ULSAC Cost Model Generic Reference Door

GENERAL INPUTS
GENERAL INPUTS:
ANNUAL PRODUCTION VOLUME 225000 parts/yr
EXOGENOUS PARAMETERS
Days per Year 240 days/yr
Wage (including benefits) $44.00 $/hr
Unit Energy Cost 0.10 $/kWhr
Interest 12%
Equipment Life 20 yr
Indirect workers/ Direct Worker (part fabricatio 0.250
Indirect workers/Line (part fabrication) 1.000
Indirect workers/ Direct Assembly Worker 1.000
Indirect Workers/Assembly Station 0.125
Building Unit Cost $1,500 $/sqm
Production Life 5 yrs
Building Life 25 yrs
Downtimes:
No shifts 8.375 hrs/day
Worker unpaid breaks 0.625 hrs/day
Worker paid breaks 1 hrs/day
PARTS FABRICATION GENERAL INPUTS:
Global Blanking Parameters

Blanking Energy Consumption Rate 150 kW
Blanking Line Space Requirement 100 sqm/line
Workers / Blank Line 1 #/line
Blanking Unplanned Downtime 2 hr/day
Blanking Installation Percent 25%
Blanking Aux. Equipment Percent 25%
Blanking Maintenance Percent 10%
Material Loss Percent 1%
Scrap Price $0.10 $/kg
Global Welding Parameters

Welding Energy Consumption Rate 400 kW
Welding Space Requirement 250 sqm/line
Workers / Welding Line 1 #/line
Welding Unplanned Downtime 4 hrs/day
Welding Installation Percent 25%
Welding Maintenance Percent 10%
Global Press Line Parameters

Press Energy Consumption Rate 150 kW
Press Station Space Requirement 50 sqm
Press Line Unplanned Downtime 3 hrs/day
Press Line Average Lot Size 1500 parts/lot
Press Line Average Die Change Time 30 minutes
Press Line Installation Percent 25%
Press Line Aux. Equipment Percent 25%
Press Line Maintenance Percent 10%
Global Sheet Hydroforming Parameters

Hydroforming Press Energy Consumption Rate 150 kW
Hydroforming Press Space Requirement 50 sqm
Hydroforming Unplanned Downtime 5 hrs/day
Hydroforming Average Lot Size 1500 parts/lot
Hydroforming Average Die Change Time 30 minutes
Hydroforming Press Installation Percent 25%
Hydroforming Press Aux. Equipment Percent 25%
Hydroforming Press Maintenance Press 10%
Global Tubular Hydroforming Parameters

BENDING:
Bending Line Unplanned Downtime 2 hrs/day
Bending Line Energy Consumption Rate 100 kW
Bending Line Space Requirement 100 sqm
Bending Line Installation Percent 25%
Bending Line Maintenance Percent 10%
PREFORMING:
Preforming Unplanned Downtime 2 hrs/day
Preforming Energy Consumption Rate 100 kW
Performing Space Requirement 100 sqm
Preforming Installation Percent 25%
Preforming Auxiliary Equipment Percent 25%
Preforming Maintenance Percent 10%
TUBE HYDROFORMING:
Preforming Unplanned Downtime 2 hrs/day
Preforming Energy Consumption Rate 100 kW
Performing Space Requirement 100 sqm
Preforming Installation Percent 25%
Preforming Auxiliary Equipment Percent 25%
Preforming Maintenance Percent 10%
TRIMMING:
Trimming Unplanned Downtime 2 hrs/day
Trimming Energy Consumption Rate 100 kW
Trimming Space Requirement 100 sqm
Trimming Installation Percent 25%
Trimming Auxiliary Equipment Percent 25%
Trimming Maintenance Percent 10%
ASSEMBLY GENERAL INPUTS:
Global Assembly Parameters

Part Loading Time 0 sec/part
Clamp/Unclamp Time 6 seconds
Transfer Time 3 seconds
Assembly Line Overtime 1.67 hr/day
Robot Cost $100,000 $/robot
Robot Energy Rate 2 kW
Transport System Cost per Station $100,000 $/station
Conveyor Energy Rate 5 kW
Ass'y Unplanned Downtime 2 hrs/day
Assembly Maintenance Cost 10%
Laser Welding Parameters

Power Requirement 115 kW
Laser Welding Rate 0.1 m/sec
Laser Gas Unit Cost $0.02 $/l
Laser Gas Flow Rate 0.33 l/m
MIG Welding Parameters

Electrode Life 10000 m
Electrode Cost $1.50
MIG Welding Rate 0.04 m/sec
MIG Gas Unit Cost $0.01 $/l
MIG Gas Flow Rate 0.2 l/m
Adhesive Bonding Parameters

Adhesive Bonding Rate 0.6 m/sec
Adhesive Unit Cost 0.01 kg/m
Adhesive Consumption Rate 4.00 $/kg
Spot Welding Parameters

Energy Requirement 0.04 kWhr/weld
Weld Tip Life 8000 # of welds
Weld Tip Cost $0.45
Hemming/Mechanical Fastening Parameters

