Cost Tutorial 2009

Cost Event
Overview and Tutorial

for 2009 Rules
Bill Riley
Version 1.0
21 Oct 2008
FSAE Workshop 10.25.2008
Cost Event
Agenda
1.
2.
3.
Rules Overview
Table Structure
Examples
1.
Machining
2.
Weldment
3.
Sub-Assembly
4.
Composite
4.
Report
5.
Background
1.
Cost Models
2.
Assembly Tools
Rules Overview
Overview
New Rules for 2009
Based on student feedback

No receipts!
All costs are in the tables
No maximum cost accuracy is focus

Costs missing from tables will be added after students submit
Add Item Request (AIR) Form
Everyone pays the same regardless of where they are in the

world
Content drives Cost Tradeoff analysis very important
Event Overview
Event comprised of three parts
Cost Report
Cost Report/Vehicle Review at Competition
Real Case Scenario
Cost Report and review remain fundamentally same as previous years
except now all costs come from SAE Cost Tables
Real Case scenario is new and has replaced the student explanation
of how certain components are manufactured
Will vary year to year
More information will be available closer to competition
No upfront planning or design is necessary
Scoring Cost Matters!

New Scoring Method and point allocation
Rephrased three categories are: Cost, Accuracy and Real Case

The actual Cost and Cost Accuracy determine majority of points
Published Cost Materials

Rules section Part C Article 3
Appendix C-1 Cost Models and Cost Methodology
Appendix C-2 Standard Part Numbering
Appendix C-3 Organized List of Systems and Assemblies
Appendix C-4 Power Tool Package Envelopes
Table: Materials
Table: Process
Table: Process Multipliers
Table: Fasteners
Table: Tooling
Add Item Request (AIR) Form
Cost Report BOM Structure

Fundamentally, the Cost Report is a costed Bill of Material (BOM)
Hierarchy: System Assembly Part Material/Process/Fastener
Tooling
Overall
Report
System
Assembly
Part
Material /
Process /
Fastener
Process
Multipliers &
Tooling (If
Applicable)
Material 1
Material 2
Process 1
Part 1
Vehicle
Part 2
System 1
Assembly
2
Part 3
System 2
Assembly
3
System 3
Tooling
Process 2
Assembly
1
Process
Multipliers
Fastener
1
Fastener
2

Eight Systems:
Brakes
Engine & Drivetrain
See Appendix C-3 for

more details
Frame & Body

Electrical
Misc. & Finish

Steering
Suspension
Wheels, Bearings & Tires

This structure is required

Sample BOM from rules:
10
Make vs. Buy

Designation of make or buy is applied to each part on the car
Determines how Cost is calculated
Made parts are those that start with raw materials (aluminum, etc.),
have operations performed on them and may have subassembly
Examples: pedals, differential housing, brake disks
Bought parts come right off the tables and get assembled to
vehicle
Bought parts can have operations if the team modifies the
standard parts
Examples: dampers, engines, safety harness

Bought parts appear in tables by manufacturer and model (generally)
Made parts will be designation with Student Built
11
Make vs. Buy

Table from rule 3.12.3
12
Penalties
Two tier system
Method A Fixed Point Deductions
The penalty system

seems complex - but
should be simple at
the Competition
Most errors will be penalized using Method A
Examples
Applied to Accuracy Score

13
Penalties
Method B Adjusted Cost Deductions
Intended to stop big errors that would not be penalized enough with
Method A
Applied to Adjusted Cost of vehicle

Without Method B teams could forget systems and take fixed point
penalty
No penalty is applied when values are over estimated
Be conservative and estimate high when part geometry is
complicated
Or when time is short and the Report is due
14
Scoring
Maximum price of car no longer specified
New scoring equation necessary
Use minimum and maximum prices for cars at competition
40 in equation is maximum points based on Cost of vehicle
40x[(Pmax)/(Pyour)-1]
[(Pmax)/Pmin)-1]
Points for your Cost will vary based on Pmax and Pmin
120%
Car Score vs. Price

Pmin = $5,000
100%
% MAximum score
Pmax=$25,000
80%
Pmax=$100,000
% Difference
60%
40%
20%
0%
0
5000
10000
15000
Vehicle Price
15
20000
25000
30000
Overview Conclusion - Definitions

When in doubt read the Definitions section
And so on
16
Table Structure
So it is said if you know the tables and know your car, you will do well in Cost
If you only know your car, but not the tables, you may or may not do well
If you know neither your car nor the tables, you will do quite badly.
Ancient FSAE Cost Proverb
(Inspired by Sun Tzu)
17
Cost Tables
Materials - Lists the costs for raw materials used to manufacture parts built by the teams
and also of finished parts purchased by the teams
Process - Operations which modify materials such as cutting, joining, assembling, etc.
Process Multipliers - Modify the standard costs of different operations to account for
material and geometric differences in the part
Fasteners - Consists of not only traditional fasteners such as bolts, nuts and rivets but
also adhesives, hose clamps and retaining rings
Tooling - The production tooling associated with processes that are specific to the part
geometry
Cost
Tables
Materials
Processes
Process
Multipliers
18
Fasteners
Tooling
Materials
General Categories (for ease of searching):
Bearings
Brake System
Composite
Control Module
Controls
Damper
Drivetrain
Electronics
Engine
Fluid
Misc.
Raw Material
Safety
Sensors
Springs
Steering
Tire
Wheel
Some Examples:
Raw Material Steel, Aluminum, Titanium
Composite Carbon Fiber, Honeycomb, Foam
Tires 13 Hoosier, 10 Hoosier, 13 Goodyear
Wheel BBS, Keizer, JongBloed
19
Process
General Categories (for ease of searching)::
Basic Forming
Composite
Electrical Attach Wires
Electrical Bundle Install
Electrical Bundle Processing
Electrical Connections
Electrical Layout
Electrical Prep
Electrical Wire in Connector
Joining
Labor
Material Removal
Sheet Materials
Fasteners
Tubing
Some Examples:
Basic Forming Die Casting, Sand Casting, Powder Metal

