Ulsab Model 9

ULSAB BODY STRUCTURE COST MODEL
Camanoe Associates
in association with:
IBIS Associates &
The MIT Materials Systems Laboratory
(see contact information sheet for details
OVERALL COST ANALYSIS

BODY STRUCTURE DESIGN SPECIFICATIONS
Total Weight (kg)
203.18
Engineering Scrap
52%
Production Scrap
2%
TOTAL BODY STRUCTURE COST WORKSHEET

Manufacturing Cost
946.87
Quality Assurance Costs
0.00
Cost of Engineering Changes
0.00
Start Up and Production Launch Costs
0.00
Marketing Costs
0.00
Transportation Costs
0.00
Departmental Costs
0.00
Preparation for Paint
0.00
Other BIW Related Costs
0.00
TOTAL BODY STRUCTURE COST
MANUFACTURING COST BREAKDOWN

Cost of Stamped Parts
Cost of Tubular & Purchased Parts
Assembly Cost
BODY STRUCTURE MANUFACTURING COST
COST BREAKDOWN: STAMPED PARTS

Material Cost
Labor Cost
Energy Cost
Total Variable Costs
946.87
583.58
81.81
281.48
946.87
352.84
35.83
5.63
394.30
Equipment Cost
Tooling Cost
Overhead Labor Cost
Building Cost
Maintenance Cost
Working Capital Cost
Total Fixed Costs
TOTAL COST OF STAMPED PARTS
88.17
51.21
26.48
7.33
14.67
1.40
189.27
583.58
COST BREAKDOWN: ASSEMBLY

Material Cost
Labor Cost
Energy Cost
Total Variable Costs
0.49
45.06
9.87
55.41
Equipment Cost
Tooling Cost
Overhead Labor Cost
Building Cost
Maintenance Cost
Working Capital Cost
Total Fixed Costs
49.88
23.40
125.31
17.74
9.10
0.63
226.07
TOTAL COST OF ASSEMBLY
281.48
ls Systems Laboratory
mation sheet for details)
COST SUMMARY CALCULATION SHEET

TOTAL COST FOR ASSEMBLED BODY STRUCTURE:
946.87
PARTS FABRICATION
<=============
===========GENERAL OUTPUT COSTS=========== ==========>
STAMPING
Part ID
001
002/003
008/009
010/011
012/013
014/015
021
022
026
028
032
034
038
040
042/043
045
046/047
048/049
050
055
057
060
061
062/063
064/065
066
068/069
070/071
074/075
080
081
082/083
Part Name
Units
Reinf Radiator Support Upper
Reinf Front Rail Extension
Rail Front Outer RH/LH
Rail Front Inner RH/LH
Rail Front Extension
Bracket Roof Rail Mount Lower
Panel Dash
Panel Dash Insert (laminate)
Member Dash Front
Panel Cowl Lower
Panel Cowl Upper
Member Front Floor Support
Reinf Floor Front Seat Rear Outer
Pan Front Floor
Panel Rocker Inner
Member Rear Suspension
Rail Rear Inner
Rail Rear Outer
Panel Spare Tire Tub (laminate)
Member Panel Back
Panel Back
Panel Body Side Outer RH
Panel Body Side Outer LH
Panel A-Pillar Inner Lower
Panel B-Pillar Inner
Reinf B-Pillar Lower
Panel Wheelhouse Inner
Panel Wheelhouse Outer
Panel A-Pillar Inner Upper
Panel Package Tray Upper
Panel Package Tray Lower
Support Package Tray RH
Total
Parts Cost
$ / parts
7.22
4.86
19.43
26.42
9.89
3.53
13.89
6.74
7.07
4.94
6.21
6.92
0.91
25.43
33.28
4.44
28.42
16.70
17.24
5.72
7.58
61.92
61.91
9.32
19.69
5.96
10.05
17.94
7.06
6.69
6.84
0.71
085
085
086
087
091
094/095
096/097
098/099
102/103
104/105
106/107
108/109
110
115
116/117
120
122
128
130/152
136
140
142
144/145
164/165
170/171
172
180/181
190
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
Panel Roof - Hydromechanical Forming Step

Panel Roof - Trimming & Flanging Steps
Panel Front Header
Panel Rear Header
Member Kick Up
Reinf Radiator Rail Closeout
Panel Skirt
Panel Gutter Deck Lid
Support Panel Rear Header
Rail Fender Support Inner
Rail Fender Support Outer
Reinf Front Rail
Plate Rear Spring Upper
Reinf Panel Dash Brake Booster
Bracket Rear Shock Absorber Mount
Reinf Floor Front Seat Rear Center
Reinf Rear Seat Inner Belt Mount
Bracket Member Pass Through Lower
Bracket Member Pass Through Up Fr & R
Reinf Panel Dash Upper
Pan Rear Floor
Reinf Hinge Decklid
Reinf A-Pillar
Closeout Fender Support Rail
Reinf Rail Dash
Assy Reinf Cowl Lower
Bracket Trailing Arm Mount Inner
Reinf Seat Belt Retractor Rear
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
18.38
3.31
4.59
3.78
6.17
5.97
12.52
4.82
0.69
13.27
9.22
5.32
1.17
1.50
1.71
0.78
0.98
0.65
0.82
0.43
13.25
0.85
1.14
0.86
3.61
0.54
1.48
0.85
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
n/a
n/a
none
none
0.00
0.00
STAMPING TOTALS
583.58
<========================GENERAL OUTPUT COSTS=========== =========>