Hemming Energy Requirement 0.5 kWhr/hem
Fastening Energy Requirement 0.02 kWhr/fastener
Fastener Cost $0.01 $/fastener
MATERIAL PRICE TABLE
Material Material
Type Price
MPa $/kg
0 $0.00
140 $0.77
210 $0.85
280 $0.89
350 $0.92
420 $0.99
600 $1.07
800 $1.16
Tube $1.60
PARTS INPUTS
Ordinary Stampings:
General Process Inputs:
Part Number
Part Name Part # Weight Required
kg #
Panel Outer RH 3501-01R 4.773 1
Panel Outer LH 3501-01L 4.773 1
Reinforcement Belt Outer RH/LH 3501-03R/L 1.258 1
Reinforcement Belt Inner RH/LH 3501-04R/L 3.148 1
Reinforcement Hinge Lower RH/LH 3501-06R/L 0.874 1
Bracket Side Intrusion Beam Front 3501-09 0.112 2
Bracket side Intrusion Beam Rear 3501-10 0.196 2
Tailor Welded Blanks Inputs:

Part Number
kg #
Panel Inner (RH) 3501-02R 7.528 1
Panel Inner (LH) 3501-02L 7.528 1
Sheet Hydroforming Inputs:

Part Number
kg #
Tubular Hydroforming Inputs:
Part Number
kg #
Purchased Parts:
Part Name Part # Part Cost
Reinforcement Hinge Upper RH/LH 3501-05R/L $0.80
Reinforcement Hinge Latch RH/LH 3501-07R/L $0.74
Side Intrusion Beam RH/LH 3501-08R/L $4.00
Tapping Plate Hinge (2 x right,2 x left) 3501-11R/L $0.35
Channel Glass Guide RH/LH 3501-12R/L $0.26
Bracket Channel Glass Guide RH/LH 3501-13R/L $0.10
Reinforcement Check Arm RH/LH 3501-14R/L $0.77
Assembly Inputs:
Assembly Process Types

Continuous Processes Discontinuous Processes
1=Laser Welding 4=Resistance Spot Welding
2=MIG Weld 5=Hemming
3=Adhesive Bonding 6=Mechanical Fastening

Process # of Discreet
Sub-assembly Name ID # Type Parts
#
Spot Welded Structure, RH (10,20,30,40,50) 001 4 6
MIG Welded Structure, RH (60,70,80,90) 002 2 6
Spot Welded Reinforcements, RH (100) 003 4 2
Attach Panel Inner, RH (110,140,150) 004 3 3
Door Inner/Outer Hemming, RH (160,170,180005 5 2
Respot, RH (190) 006 4 1
Final Fasteners, RH (220) 007 6 1
Spot Welded Structure, RH (10,20,30,40,50) 101 4 6
MIG Welded Structure, RH (60,70,80,90) 102 2 6
Spot Welded Reinforcements, RH (100) 103 4 2
Attach Panel Inner, RH (110,140,150) 104 3 3
Door Inner/Outer Hemming, RH (160,170,180105 5 2
Respot, RH (190) 106 4 1
Final Fasteners, RH (220) 107 6 1
Blanking Process Inputs:
Material Press Line Coil Coil

Type Investment Rate Width Progression
MPa $ hits/hr mm mm
210 $1,100,000 1500 1350 1050
210 $1,100,000 1500 1350 1050
140 $1,100,000 2000 1000 400
140 $1,100,000 2000 1060 420
140 $0 0 700 170
280 $0 0 250 130
280 $0 0 280 120
BLANK #1:
MPa $ hits/hr mm mm
140 $1,200,000 1500 500 1200
140 $1,200,000 1500 500 1200

MPa $ hits/hr mm mm
Bending Process Inputs:
Input Tube Total Tool Line Cycle Number of
Weight Investment Investment Time Workers
kg $ $ sec #
Assembly Requirements: Assembly Line Description:
Ass'y Length # of Attachments Required Robots Workers
(cont. process) (discont. process) Assembly Time per Station per Station
m # sec #/station #/station
0.000 26 200 0.80 0.80
1.200 0 150 1.00 0.25
0.000 22 50 2.00 0.00
3.610 0 100 0.67 0.33
0.000 1 100 0.00 0.33
0.000 22 40 2.00 0.00
0.000 2 20 0.00 1.00
0.000 26 200 0.80 0.80
1.200 0 150 1.00 0.25
0.000 22 50 2.00 0.00
3.610 0 100 0.67 0.33
0.000 1 100 0.00 0.33
0.000 22 40 2.00 0.00
0.000 2 20 0.00 1.00
Stamping Process Inputs:
Blank Reject Line Tool Line Workers

Thickness Rate Investment Investment Rate per Line
mm % $ $ hits/hr #
0.7 0.1% $7,500,000 $1,100,000 450 3
0.7 0.1% $7,500,000 $1,100,000 450 3
1.0 0.1% $4,000,000 $780,000 550 3
1.7 0.1% $4,000,000 $800,000 550 3
1.7 0.0% $750,000 $300,000 1000 1
1.8 0.0% $750,000 $120,000 2000 1
1.8 0.0% $750,000 $240,000 2000 1
BLANK #2:
Blank Reject Material Press Line Coil
Thickness Rate Type Investment Rate Width
mm % MPa $ hits/hr mm
2.0 0.1% 140 $1,200,000 1500 1100
2.0 0.1% 140 $1,200,000 1500 1100
Hydroform Process Inputs:

Blank Reject Hydroform Press Tooling Cycle Number of
Thickness Rate Investment Investment Time Workers
mm % $ $ sec #
Preforming Process Inputs: Hydroforming Process In
Reject Line Cycle Number of Reject Line
Rate Investment Time Workers Rate Investment
% $ sec # % $
Fixture Cost Equip Invest Building Space
per Station per Station per Stations
$ $/station sqm/station
$143,401 $169,999 51
$151,019 $198,481 41
$148,468 $201,532 67
$87,430 $199,570 46
$581,233 $61,767 29
$124,194 $225,806 60
$0 $209,000 43
$143,401 $169,999 51
$151,019 $198,481 41
$148,468 $201,532 67
$87,430 $199,570 46
$581,233 $61,767 29
$124,194 $225,806 60
$0 $209,000 43
Number of Reject
Hits Rate
# %
4 1.0%
4 1.0%
4 1.0%
4 1.0%
1 0.5%
1 0.5%
1 0.5%
Welding Process Inputs:
Coil Blank Reject Total Weld Line Parts per Set-up

