+A,C- INDIA IIT%D Date
Cost estimation worksheet Assembly no
Item No .
Part No.
Prepared by
Product description
Part Description
Qty
Type of of component
Checked by
aterial specification
surface protection
!ei"ht in k"
#urface area in s$.mm
%stimated Cost & Item 'IN()
20.00
Total cost 'IN()
1
M276190
Conical spring
1
Spring
2
M276460
Diaphragm
1
Ruer Diaphram
20.00
!
M"70760
#on pressure plate
1
Sheet metal component
0.00
4
M274740
$el% olt
2
stan%ar% parts
0.00
&
M"70700
'ush ro%
1
(ar ma%e
0.00
0.00
6
0.00
7
0.00
"
0.00
9
0.00
10
0.00
11
0.00
12
0.00
1!
0.00
14
0.00
1&
0.00
16
0.00
17
0.00
1"
0.00
19
0.00 Total cost
20.00
comaparison !ith similar parts
Percenta"e *ariation from similar parts
+A,C- INDIA IIT%D ( rates /pdated on eb1202
Material cost #.no 1.1 1 2 2.1 2.2 6 !.1 !.2 !.! !.4 !.& !.6 7 4.1 8 &.1 &.2 &.! &.4 &.& &.6 &.7 &." &.9 &.1 &.11 &.12 &.1! &.14 &.1& &.16 9 6.1 6.2 6.! 6.4 6.& 6.6 6.7 : 7.1 7.2 7.! 7.4 7.& ; ".1 ".2 ".! ".4 ".& ".6 ".7 < 9.1 9.2 9.! 9.4 9.& 9.6 9.7 9." 0
#.No 1 2 ! 4
aterial Aluminium 1 PD PDC SC material 14M )*+D,029 M1DC12 Aluminium 1 5D 5DC /M2& /M4 #heet metal S' R' R',+DD CR,+DD CR,D e410 Cast iron S3 iron Plas Plasti tic c #lon 6 (lack un 5ille% #lon 66 (lack un 5ille% )'Delrin &00 #atura '( 3,!0 natural #lon 6 !0 natural #lon #lon 6 !0 3 lack #lon 668 !03 #atural )'#lon 668 !03 (lack )'Delrin lack /D'+ )reprocesse% , lack(S 'lastic D'+ (lack )'+D'+ #atural )'+Mol%enum Disuphi%e 66 3re )MS2'ol : mathlene (lack )'M'ol : mathlene #atural )'M(ubb (ubber er Ruer Diaphragm,#atural ruer CDS12! *+ *+D 70"0 Mo )#(R8 70 ;RD8 ,40,4&< to "0< C*+D 04&M1 )C/R'R+#+ R=((+R8 ,40
" > "0
Cost of surface protection 'ow%er coating )*+D 2!2,2Ainc plating riBalent )*+D 2&6+D painting no%ising
Cost3 (s4k" 12!.2& 119.&9 12&.!6 12&.!6 4& 42 4& 4" 4&.& 4! 6" 200 240 120 160 210 220 26& 260 160 110 2&0 120 110 2"" 1&0 12&
24& 1"& 2&0 200 2&0 1000 2&00 6& 70 70 "& !00 70 4! 6& &1."" &1."" 47.6 6& !& 44 40 !00 4& !20 && 191 &40
(s4s$.inch 0.07 0.12 0.09 0.2&
+A,C- INDIA IIT%D
+nter %ataFs onl in ellow highlighte% cells
Cost %stimation of PDC component 'art #o
Date
'art #ame
'repare% Checke% Castin" Component cost
(s <9.2<
otal Rawmaterial Cost
Rs 47.06
#et ConBersion Cost
Rs !&.00
Sur5ace treatment cost
Rs 7."0
ther cost #l. No.
aterial cost
Rs 6.4! Input
1
+nter the 5inishe% component weight in kg
0.!1"
2
+:cess ) oBer 5low an% runner- ,10
0.0!2
!
Raw Material weight in kg
0.!&0
4
Sele Select ct the the raw raw mat materia eriall
&
Raw material cost in Rsg
12!.!
6
Raw material cost in Rspart
4!.1
7
Berhea% ) 9.16 - Rspart
!.9
A
Total ra! material cost 'in (s)
SC material 14M JED-
7:.09
%stimation of machine tonna"e = Con*ersion Cost #l. No.
