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ME470 Manufacturing Cost Analysis. Instructor: Dr. Mike L. Philpott Associate Professor of Mechanical & Industrial Engineering. Design for Economic Manufacture. A simple fork end for Pneumatic Piston. Extrusion or Stock Channel. Machine from Solid. Casting. Welded Assembly.
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ME470 Manufacturing Cost Analysis Instructor: Dr. Mike L. Philpott Associate Professor of Mechanical & Industrial Engineering
Design for Economic Manufacture A simple fork end for Pneumatic Piston Extrusion or Stock Channel Machine from Solid Casting Welded Assembly Sheet Metal Injection Mold Piece-part costs Tooling costs Production Volume: Recurring Costs versus Non-Recurring Costs
1990s DFM software – stand alone software based on MTM standard times and empirical models (e.g. Boothroyd and Dewhurst) Designers needed to know cost early in design to do what-if analysis and explore alternative designs before expensive hard tooling decisions finalized Advent of solid modeling with access to full solid definition of the part and assembly Design to Cost (DTC) strategies in place, due to high overseas competition, but no practical tools Need to know early if cost targets are being met - redesign if necessary before its too late. DFM Background
Estimating cost directly from a part models geometric features In real-time during CAD modeling with little to no extra time and without expert manufacturing knowledge In an integrated environment with direct access to enterprise cost data (e.g. updated material cost, machine parameters, labor rates, overhead rates etc.) Feature Based Costing (FBC)TM A DFM Cad-based tool
FBC Technology Patents Philpott, M.L. et al, “Integrated Real-Time Feature Based Costing (FBC),” provisional filed U.S. Patent Office, Nov. 2003, full patent serial No. 10/993,406 filed U.S. Patent Office, Nov 2004 – Assignee: University of Illinois at Urbana-Champaign Philpott, M.L. et al,“Enterprise Implementation and Customization of Feature Based Costing (FBC)”, filed U.S. Patent Office, Dec. 2004. Philpott, M.L. et al,“System and Methods for Determining Costs within an Enterprise,” 60/523,746, filed U.S. Patent office, Nov 2004.
Target Cost Constraint Function Finance Acceptable product solution Fit Target Cost Constraint Promote Cost as a True Parameter of Design (the 4th F ?) High Value to Customer Form Low Low High Profit to Company
Cost Accounting Taxonomy Non-Recurring Costs Total Fully Burdened Cost
Laser Cycle/Labor Time LaserCycleTime = Cutting Time + Piercing Time + Rapid Traverse Time + Scrap Cut Time LaserLaborTime = LaserCycleTime * LaborStandard
Bend Brake Cycle/Labor Time BendCycleTime = LoadTime + NumBends * (1 / BendRate) + ManipulationTime * (NumBends -1) + UnloadTime BendLaborTime = BendCycleTime * LaborStandard Total Labor Cost Labor Cost = LaserLaborCost + BendLaborCost LaserLaborCost = LaserCycleTime * LaserLaborRate BendLaborCost = BendCycleTime * BendLaborRate Total Direct Overhead Cost OverheadCost = LaserOverheadCost + OverheadLaborCost LaserOverheadCost = LaserLaborTime * LaserOverheadRate BendOverheadCost = BendLaborTime * BendOverheadRate