Progression Thickness Rate Length Investment Run Time
mm mm % mm $ # sec
1200 0.8 0.1% 1300 ### 1 15
1200 0.8 0.1% 1300 ### 1 15
Piercing, Trimming & Flanging Inputs:

Reject Press Line Tooling Line Number of Number of Reject
Rate Investment Investment Rate Workers Hits Rate
% $ $ hits/hr # # %
forming Process Inputs: Trimming Process Inputs:
Cycle Number of Reject Line Cycle Number of Reject
Time Workers Rate Investment Time Workers Rate
sec # % $ sec # %
Stamping Process Inputs:
Weld # of Weld Time Between Reject Line Tool

Speed Segments Welds Rate Investment Investment
mm/sec # sec % $ $
100 1 2 1% $7,500,000 ###
100 1 2 1% $7,500,000 ###
508152
171750
287451
477493
76490
237610
141125
388769
95308
467416
0
508152
171750
287451
477493
76490
237610
141125
388769
95308
467416
0
Line Workers Number of Reject
Rate per Line Hits Rate
hits/hr # # %
400 4 6 1.0%
400 4 6 1.0%
174848
171750
306799
266507
214760
190640
141125
45356
81692
369584
132000
174848
171750
306799
266507
214760
190640
141125
45356
81692
369584
132000
STAMPED PARTS
COST SUMMARY:
Part Name Part # PART COST

Panel Outer RH 3501-01R $10.71
Panel Outer LH 3501-01L $10.71
Reinforcement Belt Outer RH/LH 3501-03R/L $4.99
Reinforcement Belt Inner RH/LH 3501-04R/L $7.13
Reinforcement Hinge Lower RH/LH 3501-06R/L $1.87
Bracket Side Intrusion Beam Front 3501-09 $1.29
Bracket side Intrusion Beam Rear 3501-10 $1.49
TOTAL COST OF STAMPED PARTS $38.20

(Percent of Total) 100.0%
COST BREAKDOWNS (by process step):
BLANKING
Labor
Part Name Part # Cost
TOTAL
Summary of Blanking Costs $0.55 $0.13
(Percent of Total) 100.0% 23.5%
STAMPING
Labor
TOTAL
Summary of Stamping Costs $15.38 $1.99
INTERMEDIATE CALCULATIONS:
GENERAL:
Effective Annual
Part Name Part # Stamp Volume
parts/yr
Panel Outer RH 3501-01R 227273
Panel Outer LH 3501-01L 227273
Reinforcement Belt Outer RH/LH 3501-03R/L 227273
Reinforcement Belt Inner RH/LH 3501-04R/L 227273
Reinforcement Hinge Lower RH/LH 3501-06R/L 226131
Bracket Side Intrusion Beam Front 3501-09 452262
Bracket side Intrusion Beam Rear 3501-10 452262
0 0 0
0 0 0
0 0 0
Material Labor Energy Equipment Tooling
Cost Cost Cost Cost Cost
$6.44 $0.50 $0.17 $1.59 $1.36
$6.44 $0.50 $0.17 $1.59 $1.36
$2.27 $0.42 $0.14 $0.73 $0.96
$4.38 $0.42 $0.14 $0.73 $0.99
$1.17 $0.08 $0.02 $0.08 $0.37
$0.76 $0.10 $0.03 $0.10 $0.15
$0.80 $0.10 $0.03 $0.10 $0.30
$22.27 $2.12 $0.68 $4.92 $5.47

58.3% 5.6% 1.8% 12.9% 14.3%
Energy Equipment Tooling Building Maintenance

$0.01 $0.05 $0.00 $0.00 $0.01
$0.01 $0.05 $0.00 $0.00 $0.01
$0.01 $0.04 $0.00 $0.00 $0.00
$0.01 $0.04 $0.00 $0.00 $0.00
$0.00 $0.00 $0.00 $0.00 $0.00
$0.00 $0.00 $0.00 $0.00 $0.00
$0.00 $0.00 $0.00 $0.00 $0.00
$0.04 $0.19 $0.00 $0.02 $0.02

6.4% 34.2% 0.0% 2.8% 3.7%

$0.15 $1.53 $1.36 $0.04 $0.29
$0.15 $1.53 $1.36 $0.04 $0.29
$0.13 $0.69 $0.96 $0.03 $0.17
$0.13 $0.69 $0.99 $0.03 $0.17
$0.02 $0.08 $0.37 $0.00 $0.05
$0.03 $0.10 $0.15 $0.01 $0.03
$0.03 $0.10 $0.30 $0.01 $0.04
$0.64 $4.73 $5.47 $0.15 $1.04

4.2% 30.7% 35.6% 1.0% 6.7%
Effective Annual Blank Material Annual Input Scrap Credit

