coefficient
Process Rate Exponent
Blanking Rate
Effective Line Rate
Run-Time for One Machine
Number of Parallel Streams
Press Capacity Intercept
Press Capacity Coefficient
Blanking Press Capacity
Press Cost Intercept
Press Cost Coefficient
Power Requirement
Building Space Requirement
Installation Cost

923.01 parts/hr/lb
-0.22
433.46 strokes/hr
433.46 strokes/hr
17.48%
0.17
85.71 tons
11.29 tons/lb
436.27 tons
5.77 $
1.55 $/ton
0.1556 kWh/part
1,176.25 ft/line
20.00%

BRTE1
BRTE2
BRTE
ELRB
BRT
#BL
BPCA1
BPCA2
BCA
BPCO1
BPCO2
BPOW
BSR
BINST

Blank Weight

31.0500 lbs/part

BWGT

Number of Forming Stations

Number of Extra Piercing Stations
Number of Trimming Stations
Number of Idle Stations
Inspection Stations
Trimming Scrap Rate
Process Scrap Allowance
Direct Laborers at Line
Direct Laborers at Inspec.

4
FRM
0
PRC
4
TRM
1
IDLE
1
INS
32.35%
TSCR
3.0133 $/part
TSA
2 men/press LLAB
2 men/station ILAB

STAMPING

Process Rate Coefficient

Process Rate Exponent

923.01 parts/hr/lb LRTE1

-0.22
LRTE2

Press Line Rate

Effective Line Rate
Run-Time for One Machine
Number of Parallel Streams
Press Capacity Intercept
Press Capacity Coefficient
Press Capacity
Power Requirement
Lubricant
Press Cost Intercept
Press Cost Exponent
Installation Cost
Tooling Cost Coefficient
Complexity Contour Exp.
Complexity Deformation Exp.
Multi-Cavity Exp.
Baseline Tool Life
Productive Tool Life
Num. of Tool Sets per Line
Estimated Tool Set Cost
Building Space Requirement

<END>

250 parts/hr
250 parts/hr
30.30%
0.30
85.71 tons
39.52 tons/lb
1,312.66 tons
2.3897 kWh/part
0.0132 gal/part
5.77 $
0.69
20.00%
4,600.00 $
1.39
0.81
0.34
2,500,000 cycles
4.00 yrs
1.00
2,829,433.34 $
3,573.30 ft/line

LRTE
ELRP
LRT
#PL
LPCA1
LPCA2
PCA
LPOW
GAL
LPCO1
LPCO2
LINST
TC1
TC2
TC3
TC4
CYC
TLIFE
#TOOL
TC0
LSR

<END> <+P1>
<+Q1>
<+R1>
<+S1>
<END>
TANDEM STAMPING COST MODEL : BLANKING
TANDEM STAMPING COST MODEL : PRE
Materials Systems Laboratory
--------------- ------------------------------------------------ --------------- --------------- ------------ --------------per piece
per year percent
VARIABLE COST ELEMENTS
--------------- --------------- -----------Material Cost
$47.05 $7,056,818 97.28%
Labor Cost
$0.16
$24,468 0.34%
Energy Cost
$0.01
$1,885 0.03%
--------------- --------------- -----------Total Variable Cost ===>
$47.22 $7,083,172 97.65%
per piece
per year percent investment
FIXED COST ELEMENTS
--------------- --------------- ------------ --------------Main Machine Cost
$0.09
$13,270 0.18% $759,255
Fixed Overhead Cost
$0.10
$15,012 0.21%
Building Cost
$0.01
$771 0.01%
$88,219
Auxiliary Equipment Cost
$0.02
$2,654 0.04% $151,851
Maintenance Cost
$0.17
$26,198 0.36%
Cost of Capital
$0.75 $112,899 1.56%
--------------- --------------- ------------ --------------Total Fixed Cost ===>
$1.14 $170,804 2.35%
======== ======== =======
Total Fabrication Cost ===>
$48.36 $7,253,976
100%
======== ======== =======

CAPITAL COSTS

<END>

CRP yrs
CRF
$/yr
--------------- --------------- ------------ --------------Equipment
10.00
0.0671
$10,692
Building
20.00
0.0764
$1,179
Working Capital
0.25
0.0569
$101,028
--------------- --------------- ------------ --------------Total ===>
$112,899

<+U1)
<+V1>
<+W1>
<+X1>
<END>
COST MODEL : PRESS LINE OPERATIONS
TANDEM STAMPING COST MOD
Materials Systems Laboratory
-------------------------------------------------- ------------------------- --------------- --------------- --------------per piece
per year
percent
VARIABLE COST ELEMENTS
------------------------- --------------- --------------Material Cost
-$2.96 -$444,608
-14.39%
Labor Cost
$2.55 $381,818
12.36%
Energy Cost
$0.19
$28,966
0.94%
------------------------- --------------- --------------Total Variable Cost ===>
-$0.23 -$33,824
-1.10%
per piece
per year
percent investment
FIXED COST ELEMENTS
------------------------- --------------- --------------- --------------Main Machine Cost
$1.78 $267,676
8.67% $8,833,310
Tooling Cost
$4.95 $742,726
24.04% $2,970,905
Fixed Overhead Cost
$4.68 $702,671
22.75%
Building Cost
$0.03
$4,061
0.13% $267,997
Auxiliary Equipment Cost
$0.36
$53,535
1.73% $1,766,662
Maintenance Cost
$6.26 $939,634
30.42%
Cost of Capital
$2.75 $412,424
13.35%
------------------------- --------------- --------------- --------------Total Fixed Cost ===>
$20.82 $3,122,728 101.10%
============== ======== ========
$20.59 $3,088,904
100%
============== ======== ========

CAPITAL COSTS

<END>

CRP yrs
CRF
$/yr
------------------------- --------------- --------------- --------------Equipment
10.00
0.0671
$215,677
Tooling
4.00
0.0609
$181,020
Building
20.00
0.0764
$6,207
Working Capital
0.25
0.0569
$9,520
------------------------- --------------- --------------- --------------Total ===>
$412,424

<+Z1>
<+AA1>
<+AB1>
<+AC1>
<END>
TAMPING COST MODEL : COST SUMMARY
Materials Systems Laboratory
-------------------------------------------------- --------------- --------------- --------------- --------------per piece
per year
percent
VARIABLE COST ELEMENTS
--------------- --------------- --------------Material Cost
$44.08 $6,612,210
63.93%
Labor Cost
$2.71 $406,286
3.93%
Energy Cost
$0.21
$30,851
0.30%
--------------- --------------- --------------Total Variable Cost ===>
$47.00 $7,049,348
68.16%
FIXED COSTS

per piece
per year
percent investment
--------------- --------------- --------------- --------------Main Machine Cost
$1.87 $280,946
2.72% $9,592,565
Tooling Cost
$4.95 $742,726
7.18% $2,970,905
Fixed Overhead Cost
$4.78 $717,684
6.94%
Building Cost
$0.03
$4,831
0.05% $356,216
Auxiliary Equipment Cost
$0.37
$56,189
0.54% $1,918,513
Maintenance Cost
$6.44 $965,833
9.34%
Cost of Capital
$3.50 $525,323
5.08%
--------------- --------------- --------------- --------------Total Fixed Cost ===>
$21.96 $3,293,532
31.84%
======== ======== ========
Total Part Cost ===>
$68.95
###
100%
======== ======== ========

CAPITAL COSTS

CRP yrs
CRF
$/yr
--------------- --------------- --------------- --------------Equipment
10.00
0.0671
$226,369
Tooling
4.00
0.0609
$181,020
Building
20.00
0.0764
$7,386
Working Capital
0.25
0.0569
$110,548
--------------- --------------- --------------- --------------Total ===>
$525,323

EQUIPMENT REQUIREMENTS

capacity
count
lines
(tons)
/ line investment
--------------- --------------- --------------- --------------Blanking Press
0.17
436.27
1 $132,697
Line Press
0.30 1,312.66
9 $2,676,761
Tooling
1.00
--1 $2,829,433
QC Equipment
1.00
--1 $141,472
--------------- --------------- --------------- ---------------

Total $5,780,362

<END>

<+A1>
<+B1>
<+C1>
<+D1>
EM STAMPING COST MODEL : MATERIAL DATA
Materials Systems Laboratory
---------------------------------------------------------- ------------------------- --------------- -------------------Target Material From BIW Model Sheet
1 Revised: 2-27-94

MATERIAL RELATED INFORMATION

Material (1=aluminum;0=steel)
Density
Modulus, E
Initial yield strength
Strain hardening exponent, n
Strain rate hardening exponent, m
Uniform elongation, Eu
Total elongation, Etot
Reduction in area
Anisotropy, r
Poission's ratio
Stiffness (Oil canning resistance)
Dent resistance
Buckling resistance
Dom. req. (1=stiff;2=dent;3=buck)
Piece metal gauge
Price/lb
Scrap price/lb

0
0.2850 lbs/in
29,007,600.00 lbs/in
24,681.16 lbs/in
0.21
0.0330
25.00%
43.00%
50.00%
1.57
0.26
22,706.8400 lbs
0.0164 lbs
56.7800 ft-lbs
1
0.0280 in
0.3300 $/lb
0.0500 $/lb

CALCULATED VALUES
Stiffness (Oil canning resistance)
Dent resistance
Buckling resistance

<END>

22,706.8400 lbs
0.0164 lbs
56.7800 ft-lbs

MAT
DEN
MOD
YSTREN
STRNHD
STRNRTHD
UELONG
TELONG
REDAREA
ANISOTR
PRATIO
STIFF
DENTRES
BUCKRES
DOMREQ
PTHK
PRICE
SCRPRICE

TANDEM STA

<END> <+F1>
<+G1>
<+H1>
<+I1>
TANDEM STAMPING COST MODEL : DESIGN DATA
Materials Systems Laboratory
--------------- ---------------------------------------------------------- --------------- --------------- --------------------

PIECE DESIGN RELATED INFORMATION

Part name
1 Class A finish? (1=Y;0=N)
0.0975 Maximum piece length
10,152,660 Maximum piece width
30,275.36 Surface area
0.25 Projected surface area
-0.0060 Number of parts per hit
20.00% Piece weight
25.00% Input metal stock weight
10.00% Input metal stock surface area
0.6 Stretch limited piece?(1=Y;0=N)
0.32 Flanged stretch piece?(1=Y;0=N)
No. of re-entrant flanged sides
Number of stretch strikes
Draw limited piece? (1=Y;0=N) (NA)
Flanged draw piece? (1=Y;0=N) (NA)
0.0473 No. of re-entrant flanged sides(NA)
1.8000 Maximum draw depth (NA)
0.3000 Box draw? (1=Y;0=N) (NA)
Box length (NA)
Box width (NA)
Box corner radius (NA)
Draw depth/Box corner radius (NA)
Number of box draw strikes (NA)
Cylindrical draw? (1=Y;0=N) (NA)
Punch diameter (NA)
Draw depth/Punch diameter (NA)
Input metal stock diameter (NA)
Punch diameter/Stock diameter (NA)
Input metal stock thickness (NA)
Stock thickness/Stock diameter (NA)
Poisson regression (NA)
Num. of cylin. draw strikes (1)(NA)
Linear function index (NA)
ZD1 (NA)
ZD2 (NA)
ZD3 (NA)
ZD4 (NA)