Composite Lamination, Oven Cure, Autoclave Cure
Joining Sewing, Welding
Material Removal Turning, Facing, Milling, EDM, Cutting
20
Process Multipliers
General Categories (for ease of searching)::
Assembly
Fastener Installation
Drill, Tap
Machining
Some Examples:
Assembly Length, Disassemble

Fastener Installation Engagement Length
Drill, Tap Hole Length
Machining Material Type Similar to machinability index for different materials
21
Fasteners & Plumbing

Available soon on website
Generally will be similar to other tables
Lots of parts to add and has been lower

priority over other tables
Most fasteners will be tabulated by:
Grade
Nominal thread size
Length
Plumbing also pending but will include
Aeroquip Catalog
For now refer to Aeroquip catalog on website
Items not in Aeroquip catalog will need Add
Item Request
22
Tooling
General Categories:
Die Casting
Lamination
Plastic injection molding
Powder Metal Forming
Sand Casting
Welds
Tooling is process specific and goes only with the processes that require it
Column in Process Table labeled Tooling Required Will have Yes if needed. Blank
means no.
23
Examples
24
Examples
An A-Arm will be used as an example of working with the Cost Tables
Picture from fsae.com
Component part design by Bill Riley (not actual parts from web)
25
Example 1 Machining
A-Arm Spherical Bearing Cup
Made from Steel
26
Example 1 Machining
Process Steps
1. Start with steel cylinder
2. Rough & Finish Machine Outside

3. Rough Machine Inside
4. Finish machine Inside
Rough
1.0mm Min
Finish
0.5mm
27
Example 1 Machining
How to interpret the Part Worksheet
Part Name
System
P/N Base
DLS
PLS
Comment
MID
A-Arm Bearing Cup

Suspension
000099
A
A
Upper Left A-Arm
Part Cost
Car #
Optional
Design/Process
Rev. Level
27
Part Cost
Use
Spherical Bearing Cup - Bar
20
Material
PID
1
2
3
4
5
6
7
8
MID = Material ID
PID = Process ID
FID = Fastener ID
TID = Tooling ID
FID
Process
Lathe - Turn, Rough
Lathe - Turn, Finish
Lathe - Face, Rough
Lathe - Face, Finish
Lathe - Turn, Rough
Assemble, 1 kg, Interference
Use
Bearing Cup OD
Bearing Cup OD
Bearing Cup Top & Bottom
Bearing Cup ID
Bearing Cup ID
Bearing into Bore
Retaining Ring
Unit Cost
$
0.04
$
0.04
$
0.04
$
0.04
$
0.04
$
0.04
$
0.19
$
0.19
Use
Outboard
Spherical Bearing
Size
Use
Unit Cost
Process
Fastener
3 Spherical Bearing
4 Retaining Ring
Unit
cm^3
cm^3
cm^3
cm^3
cm^3
cm^3
unit
unit
Unit
6.35 mm
17 mm
Quantity
15.96
7.98
10.13
10.13
7.79
4.4
1
1
Multiplier
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Tooling
Tooling
Unit
Density
Sub Total
7.80E-06 $
0.178
$
Sub Total $
0.178
Mult. Val. Sub Total
3 $
1.92
3 $
0.96
3 $
1.22
3 $
1.22
3 $
0.93
$
0.18
$
0.19
$
0.19
Sub Total $
6.79
Sub Totals
Unit Cost Quantity

__
$
6.21
1
$
0.07
1
Sub Total
$
6.21
$
0.07
$
$
Sub Total $
6.28
Fastener
TID
Quantity
PVF
__
Sub Total
Sub Total $
28
13.25
Full P/N
FSAEM 08 027 SU 00099 AA
University University of the Internet
Specific Layout and

Unit Cost
Unit
Area
Length
Columns
$ not
2.25Finalized
kg
506.0
Material
1 Steel, Alloy
Example 1 Machining
Part Detail Sheet All values and format not final!
Part Name
System
P/N Base
DLS
PLS
Comment
MID
A-Arm Bearing Cup