Blanking Volume Weight Price Material Material
parts/yr kg $/kg kg kg
227501 7.789 $0.85 1789942 716017
227501 7.789 $0.85 1789942 716017
227501 3.140 $0.77 721569 438519
227501 5.941 $0.77 1365280 656980
226131 1.588 $0.77 362736 166086
452262 0.459 $0.89 209788 159388
452262 0.475 $0.89 216888 128688
0 0.000 #N/A 0 0
0 0.000 #N/A 0 0
0 0.000 #N/A 0 0
Building Maintenance Overhead
Cost Cost Cost
$0.04 $0.30 $0.32
$0.04 $0.30 $0.32
$0.03 $0.17 $0.26
$0.03 $0.18 $0.26
$0.00 $0.05 $0.10
$0.01 $0.03 $0.13
$0.01 $0.04 $0.13
$0.17 $1.06 $1.51

0.4% 2.8% 4.0%
Overhead
Cost
$0.05
$0.05
$0.03
$0.03
$0.00
$0.00
$0.00
$0.16
29.4%
Overhead
Cost
$0.27
$0.27
$0.23
$0.23
$0.10
$0.13
$0.13
$1.35
8.8%
BLANKING:
Annual Blanking Blanking Percent of Blanking
Paid Time Required Time Available Time Blanking Line Direct Workers
hrs/yr hrs/yr hrs/yr # #
3600 152 2880 5.27% 0.053
3600 152 2880 5.27% 0.053
3600 114 2880 3.95% 0.039
3600 114 2880 3.95% 0.039
3600 0 2880 0.00% 0.000
3600 0 2880 0.00% 0.000
3600 0 2880 0.00% 0.000
3600 0 2880 0.00% 0.000
3600 0 2880 0.00% 0.000
3600 0 2880 0.00% 0.000
STAMPING:
Blanking Stamping Stamping Percent of Stamping
Indirect Workers Required Time Available Time Press Line Direct Workers
# hrs/yr hrs/yr # #
0.066 581 2640 22.01% 0.660
0.066 581 2640 22.01% 0.660
0.049 489 2640 18.53% 0.556
0.049 489 2640 18.53% 0.556
0.000 302 2640 11.43% 0.114
0.000 377 2640 14.29% 0.143
0.000 377 2640 14.29% 0.143
0.000 0 2640 0.00% 0.000
0.000 0 2640 0.00% 0.000
0.000 0 2640 0.00% 0.000
Stamping
Indirect Workers
#
0.385
0.385
0.324
0.324
0.143
0.179
0.179
0.000
0.000
0.000
TAILORED BLANK PARTS
COST SUMMARY:

Panel Inner (RH) 3501-02R $22.99
Panel Inner (LH) 3501-02L $22.99
TOTAL COST OF TAILOR BLANKED PARTS $45.98

Blanking:
Labor
TOTAL
Welding:
Labor
TOTAL
Summary of Welding Costs $8.53 $1.12
Stamping:
Labor
TOTAL
Summary of Stamping Costs $10.80 $1.37
GENERAL:
Effective Annual
Part Name Part # Stamp Volume
parts/yr
Panel Inner (RH) 3501-02R 227273
Panel Inner (LH) 3501-02L 227273
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
$12.99 $1.32 $0.62 $4.07 $1.97
$12.99 $1.32 $0.62 $4.07 $1.97
$25.99 $2.65 $1.24 $8.15 $3.95

56.5% 5.8% 2.7% 17.7% 8.6%

$0.02 $0.12 $0.00 $0.01 $0.01
$0.02 $0.12 $0.00 $0.01 $0.01
$0.04 $0.24 $0.00 $0.02 $0.03

6.2% 36.0% 0.0% 2.7% 3.9%

$0.34 $2.25 $0.00 $0.17 $0.24
$0.34 $2.25 $0.00 $0.17 $0.24
$0.68 $4.51 $0.00 $0.34 $0.48

8.0% 52.8% 0.0% 4.0% 5.7%

$0.26 $1.70 $1.97 $0.06 $0.37
$0.26 $1.70 $1.97 $0.06 $0.37
$0.52 $3.40 $3.95 $0.12 $0.75

4.8% 31.5% 36.5% 1.2% 6.9%
BLANK #1:
Effective Annual Effective Volume Effective Volume Annual Blank
Weld Volume Blank #1 Blank #2 Paid Time Weight
parts/yr parts/yr parts/yr hrs/yr kg
229569 229799 229799 3600 9.42
229569 229799 229799 3600 9.42
0 0 0 3600 0
0 0 0 3600 0
0 0 0 3600 0
0 0 0 3600 0
0 0 0 3600 0
0 0 0 3600 0
0 0 0 3600 0
0 0 0 3600 0
Cost Cost Cost
$0.24 $0.63 $1.14
$0.24 $0.63 $1.14
$0.48 $1.26 $2.28

1.0% 2.7% 5.0%
Overhead
Cost
$0.09
$0.09
$0.19
28.4%
Overhead
Cost
$0.70
$0.70
$1.40
16.4%
Overhead
Cost
$0.34
$0.34
$0.69
6.4%
Material Annual Input Blanking Blanking Percent of

