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2
Content
Estimating Methodology
Component Costing
3
Introduction and Overview
4
Introduction and Overview
Ford
JLR
UK
UK
Germany
Aston Martin
Spain
UK
North America
Volvo
Mexico
Sweden
Australia
South Africa
India
Cost as a Business Driver ACostE EMC Learning Event
Terry Griggs Ford Motor Company
5
Introduction and Overview
Manufacturing
Engineering
Purchasing
Finance
PD-Finance
TVM-Finance
Cost
Estimating
6
Introduction and Overview
7
Introduction and Overview
Supplier Negotiations
Change Control
Competitive Teardown
Analysis
Launch Team
Cost Requests
8
Estimating Methodologies
9
Estimating Methodologies
10
Estimating Methodologies
11
Estimating Methodologies
12
Tools and Databases
13
Tools and Databases
CAPE
Computer Aided Parts Estimating (CAPE) is an
advanced knowledge based system designed to
evaluate best processes and optimal costs for the
manufacture of externally purchased parts worldwide.
14
Tools and Databases
Metal Stamping
Plastic Injection Moulding
Rubber Moulding
Pressure Die Casting
Tube Manipulation
Welding
Assembly
Wiring
Clean Sheet
15
Tools and Databases
CAPE Assumptions
16
Tools and Databases
GRIMM Database
Global Rates Information Machines and Materials
(GRIMM) the global DB2 mainframe system used to store
material prices, labour rates and burden values.
17
Tools and Databases
GRIMM Database
18
Tools and Databases
GRIMM Database
Britain
Germany
Spain
France
Portugal
Italy
North America
Mexico
Maquiladoras
China
Cost as a Business Driver ACostE EMC Learning Event
Terry Griggs Ford Motor Company
Czech Republic
Poland
Hungary
Turkey
Slovakia
Slovenia
Romania
India
Sweden
Australia
Korea
South Africa
19
Introduction and
Overview
Utilities
Direct Labour
Labour
Indirect Labour
Fringe
Standard Parts
Estimated
Piece Price
End Item
Scrap
Manuf.
Cost
Material
Depreciation
Interest
Profit
Floorspace
Burden
Machine
Overheads
Indirect
Materials
Insurance
Utilities
Holidays, Sickness,
Bonuses
Raw Material
SG&A
ED&T
Plant Supervision,
Plant Eng
Quality Control,
Health Dept,
Security, Canteen etc.
20
Component Costing
1. How an Estimator
Creates Manufacturing
Detail
ABS Resin:
$1.90/Kg
Fastener:
$.03/ea
Operation 1: Mold
Operation 2: Assembly
3. Calculate Manuf.
Cost Subtotals:
+ Raw Materials
+ Purchased Parts
+ Labor & Burden
$0.17
Depreciation: $0.15
Indirect Labor
0.13
Utilities:
0.04
Fringe
0.15
Floor Space:
0.03
MRO Labor
0.08
Total Labor
$0.53
Assembly:
4. Apply Markups
to Manuf. Cost:
$0.42/min.
+ Purch. Parts
Depreciation: $0.08
+ Scrap
Direct Labor
Indirect Labor
0.13
Utilities:
0.01
+ SG&A =
Fringe
0.06
Floor Space:
0.01
MRO Labor
0.04
+ Profit
Total Labor
$0.23
$0.00
Total
Estimate
21
Component Costing
22
Component Costing
23
Component Costing
Focus C-Max
Wire Material
1,7 Km
329 m
Connectors
317
Terminals
1680
Seals
440
Eyelets
42
Fuses / Relays
32
Clips / Retainer
220
24
Component Costing
1
Yearly Update
Continuous Update
Terminal &
Connector
Price
Machine
Data
Benchmarking
Data (e.g.
Materials, Clips,
Tape, Tube, etc)
Wiring
Loom Data
(Supplier/
Ford)
GRIMM
EDGS/C3P Wiring
Loom Data
Overnight Update
Final Wiring
Estimate
(local
condition)
Wiring Loom
Data
(Supplier)
Manual
Estimating
Modification
25
Component Costing
Global Rates
Machines and
Materials Database
Includes all machine,
materials and
standard
components (i.e.
Connectors,
Terminals) including
cost information
26
Component Costing
AA
CC
CC
CC
CC
CC
CC
CC
CC
CC
CC
CC
CC
CC
CC
CC
CC
CC
CC
CC
CC
DD
DD
DD
DD
DD
DD
EE
3M5T-14K733-JF
M ##
1 A/RSM3G-4603A2 A/RSKM3-G9513-A
3 A/RSKM3-G9513-A
4 A/RS95G-G14K02-4AA
5 A/RSM3G-4616A6613598AG-14A199-AA
7238098AG-14A199-GA
14 69098AG-14A199-EA
15 92098AG-14A199-KA
16 105* RE-SIN R-IBBON
17 13M5T-14A076-AB
18 13M5T-14A142-AB
19 13M5T-14A076-BB
20 13M5T-14A034-AB
21 33M5T-14474-GAA
22 143M5T-14474-GBA
134 13M5T-14489-TAA
183 101L3T-14A094-FA
184 21L3T-14A094-GA
185 13M5T-14A067-BB
4-EC2GY-RD 0,5 WK 1345 -4-PB9GY-VT 0,5 WK 2180 -15S-RD15DGN-OG 2,5 WK 960 -49S-LG11ABU-OG 0,75 WK 1520 -49S-LG18ABU
0,75 WK 480 -50-BB16_AGY-BK 1,5 WK 2130 -CRCR DATE 03/01/24
EE00-E-1
TapeTape (9mmx25m)
TapePaper tape
TapePaper tape
TapeTape
TapeTape
TubeID5 Conv tube 130C
TubeID12.9 Conv tube 130C
TubeID10.1 Conv tube 130C
TubeID16.8 Conv tube 130C
Other80X45 RIBBON/OUT
OtherUpper Cover
OtherLower Cover
OtherCover Midi Fuses
OtherABS Fuseholder
TerminalTerminal f 2.8
Terminal2.8 cbt 0.75-1.00 SN
ConnectorCF 1Pos NWP LSK 8.0
OtherFuse Mini 10A RD
OtherFuse Mini 15A BU
ConnectorBJB Frame (high assem
------1449615 -000-
27
Component Costing
Upload of Cape Estimate
with Grimm and EDGS /
C3P data
Manual Update of:
- Missing components
- Circuit twisting
- Wire single seal assembly
- Splicing & Terminal
insulation
- Terminal Insertion
- Taping & Tubing
- etc.
Cost as a Business Driver ACostE EMC Learning Event
Terry Griggs Ford Motor Company
28
Component Costing
29
Component Costing
30
Component Costing
Application of Mark-Ups
Scrap
SG&A
Profit
ED&T
31
Component Costing
Focus C-Max Cost Breakdown
Material Cost:
232.52
Labor Cost:
Machine Cost:
53.55
20.35
Scrap:
SG&A:
Profit:
R&D:
3.85
35.96
25.93
12.95
Total Estimate
385.11
Labor Minutes:
594.39 min
32
Content
Estimating Methodology
Component Costing
33
Questions
Questions ?