Suspension
000099
A
A
Upper Left A-Arm
Material
1 Steel, Alloy
PID
1
2
3
4
5
6
7
8
FID
TID
Process
Lathe - Turn, Rough
Lathe - Face, Rough
Lathe - Turn, Rough
Fastener
3 Spherical Bearing
4 Retaining Ring
Tooling
Car #
27
Part Cost
Full P/N
FSAEM 08 027 SU 00099 AA
Use
Unit Cost
Unit
$
2.25 kg
Area
Use
Bearing Cup OD
Bearing Cup OD
Bearing Cup ID
Bearing Cup ID
Bearing into Bore
Retaining Ring
Unit Cost
$
0.04
$
0.04
$
0.04
$
0.04
$
0.04
$
0.04
$
0.19
$
0.19
Quantity
15.96
7.98
10.13
10.13
7.79
4.4
1
1
Use
Outboard
Spherical Bearing
Size
Use
Unit Cost
Unit
cm^3
cm^3
cm^3
cm^3
cm^3
cm^3
unit
unit
Unit
6.35 mm
17 mm
Unit
Length
506.0
20
Multiplier
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Density
Sub Total
7.80E-06 $
0.178
$
Sub Total $
0.178
3 $
1.92
3 $
0.96
3 $
1.22
3 $
1.22
3 $
0.93
$
0.18
$
0.19
$
0.19
Sub Total $
6.79
Unit Cost Quantity

__
$
6.21
1
$
0.07
1
Sub Total
$
6.21
$
0.07
$
$
Sub Total $
6.28
Quantity
PVF
__
Sub Total
Sub Total $
13.25
29
Example 2 Weldment
A-Arm has following constituents:
1. Leg 1 tubing
2. Leg 2 tubing
3. Leg 1 machined and tapped insert
4. Leg 2 machined and tapped insert

4
5. Spherical bearing cup (outboard end)

2
6. Sheet metal gusset (outboard end)
7. Spherical bearing
8. Snap Ring
9. Two rod ends with jam nuts
30
Example 2 Overview
Part Name
System
P/N Base
DLS
PLS
Comment
A-Arm
Suspension
00001
A
A
Upper Left A-Arm
MID
Material
Steel, Alloy
Steel, Alloy
Steel, Alloy
Steel, Alloy
Steel, Alloy
Steel, Alloy
Use
Tubing-5/8" x 0.035"
Tubing-5/8" x 0.035"
Threaded Insert - Bar Stock
Gusset - Sheet
Unit Cost
$
2.25
$
2.25
$
2.25
$
2.25
$
2.25
$
2.25
Unit
kg
kg
kg
kg
kg
kg
Area
Process
Lathe - Turn, Rough
Lathe - Face, Rough
Drilled holes < 25.4" dia.
Tapping holes
Lathe - Turn, Rough
Lathe - Face, Rough
Tapping holes
Sheet Metal Stamping
Sheet Metal Bend
Tube Cut
Tube Cut
Tube End Prep for Weld
Lathe - Turn, Rough
Lathe - Face, Rough
Lathe - Turn, Rough
Weld - Round Tubing
Weld - Round Tubing
Weld - Round Tubing
Weld - Round Tubing
Weld
Use
Insert, OD
Insert, OD
Insert, Tapped Face
Threaded Insert
Threaded Insert
Insert, OD
Insert, OD
Insert, Tapped Face
Threaded Insert
Threaded Insert
Gusset
Gusset
Tubing
Tubing
Tubing
Bearing Cup OD
Bearing Cup OD
Bearing Cup ID
Bearing Cup ID
Tube
Tube
Bearing Cup to Tube 1
Gusset
Unit Cost
$
0.04
$
0.04
$
0.04
$
0.35
$
0.35
$
0.04
$
0.04
$
0.04
$
0.35
$
0.35
$
0.03
$
0.25
$
0.03
$
0.03
$
0.75
$
0.04
$
0.04
$
0.04
$
0.04
$
0.04
$
0.04
$
0.19
$
0.19
$
0.19
$
0.18
$
0.15
Unit
cm^3
cm^3
cm^3
unit
unit
cm^3
cm^3
cm^3
unit
unit
cm^2
unit
cm
cm
end
cm^3
cm^3
cm^3
cm^3
cm^3
cm^3
cm
cm
cm
cm
cm
Quantity
10.74
5.37
2.30
1
1
10.74
5.37
2.30
1
1
4.5
1
1.587
1.587
4
15.96
7.98
10.13
10.13
7.79
4.4
2.54
2.54
2.54
2.54
7
Fastener
Rod End, Precison (Aircraft)
Spherical Bearing
Retaining Ring
Nut, AN
Use
Inboard Front
Inboard Rear
Outboard
Spherical Bearing
Jam Nut
Size
Unit
mm
mm
mm
mm
mm
Unit Cost Quantity

__
$
7.02
1
$
7.02
1
$
6.21
1
$
0.07
1
$
0.12
2
Tooling
Welding Fixture
Use
Welding A-arm
Unit Cost
Unit
$ 500.00 point(s)
1
2
3
4
5
6
PID
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
FID
1
2
3
4
TID
Car #
27
Part Cost
43.54
Full P/N
FSAEM 08 027 SU 00001 AA
6.35
6.35
6.35
17
6.35
Length
41.9
41.9
229.6
203.5
450.0
506.0
250
250
20
20
1
20
Multiplier
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Sub Total
$
0.184
$
0.184
$
0.081
$
0.071
$
0.008
$
0.178
$
$
$
Sub Total $
0.705