Price Material Required Time Available Time Blanking Line
$/kg kg hrs/yr hrs/yr #
$0.77 2186572 153 2880 5.32%
$0.77 2186572 153 2880 5.32%
#N/A 0 0 2880 0.00%
#N/A 0 0 2880 0.00%
#N/A 0 0 2880 0.00%
#N/A 0 0 2880 0.00%
#N/A 0 0 2880 0.00%
#N/A 0 0 2880 0.00%
#N/A 0 0 2880 0.00%
#N/A 0 0 2880 0.00%
BLANK #2:
Blanking Blanking Blank Material Annual Input
Direct Workers Indirect Workers Weight Price Material
# # kg $/kg kg
0.053 0.066 8.29 $0.77 1924184
0.053 0.066 8.29 $0.77 1924184
0.000 0.000 0.00 #N/A 0
0.000 0.000 0.00 #N/A 0
0.000 0.000 0.00 #N/A 0
0.000 0.000 0.00 #N/A 0
0.000 0.000 0.00 #N/A 0
0.000 0.000 0.00 #N/A 0
0.000 0.000 0.00 #N/A 0
0.000 0.000 0.00 #N/A 0
Blanking Blanking Percent of Blanking Blanking
Required Time Available Time Blanking Line Direct Workers Indirect Workers
hrs/yr hrs/yr # # #
153 2880 5.32% 0.053 0.066
153 2880 5.32% 0.053 0.066
0 2880 0.00% 0.000 0.000
0 2880 0.00% 0.000 0.000
0 2880 0.00% 0.000 0.000
0 2880 0.00% 0.000 0.000
0 2880 0.00% 0.000 0.000
0 2880 0.00% 0.000 0.000
0 2880 0.00% 0.000 0.000
0 2880 0.00% 0.000 0.000
WELDING:
Scrap Credit Welding Welding Welding Percent of
(all blanks) Cycle Time Required Time Available Time Weld Line
kg sec hrs/yr hrs/yr #
2416956 30 1913 2400 79.71%
2416956 30 1913 2400 79.71%
0 0 0 2400 0.00%
0 0 0 2400 0.00%
0 0 0 2400 0.00%
0 0 0 2400 0.00%
0 0 0 2400 0.00%
0 0 0 2400 0.00%
0 0 0 2400 0.00%
0 0 0 2400 0.00%
STAMPING:
Welding Welding Stamping Stamping Percent of
Direct Workers Indirect Workers Required Time Available Time Press Line
# # hrs/yr hrs/yr #
0.797 0.996 644 2640 24.40%
0.797 0.996 644 2640 24.40%
0.000 0.000 0 2640 0.00%
0.000 0.000 0 2640 0.00%
0.000 0.000 0 2640 0.00%
0.000 0.000 0 2640 0.00%
0.000 0.000 0 2640 0.00%
0.000 0.000 0 2640 0.00%
0.000 0.000 0 2640 0.00%
0.000 0.000 0 2640 0.00%
Stamping Stamping
Direct Workers Indirect Workers
# #
0.976 0.488
0.976 0.488
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
SHEET HYDROFORMED PARTS
COST SUMMARY:
TAL COST OF SHEET HYDROFORMED PARTS $0.00

(Percent of Total) #DIV/0!
Blanking:
Labor
TOTAL
(Percent of Total) #DIV/0! #DIV/0!
Hydroforming:
Labor
TOTAL
Summary of Hydroforming Costs $0.00 $0.00
Piercing, Trimming & Flanging:

Labor
TOTAL
Summary of Piercing, etc. Costs $0.00 $0.00
GENERAL:
Effective Annual
Part Name Part # Piercing Volume
parts/yr
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
$0.00 $0.00 $0.00 $0.00 $0.00

#DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

$0.00 $0.00 $0.00 $0.00 $0.00


$0.00 $0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 $0.00

Effective Annual Effective Annual Blank Material Annual Input

Hydroform Vol Blanking Volume Weight Price Material
parts/yr parts/yr kg $/kg kg
0 0 0.00 #N/A 0
0 0 0.00 #N/A 0
0 0 0.00 #N/A 0
0 0 0.00 #N/A 0
0 0 0.00 #N/A 0
0 0 0.00 #N/A 0
0 0 0.00 #N/A 0
0 0 0.00 #N/A 0
0 0 0.00 #N/A 0
0 0 0.00 #N/A 0
Cost Cost Cost
$0.00 $0.00 $0.00

#DIV/0! #DIV/0! #DIV/0!
Overhead
Cost
$0.00
#DIV/0!
Overhead
Cost
$0.00
#DIV/0!
Overhead
Cost
$0.00
#DIV/0!
BLANKING:
Scrap Credit Annual Blanking Blanking Percent of
Material Paid Time Required Time Available Time Blanking Line
kg hrs/yr hrs/yr hrs/yr #
0 3600 0 2880 0.00%
0 3600 0 2880 0.00%
0 3600 0 2880 0.00%
0 3600 0 2880 0.00%
0 3600 0 2880 0.00%
0 3600 0 2880 0.00%
0 3600 0 2880 0.00%
0 3600 0 2880 0.00%
0 3600 0 2880 0.00%
0 3600 0 2880 0.00%
HYDROFORMING:
Blanking Blanking Hydroforming Hydroforming Percent of
Direct Workers Indirect Workers Required Time Available Time Hydroform Press
# # hrs/yr hrs/yr #
0.000 0.000 0 2160 0.00%
0.000 0.000 0 2160 0.00%
0.000 0.000 0 2160 0.00%
0.000 0.000 0 2160 0.00%
0.000 0.000 0 2160 0.00%
0.000 0.000 0 2160 0.00%
0.000 0.000 0 2160 0.00%
0.000 0.000 0 2160 0.00%
0.000 0.000 0 2160 0.00%
0.000 0.000 0 2160 0.00%
PIERCING, TRIMMING & FLANGING:
Hydroforming Hydroforming Piercing Piercing Percent of
Direct Workers Indirect Workers Required Time Available Time Press Line
# # hrs/yr hrs/yr #
0.000 0.000 0 2160 0.00%
0.000 0.000 0 2160 0.00%
0.000 0.000 0 2160 0.00%
0.000 0.000 0 2160 0.00%
0.000 0.000 0 2160 0.00%
0.000 0.000 0 2160 0.00%
0.000 0.000 0 2160 0.00%
0.000 0.000 0 2160 0.00%
0.000 0.000 0 2160 0.00%
0.000 0.000 0 2160 0.00%
Piercing Piercing
# #
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
TUBULAR HYDROFORMED PARTS
COST SUMMARY:
AL COST OF TUBULAR HYDROFORMED PARTS $0.00