OUTER
1
91.37 in
52.1 in
1561.97 in
1138.95 in
1
12.4549 lbs
36.8 lbs
4165.25 in
1
1
4
6
0
0
0
0 in
0
0 in
0 in
0 in
#N/A
#N/A
0
0 in
#DIV/0!
0 in
#N/A
0 in
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A

NAME
FINISH
MAXLEN
MAXWID
SAREA
PSAREA
CAV
PWGT
INWGT
INAREA
STRETCH
SFLANGE
SREENT
SSTRIKE
DRAW
DFLANGE
DREENT
MAXDPTH
BOX
BWDTH
BLGTH
BRAD
DB
BSTRIKE
CYLIN
PUNDIA
DD
INDIA
DS
INTHK
TD
PREGR
CSTRIKE1
INDEX
ZD1
ZD2
ZD3
ZD4

Probability(D1) (NA)
Probability(D2) (NA)
Probability(D3) (NA)
Probability(D4) (NA)
Probability(D5) (NA)
Ordered logit estimation (NA)
Num. of cylin. draw strikes (2)(NA)

#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A

PD1
PD2
PD3
PD4
PD5
OLOGIT
CSTRIKE2

Number of draw strikes (NA)

#N/A

DSTRIKE

0
0
0
0

BSTR
CSTR1
CSTR2
DSTR

PRECAUTIONS
Minimum flange corner radius
Max. 1st draw for square box (NA)
Max. 1st draw for rect. box (NA)

0.0185 in
#N/A in
#N/A in

RMIN
LSDPTH
LRDPTH

OVERRIDE SPECIFICATIONS
Estimated stretch strikes
Estimated draw strikes (NA)
User override (0=NO OVERRIDE)

<END>

6
0
0

OVRIDE

<END> <+K1>
<+L1>
<+M1>
<+N1>
TANDEM STAMPING COST MODEL
TANDEM STA
Materials Systems Laboratory
--------------- ---------------------------------------------------------- ----------------------- --------------- ------------

OVERRIDE SPECIFICATIONS
Blank Prod. Rate <optional>
Line Prod. Rate <optional>
Blank Cost <optional>
Die Set Cost <optional>
Blank Press Cost <optional>
Line Press Cost <optional>
QC Equipment Cost <optional>

0 strokes/hr BPR
250 strokes/hr LPR
0 $/blank
0 $(000)/set
0 $(000)/set
0 $(000)/set
0 $(000)/line

BLANK
DIEC
BPC
LPC
QCC

EXOGENOUS COST FACTORS

Annual Production Volume
Cumulative Rejection Rate
Effective Production Volume
Product Lifetime
Dedicated Equipment (1=Y;0=N)

150 (000)/yr
1.00%
151,515 /yr
4 yrs
0

NUM
REJ
ENUM
PLIFE
DED

Direct Wages (w/ benefits)

Working Days/Yr
Working Hours/Day
Capital Recovery Rate
Capital Recovery Period
Working Capital Period
Price of Building Space
Building Recovery Life
Price of Electricity

35 $/hr
250
16
12.00%
10 yrs
3 months
75 $/ft
20 yrs
0.08 $/KWh

WAGE
DAYS
HRS
CRR
CRP
WCP
PBLD
BLIFE
ELEC

Fixed Overhead
Auxilary Equipment Cost
Maintenance Cost

35.00%
20.00%
10.00%

OVHD
AUX
MNT

50.00%
0
6 $/gal

DOWN
CUP
LUB

PROCESS RELATED FACTORS

Average Down Time
Blanking Coupled to Line (1=Y;0=N)
Lubricant

Power Requirement Coefficient

Power Requirement Exponent
Building Space Coefficient
Building Space Exponent
Total Space Requirement

12.08 KWh/lb
35.13
21 ft/ton
0.35
5,973.68 ft/line

POW1
POW2
FLR1
FLR2

1
0.00%
0 $/part
2

BLK
BSCR
BSA
BLAB

BLANKING
Blanking Operation (1=Y;0=N)
Blanking Scrap Rate
Process Scrap Allowance
Direct Laborers per Machine
Process Rate Coefficient
Process Rate Exponent
Blanking Rate
Effective Line Rate
Run-Time for One Machine
Number of Parallel Streams
Press Capacity Intercept
Press Capacity Coefficient
Blanking Press Capacity
Press Cost Intercept
Press Cost Coefficient
Power Requirement
Building Space Requirement
Installation Cost

923.01 parts/hr/lb
-0.22
417.56 strokes/hr
417.56 strokes/hr
18.14%
0.18
85.71 tons
11.29 tons/lb
501.19 tons
5.77 $
1.55 $/ton
0.1655 kWh/part
1,185.02 ft/line
20.00%

BRTE1
BRTE2
BRTE
ELRB
BRT
#BL
BPCA1
BPCA2
BCA
BPCO1
BPCO2
BPOW
BSR
BINST

Blank Weight

36.8000 lbs/part

BWGT

Number of Forming Stations

Number of Extra Piercing Stations
Number of Trimming Stations
Number of Idle Stations
Inspection Stations
Trimming Scrap Rate
Process Scrap Allowance
Direct Laborers at Line
Direct Laborers at Inspec.

6
FRM
0
PRC
6
TRM
1
IDLE
1
INS
66.16%
TSCR
1.2173 $/part
TSA
2 men/press LLAB
2 men/station ILAB

STAMPING

Process Rate Coefficient

Process Rate Exponent

923.01 parts/hr/lb LRTE1

-0.22
LRTE2

Press Line Rate

Effective Line Rate
Run-Time for One Machine
Number of Parallel Streams
Press Capacity Intercept
Press Capacity Coefficient
Press Capacity
Power Requirement
Lubricant
Press Cost Intercept
Press Cost Exponent
Installation Cost
Tooling Cost Coefficient
Complexity Contour Exp.
Complexity Deformation Exp.
Multi-Cavity Exp.
Baseline Tool Life
Productive Tool Life
Num. of Tool Sets per Line
Estimated Tool Set Cost
Building Space Requirement

<END>

250 parts/hr
250 parts/hr
30.30%
0.30
85.71 tons
39.52 tons/lb
1,539.87 tons
3.9677 kWh/part
0.0197 gal/part
5.77 $
0.69
20.00%
4,600.00 $
1.39
0.81
0.34
2,500,000 cycles
4.00 yrs
1.00
11,127,269.65 $
4,788.66 ft/line

LRTE
ELRP
LRT
#PL
LPCA1
LPCA2
PCA
LPOW
GAL
LPCO1
LPCO2
LINST
TC1
TC2
TC3
TC4
CYC
TLIFE
#TOOL
TC0
LSR

<END> <+P1>
<+Q1>
<+R1>
<+S1>
<END>
TANDEM STAMPING COST MODEL : BLANKING
TANDEM STAMPING COST MODEL : PRE
Materials Systems Laboratory
--------------- ------------------------------------------------ --------------- --------------- ------------ --------------per piece
per year percent
VARIABLE COST ELEMENTS
--------------- --------------- -----------Material Cost
$12.27 $1,840,000 93.86%
Labor Cost
$0.17
$25,400 1.30%
Energy Cost
$0.01
$2,006 0.10%
--------------- --------------- -----------Total Variable Cost ===>
$12.45 $1,867,406 95.26%
per piece
per year percent investment
FIXED COST ELEMENTS
--------------- --------------- ------------ --------------Main Machine Cost
$0.10
$15,233 0.78% $839,628
Fixed Overhead Cost
$0.09
$13,642 0.70%
Building Cost
$0.01
$806 0.04%
$88,877
Auxiliary Equipment Cost
$0.02
$3,047 0.16% $167,926
Maintenance Cost
$0.13
$19,892 1.01%
Cost of Capital
$0.27
$40,279 2.05%
--------------- --------------- ------------ --------------Total Fixed Cost ===>
$0.62
$92,900 4.74%
======== ======== =======
Total Fabrication Cost ===>
$13.07 $1,960,306
100%
======== ======== =======

CAPITAL COSTS

<END>

CRP yrs
CRF
$/yr
--------------- --------------- ------------ --------------Equipment
10.00
0.0671
$12,274
Building
20.00
0.0764
$1,233
Working Capital
0.25
0.0569
$26,773
--------------- --------------- ------------ --------------Total ===>
$40,279

<+U1)
<+V1>
<+W1>
<+X1>
<END>
COST MODEL : PRESS LINE OPERATIONS
TANDEM STAMPING COST MOD
Materials Systems Laboratory
-------------------------------------------------- ------------------------- --------------- --------------- --------------per piece
per year
percent
VARIABLE COST ELEMENTS
------------------------- --------------- --------------Material Cost
-$1.11 -$166,498
-1.96%
Labor Cost
$3.68 $551,515
6.51%
Energy Cost
$0.32
$48,093
0.57%
------------------------- --------------- --------------Total Variable Cost ===>
$2.89 $433,111
5.11%
per piece
per year
percent investment
FIXED COST ELEMENTS
------------------------- --------------- --------------- --------------Main Machine Cost
$2.88 $431,668
5.09%
###
Tooling Cost
$19.47 $2,920,908
34.47%
###
Fixed Overhead Cost
$12.00 $1,799,560
21.24%
Building Cost
$0.04
$5,442
0.06% $359,150
Auxiliary Equipment Cost
$0.58
$86,334
1.02% $2,849,008
Maintenance Cost
$11.31 $1,697,248
20.03%
Cost of Capital
$7.33 $1,099,802
12.98%
------------------------- --------------- --------------- --------------Total Fixed Cost ===>
$53.61 $8,040,961
94.89%
============== ======== ========
$56.49 $8,474,072
100%
============== ======== ========

CAPITAL COSTS

<END>

CRP yrs
CRF
$/yr
------------------------- --------------- --------------- --------------Equipment
10.00
0.0671
$347,811
Tooling
4.00
0.0609
$711,894
Building
20.00
0.0764
$8,319
Working Capital
0.25
0.0569
$31,778
------------------------- --------------- --------------- --------------Total ===>
$1,099,802