3 $
1.29
3 $
0.64
3 $
0.28
3 $
1.05
3 $
1.05
3 $
1.29
3 $
0.64
3 $
0.28
3 $
1.05
3 $
1.05
$
0.14
$
0.25
$
0.05
$
0.05
$
3.00
3 $
1.92
3 $
0.96
3 $
1.22
3 $
1.22
3 $
0.93
$
0.18
$
0.47
$
0.47
$
0.48
$
0.46
$
1.05
Sub Total $
21.44
Sub Total
$
7.02
$
7.02
$
6.21
$
0.07
$
0.24
$
$
Sub Total $
20.56
Quantity
PVF
5
__
3000
Sub Total
$
0.83
Sub Total $
31
0.83
Density
7.80E-06
7.80E-06
7.80E-06
7.80E-06
7.80E-06
7.80E-06
1
9
4
2
8
7
5
Example 2 Materials
Part Name
System
P/N Base
DLS
PLS
Comment
A-Arm
Suspension
00001
A
A
Upper Left A-Arm
MID
Material
Steel, Alloy
Steel, Alloy
Steel, Alloy
Steel, Alloy
Steel, Alloy
Steel, Alloy
1 1
2
3 3
4
6 5
6
3
PID
8
7
FSAE
2
4
5
Car #
27
Part Cost
43.54
Full P/N
FSAEM 08 027 SU 00001 AA
Use
Tubing-5/8" x 0.035"
Tubing-5/8" x 0.035"
Gusset - Sheet
Unit Cost
$
2.25
$
2.25
$
2.25
$
2.25
$
2.25
$
2.25
Unit
kg
kg
kg
kg
kg
kg
Area
Length
Use
Insert, OD
Insert,
9 OD
Insert, Tapped Face
Threaded Insert
Threaded Insert
Insert, OD
Insert, OD
Insert, Tapped Face
Threaded Insert
Threaded Insert
Gusset
Gusset
Tubing
Tubing
Tubing
Unit Cost
$
0.04
$
0.04
$
0.04
$
0.35
$
0.35
$
0.04
$
0.04
$
0.04
$
0.35
$
0.35
$
0.03
$
0.25
$
0.03
$
0.03
$
0.75
Unit
cm^3
cm^3
cm^3
unit
unit
cm^3
cm^3
cm^3
unit
unit
cm^2
unit
cm
cm
end
Quantity
10.74
5.37
2.30
1
1
10.74
5.37
2.30
1
1
4.5
1
1.587
1.587
4
41.9
41.9
229.6
203.5
450.0
506.0
250
250
20
20
1
20
Process
11Lathe - Turn, Rough
2 Lathe - Turn, Finish
3 Lathe - Face, Rough
4
4 Drilled holes < 25.4" dia.
5 Tapping holes
6 Lathe - Turn, Rough 2
6 7 Lathe - Turn, Finish
8 Lathe - Face, Rough
9 Drilled holes < 25.4" dia.
10 Tapping holes
5 11 Sheet Metal Stamping
12 Sheet Metal Bend
13 Tube Cut
14 Tube Cut 10.25.2008
Workshop
15 Tube End Prep for Weld
32
Multiplier
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Density
7.80E-06
7.80E-06
7.80E-06
7.80E-06
7.80E-06
7.80E-06
Sub Total
$
0.184
$
0.184
$
0.081
$
0.071
$
0.008
$
0.178
$
$
$
Sub Total $
0.705

3 $
1.29
3 $
0.64
3 $
0.28
3 $
1.05
3 $
1.05
3 $
1.29
3 $
0.64
3 $
0.28
3 $
1.05
3 $
1.05
$
0.14
$
0.25
$
0.05
$
0.05
$
3.00
Part Name
System
P/N Base
DLS
PLS
Comment
A-Arm
Suspension
00001
A
A
Upper Left A-Arm
MID
1
2
3
4
5
6
Car #
27
Part Cost
Use
Tubing-5/8" x 0.035"
Tubing-5/8" x 0.035"
Gusset - Sheet
Unit Cost
$
2.25
$
2.25
$
2.25
$
2.25
$
2.25
$
2.25
Unit
kg
kg
kg
kg
kg
kg
Area
Length
41.9
41.9
229.6
203.5
450.0
506.0
250
250
20
20
1
20
PID
4
4
2
1
5
6
FID
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Process
Lathe - Turn, Rough
Lathe - Face, Rough
Tapping holes
Lathe - Turn, Rough
Lathe - Face, Rough
Tapping holes
Sheet Metal Bend
Tube Cut
Tube Cut
Lathe - Turn, Rough
Lathe - Face, Rough
Lathe - Turn, Rough
Weld - Round Tubing
Weld - Round Tubing
Weld - Round Tubing
Weld - Round Tubing
Weld
Fastener
1 Rod End, Precison (Aircraft)
2 Rod End, Precison (Aircraft)
3 Spherical Bearing
43.54
Full P/N
FSAEM 08 027 SU 00001 AA
3
Example 2 Processes
Material
Steel, Alloy
Steel, Alloy
Steel, Alloy
Steel, Alloy
Steel, Alloy
Steel, Alloy
Use
Insert, OD
Insert, OD
Insert, Tapped Face
Threaded Insert
Threaded Insert
Insert, OD
Insert, OD
Insert, Tapped Face
Threaded Insert
Threaded Insert
Gusset
Gusset
Tubing
Tubing
Tubing
Bearing Cup OD
Bearing Cup OD
Bearing Cup ID
Bearing Cup ID
Tube
Tube
Gusset
Unit Cost
$
0.04
$
0.04
$
0.04
$
0.35
$
0.35
$
0.04
$
0.04
$
0.04
$
0.35
$
0.35
$
0.03
$
0.25
$
0.03
$
0.03
$
0.75
$
0.04
$
0.04
$
0.04
$
0.04
$
0.04
$
0.04
$
0.19
$
0.19
$
0.19
$
0.18
$
0.15
Use
Inboard Front
Inboard Rear
Outboard
Size
Unit
cm^3
cm^3
cm^3
unit
unit
cm^3
cm^3
cm^3
unit
unit
cm^2
unit
cm
cm
end
cm^3
cm^3
cm^3
cm^3
cm^3
cm^3
cm
cm
cm
cm
cm
Unit
6.35 mm
6.35 mm
33
6.35 mm
Quantity
10.74
5.37
2.30
1
1
10.74
5.37
2.30
1
1
4.5
1
1.587
1.587
4
15.96
7.98
10.13
10.13
7.79
4.4
2.54
2.54
2.54
2.54
7
Multiplier
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Density
7.80E-06
7.80E-06
7.80E-06
7.80E-06
7.80E-06
8
7.80E-06
9
1
Sub Total
$
0.184
$
0.184
$
0.081
$
0.071
$
0.008
0.178
6$
$
$
$
Sub Total
0.705
5 $