(Percent of Total) #DIV/0!
Bending:
Labor
TOTAL
Summary of Bending Costs $0.00 $0.00
Preforming:
Labor
TOTAL
Summary of Preforming Costs $0.00 $0.00
Hydroforming:
Labor
TOTAL
Summary of Hydroforming Costs $0.00 $0.00
Trimming:
Labor
TOTAL
Summary of Trimming Costs $0.00 $0.00
GENERAL:
Effective Annual
Part Name Part # Trimming Volume
parts/yr
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
$0.00 $0.00 $0.00 $0.00 $0.00


$0.00 $0.00 $0.00 $0.00 $0.00


$0.00 $0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 $0.00


$0.00 $0.00 $0.00 $0.00 $0.00
Effective Annual Effective Annual Effective Annual Material Annual Input

Hydroform Vol. Preforming Vol. Bending Volume Price Material
parts/yr parts/yr parts/yr $/kg kg
0 0 0 $1.60 0
0 0 0 $1.60 0
0 0 0 $1.60 0
0 0 0 $1.60 0
0 0 0 $1.60 0
0 0 0 $1.60 0
0 0 0 $1.60 0
0 0 0 $1.60 0
0 0 0 $1.60 0
0 0 0 $1.60 0
Cost Cost Cost
$0.00 $0.00 $0.00

#DIV/0! #DIV/0! #DIV/0!
Overhead
Cost
$0.00
#DIV/0!
Overhead
Cost
$0.00
#DIV/0!
Overhead
Cost
$0.00
#DIV/0!
Overhead
Cost
$0.00
#DIV/0!
BENDING:
Scrap Credit Annual Bending Bending Percent of
Material Paid Time Required Time Available Time Bending Line
kg hrs/yr hrs/yr hrs/yr #
0 3600 0 2880 0.00%
0 3600 0 2880 0.00%
0 3600 0 2880 0.00%
0 3600 0 2880 0.00%
0 3600 0 2880 0.00%
0 3600 0 2880 0.00%
0 3600 0 2880 0.00%
0 3600 0 2880 0.00%
0 3600 0 2880 0.00%
0 3600 0 2880 0.00%
PREFORMING:
Bending Bending Preforming Preforming Percent of
Direct Workers Indirect Workers Required Time Available Time Preforming Line
# # hrs/yr hrs/yr #
0.000 0.000 0 2880 0.00%
0.000 0.000 0 2880 0.00%
0.000 0.000 0 2880 0.00%
0.000 0.000 0 2880 0.00%
0.000 0.000 0 2880 0.00%
0.000 0.000 0 2880 0.00%
0.000 0.000 0 2880 0.00%
0.000 0.000 0 2880 0.00%
0.000 0.000 0 2880 0.00%
0.000 0.000 0 2880 0.00%
HYDROFORMING:
Preforming Preforming Hydroforming Hydroforming Percent of
Direct Workers Indirect Workers Required Time Available Time Hydroform Press
# # hrs/yr hrs/yr #
0.000 0.000 0 2880 0.00%
0.000 0.000 0 2880 0.00%
0.000 0.000 0 2880 0.00%
0.000 0.000 0 2880 0.00%
0.000 0.000 0 2880 0.00%
0.000 0.000 0 2880 0.00%
0.000 0.000 0 2880 0.00%
0.000 0.000 0 2880 0.00%
0.000 0.000 0 2880 0.00%
0.000 0.000 0 2880 0.00%
TRIMMING:
Hydroforming Hydroforming Trimming Trimming Percent of
Direct Workers Indirect Workers Required Time Available Time Trimming Line
# # hrs/yr hrs/yr #
0.000 0.000 0 2880 0.00%
0.000 0.000 0 2880 0.00%
0.000 0.000 0 2880 0.00%
0.000 0.000 0 2880 0.00%
0.000 0.000 0 2880 0.00%
0.000 0.000 0 2880 0.00%
0.000 0.000 0 2880 0.00%
0.000 0.000 0 2880 0.00%
0.000 0.000 0 2880 0.00%
0.000 0.000 0 2880 0.00%
Trimming Trimming
# #
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
0.000 0.000
PURCHASED PARTS

Reinforcement Hinge Upper RH/LH 3501-05R/L $0.80
Reinforcement Hinge Latch RH/LH 3501-07R/L $0.74
Side Intrusion Beam RH/LH 3501-08R/L $4.00
Tapping Plate Hinge (2 x right,2 x left) 3501-11R/L $0.35
Channel Glass Guide RH/LH 3501-12R/L $0.26
Bracket Channel Glass Guide RH/LH 3501-13R/L $0.10
Reinforcement Check Arm RH/LH 3501-14R/L $0.77
TOTAL COST OF PURCHASED PARTS $7.02

ASSEMBLY
GENERAL ASSEMBLY INFORMATION:
Gross Line Rate 68.58 jph
Net Line Rate 59.83 jph
Station Cycle Time 52.49 seconds
COST SUMMARY:
Sub-assembly Name ID # COST