Description
1
+nter the sur5ace area at parting line )[email protected]
1&6
2
rea llowance 5or Runner an% oBer 5low 60 )[email protected]
94
!
rea llowance 5or si%e core !0 )[email protected]
47
4
#o o5 caBit
1
Total surface area 's$.cm)
2<9
&
;nEection pressure )gS@. cm-
1000
6
actor o5 sa5et
1.10
achine 1capacity 'in Tonne)
660 T Con*ersion cost table
#l. No.
achine tonna"e
(ate 4shot
1
60
10
2
"0
12
!
120
1"
4
1"0
22
&
2&0
24
6
!&0
!&
7
400
40
"
660
70
,
#elect the con*ersion cost based on the machine tonna"e from table '(s4Part)
#l. No.
68.00
#urface protection cost
1
Shot lasting ) Rs " g-
2."0
2
ettling cost )2 to " Rs'art-
&.00
C
Total surface protection cost '(s4part)
:.;0
#l. No.
-ther Cost
1
'acki 'acking ng cost cost in RS ) 2 o5 tota totall cost cost -
.;0
2
rans ranspo port rtat atio ion n cos costt in in Rs Rs ) ) Rs Rs 1 gg-
0.68
!
'ro5 'ro5it it on coBe coBers rsio ion n cost cost)1 )10 0--
7.2;
D
Total -ther Cost
9.76
Castin" component cost 'A>,>C>D) (s.
<9.2<
#l.no
(a! material cost
Input
1
+nter the casting component weight );n kg-
0.40&
2
Melting loss ,7 );nclu%ing runner8riser an% melting loss-
0.02"
!
Raw Material weight in g
0.4!!
4
Select the raw material
&
Raw material cost in Rs ,, g
6
Raw material cost in Rs ) Component weight : raw material cost -
7
Ber hea% cost in Rs ) 9.16 o5 RM-
A
inal (a! material cost in (s
LM25
#l.no
12&.!6 &4.!2 4.9" 8<.60
Con*ersion cost
1
+nter the current conBersion cost Rs kg
!2.2&
,
con*ersion cost 'con*ersion cost ? component !ei"ht
6.<;
#l.no
#urface treatment cost
ettling cost )Rs'art-
2
Shot lasting cost in ) Rs 7 g-
!
?iro inish Re@uire% )Hes#o-
4
?iro inish ) Rs & g-
&
2 G 4 Rspart
1.&0
6
2.4!
No &
0.00
eat treatment cost ) Rs. 12 g-
10
4.0&
6
ransportation cost 5or internal )Rs. 1."0 kg-
1."
0.7!
C
Total surface treatment cost
#l.no
;.:
-ther cost
/eak esting re@uire% )Hes#o-
2
/eak esting )Rs'iece-
!
No 2 Rs'art
0.00
DeliBer charges Rs 0.4& g
0.4&
0.1"
4
ReEection cost, 4 o5 conBersion
4
0.&6
&
'acking )0.&-
0.&0
0.27
D
Total other cost
Castin" Component cost 'A>,>C> D) (s4Part.
.0
;6.00
#l.no
#crap reco*ery
1
+nter the Machine% component weight in g
0.1!
2
+nter the Casting component weight in kg
0.2&
!
?olume remoBal
0.1!
A
Total #crap reco*ery cost 80 4 k"
9.28
#l.no
achinin"
1
+nter the #o.eature
2
+nter no.o5 Machining sur5aces
4
!
+nter no.o5 Critical %imension
&
,
Total achinin" cost '(s)
#l.no
20
6:.00 #urface protection
1
+nter the sur5ace area in [email protected]
2
#o. o5 [email protected] Select tpe o5 sur5ace protection
2&&&&.00 !9.61 Powder coating (JED 232-2)
!
Sur5ace protection cost [email protected] in Rs
0.07
C
#urface protection cost '(s)
2.:8
D
Total cost @ , > C1 A
66.80
Ber hea%s 10 o5 D
!.!&
Total achin" cost
69.;8
#.no
aterial Cost
1
+nter the 5inshe% component weight );n kg-
2
(lank weight )in kg-
!
Scrap recoBer )in kg-
4
Select the raw material
&
Current raw material cost in Rskg
6
Component material cost in Rs
7
+nter the current scrap rate in Rs kg ) 1&-
"
Scrap recoBer )in kg-
9
inal raw material cost
10
Ber hea% ,9.16
A
Net aterial cost
#l.no
Prcossein" cost
1
+nter the numer o5 5eature )numers-
2
cost 5eature in Rs
!
processing cost in Rs
4
oBer hea% I pro5it 10
,
Total procossin" cost ',)
#l.no
#urface protection cost
1
Sur5ace rea in [email protected]
2
Sur5ace rea in s@ inch
!