TUBULAR & PURCHASED PARTS
Part ID
072
073
090
188
XXX
XXX
XXX
n/a
n/a
n/a
n/a
n/a
n/a
Part Name
Units
Rail Side Roof RH
Rail Side Roof LH
Member Pass Through
Brace Radiator
Hinges
Small Brackets
Weld Studs
none
none
none
none
none
none
Total
Part Cost
$ / part
20.42
20.44
0.75
0.20
24.00
15.00
1.00
0.00
0.00
0.00
0.00
0.00
0.00
TUBULAR & PURCHASED PARTS TOTALS
81.81
PARTS FABRICATION TOTALS
665.38
ASSEMBLY
<=======================GENERAL OUTPUT COSTS=========== ==========>
AREA #
410
411/412
414
415
416/417
421
422
428
431
AREA NAME
Final
Body Side Outer
Framing
Underbody Complete
Body Side Inner
Front End
Front Ladder Complete
Underbody Floor
Underbody Inner
COST/
VEHICLE
$ / vehicle
55.12
26.92
38.92
15.08
35.28
15.12
32.57
27.10
13.91
439
XXX
XXX
n/a
n/a
n/a
n/a
n/a
Dash
Hinge Assembly
Miscellaneous Brackets
none
none
none
none
none
7.56
5.06
8.83
0.00
0.00
0.00
0.00
0.00
ASSEMBLY TOTALS
281.48
TOTAL BODY STRUCTURE COST
946.87
<=========
==========
==========
COST BREAKDOWN===================
==========
======>
Material
Cost
$ / parts
4.17
2.10
11.96
18.24
6.58
0.75
8.92
5.70
4.10
2.11
3.34
2.39
0.36
17.19
25.39
1.93
19.08
9.27
12.19
2.35
4.14
39.42
39.41
5.88
15.14
1.46
6.20
9.13
3.89
3.52
3.48
0.27
Labor
Cost
$ / parts
0.61
0.56
1.33
1.18
0.42
0.55
0.25
0.21
0.56
0.56
0.56
1.11
0.12
1.52
0.89
0.61
1.08
0.58
1.23
0.61
0.24
3.45
3.45
0.24
0.24
1.11
0.24
0.87
0.24
0.56
0.61
0.06
Energy
Cost
$ / parts
0.14
0.10
0.18
0.19
0.14
0.10
0.09
0.04
0.13
0.10
0.10
0.20
0.02
0.20
0.10
0.11
0.11
0.10
0.24
0.11
0.06
0.37
0.37
0.07
0.07
0.20
0.07
0.10
0.07
0.13
0.14
0.01
Equip.
Cost
$ / parts
1.06
0.97
2.76
3.15
1.06
0.96
2.17
0.21
1.03
0.80
0.80
1.56
0.12
2.29
3.53
0.81
4.07
3.17
1.62
1.24
1.68
8.46
8.46
1.62
2.13
1.46
1.62
4.07
1.62
1.03
1.12
0.06
Tooling
Cost
$ / parts
0.56
0.53
1.32
1.63
0.99
0.58
1.74
0.25
0.60
0.75
0.78
0.59
0.10
2.85
1.76
0.38
2.04
2.12
0.76
0.72
0.92
4.93
4.93
0.96
1.43
0.66
1.33
1.68
0.72
0.78
0.78
0.20
Overhead
Labor
Building
Cost
Cost
$ / parts $ / parts
0.39
0.10
0.36
0.07
1.03
0.35
1.06
0.38
0.34
0.10
0.35
0.07
0.22
0.07
0.26
0.03
0.36
0.09
0.36
0.07
0.36
0.07
0.69
0.14
0.15
0.01
0.64
0.14
0.71
0.26
0.39
0.08
0.96
0.36
0.62
0.25
0.75
0.15
0.39
0.08
0.21
0.05
2.64
1.04
2.64
1.04
0.21
0.06
0.21
0.06
0.69
0.14
0.21
0.06
0.99
0.44
0.21
0.06
0.36
0.09
0.39
0.10
0.08
0.01
Maint.
Cost
$ / parts
0.17
0.16
0.44
0.52
0.22
0.16
0.40
0.05
0.17
0.16
0.17
0.23
0.02
0.53
0.56
0.13
0.65
0.55
0.25
0.20
0.27
1.44
1.44
0.26
0.36
0.23
0.30
0.62
0.24
0.19
0.20
0.03
Working
Capital
Cost
$ / parts
0.02
0.01
0.05
0.07
0.03
0.01
0.03
0.00
0.02
0.01
0.02
0.02
0.00
0.07
0.09
0.01
0.07
0.04
0.05
0.01
0.02
0.16
0.16
0.02
0.05
0.01
0.02
0.04
0.02
0.02
0.02
0.00
9.15
0.00
1.81
1.41
3.10
2.62
6.78
1.68
0.25
9.67
5.73
2.67
0.61
1.11
1.23
0.47
0.44
0.10
0.49
0.13
9.14
0.35
0.80
0.40
1.00
0.18
1.07
0.33
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
2.34
0.84
0.67
0.56
0.56
0.61
0.51
0.61
0.06
0.24
0.24
0.61
0.12
0.06
0.10
0.06
0.12
0.12
0.06
0.06
0.24
0.12
0.06
0.06
0.61
0.06
0.10
0.12
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.16
0.08
0.12
0.07
0.13
0.14
0.10
0.14
0.01
0.06
0.06
0.11
0.02
0.01
0.02
0.01
0.02
0.02
0.01
0.01
0.06
0.02
0.01
0.01
0.11
0.01
0.02
0.02
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
4.24
1.10
0.89
0.74
1.03
1.06
2.97
1.06
0.06
1.68
1.68
0.81
0.12
0.06
0.10
0.06
0.12
0.12
0.06
0.06
2.13
0.12
0.06
0.06
0.81
0.06
0.10
0.12
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.45
0.65
0.43
0.45
0.70
0.84
0.96
0.65
0.20
1.06
0.97
0.50
0.10
0.15
0.10
0.09
0.09
0.10
0.10
0.07
1.06
0.05
0.11
0.22
0.47
0.12
0.05
0.07
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
1.40
0.42
0.42
0.36
0.36
0.39
0.54
0.39
0.08
0.21
0.21
0.39
0.15
0.08
0.12
0.08
0.15
0.15
0.08
0.08
0.21
0.15
0.08
0.08
0.39
0.08
0.12
0.15
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.11
0.05
0.09
0.05
0.09
0.10
0.22
0.10
0.01
0.05
0.05
0.08
0.01
0.01
0.01
0.01
0.01
0.01
0.01
0.01
0.05
0.01
0.01
0.01
0.08
0.01
0.01
0.01
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.48
0.18
0.14
0.12
0.18
0.20
0.41
0.18
0.03
0.28
0.27
0.14
0.02
0.02
0.02
0.02
0.02
0.02
0.02
0.01
0.32
0.02
0.02
0.03
0.14
0.02
0.02
0.02
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.05
0.01
0.01
0.01
0.01
0.01
0.03
0.01
0.00
0.03
0.02
0.01
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.03
0.00
0.00
0.00
0.01
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
352.84
35.83
5.63
88.17
51.21
26.48
7.33
14.67
1.40
<=========
==========
==========
COST BREAKDOWN==========
==========
==========
======>
Overhead
Labor
Building
Cost
Cost
$ / part
$ / part
1.23
0.15
1.23
0.15
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Material
Cost
$ / part
11.08
11.09
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Labor
Cost
$ / part
1.53
1.53
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Energy
Cost
$ / part
0.11
0.11
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Equip.
Cost
$ / part
4.87
4.87
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Tooling
Cost
$ / part
0.82
0.82
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
22.17
3.05
0.22
9.74
1.64
2.46
375.00
38.88
5.86
97.91
52.85
28.95
Maint.
Cost
$ / part
0.58
0.58
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Working
Capital
Cost
$ / part
0.05
0.05
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.31
1.17
0.10
7.64
15.84
1.50
<=========
==========
==========
COST BREAKDOWN=============
==========
==========
======>
Material
Labor
Energy
Equip.
Tooling
Cost
Cost
Cost
Cost
Cost
$ / vehicle $ / vehicle $ / vehicle $ / vehicle $ / vehicle
0.11
4.93
3.62
11.90
5.60
0.00
3.52
0.31
4.49
1.60
0.08
4.93
1.51
9.61
3.70
0.01
2.11
0.39
2.42
1.37
0.04
5.63
0.64
6.04
4.30
0.02
2.82
0.42
3.06
0.71
0.01
8.45
0.64
3.27
2.18
0.03
4.22
1.86
4.40
0.99
0.00
2.11
0.13
2.96
0.99
Overhead
Working
Labor
Building Maint.
Capital
Cost
Cost
Cost
Cost
$ / vehicle $ / vehicle $ / vehicle $ / vehicle
24.64
2.24
1.97
0.12
13.38
2.69
0.88
0.06
15.49
2.00
1.53
0.08
6.34
1.86
0.56
0.03
13.38
3.77
1.41
0.07
7.04
0.58
0.44
0.04
16.19
1.10
0.65
0.09
13.38
1.46
0.69
0.07
5.63
1.52
0.55
0.03
0.18
0.01
0.00
0.00
0.00
0.00
0.00
0.00
2.82
1.41
2.11
0.00
0.00
0.00
0.00
0.00
0.01
0.02
0.34
0.00
0.00
0.00
0.00
0.00
0.06
0.74
0.92
0.00
0.00
0.00
0.00
0.00
0.12
0.62
1.23
0.00
0.00
0.00
0.00
0.00
4.22
2.11
3.52
0.00
0.00
0.00
0.00
0.00
0.10
0.00
0.42
0.00
0.00
0.00
0.00
0.00
0.03
0.14
0.26
0.00
0.00
0.00
0.00
0.00
0.02
0.01
0.02
0.00
0.00
0.00
0.00
0.00
0.49
45.06
9.87
49.88
23.40
125.31
17.74
9.10
0.63
<=============
==INVESTMENT COSTS & MACHINE RENTS==============
===========>
Total
Investment
$
2,411,629
2,185,617
6,335,219
7,292,414
2,761,629
2,206,220
5,182,818
592,173
2,387,902
2,089,479
2,114,479
3,344,226
310,796
6,404,400
7,822,293
1,803,367
9,137,447
7,490,753
3,607,384
2,811,185
3,655,376
20,063,842
20,063,842
3,600,689
4,846,538
3,238,894
3,905,689
8,977,335
3,405,689
2,532,902
2,692,263
275,398
Machine
Tooling
Building
Investment Investment Investment
$
$
$
1,774,832
456,590
180,208
1,629,428
426,590
129,600
4,637,498
1,072,349
625,372
5,289,144
1,326,074
677,196
1,774,832
806,590
180,208
1,608,961
471,590
125,670
3,641,327
1,413,179
128,312
347,671
200,000
44,502
1,731,768
489,884
166,250
1,349,995
609,884
129,600
1,349,995
634,884
129,600
2,618,118
474,768
251,339
204,607
80,000
26,190
3,845,133
2,313,179
246,089
5,933,449
1,424,799
464,045
1,356,708
306,590
140,069
6,839,233
1,654,799
643,415
5,332,250
1,722,349
436,154
2,719,863
616,590
270,931
2,086,232
584,884
140,069
2,823,003
749,884
82,489
14,222,606
4,000,000
1,841,237
14,222,606
4,000,000
1,841,237
2,720,664
776,590
103,436
3,579,924
1,163,179
103,436
2,454,376
533,179
251,339
2,720,664
1,081,590
103,436
6,837,524
1,364,900
774,911
2,720,664
581,590
103,436
1,731,768
634,884
166,250
1,877,171
634,884
180,208
102,303
160,000
13,095
Effective Machine RENT

Model ASSUMPTIONS ONLY
Blanking
Stamping
$/hr
$/hr
138
484
138
459
138
484
159
526
138
484
138
459
265
1,446
74
133
201
484
201
374
201
374
201
374
74
133
265
807
265
1,446
138
374
180
1,446
138
1,446
138
374
201
502
201
1,141
189
942
189
942
138
1,166
265
1,421
138
374
138
1,166
138
1,190
138
1,166
201
484
201
484
74
133
7,679,061
2,468,250
1,997,768
1,702,195
2,462,902
2,636,629
6,151,086
2,481,629
275,398
3,765,376
3,690,376
1,903,367
315,796
235,398
269,592
185,398
300,796
310,796
195,398
175,398
4,525,591
267,796
205,398
295,398
1,878,367
215,398
226,592
290,796
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
7,130,024
1,854,246
1,493,024
1,247,656
1,731,768
1,774,832
4,986,563
1,774,832
102,303
2,823,003
2,823,003
1,356,708
204,607
102,303
163,645
102,303
204,607
204,607
102,303
102,303
3,579,924
204,607
102,303
102,303
1,356,708
102,303
163,645
204,607
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
363,179
525,000
351,590
361,590
564,884
681,590
782,161
526,590
160,000
859,884
784,884
406,590
85,000
120,000
85,000
70,000
70,000
80,000
80,000
60,000
863,179
37,000
90,000
180,000
381,590
100,000
42,000
60,000
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
185,857
89,004
153,155
92,949
166,250
180,208
382,362
180,208
13,095
82,489
82,489
140,069
26,190
13,095
20,947
13,095
26,190
26,190
13,095
13,095
82,489
26,190
13,095
13,095
140,069
13,095
20,947
26,190
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
265
74
138
138
201
138
138
138
74
201
201
138
74
74
74
74
74
74
74
74
265
74
74
74
138
74
74
74
74
74
74
74
74
74
74
74
74
74
74
74
74
74
74
74
74
74
74
74
410
434
374
349
484
484
1,446
484
133
1,141
1,141
374
133
133
133
133
133
133
133
133
1,397
133
133
133
374
133
133
133
44
44
44
44
44
44
44
44
44
44
44
44
44
44
44
44
44
44
44
44
0
0
202,657,837
0
0
0
0
0
0
########## 41,537,958
12,934,522
<=============
==INVESTMENT COSTS============>
Total
Investment
$
9,119,695
9,119,695
0
0
0
0
0
0
0
0
0
0
0
18,239,390
220,897,227
Machine
Tooling
Building
$
$
$
8,183,784
665,000
270,911
8,183,784
665,000
270,911
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
16,367,567
1,330,000
541,823
########## 42,867,958
13,476,345
<=====INVESTMENT COSTS============
========>
Total
Investment
$
18,145,000
9,681,500
14,324,100
6,351,000
15,035,300
4,081,500
6,358,000
6,954,500
5,876,000
Machine
Tooling Building
$
$
$
9,655,000
4,539,000
3,951,000
3,640,000
1,300,000
4,741,500
7,794,600
3,000,000
3,529,500
1,965,000
1,110,000
3,276,000
4,900,800
3,485,000
6,649,500
2,485,000
575,000
1,021,500
2,650,000
1,770,000
1,938,000
3,570,000
800,000
2,584,500
2,400,000
800,000
2,676,000
74
74
44
44
330,000
1,100,000
2,500,000
0
0
0
0
0
50,000
600,000
750,000
0
0
0
0
0
100,000
500,000
1,000,000
0
0
0
0
0
180,000
0
750,000
0
0
0
0
0
90,736,900
40,460,400
18,979,000
31,297,500
COST BREAKDOWN BY PROCESS STEP

STAMPED PARTS
===========TOTAL
<=============COST PER PROCESS STEP===========
=============
==============
=======>
Part ID
001
002/003
008/009
010/011
012/013
014/015
021
022
026
028
032
034
038
040
042/043
045
046/047
048/049
050
055
057
060
061
062/063
064/065
066
068/069
070/071
074/075
080
081
082/083
085
085
086
Material Blanking Welding Stamping