<+Z1>
<+AA1>
<+AB1>
<+AC1>
<END>
TAMPING COST MODEL : COST SUMMARY
Materials Systems Laboratory
-------------------------------------------------- --------------- --------------- --------------- --------------per piece
per year
percent
VARIABLE COST ELEMENTS
--------------- --------------- --------------Material Cost
$11.16 $1,673,502
16.04%
Labor Cost
$3.85 $576,915
5.53%
Energy Cost
$0.33
$50,099
0.48%
--------------- --------------- --------------Total Variable Cost ===>
$15.34 $2,300,516
22.05%
FIXED COSTS

per piece
per year
percent investment
--------------- --------------- --------------- --------------Main Machine Cost
$2.98 $446,901
4.28%
###
Tooling Cost
$19.47 $2,920,908
27.99%
###
Fixed Overhead Cost
$12.09 $1,813,202
17.38%
Building Cost
$0.04
$6,248
0.06% $448,026
Auxiliary Equipment Cost
$0.60
$89,380
0.86% $3,016,934
Maintenance Cost
$11.45 $1,717,141
16.46%
Cost of Capital
$7.60 $1,140,081
10.93%
--------------- --------------- --------------- --------------Total Fixed Cost ===>
$54.23 $8,133,862
77.95%
======== ======== ========
Total Part Cost ===>
$69.56
###
100%
======== ======== ========

CAPITAL COSTS

CRP yrs
CRF
$/yr
--------------- --------------- --------------- --------------Equipment
10.00
0.0671
$360,085
Tooling
4.00
0.0609
$711,894
Building
20.00
0.0764
$9,551
Working Capital
0.25
0.0569
$58,550
--------------- --------------- --------------- --------------Total ===>
$1,140,081

EQUIPMENT REQUIREMENTS

capacity
count
lines
(tons)
/ line investment
--------------- --------------- --------------- --------------Blanking Press
0.18
501.19
1 $152,333
Line Press
0.30 1,539.87
13 $4,316,679
Tooling
1.00
--1
###
QC Equipment
1.00
--1 $556,363
--------------- --------------- --------------- ---------------

Total

<END>

###

<+A1>
<+B1>
<+C1>
<+D1>
EM STAMPING COST MODEL : MATERIAL DATA
Materials Systems Laboratory
---------------------------------------------------------- ------------------------- --------------- -------------------Target Material From BIW Model Sheet
1 Revised: 2-27-94

MATERIAL RELATED INFORMATION

Material (1=aluminum;0=steel)
Density
Modulus, E
Initial yield strength
Strain hardening exponent, n
Strain rate hardening exponent, m
Uniform elongation, Eu
Total elongation, Etot
Reduction in area
Anisotropy, r
Poission's ratio
Stiffness (Oil canning resistance)
Dent resistance
Buckling resistance
Dom. req. (1=stiff;2=dent;3=buck)
Piece metal gauge
Price/lb
Scrap price/lb

0
0.2850 lbs/in
29,007,600.00 lbs/in
24,681.16 lbs/in
0.21
0.0330
25.00%
43.00%
50.00%
1.57
0.26
22,706.8400 lbs
0.0164 lbs
56.7800 ft-lbs
1
0.0280 in
0.3300 $/lb
0.0500 $/lb

CALCULATED VALUES
Stiffness (Oil canning resistance)
Dent resistance
Buckling resistance

<END>

22,706.8400 lbs
0.0164 lbs
56.7800 ft-lbs

MAT
DEN
MOD
YSTREN
STRNHD
STRNRTHD
UELONG
TELONG
REDAREA
ANISOTR
PRATIO
STIFF
DENTRES
BUCKRES
DOMREQ
PTHK
PRICE
SCRPRICE

TANDEM STA

<END> <+F1>
<+G1>
<+H1>
<+I1>
TANDEM STAMPING COST MODEL : DESIGN DATA
Materials Systems Laboratory
--------------- ---------------------------------------------------------- --------------- --------------- --------------------

PIECE DESIGN RELATED INFORMATION

Part name
1 Class A finish? (1=Y;0=N)
0.0975 Maximum piece length
10,152,660 Maximum piece width
30,275.36 Surface area
0.25 Projected surface area
-0.0060 Number of parts per hit
20.00% Piece weight
25.00% Input metal stock weight
10.00% Input metal stock surface area
0.6 Stretch limited piece?(1=Y;0=N)
0.32 Flanged stretch piece?(1=Y;0=N)
No. of re-entrant flanged sides
Number of stretch strikes
Draw limited piece? (1=Y;0=N) (NA)
Flanged draw piece? (1=Y;0=N) (NA)
0.0473 No. of re-entrant flanged sides(NA)
1.8000 Maximum draw depth (NA)
0.3000 Box draw? (1=Y;0=N) (NA)
Box length (NA)
Box width (NA)
Box corner radius (NA)
Draw depth/Box corner radius (NA)
Number of box draw strikes (NA)
Cylindrical draw? (1=Y;0=N) (NA)
Punch diameter (NA)
Draw depth/Punch diameter (NA)
Input metal stock diameter (NA)
Punch diameter/Stock diameter (NA)
Input metal stock thickness (NA)
Stock thickness/Stock diameter (NA)
Poisson regression (NA)
Num. of cylin. draw strikes (1)(NA)
Linear function index (NA)
ZD1 (NA)
ZD2 (NA)
ZD3 (NA)
ZD4 (NA)

INNER
0
63.1 in
63 in
1199.77 in
785.88 in
1
9.5668 lbs
20.85 lbs
2359.93 in
1
1
3
5
0
0
0
0 in
0
0 in
0 in
0 in
#N/A
#N/A
0
0 in
#DIV/0!
0 in
#N/A
0 in
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A

NAME
FINISH
MAXLEN
MAXWID
SAREA
PSAREA
CAV
PWGT
INWGT
INAREA
STRETCH
SFLANGE
SREENT
SSTRIKE
DRAW
DFLANGE
DREENT
MAXDPTH
BOX
BWDTH
BLGTH
BRAD
DB
BSTRIKE
CYLIN
PUNDIA
DD
INDIA
DS
INTHK
TD
PREGR
CSTRIKE1
INDEX
ZD1
ZD2
ZD3
ZD4

Probability(D1) (NA)
Probability(D2) (NA)
Probability(D3) (NA)
Probability(D4) (NA)
Probability(D5) (NA)
Ordered logit estimation (NA)
Num. of cylin. draw strikes (2)(NA)

#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A

PD1
PD2
PD3
PD4
PD5
OLOGIT
CSTRIKE2

Number of draw strikes (NA)

#N/A

DSTRIKE

0
0
0
0

BSTR
CSTR1
CSTR2
DSTR

PRECAUTIONS
Minimum flange corner radius
Max. 1st draw for square box (NA)
Max. 1st draw for rect. box (NA)

0.0185 in
#N/A in
#N/A in

RMIN
LSDPTH
LRDPTH

OVERRIDE SPECIFICATIONS
Estimated stretch strikes
Estimated draw strikes (NA)
User override (0=NO OVERRIDE)

<END>

5
0
0

OVRIDE

<END> <+K1>
<+L1>
<+M1>
<+N1>
TANDEM STAMPING COST MODEL
TANDEM STA
Materials Systems Laboratory
--------------- ---------------------------------------------------------- ----------------------- --------------- ------------

OVERRIDE SPECIFICATIONS
Blank Prod. Rate <optional>
Line Prod. Rate <optional>
Blank Cost <optional>
Die Set Cost <optional>
Blank Press Cost <optional>
Line Press Cost <optional>
QC Equipment Cost <optional>

0 strokes/hr BPR
250 strokes/hr LPR
0 $/blank
0 $(000)/set
0 $(000)/set
0 $(000)/set
0 $(000)/line

BLANK
DIEC
BPC
LPC
QCC

EXOGENOUS COST FACTORS

Annual Production Volume
Cumulative Rejection Rate
Effective Production Volume
Product Lifetime
Dedicated Equipment (1=Y;0=N)

150 (000)/yr
1.00%
151,515 /yr
4 yrs
0

NUM
REJ
ENUM
PLIFE
DED

Direct Wages (w/ benefits)

Working Days/Yr
Working Hours/Day
Capital Recovery Rate
Capital Recovery Period
Working Capital Period
Price of Building Space
Building Recovery Life
Price of Electricity

35 $/hr
250
16
12.00%
10 yrs
3 months
75 $/ft
20 yrs
0.08 $/KWh

WAGE
DAYS
HRS
CRR
CRP
WCP
PBLD
BLIFE
ELEC

Fixed Overhead
Auxilary Equipment Cost
Maintenance Cost

35.00%
20.00%
10.00%

OVHD
AUX
MNT

50.00%
0
6 $/gal

DOWN
CUP
LUB

PROCESS RELATED FACTORS

Average Down Time
Blanking Coupled to Line (1=Y;0=N)
Lubricant

Power Requirement Coefficient

Power Requirement Exponent
Building Space Coefficient
Building Space Exponent
Total Space Requirement

12.08 KWh/lb
35.13
21 ft/ton
0.35
4,937.71 ft/line

POW1
POW2
FLR1
FLR2

1
0.00%
0 $/part
2

BLK
BSCR
BSA
BLAB

BLANKING
Blanking Operation (1=Y;0=N)
Blanking Scrap Rate
Process Scrap Allowance
Direct Laborers per Machine
Process Rate Coefficient
Process Rate Exponent
Blanking Rate
Effective Line Rate
Run-Time for One Machine
Number of Parallel Streams
Press Capacity Intercept
Press Capacity Coefficient
Blanking Press Capacity
Press Cost Intercept
Press Cost Coefficient
Power Requirement
Building Space Requirement
Installation Cost

923.01 parts/hr/lb
-0.22
473.15 strokes/hr
473.15 strokes/hr
16.01%
0.16
85.71 tons
11.29 tons/lb
321.11 tons
5.77 $
1.55 $/ton
0.1347 kWh/part
1,158.32 ft/line
20.00%

BRTE1
BRTE2
BRTE
ELRB
BRT
#BL
BPCA1
BPCA2
BCA
BPCO1
BPCO2
BPOW
BSR
BINST

Blank Weight

20.8500 lbs/part

BWGT

Number of Forming Stations

Number of Extra Piercing Stations
Number of Trimming Stations
Number of Idle Stations
Inspection Stations
Trimming Scrap Rate
Process Scrap Allowance
Direct Laborers at Line
Direct Laborers at Inspec.