Select the sur5ace protection process
4
Sur5ace protection cost [email protected] in Rs
&
'ainting cost [email protected] in Rs
zinc plating Trivalent (JED 256)
6
Ber hea% 4
C
Total surface protection cost in (s
inal Component cost 'A>,>C) (s.
Input 1.04 1.61 0.&1 CR-EDD
4".00 77.0" 1&.00 7.6& 69.4! 6.!6 :8.:<
&.00 2.&0 12.&0 1.2& 6.:8
2&6!4.00 !9.7! zinc plating Trivalent (JED 256)
0.12 4.77
0.19 7.<9
<7.80
+A,C- INDIA IIT%D
+nter %ataFs onl in ellow highlighte% cells
Cost %stimation of Cast iron components 'art #o
Date
'art #ame
'repare% Checke%
#l.no
inal Component cost
(s <:.6;
otal Rawmaterial Cost
Rs 109.49
Shell I Core Cost
Rs !1.&2
#et ConBersion cost
Rs 2!.&4
ther Cost
Rs !2."4
Description
Input
1
+nter the casting component weight );n kg-
1.00
2
3ross input weight ) && casting iel%- in g
1."2
!
Scale loss ,7 );nclu%ing runner8riser an% melting loss- in g
0.1!
4
;nput put weight ) melting loss>gross input weight- in g
1.9&
&
Select the raw material
6
Current raw material cost in Rs ,, g
7
Raw material cost in Rs
"
Scrap recoBer ) 3ross input weight >weight o5 the reEection )10- ,Component weight -
9
Scrap recoBer 20Rsg
A
inal ra! aterial cost '(s)
#l.no
6".00 1!2.29 1.14 22."0 0<.7<
#hell = Core Cost Select pe o5 Component
1
shell I Core weight in kg
,
Total shell and coated sand cost ' (s <4 k")
#l.no
SG iron
Crankcase !.&0 6.82
anufacturin" cost
1
'rocess cost 5or casting ) Rs 4 kg-
7.7"
2
'rocess cost 5or making shell I core ,, ) Rs 2kg-
7.00
!
Melting cost ) Rs 4.&0kg-
".7&
C
Total manufacturin" cost '(s)
D
Total cost @ A> , >C
#l.no
26.87
97.88
-ther costs
%
oundary additi*e cost ' 2.84k")
(eBection cost ' : of D)
7.;9 .82
5
Profit ' 0 of D)
inal castin" component Cost @ D> %> > 5
9.78
<:.6;
#.No
#crap (eco*ery cost
1
+nter the Machine% component weight in g
2
+nter the Casting component weight in kg
!
?olume remoBal in kg
4
+nter current Scrap material cost kg
A
Total #crap (eco*ery cost (s
#l.no
achinin"
1
+nter the numer o5 5eatures
2
+nter no. o5 Machining si%e )setting-
!
+nter no. o5 Critical %imensions )tolerance J>, 0.0&-
,
Total achinin" cost
#.no
#urface Protection cost
1
+nter the sur5ace area in [email protected]
2
#o. o5 [email protected]
!
Sur5ace protection cost [email protected] in Rs
C
#urface protection cost
D
Total cost @ , > C1 A Ber hea%s "
Total achinin" cost
Input 0.&64 0.610 0.0& &0.00 2.60
10 & 7 79.00
7"6"2.00 121.96 0.14 :.0: 90.:: 4."6 98.97
#l.no
(a! material cost
Input
1
+nter the 5inishe% component weight );n kg-
0.01
2
3ating an% trimming loss ) 20-
0.00
!
Raw Material weight in gs
0.01
4
Select the raw material
&
Current raw material cost in Rs ,, g
6
inal Raw material cost in Rs
2.40
7
Ber hea% cost ) 9.16-
0.22
"
;nsert cost i5 n )Rs'art-
0.00
9
#o o5 ;nsert per part
A
Total aterial cost '(s)
Nylon 6 Black un filled 200.00
0 2.92
InBection oldin" achine tonna"e Calculation 1
#o o5 caBit
1
2
'art proEecte% area at 'arting /ine in S@. Cm
!