Part Name
Cost
Cost
Cost
Cost
Units
$ / part
$ / part
$ / part
$ / part
4.17
0.29
0.00
2.77
2.10
0.28
0.00
2.48
11.96
0.75
2.75
3.97
18.24
0.99
3.02
4.16
6.58
0.29
0.00
3.01
0.75
0.23
0.00
2.54
Panel Dash
8.92
0.58
0.00
4.39
5.70
0.00
0.00
1.04
Member Dash Front
4.10
0.39
0.00
2.58
Panel Cowl Lower
2.11
0.38
0.00
2.44
Panel Cowl Upper
3.34
0.39
0.00
2.47
2.39
0.65
0.00
3.87
0.36
0.00
0.00
0.55
Pan Front Floor
17.19
0.61
0.00
7.63
Panel Rocker Inner
25.39
1.07
2.20
4.63
1.93
0.28
0.00
2.23
Rail Rear Inner
19.08
1.10
3.30
4.94
Rail Rear Outer
9.27
0.74
1.95
4.74
12.19
0.31
0.00
4.73
Member Panel Back
2.35
0.38
0.00
2.98
Panel Back
4.14
0.39
0.00
3.05
39.42
1.90
9.53
11.06
39.41
1.90
9.53
11.06
5.88
0.29
0.00
3.15
15.14
0.53
0.00
4.02
1.46
0.47
0.00
4.03
6.20
0.29
0.00
3.56
9.13
0.50
4.40
3.91
3.89
0.28
0.00
2.88
3.52
0.39
0.00
2.78
3.48
0.39
0.00
2.97
0.27
0.00
0.00
0.44
Panel Roof - Hydromechanical Forming Step 9.15
0.58
0.00
8.65
0.00
0.00
0.00
3.31
Panel Front Header
1.81
0.28
0.00
2.50
087
091
094/095
096/097
098/099
102/103
104/105
106/107
108/109
110
115
116/117
120
122
128
130/152
136
140
142
144/145
164/165
170/171
172
180/181
190
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
Panel Rear Header

Member Kick Up
Panel Skirt
Reinf Front Rail
Pan Rear Floor
Reinf Hinge Decklid
Reinf A-Pillar
Reinf Rail Dash
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
1.41
3.10
2.62
6.78
1.68
0.25
9.67
5.73
2.67
0.61
1.11
1.23
0.47
0.44
0.10
0.49
0.13
9.14
0.35
0.80
0.40
1.00
0.18
1.07
0.33
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.28
0.39
0.28
0.49
0.28
0.00
0.41
0.40
0.28
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.51
0.00
0.00
0.00
0.27
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
1.64
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
2.09
2.68
3.07
3.61
2.86
0.44
3.19
3.09
2.37
0.56
0.38
0.47
0.32
0.54
0.55
0.33
0.30
3.59
0.49
0.34
0.47
2.34
0.36
0.41
0.52
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
STAMPED PARTS TOTALS
352.84
21.49
38.33
170.92
<=========
==========
BLANKING COST BREAKDOWN===============
==============
==========
======>
Material
Cost
$ / part
4.48
2.24
12.70
19.17
6.90
0.81
9.41
5.74
4.26
2.24
3.62
2.47
0.39
17.76
26.92
2.01
20.16
9.80
12.25
2.51
4.46
42.49
42.49
6.27
16.12
1.55
6.56
9.89
4.03
3.76
3.76
0.29
9.35
0.00
1.95
Labor
Cost
$ / part
0.05
0.05
0.11
0.14
0.05
0.04
0.06
0.00
0.05
0.05
0.05
0.07
0.00
0.06
0.09
0.05
0.14
0.11
0.05
0.05
0.05
0.24
0.24
0.05
0.05
0.07
0.05
0.07
0.05
0.05
0.05
0.00
0.06
0.00
0.05
Energy
Cost
$ / part
0.01
0.01
0.02
0.03
0.01
0.01
0.01
0.00
0.01
0.01
0.01
0.02
0.00
0.01
0.02
0.01
0.03
0.02
0.01
0.01
0.01
0.05
0.05
0.01
0.01
0.02
0.01
0.02
0.01
0.01
0.01
0.00
0.01
0.00
0.01
Equip.
Cost
$ / part
0.06
0.06
0.15
0.25
0.06
0.05
0.22
0.00
0.12
0.12
0.12
0.19
0.00
0.22
0.37
0.06
0.31
0.15
0.06
0.12
0.12
0.57
0.57
0.06
0.18
0.10
0.06
0.10
0.06
0.12
0.12
0.00
0.22
0.00
0.06
Tooling
Cost
$ / part
0.07
0.07
0.21
0.25
0.07
0.07
0.14
0.00
0.10
0.10
0.10
0.21
0.00
0.14
0.28
0.07
0.28
0.21
0.07
0.10
0.10
0.43
0.43
0.07
0.14
0.14
0.07
0.14
0.07
0.10
0.10
0.00
0.14
0.00
0.07
Overhead
Labor
Building
Cost
Cost
$ / part
$ / part
0.06
0.01
0.06
0.01
0.14
0.03
0.18
0.03
0.06
0.01
0.05
0.01
0.07
0.01
0.00
0.00
0.06
0.01
0.06
0.01
0.06
0.01
0.09
0.02
0.00
0.00
0.07
0.01
0.12
0.02
0.06
0.01
0.18
0.03
0.14
0.03
0.06
0.01
0.06
0.01
0.06
0.01
0.30
0.06
0.30
0.06
0.06
0.01
0.06
0.01
0.09
0.02
0.06
0.01
0.09
0.02
0.06
0.01
0.06
0.01
0.06
0.01
0.00
0.00
0.07
0.01
0.00
0.00
0.06
0.01
Maint.
Cost
$ / part
0.01
0.01
0.04
0.05
0.01
0.01
0.04
0.00
0.02
0.02
0.02
0.04
0.00
0.04
0.07
0.01
0.06
0.04
0.01
0.02
0.02
0.11
0.11
0.01
0.03
0.03
0.01
0.03
0.01
0.02
0.02
0.00
0.04
0.00
0.01
Working
Capital
Cost
$ / part
0.02
0.01
0.04
0.07
0.02
0.00
0.03
0.00
0.01
0.01
0.01
0.01
0.00
0.06
0.09
0.01
0.07
0.03
0.04
0.01
0.02
0.14
0.14
0.02
0.05
0.01
0.02
0.03
0.01
0.01
0.01
0.00
0.03
0.00
0.01
1.53
3.23
2.80
6.97
1.83
0.26
10.12
6.11
2.80
0.62
1.19
1.31
0.49
0.46
0.11
0.52
0.13
9.85
0.37
0.84
0.42
1.05
0.19
1.12
0.36
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.05
0.05
0.05
0.09
0.05
0.00
0.05
0.05
0.05
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.05
0.00
0.00
0.00
0.05
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.01
0.01
0.01
0.02
0.01
0.00
0.01
0.01
0.01
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.01
0.00
0.00
0.00
0.01
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.06
0.12
0.06
0.12
0.06
0.00
0.12
0.12
0.06
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.18
0.00
0.00
0.00
0.06
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.07
0.10
0.07
0.07
0.07
0.00
0.10
0.10
0.07
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.14
0.00
0.00
0.00
0.07
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.06
0.06
0.06
0.12
0.06
0.00
0.06
0.06
0.06
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.06
0.00
0.00
0.00
0.06
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.01
0.01
0.01
0.02
0.01
0.00
0.01
0.01
0.01
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.01
0.00
0.00
0.00
0.01
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.01
0.02
0.01
0.02
0.01
0.00
0.02
0.02
0.01
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.03
0.00
0.00
0.00
0.01
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.01
0.01
0.01
0.02
0.01
0.00
0.03
0.02
0.01
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.03
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
373.50
2.80
0.61
6.02
5.45
3.50
0.68
1.22
1.22
<=========
==========
WELDING COST BREAKDOWN===========
==================
==========
======>
Material
Cost
$ / part
0.00
0.00
-0.01
-0.02
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
-0.03
0.00
-0.02
-0.01
0.00
0.00
0.00
-0.12
-0.12
0.00
0.00
0.00
0.00
-0.01
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Labor
Cost
$ / part
0.00
0.00
0.37
0.41
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.30
0.00
0.45
0.27
0.00
0.00
0.00
1.30
1.30
0.00
0.00
0.00
0.00
0.60
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Energy
Cost
$ / part
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.01
0.01
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Equip.
Cost
$ / part
0.00
0.00
1.50
1.65
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
1.20
0.00
1.80
1.07
0.00
0.00
0.00
5.21
5.21
0.00
0.00
0.00
0.00
2.40
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Tooling
Cost
$ / part
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Overhead
Labor
Building Maint.
Cost
Cost
Cost
$ / part
$ / part
$ / part
0.00
0.00
0.00
0.00
0.00
0.00
0.47
0.23
0.17
0.51
0.25
0.19
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.37
0.18
0.14
0.00
0.00
0.00
0.56
0.27
0.21
0.33
0.16
0.12
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
1.62
0.78
0.60
1.62
0.78
0.60
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.75
0.36
0.28
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Working
Capital
Cost
$ / part
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.01
0.01
0.00
0.00
0.00
0.00
0.01
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
-0.01
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.22
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.90
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.28
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.13
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.10
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
-0.35
5.22
0.04
20.94
0.00
6.52
3.15
2.41
0.05
<=========
==========
STAMPING COST BREAKDOWN====================
==========
======>
Material
Cost
$ / part
-0.31
-0.14
-0.72
-0.91
-0.31
-0.05
-0.49
-0.03
-0.16
-0.13
-0.28
-0.08
-0.03
-0.57
-1.50
-0.08
-1.06
-0.52
-0.06
-0.16
-0.31
-2.95
-2.96
-0.39
-0.99
-0.08
-0.37
-0.75
-0.14
-0.24
-0.28
-0.02
-0.20
0.00
-0.13
Labor
Cost
$ / part
0.57
0.52
0.84
0.63
0.38
0.52
0.20
0.21
0.52
0.52
0.52
1.03
0.12
1.46
0.49
0.57
0.49
0.20
1.18
0.57
0.20
1.91
1.91
0.20
0.20
1.03
0.20
0.20
0.20
0.52
0.57
0.06
2.28
0.84
0.63
Energy
Cost
$ / part
0.13
0.09
0.15
0.15
0.13
0.09
0.08
0.04
0.12
0.09
0.09
0.18
0.02
0.19
0.08
0.10
0.08
0.08
0.23
0.10
0.05
0.31
0.31
0.06
0.06
0.18
0.06
0.08
0.06
0.12
0.13
0.01
0.15
0.08
0.11
Equip.
Cost
$ / part
1.00
0.91
1.11
1.25
1.00
0.91
1.95
0.21
0.91
0.68
0.68
1.36
0.12
2.07
1.96
0.75
1.96
1.96
1.56
1.12
1.56
2.68
2.68
1.56
1.95
1.36
1.56
1.57
1.56
0.91
1.00
0.06
4.02
1.10
0.83
Tooling
Cost
$ / part
0.49
0.46
1.11
1.39
0.92
0.51
1.60
0.25
0.50
0.65
0.68
0.38
0.10
2.71
1.47
0.31
1.76
1.91
0.69
0.62
0.82
4.50
4.50
0.89
1.29
0.52
1.26
1.54
0.65
0.68
0.68
0.20
0.31
0.65
0.36
Overhead
Labor
Building Maint.
Cost
Cost
Cost
$ / part
$ / part
$ / part
0.33
0.09
0.16
0.30
0.06
0.14
0.42
0.10
0.23
0.37
0.10
0.27
0.28
0.09
0.20
0.30
0.06
0.15
0.15
0.06
0.36
0.26
0.03
0.05
0.30
0.08
0.15
0.30
0.06
0.14
0.30
0.06
0.14
0.60
0.12
0.19
0.15
0.01
0.02
0.57
0.13
0.49
0.22
0.06
0.35
0.33
0.07
0.11
0.22
0.06
0.38
0.15
0.06
0.39
0.69
0.14
0.24
0.33
0.07
0.18
0.15
0.04
0.24
0.72
0.20
0.74
0.72
0.20
0.74
0.15
0.05
0.25
0.15
0.05
0.33
0.60
0.12
0.20
0.15
0.05
0.29
0.15
0.06
0.32
0.15
0.05
0.23
0.30
0.08
0.17
0.33
0.09
0.18
0.08
0.01
0.03
1.33
0.09
0.44
0.42
0.05
0.18
0.37
0.08
0.13
Working
Capital
Cost
$ / part
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.01
0.00
0.01
0.00
0.00
0.00
0.00
0.01
0.00
0.00
0.00
0.00
0.00
0.00
0.01
0.00
0.00
0.00
0.00
0.00
0.00
0.01
0.01
0.00
-0.12
-0.13
-0.18
-0.18
-0.14
-0.01
-0.45
-0.39
-0.13
-0.01
-0.08
-0.07
-0.03
-0.02
-0.01
-0.03
0.00
-0.70
-0.02
-0.04
-0.02
-0.05
-0.01
-0.05
-0.03
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.52
0.52
0.57
0.20
0.57
0.06
0.20
0.20
0.57
0.12
0.06
0.10
0.06
0.12
0.12
0.06
0.06
0.20
0.12
0.06
0.06
0.57
0.06
0.10
0.12
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.06
0.12
0.13
0.08
0.13
0.01
0.05
0.05
0.10
0.02
0.01
0.02
0.01
0.02
0.02
0.01
0.01
0.05
0.02
0.01
0.01
0.10
0.01
0.02
0.02
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.68
0.91
1.00
1.95
1.00
0.06
1.56
1.56
0.75
0.12
0.06
0.10
0.06
0.12
0.12
0.06
0.06
1.95
0.12
0.06
0.06
0.75
0.06
0.10
0.12
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.38
0.59
0.77
0.89
0.58
0.20
0.96
0.86
0.43
0.10
0.15
0.10
0.09
0.09
0.10
0.10
0.07
0.92
0.05
0.11
0.22
0.40
0.12
0.05
0.07
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.30
0.30
0.33
0.15
0.33
0.08
0.15
0.15
0.33
0.15
0.08
0.12
0.08
0.15
0.15
0.08
0.08
0.15
0.15
0.08
0.08
0.33
0.08
0.12
0.15
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.04
0.08
0.09
0.06
0.09
0.01
0.04
0.04
0.07
0.01
0.01
0.01
0.01
0.01
0.01
0.01
0.01
0.04
0.01
0.01
0.01
0.07
0.01
0.01
0.01
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.11
0.16
0.19
0.29
0.17
0.03
0.25
0.25
0.12
0.02
0.02
0.02
0.02
0.02
0.02
0.02
0.01
0.29
0.02
0.02
0.03
0.12
0.02
0.02
0.02
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
-20.31
27.82
4.99
61.21
45.76
16.47
3.50
11.05
0.13
INVESTMENT BREAKDOWN BY PROCESS STEP