Spot Welded Structure, RH (10,20,30,40,50) 001 $8.54
MIG Welded Structure, RH (60,70,80,90) 002 $3.95
Spot Welded Reinforcements, RH (100) 003 $0.71
Attach Panel Inner, RH (110,140,150) 004 $3.20
Door Inner/Outer Hemming, RH (160,170,180005 $4.42
Respot, RH (190) 006 $0.71
Final Fasteners, RH (220) 007 $1.84
Spot Welded Structure, RH (10,20,30,40,50) 101 $8.54
MIG Welded Structure, RH (60,70,80,90) 102 $3.95
Spot Welded Reinforcements, RH (100) 103 $0.71
Attach Panel Inner, RH (110,140,150) 104 $3.20
Door Inner/Outer Hemming, RH (160,170,180105 $4.42
Respot, RH (190) 106 $0.71
Final Fasteners, RH (220) 107 $1.84
TOTAL COST OF ASSEMBLY $46.74

Time Available
Sub-assembly Name ID # Ass'y Operations
sec
Spot Welded Structure, RH (10,20,30,40,50) 001 43.49
MIG Welded Structure, RH (60,70,80,90) 002 43.49
Spot Welded Reinforcements, RH (100) 003 43.49
Attach Panel Inner, RH (110,140,150) 004 43.49
Door Inner/Outer Hemming, RH (160,170,180005 43.49
Respot, RH (190) 006 43.49
Final Fasteners, RH (220) 007 43.49
Spot Welded Structure, RH (10,20,30,40,50) 101 43.49
MIG Welded Structure, RH (60,70,80,90) 102 43.49
Spot Welded Reinforcements, RH (100) 103 43.49
Attach Panel Inner, RH (110,140,150) 104 43.49
Door Inner/Outer Hemming, RH (160,170,180105 43.49
Respot, RH (190) 106 43.49
Final Fasteners, RH (220) 107 43.49
0 0 0.00
0 0 0.00
0 0 0.00
0 0 0.00
0 0 0.00
0 0 0.00
0 0 0.00
0 0 0.00
0 0 0.00
0 0 0.00
0 0 0.00
$0.00 $2.82 $0.10 $1.05 $0.88
$0.00 $0.70 $0.14 $0.98 $0.74
$0.00 $0.00 $0.09 $0.25 $0.18
$0.14 $0.70 $0.08 $0.74 $0.32
$0.00 $0.70 $0.05 $0.23 $2.15
$0.00 $0.00 $0.09 $0.28 $0.15
$0.02 $0.70 $0.00 $0.26 $0.00
$0.00 $2.82 $0.10 $1.05 $0.88
$0.00 $0.70 $0.14 $0.98 $0.74
$0.00 $0.00 $0.09 $0.25 $0.18
$0.14 $0.70 $0.08 $0.74 $0.32
$0.00 $0.70 $0.05 $0.23 $2.15
$0.00 $0.00 $0.09 $0.28 $0.15
$0.02 $0.70 $0.00 $0.26 $0.00
$0.34 $11.26 $1.11 $7.56 $8.88

0.7% 24.1% 2.4% 16.2% 19.0%
Required Number of Number of Equip. (ex.tools) Building

Assembly Time Stations Robots Investment Requirement
sec # # $ sqm
191 5 4 $849,996 255
141 4 4 $793,926 164
41 1 2 $201,532 67
91 3 2 $598,709 137
91 3 0 $185,301 87
31 1 2 $225,806 60
11 1 0 $209,000 43
191 5 4 $849,996 255
141 4 4 $793,926 164
41 1 2 $201,532 67
91 3 2 $598,709 137
91 3 0 $185,301 87
31 1 2 $225,806 60
11 1 0 $209,000 43
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 0 $0 0
0 0 0 $0 0
TOTALS 36 28 $6,128,540 1626

Cost Cost Cost
$0.22 $0.21 $3.26
$0.14 $0.19 $1.06
$0.06 $0.05 $0.09
$0.12 $0.12 $0.97
$0.07 $0.25 $0.97
$0.05 $0.05 $0.09
$0.04 $0.03 $0.79
$0.22 $0.21 $3.26
$0.14 $0.19 $1.06
$0.06 $0.05 $0.09
$0.12 $0.12 $0.97
$0.07 $0.25 $0.97
$0.05 $0.05 $0.09
$0.04 $0.03 $0.79
$1.38 $1.78 $14.43

3.0% 3.8% 30.9%
Number of Number of Energy

Direct Workers Indirect Workers Requirement
# of workers # of workers kWhr
4 5 1.04
1 2 1.38
0 0 0.88
1 1 0.83
1 1 0.50
0 0 0.88
1 1 0.04
4 5 1.04
1 2 1.38
0 0 0.88
1 1 0.83
1 1 0.50
0 0 0.88
1 1 0.04
0 0 0.00
0 0 0.00
0 0 0.00
0 0 0.00
0 0 0.00
0 0 0.00
0 0 0.00
0 0 0.00
0 0 0.00
0 0 0.00
0 0 0.00
16 21 11.10
COST SUMMARY - Generic Door
TOTAL DOOR STRUCTURE COST WORKSHEET Manufacturing Cost Breakdown

Manufacturing Cost $138 Unit Cost Percent
Quality Assurance Costs $0 (per door pair) of Total
Cost of Engineering Changes $0 Parts Fabrication $91.20 66.1%
Start Up and Production Launch Costs $0 Assembly $46.74 33.9%
Marketing Costs $0
Transportation Costs $0 TOTAL COST OF PAIR OF DOORS $137.94 100.0%
Departmental Costs $0
Preparation for Paint $0
Other BIW Related Costs $0 Parts Fabrication Cost Breakdown by Process
TOTAL BODY STRUCTURE COST $138 Unit Cost Percent of Percent of