3 $
1.29
3 $
0.64
3 $
0.28
3 $
1.05
3 $
1.05
3 $
1.29
3 $
0.64
3 $
0.28
3 $
1.05
3 $
1.05
$
0.14
$
0.25
$
0.05
$
0.05
$
3.00
3 $
1.92
3 $
0.96
3 $
1.22
3 $
1.22
3 $
0.93
$
0.18
$
0.47
$
0.47
$
0.48
$
0.46
$
1.05
Sub Total $
21.44
Unit Cost Quantity

__
$
7.02
1
$
7.02
1
$
6.21
1
Sub Total
$
7.02
$
7.02
$
6.21
9
4
Example 2 Fasteners
and Tooling
10
9
4
7
5
FID
Fastener
9
7
Spherical Bearing
8
Retaining Ring
9 Nut, AN
1
2
3
4
TID
10
Tooling
Welding Fixture
Use
Inboard Front
Inboard Rear
Outboard
Spherical Bearing
Jam Nut
Size
Use
Welding A-arm
Unit Cost
Unit
$ 500.00 point(s)
6.35
6.35
6.35
17
6.35
Unit
mm
mm
mm
mm
mm
Unit Cost Quantity

__
$
7.02
1
$
7.02
1
$
6.21
1
$
0.07
1
$
0.12
2
Sub Total
$
7.02
$
7.02
$
6.21
$
0.07
$
0.24
$
$
Sub Total $
20.56
Quantity
PVF
5
__
3000
Sub Total
$
0.83
Sub Total $
34
0.83
Example 2 Finished Part

Part Name
System
P/N Base
DLS
PLS
Comment
A-Arm
Suspension
00001
A
A
Upper Left A-Arm
MID
Material
Steel, Alloy
Steel, Alloy
Steel, Alloy
Steel, Alloy
Steel, Alloy
Steel, Alloy
Use
Tubing-5/8" x 0.035"
Tubing-5/8" x 0.035"
Gusset - Sheet
Unit Cost
$
2.25
$
2.25
$
2.25
$
2.25
$
2.25
$
2.25
Unit
kg
kg
kg
kg
kg
kg
Area
Process
Lathe - Turn, Rough
Lathe - Face, Rough
Tapping holes
Lathe - Turn, Rough
Lathe - Face, Rough
Tapping holes
Sheet Metal Bend
Tube Cut
Tube Cut
Lathe - Turn, Rough
Lathe - Face, Rough
Lathe - Turn, Rough
Weld - Round Tubing
Weld - Round Tubing
Weld - Round Tubing
Weld - Round Tubing
Weld
Use
Insert, OD
Insert, OD
Insert, Tapped Face
Threaded Insert
Threaded Insert
Insert, OD
Insert, OD
Insert, Tapped Face
Threaded Insert
Threaded Insert
Gusset
Gusset
Tubing
Tubing
Tubing
Bearing Cup OD
Bearing Cup OD
Bearing Cup ID
Bearing Cup ID
Tube
Tube
Gusset
Unit Cost
$
0.04
$
0.04
$
0.04
$
0.35
$
0.35
$
0.04
$
0.04
$
0.04
$
0.35
$
0.35
$
0.03
$
0.25
$
0.03
$
0.03
$
0.75
$
0.04
$
0.04
$
0.04
$
0.04
$
0.04
$
0.04
$
0.19
$
0.19
$
0.19
$
0.18
$
0.15
Unit
cm^3
cm^3
cm^3
unit
unit
cm^3
cm^3
cm^3
unit
unit
cm^2
unit
cm
cm
end
cm^3
cm^3
cm^3
cm^3
cm^3
cm^3
cm
cm
cm
cm
cm
Quantity
10.74
5.37
2.30
1
1
10.74
5.37
2.30
1
1
4.5
1
1.587
1.587
4
15.96
7.98
10.13
10.13
7.79
4.4
2.54
2.54
2.54
2.54
7
Fastener
Spherical Bearing
Retaining Ring
Nut, AN
Use
Inboard Front
Inboard Rear
Outboard
Spherical Bearing
Jam Nut
Size
Unit
mm
mm
mm
mm
mm
Unit Cost Quantity