(investments take into account the time the equipment is used for the particular part)
STAMPED PARTS
<=============
=========TOTAL INVESTMENT PER PROCESS STEP=====================>
Part ID
001
002/003
008/009
010/011
012/013
014/015
021
022
026
028
032
034
038
040
042/043
045
046/047
048/049
050
055
057
060
061
062/063
064/065
066
068/069
070/071
074/075
080
081
082/083
085
085
Blanking
Total
Part Name
Investment
Units
$
178,578
178,578
469,572
676,497
178,578
154,180
Panel Dash
505,179
0
Member Dash Front
309,212
Panel Cowl Lower
309,212
Panel Cowl Upper
309,212
528,691
0
Pan Front Floor
505,179
Panel Rocker Inner
893,064
178,578
Rail Rear Inner
809,117
Rail Rear Outer
469,572
178,578
Member Panel Back
309,212
Panel Back
309,212
1,411,434
1,411,434
178,578
439,846
308,360
178,578
313,048
178,578
309,212
309,212
0
Panel Roof - Hydromechanical Forming Step 505,179
0
Welding
Total
Investment
$
0
0
2,922,753
3,215,029
0
0
0
0
0
0
0
0
0
0
2,338,203
0
3,507,304
2,075,155
0
0
0
10,139,224
10,139,224
0
0
0
0
4,676,406
0
0
0
0
0
0
Stamping
Total
Investment
$
2,233,052
2,007,040
2,942,894
3,400,888
2,583,052
2,052,040
4,677,639
592,173
2,078,690
1,780,267
1,805,267
2,815,535
310,796
5,899,221
4,591,026
1,624,789
4,821,026
4,946,026
3,428,806
2,501,973
3,346,164
8,513,185
8,513,185
3,422,111
4,406,692
2,930,535
3,727,111
3,987,881
3,227,111
2,223,690
2,383,052
275,398
7,173,881
2,468,250
086
087
091
094/095
096/097
098/099
102/103
104/105
106/107
108/109
110
115
116/117
120
122
128
130/152
136
140
142
144/145
164/165
170/171
172
180/181
190
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
Panel Front Header

Panel Rear Header
Member Kick Up
Panel Skirt
Reinf Front Rail
Pan Rear Floor
Reinf Hinge Decklid
Reinf A-Pillar
Reinf Rail Dash
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
178,578
178,578
309,212
178,578
303,603
178,578
0
309,212
309,212
178,578
0
0
0
0
0
0
0
0
439,846
0
0
0
178,578
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1,744,844
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1,819,190
1,523,617
2,153,690
2,458,052
4,102,639
2,303,052
275,398
3,456,164
3,381,164
1,724,789
315,796
235,398
269,592
185,398
300,796
310,796
195,398
175,398
4,085,746
267,796
205,398
295,398
1,699,789
215,398
226,592
290,796
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
STAMPED PART INVESTMENTS
15,736,010
40,758,143
146,163,684

<=============
=========TOTAL INVESTMENT PER PROCESS STEP===========
============>
Part ID
072
073
090
188
XXX
XXX
XXX
n/a
n/a
n/a
n/a
n/a
n/a
Part Name
Units
Rail Side Roof RH
Rail Side Roof LH
Member Pass Through
Brace Radiator
Hinges
Small Brackets
Weld Studs
none
none
none
none
none
none
TUBULAR PART INVESTMENTS
Hydroforming Hydroforming Hydroforming

Line
Tooling
Building
Invest.
Invest.
Invest.
$
$
$
8,183,784
665,000
270,911
8,183,784
665,000
270,911
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
16,367,567
1,330,000
541,823
ASSEMBLY
<=============
========= INVESTMENT BREAKDOWN==========================>
============>
AREA #
410
411/412
414
415
416/417
421
422
428
431
439
XXX
AREA NAME
Final
Body Side Outer
Framing
Underbody Complete
Body Side Inner
Front End
Underbody Floor
Underbody Inner
Dash
Hinge Assembly
Equipment
Investment
$
9,655,000
3,640,000
7,794,600
1,965,000
4,900,800
2,485,000
2,650,000
3,570,000
2,400,000
50,000
600,000
Tooling
Investment
$
4,539,000
1,300,000
3,000,000
1,110,000
3,485,000
575,000
1,770,000
800,000
800,000
100,000
500,000
Building
Investment
$
3,951,000
4,741,500
3,529,500
3,276,000
6,649,500
1,021,500
1,938,000
2,584,500
2,676,000
180,000
0
XXX
n/a
n/a
n/a
n/a
n/a
none
none
none
none
none
ASSEMBLY INVESTMENT TOTALS
750,000
0
0
0
0
0
1,000,000
0
0
0
0
0
750,000
0
0
0
0
0
40,460,400
18,979,000
31,297,500
<===================INVESTMENT BREAKDOWN================ ==============