(per door pair) Parts Total Assembled Total
Ordinary Stampings $38.20 41.9% 27.7%
Tailored Blank Stampings $45.98 50.4% 33.3%
Sheet Hydroformings $0.00 0.0% 0.0%
Tubular Hydroformings $0.00 0.0% 0.0%
Purchased Parts $7.02 7.7% 5.1%
PARTS FABRICATION TOTALS $91.20 100.0% 66.1%
Parts Fabrication Cost Breakdown by Individual Process Step
Unit Cost Percent of Percent of Percent of

(per door pair) Process Costs Parts Total AssembledTotal
Ordinary Stampings (total) $38.20 100.0% 41.9% 27.7%
Material $22.27 58.3% 24.4% 16.1%
Blanking $0.55 1.4% 0.6% 0.4%
Stamping $15.38 40.3% 16.9% 11.1%
Tailored Blank Stampings (total) $45.98 100.0% 50.4% 33.3%
Material $25.99 56.5% 28.5% 18.8%
Blanking $0.66 1.4% 0.7% 0.5%
Welding $8.53 18.6% 9.4% 6.2%
Stamping $10.80 23.5% 11.8% 7.8%
Sheet Hydroformings (total) $0.00 #DIV/0! 0.0% 0.0%
Material $0.00 #DIV/0! 0.0% 0.0%
Blanking $0.00 #DIV/0! 0.0% 0.0%
Hydroforming $0.00 #DIV/0! 0.0% 0.0%
Trimming, Piercing & Flanging $0.00 #DIV/0! 0.0% 0.0%
Tubular Hydroforming (total) $0.00 #DIV/0! 0.0% 0.0%
Material $0.00 #DIV/0! 0.0% 0.0%
Bending $0.00 #DIV/0! 0.0% 0.0%
Preforming $0.00 #DIV/0! 0.0% 0.0%
Hydroforming $0.00 #DIV/0! 0.0% 0.0%
Trimming $0.00 #DIV/0! 0.0% 0.0%
Purchased Parts (total) $7.02 100.0% 7.7% 5.1%
ULSAC COST MODEL
Camanoe Associates
Kendall Square P.O. Box 425242
Cambridge, MA 02142
USA
contact person:
Dr. Richard Roth
tel: 1-617-253-6487
fax: 1-617-258-7471
e-mail: rroth@mit.edu
model developed by:
Camanoe Associates
in association with:
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

ULSAC Cost Model Generic Reference Door

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GENERAL INPUTS

ANNUAL PRODUCTION VOLUME 225000 parts/yr

Global Blanking Parameters

Global Welding Parameters

Global Press Line Parameters

Global Sheet Hydroforming Parameters

Global Tubular Hydroforming Parameters

Global Assembly Parameters

Laser Welding Parameters

MIG Welding Parameters

Adhesive Bonding Parameters

Spot Welding Parameters

Hemming/Mechanical Fastening Parameters

Tailor Welded Blanks Inputs:

Sheet Hydroforming Inputs:

Assembly Process Types

General Process Inputs:

Material Press Line Coil Coil

Blanking Process Inputs:

Blanking Process Inputs:

Blank Reject Line Tool Line Workers

Hydroform Process Inputs:

Welding Process Inputs:

Coil Blank Reject Total Weld Line Parts per Set-up

Piercing, Trimming & Flanging Inputs:

Weld # of Weld Time Between Reject Line Tool

Part Name Part # PART COST

TOTAL COST OF STAMPED PARTS $38.20

COST BREAKDOWNS (by process step):

$22.27 $2.12 $0.68 $4.92 $5.47

Energy Equipment Tooling Building Maintenance

$0.04 $0.19 $0.00 $0.02 $0.02

Energy Equipment Tooling Building Maintenance

$0.64 $4.73 $5.47 $0.15 $1.04

Effective Annual Blank Material Annual Input Scrap Credit

$0.17 $1.06 $1.51

Part Name Part # PART COST

TOTAL COST OF TAILOR BLANKED PARTS $45.98

COST BREAKDOWNS (by process step):

$25.99 $2.65 $1.24 $8.15 $3.95

Energy Equipment Tooling Building Maintenance

$0.04 $0.24 $0.00 $0.02 $0.03

Energy Equipment Tooling Building Maintenance

$0.68 $4.51 $0.00 $0.34 $0.48

Energy Equipment Tooling Building Maintenance

$0.52 $3.40 $3.95 $0.12 $0.75

$0.48 $1.26 $2.28

Material Annual Input Blanking Blanking Percent of

Part Name Part # PART COST

TAL COST OF SHEET HYDROFORMED PARTS $0.00

COST BREAKDOWNS (by process step):

Piercing, Trimming & Flanging:

$0.00 $0.00 $0.00 $0.00 $0.00

Energy Equipment Tooling Building Maintenance

$0.00 $0.00 $0.00 $0.00 $0.00

Energy Equipment Tooling Building Maintenance

Energy Equipment Tooling Building Maintenance

$0.00 $0.00 $0.00 $0.00 $0.00

Effective Annual Effective Annual Blank Material Annual Input

$0.00 $0.00 $0.00

Part Name Part # PART COST

AL COST OF TUBULAR HYDROFORMED PARTS $0.00

COST BREAKDOWNS (by process step):

$0.00 $0.00 $0.00 $0.00 $0.00