5
FRM
0
PRC
5
TRM
1
IDLE
1
INS
54.12%
TSCR
0.5642 $/part
TSA
2 men/press LLAB
2 men/station ILAB

STAMPING

Process Rate Coefficient

Process Rate Exponent

923.01 parts/hr/lb LRTE1

-0.22
LRTE2

Press Line Rate

Effective Line Rate
Run-Time for One Machine
Number of Parallel Streams
Press Capacity Intercept
Press Capacity Coefficient
Press Capacity
Power Requirement
Lubricant
Press Cost Intercept
Press Cost Exponent
Installation Cost
Tooling Cost Coefficient
Complexity Contour Exp.
Complexity Deformation Exp.
Multi-Cavity Exp.
Baseline Tool Life
Productive Tool Life
Num. of Tool Sets per Line
Estimated Tool Set Cost
Building Space Requirement

<END>

250 parts/hr
250 parts/hr
30.30%
0.30
85.71 tons
39.52 tons/lb
909.60 tons
3.0520 kWh/part
0.0164 gal/part
5.77 $
0.69
20.00%
4,600.00 $
1.39
0.81
0.34
2,500,000 cycles
4.00 yrs
1.00
7,376,787.57 $
3,779.38 ft/line

LRTE
ELRP
LRT
#PL
LPCA1
LPCA2
PCA
LPOW
GAL
LPCO1
LPCO2
LINST
TC1
TC2
TC3
TC4
CYC
TLIFE
#TOOL
TC0
LSR

<END> <+P1>
<+Q1>
<+R1>
<+S1>
<END>
TANDEM STAMPING COST MODEL : BLANKING
TANDEM STAMPING COST MODEL : PRE
Materials Systems Laboratory
--------------- ------------------------------------------------ --------------- --------------- ------------ --------------per piece
per year percent
VARIABLE COST ELEMENTS
--------------- --------------- -----------Material Cost
$6.95 $1,042,500 92.51%
Labor Cost
$0.15
$22,416 1.99%
Energy Cost
$0.01
$1,632 0.14%
--------------- --------------- -----------Total Variable Cost ===>
$7.11 $1,066,548 94.65%
per piece
per year percent investment
FIXED COST ELEMENTS
--------------- --------------- ------------ --------------Main Machine Cost
$0.07
$10,169 0.90% $635,138
Fixed Overhead Cost
$0.06
$9,272 0.82%
Building Cost
$0.00
$695 0.06%
$86,874
Auxiliary Equipment Cost
$0.01
$2,034 0.18% $127,028
Maintenance Cost
$0.09
$13,594 1.21%
Cost of Capital
$0.16
$24,569 2.18%
--------------- --------------- ------------ --------------Total Fixed Cost ===>
$0.40
$60,334 5.35%
======== ======== =======
Total Fabrication Cost ===>
$7.51 $1,126,882
100%
======== ======== =======

CAPITAL COSTS

<END>

CRP yrs
CRF
$/yr
--------------- --------------- ------------ --------------Equipment
10.00
0.0671
$8,194
Building
20.00
0.0764
$1,063
Working Capital
0.25
0.0569
$15,312
--------------- --------------- ------------ --------------Total ===>
$24,569

<+U1)
<+V1>
<+W1>
<+X1>
<END>
COST MODEL : PRESS LINE OPERATIONS
TANDEM STAMPING COST MOD
Materials Systems Laboratory
-------------------------------------------------- ------------------------- --------------- --------------- --------------per piece
per year
percent
VARIABLE COST ELEMENTS
------------------------- --------------- --------------Material Cost
-$0.47 -$70,534
-1.25%
Labor Cost
$3.11 $466,667
8.28%
Energy Cost
$0.25
$36,994
0.66%
------------------------- --------------- --------------Total Variable Cost ===>
$2.89 $433,128
7.68%
per piece
per year
percent investment
FIXED COST ELEMENTS
------------------------- --------------- --------------- --------------Main Machine Cost
$1.69 $254,006
4.50% $8,382,185
Tooling Cost
$12.91 $1,936,407
34.34% $7,745,627
Fixed Overhead Cost
$7.78 $1,166,713
20.69%
Building Cost
$0.03
$4,295
0.08% $283,454
Auxiliary Equipment Cost
$0.34
$50,801
0.90% $1,676,437
Maintenance Cost
$7.25 $1,087,959
19.29%
Cost of Capital
$4.71 $705,946
12.52%
------------------------- --------------- --------------- --------------Total Fixed Cost ===>
$34.71 $5,206,126
92.32%
============== ======== ========
$37.60 $5,639,254
100%
============== ======== ========

CAPITAL COSTS

<END>

CRP yrs
CRF
$/yr
------------------------- --------------- --------------- --------------Equipment
10.00
0.0671
$204,662
Tooling
4.00
0.0609
$471,948
Building
20.00
0.0764
$6,565
Working Capital
0.25
0.0569
$22,771
------------------------- --------------- --------------- --------------Total ===>
$705,946

<+Z1>
<+AA1>
<+AB1>
<+AC1>
<END>
TAMPING COST MODEL : COST SUMMARY
Materials Systems Laboratory
-------------------------------------------------- --------------- --------------- --------------- --------------per piece
per year
percent
VARIABLE COST ELEMENTS
--------------- --------------- --------------Material Cost
$6.48 $971,966
14.37%
Labor Cost
$3.26 $489,082
7.23%
Energy Cost
$0.26
$38,627
0.57%
--------------- --------------- --------------Total Variable Cost ===>
$10.00 $1,499,676
22.16%
FIXED COSTS

per piece
per year
percent investment
--------------- --------------- --------------- --------------Main Machine Cost
$1.76 $264,175
3.90% $9,017,323
Tooling Cost
$12.91 $1,936,407
28.62% $7,745,627
Fixed Overhead Cost
$7.84 $1,175,986
17.38%
Building Cost
$0.03
$4,990
0.07% $370,328
Auxiliary Equipment Cost
$0.35
$52,835
0.78% $1,803,465
Maintenance Cost
$7.34 $1,101,553
16.28%
Cost of Capital
$4.87 $730,515
10.80%
--------------- --------------- --------------- --------------Total Fixed Cost ===>
$35.11 $5,266,461
77.84%
======== ======== ========
Total Part Cost ===>
$45.11 $6,766,137
100%
======== ======== ========

CAPITAL COSTS

CRP yrs
CRF
$/yr
--------------- --------------- --------------- --------------Equipment
10.00
0.0671
$212,856
Tooling
4.00
0.0609
$471,948
Building
20.00
0.0764
$7,629
Working Capital
0.25
0.0569
$38,083
--------------- --------------- --------------- --------------Total ===>
$730,515

EQUIPMENT REQUIREMENTS

capacity
count
lines
(tons)
/ line investment
--------------- --------------- --------------- --------------Blanking Press
0.16
321.11
1 $101,693
Line Press
0.30
909.60
11 $2,540,056
Tooling
1.00
--1 $7,376,788
QC Equipment
1.00
--1 $368,839
--------------- --------------- --------------- ---------------

Total

<END>

###

<+A1>============================
======== ======== =======
=======<END> <+F1>============
|
SMC MOLDING MODEL
||
SMC MOLDI
|
Materials Systems Laboratory MIT
| ===
=========================== ======== ======== ======= ========
Model Revision Date: 10/28/93
Input Revision Date:
05/03/93
#
COMPONENT SPECIFICATIONS
----Part Name/Material Type:
ROOF
SMC
0
Formulation Number
1
MAT
(see menu)
1
Weight
19 lbs
WGT
2
Maximum Wall Thickness
0.09 in
THKM (see menu)
3
Total External Surface Area
3380 sq in
SAREA
4
Projected Area
3,073 sq in
PAREA
5
6
Number of Cavities
1
CAV
7
Number of Actions in Tool
0
ACT
8
Backup Mold
0 (1=Y;0=N) BACK
----Molding Cy. Time <optional>
0 sec
CYC
Tool Cost/Set <optional>
$0 ($000/set) MOLD
===
Press Tonnage <optional>
% PART THICKNESS
0 tonsCALCULATION
TONS SUBROUTINE %
Does not take into account reinforcing ribs
EXOGENOUS COST FACTORS
Annual Production Volume
150 (000)/yr
NUM
Target panel stiffness
Product Lifetime
4 yrs
Recommended
PLIFE
panel thickness
Dedicated Equipment
0 (1=Y;0=N) DED
Process Rejection Rate
1.00%
PREJ
----Intermediate "LOOKUP" Data Buffer - For Thickness Calculations
Direct Wages (w/ benefits)
$25 /hr
WAGE
----Working Days/Yr
250
DAYS
Material Density
Working Hours/Day
16
HRS
Material Price
Capital Recovery Rate
10.0%
CRR
Material Modulus
Capital Recovery Period
10 yrs
CRP
Working Capital Period
3 months
WCP
===
Price of Building Space
75 /sq ft
PBLD
Building Recovery Life
20 yrs
BLIFE
Price of Electricity
0.08 /KWh
ELEC
===
% POLICY IMPACTS ESTIMATION SUBROUTINE %
Fixed Overhead
35.00%
OVHD
Auxiliary Equipment Cost find
15.00%
formula relating increasing
AUX
oil price to increase in resin price
Maintenance Cost
4.00%
MNT
PROCESS RELATED FACTORS
Average Downtime
Material Scrap Rate
Molding Cycle Time Intercept

15.00%
DOWN
2.50%
SCR
----Linkages with Improv - For Policy Calculations
50 sec
CYC1
-----

Molding Cycle Time Factor

250 sec/in

CYC2

Machine Cost Coefficient

Machine Cost Scaling Exp.
Direct Laborers Per Machine
Installation Cost

8621
0.65
2
20.00%

MCH1
MCH2
NLAB
INST

Internal Molding Pressure

Press Tonnage Safety Factor

1200 psi
20.00%

PRES1
PRES2

Mold Cost Coefficient

Complexity Deformation Exp.
Complexity Actions Exponent
Weight Factor Exponent
Baseline Physical Mold Life
Electrical Heat
Electrical Mechanical Energy
Floor Space Coefficient
Floor Space Scaling Exponent

48280
1.08
0.4
0.6
1200000 cycles

Oil Tax
Material Price
Material Modulus

MOL1
MOL2
MOL3
MOL4
MOLLI

0.5 kWh/lb
POW1
0.08kW/press ton POW2
251.19 sq ft
0.71

FLR1
FLR2

In-Mold Coating Paramters

Coating in Use
Additional Capital Invest.
Added Cycle Time
Coating Thickness
Sides Coated (1 or 2)
Coating Material Price
Coating Transfer Efficiency

1 (1=Y;0=N)
60000 /press
30 sec
0.01 in
1
20 /gal
95.00%

COAT

Trimming & Drilling Parameters

Process in use
Machine Cost
Toolind & Fixture Cost
Tool Lifetime
Process Rejection Rate
Number of Additional Laborers
Trimming & Drilling Cy. Time
Simulataneous Trimming

1 (1=Y;0=N)
252000
10000
150000 cycles
0.50%
0.5
10 sec
1 parts

CUT
CMACH
CDIE
CDLIFE
TREJ
ADDLAB
CUTIME
SIMTRIM

<END>

===

<END>

<+F1>============
=========== ======== ======== ======== ======== ====<END>
|
SMC MOLDING MODEL: MATERIAL DATABASE
|
=========== =========== ======== ======== ======== ======== ========
Modulus
Price
Density
Grade
Material
(psi)
($/lb)
(lb/in^3)
XCY
XML
-------------------- -------------------- --------------- --------------- --------------- --------------- --------------No Sheet
Gen. Purp
PE/GF 1.20E+06
$0.80
0.063
1.00
1.00
Low Prof-1
LP,PE/GF 1.20E+06
$0.83
0.070
1.50
1.00
Low Prof-2
LP,PE/GF 1.20E+06
$0.82
0.072
1.50
1.00
High Str-1
IPN/GF 1.40E+06
$0.83
0.059
0.90
0.80
High Str-2
VE/GF 1.40E+06
$0.86
0.071
1.00
1.00
Hi Mod CF(30%)/PE 1.80E+06
$12.78
0.070
1.00
1.00