Blanking
Press
Invest.
$
102,339
102,339
249,348
415,580
102,339
81,871
368,421
0
204,678
204,678
204,678
327,485
0
368,421
623,370
102,339
519,475
249,348
102,339
204,678
204,678
959,127
959,127
102,339
307,018
163,742
102,339
166,232
102,339
204,678
204,678
0
368,421
0
Blanking
Tooling
Invest.
$
56,590
56,590
172,349
201,074
56,590
56,590
113,179
0
84,884
84,884
84,884
169,768
0
113,179
229,799
56,590
229,799
172,349
56,590
84,884
84,884
350,000
350,000
56,590
113,179
113,179
56,590
114,900
56,590
84,884
84,884
0
113,179
0
Blanking
Building
Invest.
$
19,649
19,649
47,875
59,843
19,649
15,719
23,579
0
19,649
19,649
19,649
31,439
0
23,579
39,896
19,649
59,843
47,875
19,649
19,649
19,649
102,307
102,307
19,649
19,649
31,439
19,649
31,917
19,649
19,649
19,649
0
23,579
0
Welding
Line
Invest.
$
0
0
2,524,196
2,776,616
0
0
0
0
0
0
0
0
0
0
2,019,357
0
3,029,035
1,792,179
0
0
0
8,756,603
8,756,603
0
0
0
0
4,038,714
0
0
0
0
0
0
Welding
Building
Invest.
$
0
0
398,557
438,413
0
0
0
0
0
0
0
0
0
0
318,846
0
478,269
282,976
0
0
0
1,382,621
1,382,621
0
0
0
0
637,692
0
0
0
0
0
0
Stamping
Press
Invest.
$
1,672,492
1,527,089
1,863,954
2,096,948
1,672,492
1,527,089
3,272,906
347,671
1,527,089
1,145,317
1,145,317
2,290,634
204,607
3,476,712
3,290,723
1,254,369
3,290,723
3,290,723
2,617,524
1,881,554
2,618,325
4,506,876
4,506,876
2,618,325
3,272,906
2,290,634
2,618,325
2,632,578
2,618,325
1,527,089
1,672,492
102,303
6,761,603
1,854,246
Stamping
Tooling
Invest.
$
400,000
370,000
900,000
1,125,000
750,000
415,000
1,300,000
200,000
405,000
525,000
550,000
305,000
80,000
2,200,000
1,195,000
250,000
1,425,000
1,550,000
560,000
500,000
665,000
3,650,000
3,650,000
720,000
1,050,000
420,000
1,025,000
1,250,000
525,000
550,000
550,000
160,000
250,000
525,000
102,339
102,339
204,678
102,339
206,746
102,339
0
204,678
204,678
102,339
0
0
0
0
0
0
0
0
307,018
0
0
0
102,339
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
56,590
56,590
84,884
56,590
57,161
56,590
0
84,884
84,884
56,590
0
0
0
0
0
0
0
0
113,179
0
0
0
56,590
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
19,649
19,649
19,649
19,649
39,695
19,649
0
19,649
19,649
19,649
0
0
0
0
0
0
0
0
19,649
0
0
0
19,649
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1,506,911
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
237,933
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1,390,685
1,145,317
1,527,089
1,672,492
3,272,906
1,672,492
102,303
2,618,325
2,618,325
1,254,369
204,607
102,303
163,645
102,303
204,607
204,607
102,303
102,303
3,272,906
204,607
102,303
102,303
1,254,369
102,303
163,645
204,607
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
295,000
305,000
480,000
625,000
725,000
470,000
160,000
775,000
700,000
350,000
85,000
120,000
85,000
70,000
70,000
80,000
80,000
60,000
750,000
37,000
90,000
180,000
325,000
100,000
42,000
60,000
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
====>
====>
######### 4,423,958
1,191,768 35,200,214
5,557,929 ########## 37,114,000
=======>
Stamping
Building
Invest.
$
160,559
109,950
178,940
178,940
160,559
109,950
104,733
44,502
146,601
109,950
109,950
219,901
26,190
222,510
105,303
120,419
105,303
105,303
251,282
120,419
62,840
356,308
356,308
83,786
83,786
219,901
83,786
105,303
83,786
146,601
160,559
13,095
162,278
89,004
133,506
73,300
146,601
160,559
104,733
160,559
13,095
62,840
62,840
120,419
26,190
13,095
20,947
13,095
26,190
26,190
13,095
13,095
62,840
26,190
13,095
13,095
120,419
13,095
20,947
26,190
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
6,184,825
GENERAL INPUTS
These parameters are global for all parts and processes
ANNUAL PRODUCTION VOLUME
225000 parts/yr
Important Note: The production is determined by the line rate for which the ULSAB
assembly line is designed. Changing the production volume requires using a
different assembly line rate (see cell B104). However, the equipment and tooling
costs in the model were explicitly determined for the current line rate (72 vehicles/hr).
Changing the line rate therefore REQUIRES the user to also change all of the
equipment and tooling investment inputs.
Exogenous Parameters
Days per Year
Wage (including benefits)
Unit Energy Cost
Interest
Equipment Life
Indirect workers/ Direct Press Shop Worker
Indirect workers/ Press Shop Line
Indirect workers/ Direct Assembly Worker
Indirect Workers/Assembly Station
Building Unit Cost
Production Life
Building Life
Idle Space
Working Capital Period
Downtimes:
No shifts
Worker unpaid breaks
Worker paid breaks
Use Part Groups? (1=yes,0=no)
STAMPED PARTS
Global Blanking Parameters
Blanking Energy Consumption Rate
Blanking Line Space Requirement
Workers / Blank Line
Blanking Unplanned Downtime
Average Blanking Lot Size
Average Blanking Die Change Time
Blanking Installation Percent
Blanking Aux. Equipment Percent
Blanking Maintenance Percent
Blanking Cutting Tool Life
240
44.00
0.10
12%
20
0.25
1.00
1.00
1.00
1500
5
25
100%
2
days/yr
$/hr
$/kWhr
yr
$/sqm
yrs
yrs
months
8.375 hrs/day
0.625 hrs/day
1 hrs/day
0
For Part Specific Process Parameter, Go to Part Inpu

150 kW
100 sqm/line
1 #/line
2 hr/day
3000
0.5 hrs
25%
25%
10%
1,000,000 hits
Global Welding Parameters

Filler Wire Unit Cost
Welding Space Requirement
Workers / Welding Line
Welding Unplanned Downtime
Welding Installation Percent
Welding Maintenance Percent

2.00 $/kg
250 sqm/line
1 #/line
4 hrs/day
25%
10%
Global Press Line Parameters

Press Energy Consumption Rate
Press Station Space Requirement
Press Line Unplanned Downtime
Average Stamping Lot Size
Average Stamping Die Change Time
Press Line Installation Percent
Press Line Aux. Equipment Percent
Press Line Maintenance Percent

150 kW
50 sqm
5 hrs/day
1500
0.5 hrs
25%
25%
10%
TUBULAR PARTS
Global Parameters
Bending Line Unplanned Downtime
Average Bending Lot Size
Average Bending Die Change Time
Bending Line Energy Consumption Rate
Bending Line Space Requirement
Bending Line Installation Percent
Bending Line Maintenance Percent

2 hrs/day
1500
0.5 hrs
100 kW
100 sqm
25%
10%
ASSEMBLY
Global Assembly Parameters
Spot Weld Tip Life (#of welds)
Spot Weld Tip Cost
Spot Weld Energy Consumption
Adhesive Application
Adhesive Unit Cost
Adhesive Bonding Energy Rate
Adhesive Bonding Rate
MIG Electrode Life
MIG Electrode Cost
MIG Filler Metal Needed
MIG Filler Metal Cost
MIG Gas Unit Cost
MIG Gas Flow Rate
MIG Weld Energy Rate
MIG Weld Speed
Laser Energy Rate
Laser Welding Rate
8000
0.45
0.04
0.01
4.00
30
0.6
10000
1.50
0.011
3.94
0.01
0.2
33
0.04
115
0.1
kWhr/weld
kg/m
$/kg
kW
m/sec
m
kg/m
kg/m
$/l
l/m
kW
m/sec
kW
m/sec
Laser Gas Unit Cost

Laser Gas Flow Rate
Robot Energy Rate
Conveyor Energy Rate
Robot Transport Time
Conveyor Transport Time
Ass'y Unplanned Downtime
Assembly Maintenance Cost
Assembly Line Running Rate
0.02
0.33
2
5
5
10
1
10%
72
$/l
l/m
kW
kW
sec
sec
hrs/day
vehicles/hr
MATERIAL PRICE TABLE

Material
Material
Type
Price
MPa
$/kg
0
0.00
140
0.77
TB96
0.77
80% Mild Steel, 20% HSS Mix
Mix
0.80
TB70
0.81
210
0.85
280
0.89
TB60
0.89
350
0.92
TB8
0.92
TB10
0.92
TB42
0.92
TB46
0.92
TB48
0.92
420
0.99
600
1.07
800
1.16
Tube
1.60
Sandwich
3.60
ULSAB
icles/hr).
meter, Go to Part Input
<===========
========GENERAL ASSEMBLY INFORMATION=======
============
===========
===========
Area #
410
411/412
414
415
416/417
421
422
428
431
439
Area Name
Final
Body Side Outer
Framing
Underbody Complete
Body Side Inner
Front End
Underbody Floor
Underbody Inner
Dash
# of
# of
# of
Workers Robots Stations
#
#
#
7
40
28
5
6
14
7
20
15
3
6
6
8
8
11
4
8
6
12
11
11
6
29
13
3
1
5
4
0
2
=======>
Space
Req'd
sqm
2634
3161
2353
2184
4433
681
1292
1723
1784
120
<========= =========== ASSEMBLY METHOD INPUTS====== =========>

# of
Spot
Welds
#
802
72
317
92
128
96
150
437
32
0
Length of
Adhesive
Bonding
m
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
4.400
Length of
MIG
Welds
m
0.072
0.000
0.562
0.000
0.314
0.250
0.000
0.000
0.000
0.000
Length of
Laser
Equipment
Tooling
Welds
Investment Investment
m
$
$
8.956
9,655,000
4,539,000
0.000
3,640,000
1,300,000
5.162
7,794,600
3,000,000
0.000
1,965,000
1,110,000
3.078
4,900,800
3,485,000
0.150
2,485,000
575,000
0.090
2,650,000
1,770,000
0.850
3,570,000
800,000
0.000
2,400,000
800,000
0.000
50,000
100,000
INTERMEDIATE CALCULATIONS
STAMPED PARTS
<========== =========GENERAL CALCULATIONS===================

===================
===================
Part ID
Part Name
001
002/003
008/009
010/011
012/013
014/015
021
022
026
028
032
034
038
040
042/043
045
046/047
048/049
050
055
057
060
061
062/063
064/065
066
068/069
070/071
074/075
080
081
082/083
085
085
086

Panel Dash
Member Dash Front
Panel Cowl Lower
Panel Cowl Upper
Pan Front Floor
Panel Rocker Inner
Rail Rear Inner
Rail Rear Outer
Member Panel Back
Panel Back
Panel Roof - Hydromechanical Forming Step
Panel Front Header
Units
Annual
Paid
Time
hr/yr
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
Total
Input
Steel
kg/yr
1099120
549560
3116880
4703227
1692644
197842
2500509
358779
897614
595368
961741
480858
98845
4718888
6605703
493694
4946838
2404337
766163
666799
1307953
10778737
10779709
1538768
3956831
379207
1743213
2772845
989208
1000199
1000199
73201
2485271
0
493694
087
091
094/095
096/097
098/099
102/103
104/105
106/107
108/109
110
115
116/117
120
122
128
130/152
136
140
142
144/145
164/165
170/171
172
180/181
190
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
Panel Rear Header

Member Kick Up
Panel Skirt
Reinf Front Rail
Pan Rear Floor
Reinf Hinge Decklid
Reinf A-Pillar
Reinf Rail Dash
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
none
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
448796
628342
686962
2043662
535815
76861
2308152
1500310
686962
152277
292805
320267
120782
114045
26343
128102
32031
2615905
90592
205872
102948
257908
46951
274504
87841
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
<========== =========GENERAL CALCULATIONS===================

=========================
===================
Part ID
Part Name
Units
072
073
090
188
XXX
XXX
XXX
n/a
n/a
n/a
n/a
n/a
n/a
Rail Side Roof RH

Rail Side Roof LH
Member Pass Through
Brace Radiator
Hinges
Small Brackets
Weld Studs
none
none
none
none
none
none
Annual
Paid
Time
hr/yr
3600
3600
0
0
0
0
0
0
0
0
0
0
0
Tube
Weight
kg
7.00
7.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
ASSEMBLY
<=============
===========GENERAL OUTPUT COSTS===========
==============
==============
AREA #
410
411/412
414
415
416/417
421
422
428
431
439
XXX
XXX
n/a
n/a
n/a
AREA NAME
Final
Body Side Outer
Framing
Underbody Complete
Body Side Inner
Front End
Underbody Floor
Underbody Inner
Dash
Hinge Assembly
none
none
none
Production Production
Volume
Time
#
hr
225000
3120
225000
3120
225000
3120
225000
3120
225000
3120
225000
3120
225000
3120
225000
3120
225000
3120
225000
3120
225000
3120
225000
3120
225000
3120
225000
3120
225000
3120
n/a
n/a
none
none
Material Utilization Calculations