Runner proEecte% area ) 1&- in [email protected]
4
Shot proEecte% area in [email protected]
11&
&
CaBit pressure )in g[email protected]
4"0
6
actor o5 sa5et
1.2
:
Clampin" force 4 achine Tonna"e 'in Tonnes)
:2
100 1&.0
achine Cost Per #hift 1
&0
1000
2
60
1400
!
"0
1&00
4
100
1600
&
1&0
2000
6
200
2700
#l.no
Con*ersion cost
1
're,heating ) Rs 2.00 kg-
2
+nter Machine onnage Consi%ere%
!
+nter Machine cost per shi5t
4
+nter #o o5 Shots per shi5t
400
&
Mol%ing Cost per part
!.7&
6
De,5lashing charges ) Rs 1&0 per shi5t -
0.!"
7
Ber hea% cost )10-
0.41
,
Total con*ersion '(s)
7.89
#l.no
0.02 ;0 1&00
-ther cost
1
Machining cost ) i5 re@%-
0.&0
2
Container cost
0.10
!
3auge cost
0.10
4
ool maintenance cost
0.10
C
Total other cost
0.;0
inal Component cost 'A>,>C) (s.
:.<;
+A,C- INDIA IIT%D
+nter %ataFs onl in ellow highlighte
Cost estimation of machined bar '#teel) 'art #o
Date
'art #ame
'repare% Checke% inal Component cost otal Rawmaterial Cost ConBersion Cost Sur5ace protection cost
#.no
(a!material cost
1
+nter inishe% component weight )g-
2
+nter Ma:imum %ia o5 the part )mm-
!
+nter Ma:imum length o5 the part )mm-
4
Raw material $eight inclu%ing wastages )g-
&
Select tpe o5 Raw material
6
Raw material rate )Rsg-
7
Raw material cost )Rs-
"
Scrap weight
9
Scrap cost ) 1& Rsg-
A
Net aterial Cost '(s)
#.no
EN 2A
Con*ersion cost
1
+nter the raw material weight in grams )unmachine%-
2
+nter the 5inishe% component weight in grams
!
mount o5 material remoBe% in grams
4
+nter the total numer o5 %imensions
&
+nter the numer o5 critical %imensions
6
Con%ition 1
7
Con%ition 2
"
Con%ition !
,
Total machinin" cost
#urface protection cost 1
+nter the sur5ace rea in [email protected]
2
Sur5ace rea in s@ inch Select the tpe o5 sur5ace protection
!
Current sur5ace protection cost [email protected] in Rs
4
Sur5ace protection cost in Rs
C
Net #urface protection cost '!ith -*er head 7)
inal component cost 'A>,>C)
Powder coating (JED 232-2)
% cells Compone nt cost Material
Rs 2&.19 Rs 9.79
ConBersio
Rs 1&.20
Sur5ace pr
Rs 0.19
(s 28.< Rs 9.79 Rs 1&.20 Rs 0.19 Sur5ace protection Rs 0.19 1
Input 0.20 2&.0 &0.0 0.2"0 EN 2A
!&.00 9.79 0.0" 1.20 ;.90 Input 2"0.00 200.00 "0.00 10.00 1.00 1&.20 1&.20
ConBersion Rs 1&.20 60
Material Rs 9.79 !9
1&.20 8.20
1669.00 2.&9 der coating (JED 232-2)
0.07 0.1" 0.<
28.<
#l.no
%stimation of mouldin" cost per component 4shift
Input
1
+nter no.o5 list per shi5t
!&.00
2
+nter ma:imum %imension o5 component
140.00
!
#o.o5 caBitlist
4
otal component shi5t
140.00
&
+nter costshi5t
6&0.00
6
Cost component shi5t )Rs-
4.64
7
De,5lashing charges Rs 1&0 per shi5t
1.07
A
Total con*erstion cost '(s)
8.:
#l.no
4.00
Description
Input
1
+nter the 5inishe% component weight );n gs-
0.00&
2
'rocess loss > 3ating I triming loss )!0-
0.001
!
otal Raw Material weight in gs
0.006
4
Select the raw material
&
+nter the the raw material cost in Rs ,, g
6
inal Raw material cost in Rs
1.1"
7
Mi:ing cost cost )" kg-
0.0&
,
Total aterial cost
.26
#l.no
CDS123
1"&.00
-ther cost
1
Container cost )ctual-
0.2&
2
packing > transportation )2-
0.14
!