-------------------- -------------------- --------------- --------------- --------------- --------------- --------------=========== =========== ======== ======== ======== ======== ========

account reinforcing ribs

Target panel stiffness

9,700 lbs
0.0899 in

-------------------- -------------------- --------------- --------------- --------------- --------------- ---------------------------------- -------------------- --------------- --------------- --------------- --------------- --------------0.063 lbs/in^3
DENSITY
$0.80 /lb
MAT_$
1.20E+06 psi
MOD
=========== =========== ======== ======== ======== ======== ========

=========== =========== ======== ======== ======== ======== ========

increase in resin price

-------------------- -------------------- --------------- --------------- --------------- --------------- ---------------------------------- -------------------- --------------- --------------- --------------- --------------- ---------------

$0.25/gallon
#N/A /lb
#N/A psi

MAT_$
MOD

=========== =========== ======== ======== ======== ======== ========

<END>

<+N1>--------------------------------------------------------------- --------------- ------------------------<END>

|
SMC MOLDING & COATING: COST ESTIMATE
|
------------------------------------------------ --------------- --------------- ------------ --------------Cumulative Piece Cost
$26.46
ROOF
$/piece
$/year
percent
VARIABLE COST ELEMENTS
--------------- --------------- -----------Material Cost
$17.39 $2,608,491 65.7%
Direct Labor Cost
$1.70 $255,038
6.4%
Energy Cost
$1.17 $175,891
4.4%
--------------- --------------- -----------TOTAL VARIABLE COST ===>
$20.26 $3,039,420 76.6%
investment
$/piece
$/year
percent
per line
FIXED COST ELEMENTS
--------------- --------------- ------------ --------------Equipment Cost
$1.37 $206,184
5.2% $1,616,883
Tooling Cost
$1.04 $156,565
3.9% $313,129
Fixed Overhead Cost
$1.24 $185,871
4.7%
Building Cost
$0.06
$9,717
0.2% $152,397
Auxiliary Equipment Cost
$0.21
$30,928
0.8% $242,532
Maintenance Cost
$0.85 $127,668
3.2%
Cost of Capital
$1.42 $213,032
5.4%
--------------- --------------- ------------ --------------TOTAL FIXED COST ===>
$6.20 $929,964 23.4%

TOTAL OPERATION COST ===>

======== ======== =======

$26.46 $3,969,384 100.0%
======== ======== =======

------------------------------------------------ --------------- --------------ADDITIONAL INFORMATION

------------------------------------------------ --------------- --------------Sheet Price
$0.80 /lb
Material Scrap Rate
2.5%
Cumulative Rejection Rate
1.5%
Effective Production Volume
152,277 /yr
Press Tonnage
2,212 tons
Press Cycle Time
102.5 sec
Run-Time for One Machine
127.5%
Number of Parallel Streams
1.28
Productive Mold Life
4.00 yrs
# of Molds (not incl backup)
1 /line
Mold Cost $313,129 /mold
In-Mold Coating Use
0.077 gal/pc
Building Space Requirement
2,032 sq ft/line
Approximate Machine Rent
$281.99 /hr

------------ -------------------------- --------------PRICE

SCRAP
REJ
ENUM
FORCE
CTIME
RTIME
#PL
TLIFE
#TOOL
MOLD$
IMC
SPACE
RENT

Total Capital Investment $3,191,705 (all streams)

CAPITAL COST

<END>

CRP yrs
CRF
$/yr
--------------- --------------- ------------ --------------Equipment
10.00
0.0551
$130,679
Tooling
4.00
0.0507
$31,736
Building
20.00
0.0620
$12,039
Working Capital
0.25
0.0478
$38,578
--------------- --------------- ------------ --------------Total ===>
$213,032

<+S1>---------------------------------------------------------------- --------------- -------------------------<END>

|
SMC TRIMMING & DRILLING: COST ESTIMATE
|
------------------------------------------------ --------------- --------------- ------------ --------------Cumulative Piece Cost
$27.01
ROOF
$/piece
$/year
percent
VARIABLE COST ELEMENTS
--------------- --------------- -----------Material Cost
$0.00
$0
0.0%
Direct Labor Cost
$0.04
$6,158
7.5%
Energy Cost
$0.29
$43,973 53.3%
--------------- --------------- -----------TOTAL VARIABLE COST ===>
$0.33
$50,131 60.8%
per line
$/piece
$/year
percent investment
FIXED COST ELEMENTS
--------------- --------------- ------------ --------------Equipment Cost
$0.02
$3,104
3.8% $252,000
Tooling Cost
$0.08
$12,500 15.2%
$50,000
Fixed Overhead Cost
$0.05
$6,972
8.5%
Building Cost
$0.00
$235
0.3%
$38,099
Auxiliary Equipment Cost
$0.00
$466
0.6%
$37,800
Maintenance Cost
$0.02
$3,615
4.4%
Cost of Capital
$0.04
$5,475
6.6%
--------------- --------------- ------------ --------------TOTAL FIXED COST ===>
$0.22
$32,366 39.2%

TOTAL OPERATION COST ===>

======== ======== =======

$0.55
$82,497 100.0%
======== ======== =======

------------------------------------------------ --------------- --------------- ------------ --------------ADDITIONAL INFORMATION

------------------------------------------------ --------------- --------------- ------------ --------------Cumulative Rejection Rate
0.5%
REJ
Effective Production Volume
150,754 /yr
ENUM
Cycle Time
10.0 sec
CTIME
Run-Time for One Machine
12.3%
RTIME
Number of Parallel Streams
0.12
#CL
Productive Tool Life
1.00 yrs
CLIFE
# Cutting Tools
5 /line
#CTOOL
Building Space Requirement
508 sq ft/line
SPACE
Approximate Machine Rent
$167.99 /hr
Total Capital Investment $377,899 (all streams)
CAPITAL COST

CRP yrs
CRF
$/yr
--------------- --------------- ------------ --------------Equipment
10.00
0.0551
$1,967

Tooling
Building
Working Capital

<END>

4.00
0.0507
$2,534
20.00
0.0620
$291
0.25
0.0478
$683
--------------- --------------- ------------ --------------Total ===>
$5,475

<+X1>---------------------------------------------------------------------- --------------- ------------------------<END>

|
SMC MOLDING & TRIMMING: COST SUMMARY
|
------------------------------------------------ --------------- --------------- ------------ --------------Cumulative Piece Cost
$27.01
ROOF
$/piece
$/year
percent
VARIABLE COST ELEMENTS
--------------- --------------- -----------Material Cost
$17.39 $2,608,491 64.4%
Direct Labor Cost
$1.74 $261,197
6.4%
Energy Cost
$1.47 $219,864
5.4%
--------------- --------------- -----------TOTAL VARIABLE COST ===>
$20.60 $3,089,551 76.2%
per line
$/piece
$/year
percent investment
FIXED COST ELEMENTS
--------------- --------------- ------------ --------------Equipment Cost
$1.40 $209,287
5.2% $1,868,883
Tooling Cost
$1.13 $169,065
4.2% $363,129
Fixed Overhead Cost
$1.29 $192,843
4.8%
Building Cost
$0.07
$9,951
0.2% $190,496
Auxiliary Equipment Cost
$0.21
$31,393
0.8% $280,332
Maintenance Cost
$0.88 $131,284
3.2%
Cost of Capital
$1.46 $218,507
5.4%
--------------- --------------- ------------ --------------TOTAL FIXED COST ===>
$6.42 $962,330 23.8%

TOTAL OPERATION COST ===>

======== ======== =======

$27.01 $4,051,881 100.0%
======== ======== =======

------------------------------------------------ --------------- --------------- ------------ --------------ADDITIONAL INFORMATION

------------------------------------------------ --------------- --------------- ------------ --------------Total Building Space
2,540 sq ft/line
Eff. Production Volume
152,277 /yr
EQUIPMENT REQUIREMENTS <minimum>
Total
# of Lines
Cost
Investment
--------------- --------------- ------------ --------------Molding Press
1.28 $1,616,883
$2,061,836
Trimming & Drilling Eq.
1 $302,000
$302,000
Mold & Fixtures
2 $313,129
$626,258
--------------- --------------- ------------ --------------TOTAL ===>
$2,990,094
<END>

<+N1>-------------------------------------- --------------- ------------ ------<END>

|
SMC MOLDING & COATING: COST ESTIMATE
|
------------------------------------------------ --------------- --------------- ------------ --------------Cumulative Piece Cost
$24.60
Roof Outer
$/piece
$/year
percent
VARIABLE COST ELEMENTS
--------------- --------------- -----------Material Cost
$14.99 $449,801 60.9%
Direct Labor Cost
$1.01
$30,306
4.1%
Energy Cost
$1.00
$29,921
4.1%
--------------- --------------- -----------TOTAL VARIABLE COST ===>
$17.00 $510,029 69.1%
investment
$/piece
$/year
percent
per line
FIXED COST ELEMENTS
--------------- --------------- ------------ --------------Equipment Cost
$0.59
$17,837
2.4% $1,483,194
Tooling Cost
$3.17
$95,000 12.9% $380,000
Fixed Overhead Cost
$1.64
$49,177
6.7%
Building Cost
$0.03
$882
0.1% $146,658
Auxiliary Equipment Cost
$0.09
$2,676
0.4% $222,479
Maintenance Cost
$0.80
$24,111
3.3%
Cost of Capital
$1.28
$38,343
5.2%
--------------- --------------- ------------ --------------TOTAL FIXED COST ===>
$7.60 $228,025 30.9%

TOTAL OPERATION COST ===>

======== ======== =======

$24.60 $738,054 100.0%
======== ======== =======

------------------------------------------------ --------------- --------------ADDITIONAL INFORMATION

------------------------------------------------ --------------- --------------Sheet Price
$0.80 /lb
Material Scrap Rate
2.5%
Cumulative Rejection Rate
1.5%
Effective Production Volume
30,455 /yr
Press Tonnage
2,078 tons
Press Cycle Time
72.5 sec
Run-Time for One Machine
12.0%
Number of Parallel Streams
0.12
Productive Mold Life
4.00 yrs
# of Molds (not incl backup)
1 /line
Mold Cost $380,000 /mold
In-Mold Coating Use
0.000 gal/pc
Building Space Requirement
1,955 sq ft/line
Approximate Machine Rent
$319.87 /hr

------------ -------------------------- --------------PRICE

SCRAP
REJ
ENUM
FORCE
CTIME
RTIME
#PL
TLIFE
#TOOL
MOLD$
IMC
SPACE
RENT

Total Capital Investment

CAPITAL COST

<END>

$602,765 (all streams)