Total Weight of Input Blanks
Total Weight of Input Tubes
Weight of Purchased Parts
Weight of Blanks & Tubes per Body Structure
225000
225000
90939478.5
3150000
9.47
399.74
3120
3120
kg
kg
kg
kg
TS
===================
===================
===================
========>
Unit
Material
Cost
$/kg
0.92
0.92
0.92
0.92
0.92
0.92
0.85
3.60
1.07
0.85
0.85
1.16
0.89
0.85
0.92
0.92
0.92
0.92
3.60
0.85
0.77
0.89
0.89
0.92
0.92
0.92
0.85
0.81
0.92
0.85
0.85
0.89
0.85
0.85
0.89
Weight
of All
Parts
kg
1.613
0.974
6.05
10.97
4.157
0.303
5.83
0.875
2.28
1.272
1.374
1.29
0.12
14.65
13.115
1.344
10.49
5.092
2.107
1.305
2.502
15.78
15.65
2.74
7.172
0.83
3.854
4.31
2.841
1.876
1.497
0.16
8.68
0
0.813
Weight
of All
Material
Blanks Ulitization
kg
%
4.71
34%
2.355
41%
13.1566
46%
19.8527
55%
7.2534
57%
0.8478
36%
10.7153
54%
1.539
57%
3.8465
59%
2.5513
50%
4.1213
33%
2.0606
63%
0.424
28%
20.2216
72%
27.8832
47%
2.1156
64%
20.881
50%
10.1489
50%
3.2832
64%
2.8574
46%
5.6049
45%
44.356
36%
44.36
35%
6.594
42%
16.956
42%
1.625
51%
7.4701
52%
11.7044
37%
4.239
67%
4.2861
44%
4.2861
35%
0.314
51%
10.65
82%
0
0%
2.1156
38%
<============
========== BLANKING CALCULATION
Blanking
Effective
Prod. Vol.
#/yr
226358
226358
689397
689397
226358
226358
226358
226131
226358
226358
226358
452715
452262
226358
459598
226358
689397
689397
226358
226358
226358
1178575
1178575
226358
226358
452715
226358
459598
226358
226358
226358
226131
226358
226131
226358
Blanking
Blanking
Recovered Production
Scrap
Time
kg/yr
hr/yr
34043
151
17021
151
96532
345
145663
460
52426
151
6128
113
77448
189
10763
#N/A
27802
151
18440
151
29788
151
14892
226
2965
#N/A
146157
189
204584
306
15291
151
153208
460
74464
345
23730
151
20653
151
40511
151
333830
786
333860
786
47660
151
122554
151
11744
226
53992
151
85877
230
30638
151
30979
151
30979
151
2196
#N/A
76976
189
0
#N/A
15291
151
0.77
1.16
0.92
0.77
0.77
0.77
0.99
0.92
0.92
0.92
0.92
0.92
0.92
0.92
0.92
0.92
0.92
0.85
0.92
0.92
0.92
0.92
0.92
0.92
0.92
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.773
1.397
1.142
6.925
0.871
0.196
5.411
2.594
1.668
0.526
0.454
0.674
0.25
0.244
0.056
0.274
0.1
4.24
0.224
0.459
0.23
0.621
0.127
0.674
0.104
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1.9232
2.6926
2.9438
8.67
2.2961
0.3297
9.891
6.4292
2.9438
0.6532
1.256
1.3738
0.5181
0.4892
0.113
0.5495
0.1374
11.2098
0.3886
0.8831
0.4416
1.1052
0.2014
1.1775
0.3768
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
40%
52%
39%
80%
38%
59%
55%
40%
57%
81%
36%
49%
48%
50%
50%
50%
73%
38%
58%
52%
52%
56%
63%
57%
28%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
226358
226358
226358
457290
226358
226131
226358
226358
226358
452262
226131
226131
226131
452262
452262
226131
226131
226358
452262
226131
226131
226358
226131
226131
452262
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
13900
19461
21277
63295
16596
2306
71490
46469
21277
4568
8784
9608
3623
3421
790
3843
961
81022
2718
6176
3088
7988
1409
8235
2635
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
151
151
151
305
151
#N/A
151
151
151
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
151
#N/A
#N/A
#N/A
151
#N/A
#N/A
#N/A
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
=========================
=========================
=========================
========>
<============
=========================
PROCESS CALCULATION
Unit
Material
Cost
$/kg
1.60
1.60
0.77
0.92
0.89
0.77
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Weight
of All
Materials
Parts
Utilization
kg
%
4.7
67%
4.86
69%
0.662
0%
0.25
0%
2.128
0%
6.113
0%
0.32
0%
0
0%
0
0%
0
0%
0
0%
0
0%
0
0%
==============
==============
==========
=========>
Hydroform Hydroform Hydroform