Ber hea% cost 10 o5 )>(-
0.69
4
'ro5it 10 o5 )>(-
0.69
C
-ther cost
.:;
inal component cost 'A>,>C) (s.
;.:2
#l.no
%stimation of mouldin" cost per component 4shift
1
+nter no.o5 list per shi5t
2
+nter ma:imum %imension o5 component
!
#o.o5 caBitlist
4
otal component shi5t
&
+nter costshi5t
6
Machine cost )Machine per shi5t )#o.o5 li5t per shi5t : no o5 caBit- -
7
De,5lashing charges Rs 1&0 per shi5t
A
Con*erstion cost '(s)
#l.no
(a! material cost 'A)
1
inishe% component weight );n gs-
2
'rocess loss > 3ating I riming loss )!0-
!
otal Raw Material weight in gs
4
Raw material cost in Rs ,, g
&
inal Raw material cost in Rs
6
Mi:ing cost cost )" kg-
,
Total aterial cost
#l.no
abric = bondin" cost
Sur5ace area o5 5aric use% )[email protected]
2
aric Cost ) 27& Rs[email protected]
6
(on%ing cost )Rs 0.2 [email protected]
C
Net abric = ,ondin" cost
#l.no
-ther cost
1
Container cost )ctual-
2
packing >trans )2-
!
Ber hea% cost 10 o5 )>(>C-
4
'ro5it 10 o5 )>(>C-
D
-ther cost
inal Component cost 'A>,>C) (s.
Input !& 140 4 140 6&0 4.6 1.1 8.:
Input 0.00& 0.001 0.006 1&0.00 0.9&6 0.0&1 .0
!600 0.99 1.12 2.
0.2&0 0.177 0.""! 0.""! 2.<
.0
#l.no
(a! material cost 'A)
1
+nter the 5inishe% component weight );n kg-
2
'rocess loss )10-
!
Raw Material weight in g
4
Select the raw material
&
+nter the raw material cost in Rs ,, g
6
Raw material cost in Rs ) Component weight : raw material cost -
7
Ber hea% > pro5it 9.16
A
inal (a! material cost in (s
#l.no
Coilin" cost
1
+nter %eBelope% length )mm-
2
Current coiling cost Rs min
!
utput per minute
,
Coilin" cost '(s)
#l.no
Post processin" cost
1
Stress reliBeing )Rs4 g-
2
+nter shot peening cost kg
!
Shot peening cost in Rs
4
+n% coil grin%ing
&
ResiAing
C
Post processin" cost 'C)
#l.no
#urface treatment cost
1
Sur5ace rea in [email protected]
2
Sur5ace rea in s@ inch
!
Select the sur5ace protection process
4
+nter the Current sur5ace protection rate [email protected] in Rs
&
Sur5ace treatment cost in Rs
6
Ber hea% 4
D
Total surface protection cost
otal cost without pro5it K > (> C> D 10 pro5it Total cost
Input 0.06 0.01 0.06 Grade 4
"&.00 &.14 0.47 8.9
400 4.&0 !4 0.6
0.24 4.00 0.24 0.2& 0.1& 0.;;
1660.00 2.&7 zinc plating Trivalent (JED 256)
0.12 0.!1 0.01 0.62
6.9& 0.70 :.98
#l.no
(a! material cost 'A)
1
+nter the 5orge% component weight );n kg-
2
Shear loss ,& );nclu%ing runner8riser an% melting loss-
!
Scale loss ,7 );nclu%ing runner8riser an% melting loss-
4
lash loss ,!0 );nclu%ing runner8riser an% melting loss-
&
otal input Raw Material weight in kg
6
Select the raw material
7
Raw material cost in Rs ,, g
A
inal (a! material cost in (s
#l.no
Con*ersion cost Current ConBersion cost )Rs kg-
,
#l.no
Con*ersion cost '(s)
eat Treatment cost 'C)
1
+nter the current Shot lasting Rate )Rsg-
2
Shot lasting cost )Rs-
!
+nte the current #ormalising cost )Rsg-
4
#ormalising cost cost ) Rs-
&
ransportation cost 5or internal )Rs1.&0 kg-
C
Total eat Treatment cost
D
Total cost !ithout profit @A>, >C 'ro5it 10 o5 D
inal for"e component cost
Input 0.11 0.01 0.01 0.0! 0.16 En 9 (forging quality)
70.00 0.<6
12.00 .;:
2.00 0.!1 4.00 0.62 0.2! .:
6.<; .70 8.6;