CRP yrs
CRF
$/yr
--------------- --------------- ------------ --------------Equipment
10.00
0.0551
$11,305
Tooling
4.00
0.0507
$19,257
Building
20.00
0.0620
$1,093
Working Capital
0.25
0.0478
$6,689
--------------- --------------- ------------ --------------Total ===>
$38,343

<+A1>============================
======== ======== =======
=======<END> <+F1>============
|
SMC MOLDING MODEL
||
SMC MOLDI
|
Materials Systems Laboratory MIT
| ===
=========================== ======== ======== ======= ========
Model Revision Date: 10/28/93
Input Revision Date:
05/03/93
#
COMPONENT SPECIFICATIONS
----Part Name/Material Type:
FLOOR
SMC
0
Formulation Number
1
MAT
(see menu)
1
Weight
51 lbs
WGT
2
Maximum Wall Thickness
0.18 in
THKM (see menu)
3
Total External Surface Area
4500 sq in
SAREA
4
Projected Area
4,091 sq in
PAREA
5
6
Number of Cavities
1
CAV
7
Number of Actions in Tool
0
ACT
8
Backup Mold
0 (1=Y;0=N) BACK
----Molding Cy. Time <optional>
0 sec
CYC
Tool Cost/Set <optional>
0 ($000/set) MOLD
===
Press Tonnage <optional>
% PART THICKNESS
0 tonsCALCULATION
TONS SUBROUTINE %
Does not take into account reinforcing ribs
EXOGENOUS COST FACTORS
Annual Production Volume
150 (000)/yr
NUM
Target panel stiffness
Product Lifetime
4 yrs
Recommended
PLIFE
panel thickness
Dedicated Equipment
0 (1=Y;0=N) DED
Process Rejection Rate
1.00%
PREJ
----Intermediate "LOOKUP" Data Buffer - For Thickness Calculations
Direct Wages (w/ benefits)
25 /hr
WAGE
----Working Days/Yr
250
DAYS
Material Density
Working Hours/Day
16
HRS
Material Price
Capital Recovery Rate
10.00%
CRR
Material Modulus
Capital Recovery Period
10 yrs
CRP
Working Capital Period
3 months
WCP
===
Price of Building Space
75 /sq ft
PBLD
Building Recovery Life
20 yrs
BLIFE
Price of Electricity
0.08 /KWh
ELEC
===
% POLICY IMPACTS ESTIMATION SUBROUTINE %
Fixed Overhead
35.00%
OVHD
Auxiliary Equipment Cost find
15.00%
formula relating increasing
AUX
oil price to increase in resin price
Maintenance Cost
4.00%
MNT
PROCESS RELATED FACTORS
Average Downtime
Material Scrap Rate
Molding Cycle Time Intercept

15.00%
DOWN
2.50%
SCR
----Linkages with Improv - For Policy Calculations
50 sec
CYC1
-----

Molding Cycle Time Factor

250 sec/in

CYC2

Machine Cost Coefficient

Machine Cost Scaling Exp.
Direct Laborers Per Machine
Installation Cost

8621
0.65
2
20.00%

MCH1
MCH2
NLAB
INST

Internal Molding Pressure

Press Tonnage Safety Factor

1200 psi
20.00%

PRES1
PRES2

Mold Cost Coefficient

Complexity Deformation Exp.
Complexity Actions Exponent
Weight Factor Exponent
Baseline Physical Mold Life
Electrical Heat
Electrical Mechanical Energy
Floor Space Coefficient
Floor Space Scaling Exponent

48280
1.08
0.4
0.6
1200000 cycles

Oil Tax
Material Price
Material Modulus

MOL1
MOL2
MOL3
MOL4
MOLLI

0.5 kWh/lb
POW1
0.08kW/press ton POW2
251.19 sq ft
0.71

FLR1
FLR2

In-Mold Coating Paramters

Coating in Use
Additional Capital Invest.
Added Cycle Time
Coating Thickness
Sides Coated (1 or 2)
Coating Material Price
Coating Transfer Efficiency

0 (1=Y;0=N)
60000 /press
30 sec
0.01 in
1
20 /gal
95.00%

COAT

Trimming & Drilling Parameters

Process in use
Machine Cost
Toolind & Fixture Cost
Tool Lifetime
Process Rejection Rate
Number of Additional Laborers
Trimming & Drilling Cy. Time
Simulataneous Trimming

1 (1=Y;0=N)
252000
10000
150000 cycles
0.50%
0.5
10 sec
1 parts

CUT
CMACH
CDIE
CDLIFE
TREJ
ADDLAB
CUTIME
SIMTRIM

<END>

===

<END>

<+F1>============
=========== ======== ======== ======== ======== ====<END>
|
SMC MOLDING MODEL: MATERIAL DATABASE
|
=========== =========== ======== ======== ======== ======== ========
Modulus
Price
Density
Grade
Material
(psi)
($/lb)
(lb/in^3)
XCY
XML
-------------------- -------------------- --------------- --------------- --------------- --------------- --------------No Sheet
Gen. Purp
PE/GF 1.20E+06
$0.80
0.063
1.00
1.00
Low Prof-1
LP,PE/GF 1.20E+06
$0.83
0.070
1.50
1.00
Low Prof-2
LP,PE/GF 1.20E+06
$0.82
0.072
1.50
1.00
High Str-1
IPN/GF 1.40E+06
$0.83
0.059
0.90
0.80
High Str-2
VE/GF 1.40E+06
$0.86
0.071
1.00
1.00
Hi Mod CF(30%)/PE 1.80E+06
$12.78
0.070
1.00
1.00

-------------------- -------------------- --------------- --------------- --------------- --------------- --------------=========== =========== ======== ======== ======== ======== ========

account reinforcing ribs

Target panel stiffness

9,700 lbs
0.0899 in

-------------------- -------------------- --------------- --------------- --------------- --------------- ---------------------------------- -------------------- --------------- --------------- --------------- --------------- --------------0.063 lbs/in^3
DENSITY
$0.80 /lb
MAT_$
1.20E+06 psi
MOD
=========== =========== ======== ======== ======== ======== ========

=========== =========== ======== ======== ======== ======== ========

increase in resin price

-------------------- -------------------- --------------- --------------- --------------- --------------- ---------------------------------- -------------------- --------------- --------------- --------------- --------------- ---------------

$0.25/gallon
#N/A /lb
#N/A psi

MAT_$
MOD

=========== =========== ======== ======== ======== ======== ========

<END>

<+N1>--------------------------------------------------------------- --------------- ------------------------<END>

|
SMC MOLDING & COATING: COST ESTIMATE
|
------------------------------------------------ --------------- --------------- ------------ --------------Cumulative Piece Cost
$55.10
FLOOR
$/piece
$/year
percent
VARIABLE COST ELEMENTS
--------------- --------------- -----------Material Cost
$42.48 $6,372,187 77.1%
Direct Labor Cost
$1.58 $236,377
2.9%
Energy Cost
$2.57 $384,880
4.7%
--------------- --------------- -----------TOTAL VARIABLE COST ===>
$46.62 $6,993,444 84.6%
investment
$/piece
$/year
percent
per line
FIXED COST ELEMENTS
--------------- --------------- ------------ --------------Equipment Cost
$1.47 $219,919
2.7% $1,860,749
Tooling Cost
$1.89 $283,128
3.4% $566,257
Fixed Overhead Cost
$1.67 $250,312
3.0%
Building Cost
$0.12
$18,154
0.2% $307,211
Auxiliary Equipment Cost
$0.22
$32,988
0.4% $279,112
Maintenance Cost
$1.07 $160,987
1.9%
Cost of Capital
$2.04 $305,912
3.7%
--------------- --------------- ------------ --------------TOTAL FIXED COST ===>
$8.48 $1,271,401 15.4%

TOTAL OPERATION COST ===>

======== ======== =======

$55.10 $8,264,845 100.0%
======== ======== =======

------------------------------------------------ --------------- --------------ADDITIONAL INFORMATION

------------------------------------------------ --------------- --------------Sheet Price
$0.80 /lb
Material Scrap Rate
2.5%
Cumulative Rejection Rate
1.5%
Effective Production Volume
152,277 /yr
Press Tonnage
2,945 tons
Press Cycle Time
95.0 sec
Run-Time for One Machine
118.2%
Number of Parallel Streams
1.18
Productive Mold Life
4.00 yrs
# of Molds (not incl backup)
1 /line
Mold Cost $566,257 /mold
In-Mold Coating Use
0.000 gal/pc
Building Space Requirement
4,096 sq ft/line
Approximate Machine Rent
$406.62 /hr

------------ -------------------------- --------------PRICE

SCRAP
REJ
ENUM
FORCE
CTIME
RTIME
#PL
TLIFE
#TOOL
MOLD$
IMC
SPACE
RENT

Total Capital Investment $4,024,672 (all streams)

CAPITAL COST

<END>

CRP yrs
CRF
$/yr
--------------- --------------- ------------ --------------Equipment
10.00
0.0551
$139,384
Tooling
4.00
0.0507
$57,391
Building
20.00
0.0620
$22,494
Working Capital
0.25
0.0478
$86,643
--------------- --------------- ------------ --------------Total ===>
$305,912

<+S1>---------------------------------------------------------------- --------------- -------------------------<END>

|
SMC TRIMMING & DRILLING: COST ESTIMATE
|
------------------------------------------------ --------------- --------------- ------------ --------------Cumulative Piece Cost
$56.01
FLOOR
$/piece
$/year
percent
VARIABLE COST ELEMENTS
--------------- --------------- -----------Material Cost
$0.00
$0
0.0%
Direct Labor Cost
$0.04
$6,158
4.5%
Energy Cost
$0.64
$96,220 70.6%
--------------- --------------- -----------TOTAL VARIABLE COST ===>
$0.68 $102,378 75.1%
per line
$/piece
$/year
percent investment
FIXED COST ELEMENTS
--------------- --------------- ------------ --------------Equipment Cost
$0.02
$3,104
2.3% $252,000
Tooling Cost
$0.08
$12,500
9.2%
$50,000
Fixed Overhead Cost
$0.05
$7,122
5.2%
Building Cost
$0.00
$473
0.3%
$76,803
Auxiliary Equipment Cost
$0.00
$466
0.3%
$37,800
Maintenance Cost
$0.03
$3,806
2.8%
Cost of Capital
$0.04
$6,397
4.7%
--------------- --------------- ------------ --------------TOTAL FIXED COST ===>
$0.23
$33,867 24.9%

TOTAL OPERATION COST ===>

======== ======== =======

$0.91 $136,245 100.0%
======== ======== =======

------------------------------------------------ --------------- --------------- ------------ --------------ADDITIONAL INFORMATION