__
$
7.02
1
$
7.02
1
$
6.21
1
$
0.07
1
$
0.12
2
Tooling
Welding Fixture
Use
Welding A-arm
Unit Cost
Unit
$ 500.00 point(s)
1
2
3
4
5
6
PID
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
FID
1
2
3
4
TID
Car #
27
Part Cost
43.54
Full P/N
FSAEM 08 027 SU 00001 AA
6.35
6.35
6.35
17
6.35
Length
41.9
41.9
229.6
203.5
450.0
506.0
250
250
20
20
1
20
Multiplier
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Mtl - Steel
Sub Total
$
0.184
$
0.184
$
0.081
$
0.071
$
0.008
$
0.178
$
$
$
Sub Total $
0.705

3 $
1.29
3 $
0.64
3 $
0.28
3 $
1.05
3 $
1.05
3 $
1.29
3 $
0.64
3 $
0.28
3 $
1.05
3 $
1.05
$
0.14
$
0.25
$
0.05
$
0.05
$
3.00
3 $
1.92
3 $
0.96
3 $
1.22
3 $
1.22
3 $
0.93
$
0.18
$
0.47
$
0.47
$
0.48
$
0.46
$
1.05
Sub Total $
21.44
Sub Total
$
7.02
$
7.02
$
6.21
$
0.07
$
0.24
$
$
Sub Total $
20.56
Quantity
PVF
5
__
3000
Sub Total
$
0.83
Sub Total $
35
0.83
Density
7.80E-06
7.80E-06
7.80E-06
7.80E-06
7.80E-06
7.80E-06
1
9
4
2
8
7
5
Part is complete out

of fixture but not
installed to car
Example 3 Sub-Assembly
Part Name
System
P/N Base
DLS
PLS
Comment
A-Arm
Suspension
00001
A
A
Upper Left A-Arm
MID
Material
Car #
27
Part Cost
Unit Cost
Unit
Area
Length
Quantity Multiplier
2.00
2.00
2.00
Density
Sub Total
$
$
Sub Total $
-
PID
Process
1 Assemble, 1 kg, Line-on-Line
2 Power Tool <= 0.25"
3 Reaction Tool <= 0.25"
Use
Unit Cost
Inboard rod ends
$
0.13
Inboard bolts
$
0.25
Inboard bolt nuts
$
0.25
Outboard bolt included with upright
Unit
unit
unit
unit
FID
Fastener
1 Bolt, AN
2 Nut, AN
Use
Inboard Rod Ends
Inboard Rod Ends
Size 1
Size 2
Unit Cost Unit
28.575 $
0.27 unit
$
0.13 unit
Quantity
Use
Unit Cost
Unit
__
TID
Tooling
2.06
Full P/N
FSAEM 08 027 SU 00001 AA
Use
6.35
6.35
Quantity
PVF

$
0.26
$
0.50
$
0.50
$
$
$
Sub Total $
1.26
Sub Total
2 $
0.54
2 $
0.26
$
$
Sub Total $
0.80
Sub Total
9
4
7
Sub Total $
2
6
5
36
Example 3 Sub-Assembly
Review your work!
Did we forget anything?
Jam nuts were included on BOM but no installation
step was included
1
9
4
Anything else?
Other points:
The bearing cups and threaded inserts did not

include a setup cost in their machining
operations
These would be fed from continuous stock
through the machine spindle
An upright or other part made from billet
would need to include a Machining Setup,
Install/Remove and probably Machining
Setup, Change
Include pictures or sketches of your fixtures to
avoid discussion at the event
37
When making
assumptions like
continuous fed stock
make sure to write
them out!
Example 4 Composite
Part Name
System
P/N Base
DLS
PLS
Comment
Dashpanel
Electrical
000043
B
A
MID
Car #
27
Part Cost
151.42
Full P/N
FSAEM 08 027 SU 00043 AA
Material
Carbon Fiber, 1 Ply
Carbon Fiber, 1 Ply
Carbon Fiber, 1 Ply
Honecomb, Nomex
Carbon Fiber, 1 Ply
Carbon Fiber, 1 Ply
Carbon Fiber, 1 Ply
Use
Dry Fiber, 0/90 deg.
Core
Unit Cost
$ 200.00
$ 200.00
$ 200.00
$ 125.00
$ 200.00
$ 200.00
$ 200.00
Unit
kg
kg
kg
kg
kg
kg
kg
Quantity __
0.04
0.04
0.04
0.09
0.04
0.04
0.04
___
PID
Process
Lamination
Resin application, Manual
Resin application, Manual
Cure, Autoclave
Cure, Autoclave
Cure, Autoclave
Waterjet Cut
Drilled holes < 1" dia.
Drilled hole < 2" dia.
Assemble, 1 kg, Loose
Power Tool <= 25.4 mm
Use
All plies
All plies
All plies
Initial consolidation of lower
Honecomb to lower
Final cure
Part trim
Mounting & Instruments
Instruments
4 Mounting Screws
4 Mounting Screws
Unit Cost
$
35.00
$
5.00
$
5.00
$
50.00
$
50.00
$
50.00
$
0.04
$
0.35
$
0.70
$
0.06
$
0.25
Unit
m^2
m^2
m^2
m^2
m^2
m^2
cm
hole
hole
unit
unit
Quantity
0.20
0.20
0.20
0.20
0.2
0.2
178
12
4
4
4.00