Effective Production Available
Prod. Vol.
Time
Time
#/yr
hr/yr
hr/yr
227250
2525
2880
227250
2525
2880
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
<=============
========== ENERGY CALCULATIONS
Total
Energy
kWhr
36.18
3.06
15.07
3.86
6.42
4.19
6.36
18.64
1.31
0.06
0.19
3.35
0.00
0.00
0.00
Spot
Welding
Energy
kWhr
32.08
2.88
12.68
3.68
5.12
3.84
6.00
17.48
1.28
0.00
0.00
3.20
0.00
0.00
0.00
Adhesive
Bonding
Energy
kWhr
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.06
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
KING CALCULATIONS===========
==============
========>
Blanking
Available
Time
hr/yr
2880
2880
2880
2880
2880
2880
2880
#N/A
2880
2880
2880
2880
#N/A
2880
2880
2880
2880
2880
2880
2880
2880
2880
2880
2880
2880
2880
2880
2880
2880
2880
2880
#N/A
2880
#N/A
2880
Blanking
Time
Required
hr/yr
189
189
460
574
189
151
226
#N/A
189
189
189
302
#N/A
226
383
189
574
460
189
189
189
982
982
189
189
302
189
306
189
189
189
#N/A
226
#N/A
189
Blanking
% of Line
Required
%
7%
7%
16%
20%
7%
5%
8%
#N/A
7%
7%
7%
10%
#N/A
8%
13%
7%
20%
16%
7%
7%
7%
34%
34%
7%
7%
10%
7%
11%
7%
7%
7%
#N/A
8%
#N/A
7%
Blanking
Indirect
Workers
#
0.08
0.08
0.20
0.25
0.08
0.07
0.10
#N/A
0.08
0.08
0.08
0.13
#N/A
0.10
0.17
0.08
0.25
0.20
0.08
0.08
0.08
0.43
0.43
0.08
0.08
0.13
0.08
0.13
0.08
0.08
0.08
#N/A
0.10
#N/A
0.08
<===========
========== WELDING CALCULATI
Welding
Welding
Effective
Scrap
Prod. Vol. Recovered
#/yr
kg/yr
226131
#N/A
226131
#N/A
229569
30208
229569
45582
226131
#N/A
226131
#N/A
226131
#N/A
226131
#N/A
226131
#N/A
226131
#N/A
226131
#N/A
452262
#N/A
452262
#N/A
226131
#N/A
229569
64020
226131
#N/A
229569
47943
229569
23302
226131
#N/A
226131
#N/A
226131
#N/A
235479
261124
235479
261147
226131
#N/A
226131
#N/A
452262
#N/A
226131
#N/A
229569
26873
226131
#N/A
226131
#N/A
226131
#N/A
226131
#N/A
226131
#N/A
226131
#N/A
226131
#N/A
Welding
Labor
Time
hr/yr
#N/A
#N/A
1913
2104
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
1530
#N/A
2296
1358
#N/A
#N/A
#N/A
6637
6637
#N/A
#N/A
#N/A
#N/A
3061
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
2880
2880
2880
2880
2880
#N/A
2880
2880
2880
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
2880
#N/A
#N/A
#N/A
2880
#N/A
#N/A
#N/A
2880
2880
2880
2880
2880
2880
2880
2880
2880
2880
2880
2880
2880
2880
2880
2880
2880
2880
2880
2880
2880
2880
189
189
189
381
189
#N/A
189
189
189
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
189
#N/A
#N/A
#N/A
189
#N/A
#N/A
#N/A
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
7%
7%
7%
13%
7%
#N/A
7%
7%
7%
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
7%
#N/A
#N/A
#N/A
7%
#N/A
#N/A
#N/A
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0.08
0.08
0.08
0.17
0.08
#N/A
0.08
0.08
0.08
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
0.08
#N/A
#N/A
#N/A
0.08
#N/A
#N/A
#N/A
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
226131
226131
226131
228416
226131
226131
226131
226131
226131
452262
226131
226131
226131
452262
452262
226131
226131
226131
452262
226131
226131
226131
226131
226131
452262
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
#N/A
#N/A
#N/A
19811
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
1142
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
CESS CALCULATIONS===========
=========================
=========>
<=======PROCESS SUMMATIONS========>
Hydroform Hydroform Hydroform Purchased
Time
% of Line
Indirect
Part
Required
Required
Workers
Weight
hr/yr
%
#
kg
2600.75 0.90303819
1.75
0.00
2600.75 0.90303819
1.75
0.00
0
0
0
0.66
0
0
0
0.25
0
0
0
2.13
0
0
0
6.11
0
0
0
0.32
0
0
0
0.00
0
0
0
0.00
0
0
0
0.00
0
0
0
0.00
0
0
0
0.00
0
0
0
0.00
GY CALCULATIONS===========
===========
==========>
MIG
Welding
Energy
kWhr
0.02
0.00
0.13
0.00
0.07
0.06
0.00
0.00
0.00
0.00
0.07
0.00
0.00
0.00
0.00
Laser
Welding
Energy
kWhr
2.86
0.00
1.65
0.00
0.98
0.05
0.03
0.27
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Robot
Energy
kWhr
1.22
0.18
0.61
0.18
0.24
0.24
0.34
0.89
0.03
0.00
0.12
0.15
0.00
0.00
0.00
# of
Line
Tooling
Workers Investment Investment
#
$
$
3
7,250,000
665,000
3
7,250,000
665,000
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
<==========
MATERIAL & LABOR CALCULATIO
Worker
Overhead
Paid Time Workers
hr/yr
#
3600
35
3600
19
3600
22
3600
9
3600
19
3600
10
3600
23
3600
19
3600
8
3600
6
3600
3
3600
5
3600
0
3600
0
3600
0
Spot
Welding
Material
$
0.05
0.00
0.02
0.01
0.01
0.01
0.01
0.02
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
3600
3600
0
0
0.00
0.00
DING CALCULATIONS===========
===============
=============
=======>
Welding
Lines
Required
#
#N/A
#N/A
0.53
0.58
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
0.43
#N/A
0.64
0.38
#N/A
#N/A
#N/A
1.84
1.84
#N/A
#N/A
#N/A
#N/A
0.85
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
Welding
Cycle
Time
sec/part
#N/A
#N/A
20.00
22.00
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
16.00
#N/A
24.00
14.20
#N/A
#N/A
#N/A
67.64
67.64
#N/A
#N/A
#N/A
#N/A
32.00
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
Welding
Required
Time
hr/yr
#N/A
#N/A
1275
1403
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
1020
#N/A
1530
906
#N/A
#N/A
#N/A
4424
4424
#N/A
#N/A
#N/A
#N/A
2041
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
Actual
Welding
Time
hr/yr
#N/A
#N/A
1020
1148
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
765
#N/A
1275
650
#N/A
#N/A
#N/A
3770
3770
#N/A
#N/A
#N/A
#N/A
1786
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
Welding
Indirect
Workers
#
#N/A
#N/A
0.66
0.73
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
0.53
#N/A
0.80
0.47
#N/A
#N/A
#N/A
2.30
2.30
#N/A
#N/A
#N/A
#N/A
1.06
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
<==============
===========
Stamping
Effective
Prod. Vol.
#/yr
226131
226131
227273
227273
226131
226131
226131
226131
226131
226131
226131
452262
452262
226131
227273
226131
227273
227273
226131
226131
226131
229592
229592
226131
226131
452262
226131
227273
226131
226131
226131
226131
226131
226131
226131
Stamping
Scrap
Recovered
kg/yr
702152
313389
1628890
2043733
704894
123539
1111312
151141
356813
290728
622804
175716
68880
1276481
3386224
176003
2385438
1160871
268358
352522
704492
6633283
6663451
874608
2220577
180713
822071
1690344
319344
547120
632395
35005
455295
0
295478
#N/A
#N/A
#N/A
0.32
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
12.00
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
761
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
508
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
0.40
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
226131
226131
226131
226131
226131
226131
226131
226131
226131
452262
226131
226131
226131
452262
452262
226131
226131
226131
452262
226131
226131
226131
226131
226131
452262
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
260970
294555
408734
402431
323244
30455
1019187
870191
290384
29359
181871
159009
60908
55723
12953
62609
8570
1580883
37475
96421
48109
110195
16968
114619
61806
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
IONS========>
Cycle
Time
sec/part
40
40
0
0
0
0
0
0
0
0
0
0
0
OR CALCULATIONS========
=========>
Adhesive
Bonding
Material
$
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.18
0.00
0.00
0.00
0.00
0.00
MIG
Welding
Material
$
0.00
0.00
0.03
0.00
0.01
0.01
0.00
0.00
0.00
0.00
0.01
0.00
0.00
0.00
0.00
Laser
Welding
Material
$
0.06
0.00
0.03
0.00
0.02
0.00
0.00
0.01
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
STAMPING CALCULATIONS===
=========== =========>
Press
Time
Required
hr/yr
578
528
644
644
578
528
302
641
528
528
528
1056
377
641
303
578
303
303
1206
578
302
733
733
302
302
1056
302
303
302
528
578
189
2337
641
641
Stamping
Percent
Production of Press Line
Time
Required
hr/yr
%
503
27%
452
24%
568
30%
568
30%
503
27%
452
24%
226
14%
565
30%
452
24%
452
24%
452
24%
905
49%
226
17%
565
30%
227
14%
503
27%
227
14%
227
14%
1131
56%
503
27%
226
14%
656
34%
656
34%
226
14%
226
14%
905
49%
226
14%
227
14%
226
14%
452
24%
503
27%
113
9%
2261
108%
565
30%
565
30%
Stamping
Indirect
Workers
#
0.47
0.43
0.60
0.52
0.40
0.43
0.21
0.37
0.43
0.43
0.43
0.86
0.22
0.82
0.32
0.47
0.32
0.21
0.98
0.47
0.21
1.02
1.02
0.21
0.21
0.86
0.21
0.21
0.21
0.43
0.47
0.11
1.89
0.59
0.52
<============
============
Blanking
Blanking
Energy
Equipment
$/hr
$/hr
15.00
58.11
15.00
58.11
15.00
58.11
15.00
77.48
15.00
58.11
15.00
58.11
15.00
174.32
15.00
0.00
15.00
116.21
15.00
116.21
15.00
116.21
15.00
116.21
15.00
0.00
15.00
174.32
15.00
174.32
15.00
58.11
15.00
96.85
15.00
58.11
15.00
58.11
15.00
116.21
15.00
116.21
15.00
104.59
15.00
104.59
15.00
58.11
15.00
174.32
15.00
58.11
15.00
58.11
15.00
58.11
15.00
58.11
15.00
116.21
15.00
116.21
15.00
0.00
15.00
174.32
15.00
0.00
15.00
58.11
528
528
578
302
578
189
302
302
578
377
189
302
189
377
377
189
189
302
377
189
189
578
189
302
377
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
452
452
503
226
503
113
226
226
503
226
113
226
113
226
226
113
113
226
226
113
113
503
113
226
226
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
24%
24%
27%
14%
27%
9%
14%
14%
27%
17%
9%
14%
9%
17%
17%
9%
9%
14%
17%
9%
9%
27%
9%
14%
17%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0%
0.43
0.43
0.47
0.21
0.47
0.11
0.21
0.21
0.47
0.22
0.11
0.17
0.11
0.22
0.22
0.11
0.11
0.21
0.22
0.11
0.11
0.47
0.11
0.17
0.22
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
58.11
116.21
58.11
58.11
58.11
0.00
116.21
116.21
58.11
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
174.32
0.00
0.00
0.00
58.11
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
============
MACHINE RENT CALCULATIONS==================
============
============
============
Blanking
Overhead
$/hr
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
Blanking
Blanking
Building Maintenance
$/hr
$/hr
13.28
7.14
13.28
7.14
13.28
7.14
13.28
9.08
13.28
7.14
13.28
7.14
13.28
18.76
13.28
1.33
13.28
12.95
13.28
12.95
13.28
12.95
13.28
12.95
13.28
1.33
13.28
18.76
13.28
18.76
13.28
7.14
13.28
11.01
13.28
7.14
13.28
7.14
13.28
12.95
13.28
12.95
13.28
11.79
13.28
11.79
13.28
7.14
13.28
18.76
13.28
7.14
13.28
7.14
13.28
7.14
13.28
7.14
13.28
12.95
13.28
12.95
13.28
1.33
13.28
18.76
13.28
1.33
13.28
7.14
Blanking
W. Cap.
$/hr
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Stamping Stamping
Energy
Equipment
$/hr
$/hr
60.00
309.90
45.00
309.90
60.00
309.90
60.00
348.64
60.00
309.90
45.00
309.90
75.00
1162.14
15.00
58.11
60.00
309.90
45.00
232.43
45.00
232.43
45.00
232.43
15.00
58.11
75.00
581.07
75.00
1162.14
45.00
232.43
75.00
1162.14
75.00
1162.14
45.00
232.43
45.00
348.64
45.00
929.71
105.00
658.55
105.00
658.55
60.00
929.71
60.00
1162.14
45.00
232.43
60.00
929.71
75.00
929.71
60.00
929.71
60.00
309.90
60.00
309.90
15.00
58.11
15.00
309.90
30.00
309.90
45.00
232.43
Stamping
Overhead
$/hr
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
13.28
7.14
12.95
7.14
7.14
7.14
1.33
12.95
12.95
7.14
1.33
1.33
1.33
1.33
1.33
1.33
1.33
1.33
18.76
1.33
1.33
1.33
7.14
1.33
1.33
1.33
1.33
1.33
1.33
1.33
1.33
1.33
1.33
1.33
1.33
1.33
1.33
1.33
1.33
1.33
1.33
1.33
1.33
1.33
1.33
1.33
1.33
1.33
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
30.00
60.00
60.00
75.00
60.00
15.00
45.00
45.00
45.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
15.00
45.00
15.00
15.00
15.00
45.00
15.00
15.00
15.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
232.43
309.90
309.90
1162.14
309.90
58.11
929.71
929.71
232.43
58.11
58.11
58.11
58.11
58.11
58.11
58.11
58.11
1162.14
58.11
58.11
58.11
232.43
58.11
58.11
58.11
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
44.00
============
=====================>
Stamping
Stamping
Building Maintenance
$/hr
$/hr
35.42
34.53
26.56
33.65
35.42
34.53
35.42
38.41
35.42
34.53
26.56
33.65
44.27
120.64
8.85
6.70
35.42
34.53
26.56
25.90
26.56
25.90
26.56
25.90
8.85
6.70
44.27
62.53
44.27
120.64
26.56
25.90
44.27
120.64
44.27
120.64
26.56
25.90
26.56
37.52
26.56
95.63
61.98
72.05
61.98
72.05
35.42
96.51
35.42
119.76
26.56
25.90
35.42
96.51
44.27
97.40
35.42
96.51
35.42
34.53
35.42
34.53
8.85
6.70
8.85
31.88
17.71
32.76
26.56
25.90
Stamping
W. Cap.
$/hr
0.01
0.01
0.01
0.01
0.01
0.01
0.02
0.00
0.01
0.01
0.01
0.01
0.00
0.01
0.02
0.01
0.02
0.02
0.01
0.01
0.02
0.01
0.01
0.02
0.02
0.01
0.02
0.02
0.02
0.01
0.01
0.00
0.01
0.01
0.01
17.71
35.42
35.42
44.27
35.42
8.85
26.56
26.56
26.56
8.85
8.85
8.85
8.85
8.85
8.85
8.85
8.85
26.56
8.85
8.85
8.85
26.56
8.85
8.85
8.85
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
25.01
34.53
34.53
120.64
34.53
6.70
95.63
95.63
25.90
6.70
6.70
6.70
6.70
6.70
6.70
6.70
6.70
118.87
6.70
6.70
6.70
25.90
6.70
6.70
6.70
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.01
0.01
0.02
0.01
0.00
0.02
0.02
0.01
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.02
0.00
0.00
0.00
0.01
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
MACHINE RENT ESTIMATION