------------------------------------------------ --------------- --------------- ------------ --------------Cumulative Rejection Rate
0.5%
REJ
Effective Production Volume
150,754 /yr
ENUM
Cycle Time
10.0 sec
CTIME
Run-Time for One Machine
12.3%
RTIME
Number of Parallel Streams
0.12
#CL
Productive Tool Life
1.00 yrs
CLIFE
# Cutting Tools
5 /line
#CTOOL
Building Space Requirement
1,024 sq ft/line
SPACE
Approximate Machine Rent
$296.99 /hr
Total Capital Investment $416,603 (all streams)
CAPITAL COST

CRP yrs
CRF
$/yr
--------------- --------------- ------------ --------------Equipment
10.00
0.0551
$1,967

Tooling
Building
Working Capital

<END>

4.00
0.0507
$2,534
20.00
0.0620
$586
0.25
0.0478
$1,310
--------------- --------------- ------------ --------------Total ===>
$6,397

<+X1>---------------------------------------------------------------------- --------------- ------------------------<END>

|
SMC MOLDING & TRIMMING: COST SUMMARY
|
------------------------------------------------ --------------- --------------- ------------ --------------Cumulative Piece Cost
$56.01
FLOOR
$/piece
$/year
percent
VARIABLE COST ELEMENTS
--------------- --------------- -----------Material Cost
$42.48 $6,372,187 75.8%
Direct Labor Cost
$1.62 $242,535
2.9%
Energy Cost
$3.21 $481,100
5.7%
--------------- --------------- -----------TOTAL VARIABLE COST ===>
$47.31 $7,095,822 84.5%
per line
$/piece
$/year
percent investment
FIXED COST ELEMENTS
--------------- --------------- ------------ --------------Equipment Cost
$1.49 $223,023
2.7% $2,112,749
Tooling Cost
$1.97 $295,628
3.5% $616,257
Fixed Overhead Cost
$1.72 $257,434
3.1%
Building Cost
$0.12
$18,627
0.2% $384,013
Auxiliary Equipment Cost
$0.22
$33,453
0.4% $316,912
Maintenance Cost
$1.10 $164,793
2.0%
Cost of Capital
$2.08 $312,309
3.7%
--------------- --------------- ------------ --------------TOTAL FIXED COST ===>
$8.70 $1,305,268 15.5%

TOTAL OPERATION COST ===>

======== ======== =======

$56.01 $8,401,090 100.0%
======== ======== =======

------------------------------------------------ --------------- --------------- ------------ --------------ADDITIONAL INFORMATION

------------------------------------------------ --------------- --------------- ------------ --------------Total Building Space
5,120 sq ft/line
Eff. Production Volume
152,277 /yr
EQUIPMENT REQUIREMENTS <minimum>
Total
# of Lines
Cost
Investment
--------------- --------------- ------------ --------------Molding Press
1.18 $1,860,749
$2,199,192
Trimming & Drilling Eq.
1 $302,000
$302,000
Mold & Fixtures
2 $566,257
$1,132,514
--------------- --------------- ------------ --------------TOTAL ===>
$3,633,705
<END>

<+N1>-------------------------------------- --------------- ------------ ------<END>

|
SMC MOLDING & COATING: COST ESTIMATE
|
------------------------------------------------ --------------- --------------- ------------ --------------Cumulative Piece Cost
$24.60
Roof Outer
$/piece
$/year
percent
VARIABLE COST ELEMENTS
--------------- --------------- -----------Material Cost
$14.99 $449,801 60.9%
Direct Labor Cost
$1.01
$30,306
4.1%
Energy Cost
$1.00
$29,921
4.1%
--------------- --------------- -----------TOTAL VARIABLE COST ===>
$17.00 $510,029 69.1%
investment
$/piece
$/year
percent
per line
FIXED COST ELEMENTS
--------------- --------------- ------------ --------------Equipment Cost
$0.59
$17,837
2.4% $1,483,194
Tooling Cost
$3.17
$95,000 12.9% $380,000
Fixed Overhead Cost
$1.64
$49,177
6.7%
Building Cost
$0.03
$882
0.1% $146,658
Auxiliary Equipment Cost
$0.09
$2,676
0.4% $222,479
Maintenance Cost
$0.80
$24,111
3.3%
Cost of Capital
$1.28
$38,343
5.2%
--------------- --------------- ------------ --------------TOTAL FIXED COST ===>
$7.60 $228,025 30.9%

TOTAL OPERATION COST ===>

======== ======== =======

$24.60 $738,054 100.0%
======== ======== =======

------------------------------------------------ --------------- --------------ADDITIONAL INFORMATION

------------------------------------------------ --------------- --------------Sheet Price
$0.80 /lb
Material Scrap Rate
2.5%
Cumulative Rejection Rate
1.5%
Effective Production Volume
30,455 /yr
Press Tonnage
2,078 tons
Press Cycle Time
72.5 sec
Run-Time for One Machine
12.0%
Number of Parallel Streams
0.12
Productive Mold Life
4.00 yrs
# of Molds (not incl backup)
1 /line
Mold Cost $380,000 /mold
In-Mold Coating Use
0.000 gal/pc
Building Space Requirement
1,955 sq ft/line
Approximate Machine Rent
$319.87 /hr

------------ -------------------------- --------------PRICE

SCRAP
REJ
ENUM
FORCE
CTIME
RTIME
#PL
TLIFE
#TOOL
MOLD$
IMC
SPACE
RENT

Total Capital Investment

CAPITAL COST

<END>

$602,765 (all streams)

CRP yrs
CRF
$/yr
--------------- --------------- ------------ --------------Equipment
10.00
0.0551
$11,305
Tooling
4.00
0.0507
$19,257
Building
20.00
0.0620
$1,093
Working Capital
0.25
0.0478
$6,689
--------------- --------------- ------------ --------------Total ===>
$38,343

<+A1>============================
======== ======== =======
=======<END> <+F1>============
|
SMC MOLDING MODEL
||
SMC MOLDI
|
Materials Systems Laboratory MIT
| ===
=========================== ======== ======== ======= ========
Model Revision Date: 10/28/93
Input Revision Date:
05/03/93
#
COMPONENT SPECIFICATIONS
----Part Name/Material Type:
OUTER
SMC
0
Formulation Number
1
MAT
(see menu)
1
Weight
11 lbs
WGT
2
Maximum Wall Thickness
0.11 in
THKM (see menu)
3
Total External Surface Area
1600 sq in
SAREA
4
Projected Area
1,455 sq in
PAREA
5
6
Number of Cavities
1
CAV
7
Number of Actions in Tool
0
ACT
8
Backup Mold
0 (1=Y;0=N) BACK
----Molding Cy. Time <optional>
0 sec
CYC
Tool Cost/Set <optional>
0 ($000/set) MOLD
===
Press Tonnage <optional>
% PART THICKNESS
0 tonsCALCULATION
TONS SUBROUTINE %
Does not take into account reinforcing ribs
EXOGENOUS COST FACTORS
Annual Production Volume
150 (000)/yr
NUM
Target panel stiffness
Product Lifetime
4 yrs
Recommended
PLIFE
panel thickness
Dedicated Equipment
0 (1=Y;0=N) DED
Process Rejection Rate
1.00%
PREJ
----Intermediate "LOOKUP" Data Buffer - For Thickness Calculations
Direct Wages (w/ benefits)
25 /hr
WAGE
----Working Days/Yr
250
DAYS
Material Density
Working Hours/Day
16
HRS
Material Price
Capital Recovery Rate
10.00%
CRR
Material Modulus
Capital Recovery Period
10 yrs
CRP
Working Capital Period
3 months
WCP
===
Price of Building Space
75 /sq ft
PBLD
Building Recovery Life
20 yrs
BLIFE
Price of Electricity
0.08 /KWh
ELEC
===
% POLICY IMPACTS ESTIMATION SUBROUTINE %
Fixed Overhead
35.00%
OVHD
Auxiliary Equipment Cost find
15.00%
formula relating increasing
AUX
oil price to increase in resin price
Maintenance Cost
4.00%
MNT
PROCESS RELATED FACTORS
Average Downtime
Material Scrap Rate
Molding Cycle Time Intercept

15.00%
DOWN
2.50%
SCR
----Linkages with Improv - For Policy Calculations
50 sec
CYC1
-----

Molding Cycle Time Factor

250 sec/in

CYC2

Machine Cost Coefficient

Machine Cost Scaling Exp.
Direct Laborers Per Machine
Installation Cost

8621
0.65
2
20.00%

MCH1
MCH2
NLAB
INST

Internal Molding Pressure

Press Tonnage Safety Factor

1200 psi
20.00%

PRES1
PRES2

Mold Cost Coefficient

Complexity Deformation Exp.
Complexity Actions Exponent
Weight Factor Exponent
Baseline Physical Mold Life
Electrical Heat
Electrical Mechanical Energy
Floor Space Coefficient
Floor Space Scaling Exponent

48280
1.08
0.4
0.6
1200000 cycles

Oil Tax
Material Price
Material Modulus

MOL1
MOL2
MOL3
MOL4
MOLLI

0.5 kWh/lb
POW1
0.08kW/press ton POW2
251.19 sq ft
0.71

FLR1
FLR2

In-Mold Coating Paramters

Coating in Use
Additional Capital Invest.
Added Cycle Time
Coating Thickness
Sides Coated (1 or 2)
Coating Material Price
Coating Transfer Efficiency

1 (1=Y;0=N)
60000 /press
30 sec
0.01 in
1
20 /gal
95.00%

COAT

Trimming & Drilling Parameters

Process in use
Machine Cost
Toolind & Fixture Cost
Tool Lifetime
Process Rejection Rate
Number of Additional Laborers
Trimming & Drilling Cy. Time
Simulataneous Trimming

1 (1=Y;0=N)
252000
10000
150000 cycles
0.50%
0.5
10 sec
1 parts

CUT
CMACH
CDIE
CDLIFE
TREJ
ADDLAB
CUTIME
SIMTRIM

<END>

===

<END>

<+F1>============
=========== ======== ======== ======== ======== ====<END>
|
SMC MOLDING MODEL: MATERIAL DATABASE
|
=========== =========== ======== ======== ======== ======== ========
Modulus
Price
Density
Grade
Material
(psi)
($/lb)
(lb/in^3)
XCY
XML
-------------------- -------------------- --------------- --------------- --------------- --------------- --------------No Sheet
Gen. Purp
PE/GF 1.20E+06
$0.80
0.063
1.00
1.00
Low Prof-1
LP,PE/GF 1.20E+06
$0.83
0.070
1.50
1.00
Low Prof-2
LP,PE/GF 1.20E+06
$0.82
0.072
1.50
1.00
High Str-1
IPN/GF 1.40E+06
$0.83
0.059
0.90
0.80
High Str-2
VE/GF 1.40E+06
$0.86
0.071
1.00
1.00
Hi Mod CF(30%)/PE 1.80E+06
$12.78
0.070
1.00
1.00