5 $
35.00
5 $
5.00
5 $
5.00
$
10.00
$
10.00
$
10.00
$
7.12
$
4.20
$
2.80
$
0.24
$
1.00
$
Sub Total $
90.36
FID
Fastener
Bolt, Grade 8.8 (SAE 5)
Use
4 Mounting Screws
Size 1
Size 2
Unit Cost Unit

20 $
0.12 unit
Tooling
Composite Tool
Composite Tool
Use
Base
Upper
Unit Cost
Unit
$ 100.00 cm^2
$ 100.00 cm^2
Quantity PVF
20
20
1
2
3
4
5
6
7
TID
38
Sub Total
$
8.00
$
8.00
$
8.00
$
11.25
$
8.00
$
8.00
$
8.00
$
Sub Total $
59.25
Multiplier
Repeat
Repeat
Repeat
Quantity
Sub Total
4 $
0.48
$
$
$
Sub Total $
0.48
__
3000
3000
Sub Total
$
0.67
$
0.67
Sub Total $
1.33
Report
39
Cost Report Format

The format of the Cost Report is still being finalized
An internet based database is planned but probably not for 2009 as
we work through the new system
For 2009 looking at Excel tools with possibility of MS Access
database
Hard copy will be very similar to previous years with exception of
No receipts
No length limit
Will need good, clear supporting documentation
40
Part Numbers
Sample Part Number (P/N)
FSAEM 08 027 FR 00001 AA
Syntax:
Competition Code Date Code - Car Number System Designation Base Number
Suffix
Competition Code A code for the competition entered. Refer to A2.6
Date Code Last two digits of the year of the event
Car Number - A three digit number assigned to the car for the specific event
System Designation - A two (2) letter code for the system under which the part is
associated. These can be found in Appendix C-3.
Base Number - Five (5) digit numbers assigned at the students discretion. For
assemblies this becomes a four (4) digit number with preceding character of A.
Suffix Optional two character code showing part change history. These are provided
for student use only so if desired all can be AA. First character is for design changes
and second character is for process changes.
41
Addenda
A unique addendum is permitted for every competition entered
Allows teams to change design and content between events
A modifier is used for all changes to the BOM made through addenda
Items added in an addendum have 125% of the table cost
Items removed in an addendum are credited 75% of the table cost
Limits teams submitting entire Cost Report as an addendum

Do not want length limits since accuracy is scored
From Rule 3.16.3:
42
Cost Models
43
Raw Materials
Covers what is normally regarded as a material Aluminum, Steel, etc.
Two types of mass
Gross The mass of the material before any processing
Net The mass of the material after all processing
All materials are costed by their gross mass
To calculate gross mass for use following machine stock allowances:
Rough machining 1.0mm

Finish machining 0.5mm
Grinding 0.25mm
Each material includes a Process Multiplier which modifies the Material Removal
Process Multiplier
processes to account for ease of machining each material
Similar to a machinability index
Baseline is Aluminum (Multiplier = 1)
Applied only to Machining processes
44
Material - Composite
Material - Aluminum
Material - Brass
Material - Bronze
Material - Cast Iron
Multiplier
2
1
0.8
1.33
2.5
Others in table
Machining
Rough surfaces allow tolerances of +/- 0.5mm and are for surfaces that dont
interface with other parts
Finish surfaces allow tighter tolerances and are for surfaces that interface with other
parts
Examples of surfaces that need finish machining:
Mating surfaces, bearing bores, tight clearance zones, slip fits, etc.
Near Net Shape refers to parts that are very close to finished size when they come
out of the Basic Forming process
Examples: Die cast, powder metal, plastic injection molding
Near net shape requires only one finish machining pass to get final shape
Parts that cannot be auto-fed into a fixture need to include a Machining Setup,
Install and remove process step
If the part needs to be repositioned to gain access to a different surface than a
Machining Setup, Change process needs to be included
Note, the Install/Remove includes both operations as one line item and cost
45
Fastener Installation
All dimensions are nominal diameter of fastener in mm (Full Diameter)
Maximum extension length is 0.35m for the ratchet and power tools
Screwdriver
Wrench
Ratchet
<= 6.35
<= 25.4
> 25.4
<= 6.35
<= 25.4
> 25.4
0.50 $ 1.00 $ 1.50 $ 2.00 $ 0.50 $ 0.75 $ 1.50
< 1 Turn > 1 Turn