This page is provided for those users who prefer to analyze cost from machine rents.
This is NOT an approach advocated by the model designers, and thus the model
does not use the calculated machine rents to arrive at the final costs. This is provided
strictly as a basis for comparison for those users who prefer this approach.
This model considers only the items listed below to be part of the machine rent. To
ensure consistency of results, the user MUST be certain that their own machine
rent values contain the EXACT same cost elements. To use this sheet, the user
should first enter the number of the part to be examined. (Note, this sheet only gives
the user the ability to test a single part at a time). The "Test Part Number" must be
entered as TEXT and must appear exactly as it does in the Part Inputs sheet.
A test table is provided below. The first column contains the relevant model data for
the specified part. This is used to calculate the machine rents for the blanking and
stamping lines. The user is invited to use the adjacent "test values" column to see
the effects of changes in the inputs on the machine rents. If the user would like the
overall model to reflect these machine rents he should use the test values column
to determine the set of inputs which will result in the desired machine rent value.
These inputs can then be copied to the actual model input pages (general and
parts inputs) and will then result in the same final part costs.
Test Part Number 001
Inputs
Blanking Line Energy Consumption Rate
Press Energy Consumption Rate
Number of Presses
Unit Energy Cost
Blanking Press Cost
Stamping Press Line Cost
Blanking Auxiliary Equipment Percent
Stamping Auxiliary Equipment Percent
Interest Rate
Equipment Life
Days per Year
No shifts
Worker unpaid breaks
Worker paid breaks
Blanking Line Unplanned Downtime
Current
Model
Values
150
150
4
0.10
1000000
4000000
25%
25%
12%
20
240
8.375
0.625
1
2
Test
Values
150
150
4
0.10
1000000
4000000
25%
25%
12%
20
240
8.375
0.625
1
2
Stamping Line Unplanned Downtime

Indirect workers/Line
Wage (including benefits)
Blanking Line Space Requirement
Press Space Requirement
Idle Space Percent
Building Unit Cost
Building Life
Blanking Line Maintenance Percent
Press Line Maintenance Percent
Working Capital Period
5
1
44
100
50
100%
1500
25
10%
10%
2
5
1
44
100
50
100%
1500
25
10%
10%
2
BLANKING RENTS ($/hr)

Contribution from Energy
Contribution from Equipment
Contribution from Overhead Labor
Contribution from Building
Contribution from Maintenance
Contribution from Working Capital
15.00
58.11
44.00
13.28
7.14
0.00
15.00
58.11
44.00
13.28
7.14
0.00
137.53
137.53
60.00
309.90
44.00
35.42
34.53
0.01
60.00
309.90
44.00
35.42
34.53
0.01
483.86
483.86
BLANKING MACHINE RENT
STAMPING RENTS ($/hr)

Contribution from Energy
Contribution from Equipment
Contribution from Overhead Labor
Contribution from Building
Contribution from Maintenance
Contribution from Working Capital
STAMPING MACHINE RENT
INFORMATION SHEET: BLANK SIZES
* Note: For parts made from pro

the blank length is the advance
needed to produce the part.
Part ID
001
002/003
008/009
Part Name
010/011
012/013
014/015
021
022
026
028
032
034
038
040
042/043

Panel Dash
Member Dash Front
Panel Cowl Lower
Panel Cowl Upper
Pan Front Floor
Panel Rocker Inner
045
046/047

Rail Rear Inner
048/049
Rail Rear Outer
050
055
057
060
061
062/063
064/065
066
068/069
070/071

Member Panel Back
Panel Back
Blank Length
Blank #
mm
1
1500
1
1200
1
800
2
800
3
800
1
500
2
500
3
700
1
600
1
300
1
1300
Laminate
450
1
350
1
650
1
500
1
250
Progressive
200
1
1600
1
1200
2
1200
1
350
1
1000
2
1000
3
1000
1
650
2
650
3
650
Laminate
1000
1
400
1
600
The five blanks making upper the b
are NOT rectangular. See blank draw
1
700
1
1200
1
460
1
1220
1
1400
074/075
080
081
082/083
085
086
087
091
094/095
096/097

Panel Roof
Panel Front Header
Panel Rear Header
Member Kick Up
Panel Skirt
098/099
102/103
104/105
106/107
108/109
110
115
116/117
120
122
128
130/152
136
140
142
144/145
164/165
170/171
172
180/181
190

Reinf Front Rail
Pan Rear Floor
Reinf Hinge Decklid
Reinf A-Pillar
Reinf Rail Dash
2
3
1
1
1
Progressive
1
1
1
1
1
1
2
1
Progressive
1
1
1
Progressive
Progressive
Progressive
Progressive
Progressive
Progressive
Progressive
Progressive
1
Progressive
Progressive
Progressive
1
Progressive
Progressive
Progressive
1400
1400
400
600
600
350
1250
350
350
350
500
800
800
500
300
1000
700
500
160
500
300
550
205
120
350
175
1200
220
500
450
190
190
300
200
For parts made from progressive dies,

k length is the advance of the coil
o produce the part.
Blank Width Thickness

Density
mm
mm
g/cc
400
1.00
7.85
250
1.00
7.85
450
1.50
7.85
450
1.60
7.85
350
2.00
7.85
900
1.50
7.85
900
1.60
7.85
900
1.80
7.85
1100
1.40
7.85
300
1.20
7.85
1500
0.70
7.85
1000
1.00
3.42
1400
1.00
7.85
500
1.00
7.85
1500
0.70
7.85
750
0.70
7.85
150
0.90
7.85
2300
0.70
7.85
1100
1.30
7.85
900
1.70
7.85
1100
0.70
7.85
600
1.00
7.85
600
1.30
7.85
800
1.60
7.85
510
1.00
7.85
510
1.30
7.85
510
1.60
7.85
1000
0.96
3.42
1400
0.65
7.85
1700
0.70
7.85
ks making upper the body side outers
ngular. See blank drawings for details
1200
1.00
7.85
1200
1.50
7.85
250
0.90
7.85
1200
0.65
7.85
300
0.80
7.85
Weight
Mat. Type
kg
MPa
4.71
350
2.36
350
4.24
350
4.52
350
4.40
350
5.30
350
5.65
350
8.90
350
7.25
350
0.85
350
10.72
210
1.54 Sandwich
3.85
600
2.55
210
4.12
210
1.03
800
0.21
280
20.22
210
13.47
350
14.41
350
2.12
350
4.71
350
6.12
350
10.05
350
2.60
350
3.38
350
4.16
350
3.28 Sandwich
2.86
210
5.60
140
TB60
TB60
6.59
350
16.96
350
0.81
350
7.47
210
2.64
210
900
300
900
1400
1400
200
1550
1100
1000
1400
750
450
300
900
200
1500
1300
750
130
320
250
100
76
60
200
100
1700
75
150
125
570
135
250
100
0.65
0.80
1.50
0.65
0.65
0.80
0.70
0.70
0.70
0.70
1.00
2.00
1.60
0.65
0.70
0.90
0.90
1.00
2.00
1.00
2.00
1.20
2.00
1.00
1.00
1.00
0.70
1.50
1.50
1.00
1.30
1.00
2.00
1.20
7.85
7.85
7.85
7.85
7.85
7.85
7.85
7.85
7.85
7.85
7.85
7.85
7.85
7.85
7.85
7.85
7.85
7.85
7.85
7.85
7.85
7.85
7.85
7.85
7.85
7.85
7.85
7.85
7.85
7.85
7.85
7.85
7.85
7.85
6.43
2.64
4.24
4.29
4.29
0.44
10.65
2.12
1.92
2.69
2.94
5.65
3.01
2.30
0.33
10.60
6.43
2.94
0.33
1.26
1.18
0.52
0.24
0.06
0.55
0.14
11.21
0.19
0.88
0.44
1.11
0.20
1.18
0.19
140
210
350
210
210
280
210
280
140
800
350
140
140
140
140
420
350
350
350
350
350
350
350
350
350
350
210
350
350
350
350
350
350
350
ULSAB BODY STRUCTURE COST MODEL
Camanoe Associates
Kendall Square P.O. Box 842
Cambridge, MA 02142
USA
IBIS Associates
55 Williams Street, Suite 220
Wellesley, MA 02181-4003
USA
contact person:
Dr. Richard Roth
tel: 1-617-253-6487
fax: 1-617-258-7471
e-mail: rroth@mit.edu
contact person:
Jeff Dieffenbach
tel: 1-781-239-0666
fax: 1-781-239-0852
e-mail: JRDibis@aol.com
Camanoe Associates
in association with:
IBIS Associates &
The MIT Materials Systems Laboratory
MIT Materials Systems Laboratory

77 Massachusetts Avenue, Rm E40-202
Cambridge, MA 02139
USA
contact person:
Dr. Frank Field
tel: 1-617-253-2146
fax: 1-617-258-7471
e-mail: furd@mit.edu

Ulsab Model 9

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Ulsab Model 9

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ULSAB BODY STRUCTURE COST MODEL

OVERALL COST ANALYSIS

TOTAL BODY STRUCTURE COST WORKSHEET

MANUFACTURING COST BREAKDOWN

COST BREAKDOWN: STAMPED PARTS

COST BREAKDOWN: ASSEMBLY

TOTAL COST OF ASSEMBLY

COST SUMMARY CALCULATION SHEET

Panel Roof - Hydromechanical Forming Step

<========================GENERAL OUTPUT COSTS=========== =========>

TUBULAR & PURCHASED PARTS TOTALS

PARTS FABRICATION TOTALS

TOTAL BODY STRUCTURE COST

Effective Machine RENT

COST BREAKDOWN BY PROCESS STEP

Material Blanking Welding Stamping

Panel Rear Header

STAMPED PARTS TOTALS

INVESTMENT BREAKDOWN BY PROCESS STEP

Panel Front Header

STAMPED PART INVESTMENTS

TUBULAR & PURCHASED PARTS

Hydroforming Hydroforming Hydroforming

<===================INVESTMENT BREAKDOWN================ ==============

5,557,929 ########## 37,114,000

ANNUAL PRODUCTION VOLUME

For Part Specific Process Parameter, Go to Part Inpu

Global Welding Parameters

For Part Specific Process Parameter, Go to Part Inpu

Global Press Line Parameters

For Part Specific Process Parameter, Go to Part Inpu

For Part Specific Process Parameter, Go to Part Inpu

Laser Gas Unit Cost

MATERIAL PRICE TABLE

meter, Go to Part Input

meter, Go to Part Input

meter, Go to Part Input

meter, Go to Part Input

<========= =========== ASSEMBLY METHOD INPUTS====== =========>

<========== =========GENERAL CALCULATIONS===================

Reinf Radiator Support Upper

Panel Rear Header

TUBULAR & PURCHASED PARTS

<========== =========GENERAL CALCULATIONS===================

Rail Side Roof RH

Material Utilization Calculations

Hydroform Hydroform Hydroform

MACHINE RENT ESTIMATION

Test Part Number 001

Stamping Line Unplanned Downtime

BLANKING RENTS ($/hr)

BLANKING MACHINE RENT

STAMPING RENTS ($/hr)

INFORMATION SHEET: BLANK SIZES

* Note: For parts made from pro

Rail Front Inner RH/LH

Rail Front Extension

Member Rear Suspension

Rail Rear Outer

Panel Spare Tire Tub (laminate)

Panel A-Pillar Inner Upper

Panel Gutter Deck Lid

For parts made from progressive dies,

Blank Width Thickness