-------------------- -------------------- --------------- --------------- --------------- --------------- --------------=========== =========== ======== ======== ======== ======== ========

account reinforcing ribs

Target panel stiffness

9,700 lbs
0.0899 in

-------------------- -------------------- --------------- --------------- --------------- --------------- ---------------------------------- -------------------- --------------- --------------- --------------- --------------- --------------0.063 lbs/in^3
DENSITY
$0.80 /lb
MAT_$
1.20E+06 psi
MOD
=========== =========== ======== ======== ======== ======== ========

=========== =========== ======== ======== ======== ======== ========

increase in resin price

-------------------- -------------------- --------------- --------------- --------------- --------------- ---------------------------------- -------------------- --------------- --------------- --------------- --------------- ---------------

$0.25/gallon
#N/A /lb
#N/A psi

MAT_$
MOD

=========== =========== ======== ======== ======== ======== ========

<END>

<+N1>--------------------------------------------------------------- --------------- ------------------------<END>

|
SMC MOLDING & COATING: COST ESTIMATE
|
------------------------------------------------ --------------- --------------- ------------ --------------Cumulative Piece Cost
$16.55
OUTER
$/piece
$/year
percent
VARIABLE COST ELEMENTS
--------------- --------------- -----------Material Cost
$9.90 $1,485,417 59.8%
Direct Labor Cost
$1.78 $267,479 10.8%
Energy Cost
$0.65
$96,870
3.9%
--------------- --------------- -----------TOTAL VARIABLE COST ===>
$12.33 $1,849,766 74.5%
investment
$/piece
$/year
percent
per line
FIXED COST ELEMENTS
--------------- --------------- ------------ --------------Equipment Cost
$0.91 $136,698
5.5% $1,022,118
Tooling Cost
$0.75 $112,792
4.5% $225,583
Fixed Overhead Cost
$0.85 $127,178
5.1%
Building Cost
$0.05
$6,913
0.3% $103,383
Auxiliary Equipment Cost
$0.14
$20,505
0.8% $153,318
Maintenance Cost
$0.58
$86,458
3.5%
Cost of Capital
$0.94 $141,714
5.7%
--------------- --------------- ------------ --------------TOTAL FIXED COST ===>
$4.22 $632,257 25.5%

TOTAL OPERATION COST ===>

======== ======== =======

$16.55 $2,482,024 100.0%
======== ======== =======

------------------------------------------------ --------------- --------------ADDITIONAL INFORMATION

------------------------------------------------ --------------- --------------Sheet Price
$0.80 /lb
Material Scrap Rate
2.5%
Cumulative Rejection Rate
1.5%
Effective Production Volume
152,277 /yr
Press Tonnage
1,047 tons
Press Cycle Time
107.5 sec
Run-Time for One Machine
133.7%
Number of Parallel Streams
1.34
Productive Mold Life
4.00 yrs
# of Molds (not incl backup)
1 /line
Mold Cost $225,583 /mold
In-Mold Coating Use
0.036 gal/pc
Building Space Requirement
1,378 sq ft/line
Approximate Machine Rent
$197.32 /hr

------------ -------------------------- --------------PRICE

SCRAP
REJ
ENUM
FORCE
CTIME
RTIME
#PL
TLIFE
#TOOL
MOLD$
IMC
SPACE
RENT

Total Capital Investment $2,161,455 (all streams)

CAPITAL COST

<END>

CRP yrs
CRF
$/yr
--------------- --------------- ------------ --------------Equipment
10.00
0.0551
$86,639
Tooling
4.00
0.0507
$22,863
Building
20.00
0.0620
$8,566
Working Capital
0.25
0.0478
$23,646
--------------- --------------- ------------ --------------Total ===>
$141,714

<+S1>---------------------------------------------------------------- --------------- -------------------------<END>

|
SMC TRIMMING & DRILLING: COST ESTIMATE
|
------------------------------------------------ --------------- --------------- ------------ --------------Cumulative Piece Cost
$16.96
OUTER
$/piece
$/year
percent
VARIABLE COST ELEMENTS
--------------- --------------- -----------Material Cost
$0.00
$0
0.0%
Direct Labor Cost
$0.04
$6,158
9.9%
Energy Cost
$0.16
$24,217 38.9%
--------------- --------------- -----------TOTAL VARIABLE COST ===>
$0.20
$30,376 48.8%
per line
$/piece
$/year
percent investment
FIXED COST ELEMENTS
--------------- --------------- ------------ --------------Equipment Cost
$0.02
$3,104
5.0% $252,000
Tooling Cost
$0.08
$12,500 20.1%
$50,000
Fixed Overhead Cost
$0.05
$6,924 11.1%
Building Cost
$0.00
$159
0.3%
$25,846
Auxiliary Equipment Cost
$0.00
$466
0.7%
$37,800
Maintenance Cost
$0.02
$3,555
5.7%
Cost of Capital
$0.03
$5,144
8.3%
--------------- --------------- ------------ --------------TOTAL FIXED COST ===>
$0.21
$31,852 51.2%

TOTAL OPERATION COST ===>

======== ======== =======

$0.41
$62,228 100.0%
======== ======== =======

------------------------------------------------ --------------- --------------- ------------ --------------ADDITIONAL INFORMATION

------------------------------------------------ --------------- --------------- ------------ --------------Cumulative Rejection Rate
0.5%
REJ
Effective Production Volume
150,754 /yr
ENUM
Cycle Time
10.0 sec
CTIME
Run-Time for One Machine
12.3%
RTIME
Number of Parallel Streams
0.12
#CL
Productive Tool Life
1.00 yrs
CLIFE
# Cutting Tools
5 /line
#CTOOL
Building Space Requirement
345 sq ft/line
SPACE
Approximate Machine Rent
$119.35 /hr
Total Capital Investment $365,646 (all streams)
CAPITAL COST

CRP yrs
CRF
$/yr
--------------- --------------- ------------ --------------Equipment
10.00
0.0551
$1,967

Tooling
Building
Working Capital

<END>

4.00
0.0507
$2,534
20.00
0.0620
$197
0.25
0.0478
$446
--------------- --------------- ------------ --------------Total ===>
$5,144

<+X1>---------------------------------------------------------------------- --------------- ------------------------<END>

|
SMC MOLDING & TRIMMING: COST SUMMARY
|
------------------------------------------------ --------------- --------------- ------------ --------------Cumulative Piece Cost
$16.96
OUTER
$/piece
$/year
percent
VARIABLE COST ELEMENTS
--------------- --------------- -----------Material Cost
$9.90 $1,485,417 58.4%
Direct Labor Cost
$1.82 $273,637 10.8%
Energy Cost
$0.81 $121,087
4.8%
--------------- --------------- -----------TOTAL VARIABLE COST ===>
$12.53 $1,880,142 73.9%
per line
$/piece
$/year
percent investment
FIXED COST ELEMENTS
--------------- --------------- ------------ --------------Equipment Cost
$0.93 $139,801
5.5% $1,274,118
Tooling Cost
$0.84 $125,292
4.9% $275,583
Fixed Overhead Cost
$0.89 $134,102
5.3%
Building Cost
$0.05
$7,072
0.3% $129,229
Auxiliary Equipment Cost
$0.14
$20,970
0.8% $191,118
Maintenance Cost
$0.60
$90,013
3.5%
Cost of Capital
$0.98 $146,858
5.8%
--------------- --------------- ------------ --------------TOTAL FIXED COST ===>
$4.43 $664,109 26.1%

TOTAL OPERATION COST ===>

======== ======== =======

$16.96 $2,544,251 100.0%
======== ======== =======

------------------------------------------------ --------------- --------------- ------------ --------------ADDITIONAL INFORMATION

------------------------------------------------ --------------- --------------- ------------ --------------Total Building Space
1,723 sq ft/line
Eff. Production Volume
152,277 /yr
EQUIPMENT REQUIREMENTS <minimum>
Total
# of Lines
Cost
Investment
--------------- --------------- ------------ --------------Molding Press
1.34 $1,022,118
$1,366,977
Trimming & Drilling Eq.
1 $302,000
$302,000
Mold & Fixtures
2 $225,583
$451,167
--------------- --------------- ------------ --------------TOTAL ===>
$2,120,144
<END>

<+N1>-------------------------------------- --------------- ------------ ------<END>

|
SMC MOLDING & COATING: COST ESTIMATE
|
------------------------------------------------ --------------- --------------- ------------ --------------Cumulative Piece Cost
$24.60
Roof Outer
$/piece
$/year
percent
VARIABLE COST ELEMENTS
--------------- --------------- -----------Material Cost
$14.99 $449,801 60.9%
Direct Labor Cost
$1.01
$30,306
4.1%
Energy Cost
$1.00
$29,921
4.1%
--------------- --------------- -----------TOTAL VARIABLE COST ===>
$17.00 $510,029 69.1%
investment
$/piece
$/year
percent
per line
FIXED COST ELEMENTS
--------------- --------------- ------------ --------------Equipment Cost
$0.59
$17,837
2.4% $1,483,194
Tooling Cost
$3.17
$95,000 12.9% $380,000
Fixed Overhead Cost
$1.64
$49,177
6.7%
Building Cost
$0.03
$882
0.1% $146,658
Auxiliary Equipment Cost
$0.09
$2,676
0.4% $222,479
Maintenance Cost
$0.80
$24,111
3.3%
Cost of Capital
$1.28
$38,343
5.2%
--------------- --------------- ------------ --------------TOTAL FIXED COST ===>
$7.60 $228,025 30.9%

TOTAL OPERATION COST ===>

======== ======== =======

$24.60 $738,054 100.0%
======== ======== =======

------------------------------------------------ --------------- --------------ADDITIONAL INFORMATION

------------------------------------------------ --------------- --------------Sheet Price
$0.80 /lb
Material Scrap Rate
2.5%
Cumulative Rejection Rate
1.5%
Effective Production Volume
30,455 /yr
Press Tonnage
2,078 tons
Press Cycle Time
72.5 sec
Run-Time for One Machine
12.0%
Number of Parallel Streams
0.12
Productive Mold Life
4.00 yrs
# of Molds (not incl backup)
1 /line
Mold Cost $380,000 /mold
In-Mold Coating Use
0.000 gal/pc
Building Space Requirement
1,955 sq ft/line
Approximate Machine Rent
$319.87 /hr

------------ -------------------------- --------------PRICE

SCRAP
REJ
ENUM
FORCE
CTIME
RTIME
#PL
TLIFE
#TOOL
MOLD$
IMC
SPACE
RENT

Total Capital Investment

CAPITAL COST

<END>

$602,765 (all streams)

CRP yrs
CRF
$/yr
--------------- --------------- ------------ --------------Equipment
10.00
0.0551
$11,305
Tooling
4.00
0.0507
$19,257
Building
20.00
0.0620
$1,093
Working Capital
0.25
0.0478
$6,689
--------------- --------------- ------------ --------------Total ===>
$38,343