Zeus, camlock
0.12 $
Hand
Run Down
Power Tool
Start Only
Loose
Tight
<= 6.35
<= 25.4
> 25.4
NA
<= 6.35
<= 25.4
> 25.4
<= 6.35
$ 0.25 $ 0.25 $ 0.50 $ 0.12 $ 0.25 $ 0.50 $ 0.75 $ 0.50
Process Multiplier for Engagement Length (Grip)
Process Multiplier
Fastener Engagement Length > 2D
Fastener Engagement Length > 4D
Multiplier
1.25
1.5
46
Assembly Labor
Based loosely off standard work measurement systems
Parameters are:
Mass
Fit Type
Number of connections (quantity)
Process Multipliers
Over sized (> 0.5m)
Disassemble For example removing stock oil pan from engine
Part Mass
1 kg
3 kg
5 kg
10 kg
15 kg
20 kg
> 20 kg
Process Multiplier
Assemble - Length > 0.5m
Disassemble
Fit Type
Line-on-Line
$0.13
$0.38
$0.63
$1.25
$1.88
$2.50
$3.75
Loose
$0.06
$0.19
$0.31
$0.63
$0.94
$1.25
$1.88
Multiplier
1.25
0.8
47
Interference
$0.19
$0.56
$0.94
$1.88
$2.81
$3.75
$5.63
Power Tools
To cost assembly labor using cheaper Power Tool labor rate mockup model
must actually fit on fastener! Will be checked at Competition.
Catalog data used to determine package envelopes for power tool use
Complex geometry simplified for each team to construct mockup
Solid models will be made available on website
48
Composites
Composite rules consist of only a few categories:
Lamination
Manual lamination of each ply
For other processes submit Add Item Request
Same price regardless of material or thickness including UD/woven, honeycomb, foam, metal, etc.
Includes price of trimming ply to correct shape (if possible by hand) and positioning in mold
Metal and other hard inserts need separate machining operations for trimming. Materials that can
be hand trimmed are shown in the Material Table with a note Hand trimming allowed.
Core
Potting
Integration of insert into the laminate
Charged by circumference of insert
Resin Infusion
Manual Brush, spray, etc.
Infusion Molding Vacuum infusion of resin through part
Prepreg No extra charge (included in cost of lamination and material cost)
Curing
Room Temperature Vacuum only - 1 atmosphere P max across vacuum bag
Oven Heat and vacuum 1 atmosphere P max across vacuum bag
Autoclave Heat, vacuum in pressure vessel, No max P across vacuum bag
49
Ply
Face Skin
Electrical Wiring
Wires are defined into three general categories by use
Actual wire gauge is not used
Wire is cost by use and length

Wire use categories:
50
Electrical Wiring
Uses diagram below for terminology and operations
From Product Design for Manufacture & Assembly

By Geoffrey Boothroy
51
Tooling
Processes that require tooling are indicated in the Process Table as Tooling Required
Examples are casting, injection molding, powder metal forming and welding
The cost of tooling is included for each part not in a separate section
To include the cost it must be converted to a piece price by use of the Production Volume Factor
(PVF) which spreads the cost of the tool out over three years of vehicle production
The standard PVF for all parts unless specifically listed is 3000
Appendix C-1 lists PVF for all parts
Examples of using PVF:
52
Commodity Table
Methodology
53
Commodity Tables Example

The commodities are the most time consuming and difficult to
parameterize of the table items
Example below is for AN fasteners.
In this case diameter and length were used for parameterization.
Raw Data
Fit Accuracy
54
Commodity Tables Example

Calculated Surface Showing Table Price 2nd Order Quadratic
55
Questions?
56

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Cost Event

Overview and Tutorial

FSAE Workshop 10.25.2008

FSAE Workshop 10.25.2008

Based on student feedback

No maximum cost accuracy is focus

Everyone pays the same regardless of where they are in the

FSAE Workshop 10.25.2008

Scoring Cost Matters!

Rephrased three categories are: Cost, Accuracy and Real Case

Published Cost Materials

Cost Report BOM Structure

FSAE Workshop 10.25.2008

Cost Report BOM Structure

See Appendix C-3 for

Frame & Body

Misc. & Finish

Wheels, Bearings & Tires

FSAE Workshop 10.25.2008

Cost Report BOM Structure

FSAE Workshop 10.25.2008

Make vs. Buy

Examples: dampers, engines, safety harness

Make vs. Buy

FSAE Workshop 10.25.2008

The penalty system

Most errors will be penalized using Method A

Applied to Accuracy Score

Applied to Adjusted Cost of vehicle

Car Score vs. Price

FSAE Workshop 10.25.2008

Overview Conclusion - Definitions

FSAE Workshop 10.25.2008

(Inspired by Sun Tzu)

FSAE Workshop 10.25.2008

FSAE Workshop 10.25.2008

Wheel BBS, Keizer, JongBloed

FSAE Workshop 10.25.2008

Basic Forming Die Casting, Sand Casting, Powder Metal

Assembly Length, Disassemble

FSAE Workshop 10.25.2008

Fasteners & Plumbing

Lots of parts to add and has been lower

FSAE Workshop 10.25.2008

FSAE Workshop 10.25.2008

FSAE Workshop 10.25.2008

FSAE Workshop 10.25.2008

FSAE Workshop 10.25.2008

2. Rough & Finish Machine Outside

FSAE Workshop 10.25.2008

A-Arm Bearing Cup

Unit Cost Quantity

Specific Layout and

A-Arm Bearing Cup

Unit Cost Quantity

FSAE Workshop 10.25.2008

3. Leg 1 machined and tapped insert

4. Leg 2 machined and tapped insert

5. Spherical bearing cup (outboard end)

6. Sheet metal gusset (outboard end)

9. Two rod ends with jam nuts

FSAE Workshop 10.25.2008

Unit Cost Quantity

Mult. Val. Sub Total