LAB EXAM
BITS Pilani
Pilani | Dubai | Goa | Hyderabad
Date-November 2024
Students Details : DARIA COLETTE D'SOUZA
Student ID : 2024HT79053
BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, PILANI
1st Semester 2024
Lab Exam Question:
Lab Exam Question:
Statement of the problem:
(Design for Manufacturing and Assembly) - to
recommend optimal manufacturing costs and timings.
Key elements include:
1.Batch Size and Volume: Expected batch size is 200,000 pieces
with a life volume of 12,000.
2.Material Selection: Options for the sheet metal stamped
component include Carbon Steel and Aluminum Alloy.
3.A compound die analysis is preferred for the part.
4.Report on cost and process timing for management to support
informed decision-making.
Lab Exam Question: DFM – Sheet Metal–
Compound Die Stamping
Specifying Licence and Host Name
Updating Manufacturing Profiles for North America and China
Lab Exam Question: DFM – Sheet Metal–
Compound Die Stamping
Life Volume: 200,000 pieces
Batch Quantity: 12,000 pieces
Process Preference :Compound Die Stamping
Lab Exam Question: DFM – Sheet Metal–
Compound Die Stamping
Maintain consistent production rates with minimized scrap and rework.
Lab Exam Question: DFM – Sheet Metal–
Compound Die Stamping
Optimize labor, overhead cost to achieve competitive unit pricing.
Lab Exam Question: DFM – Sheet Metal–
Compound Die Stamping
Material Options: Aluminium Alloy
Units selection : English
Lab Exam Question: DFM – Sheet Metal–
Compound Die Stamping
The high-cost compound dies over life volume for efficient production rates.
Lab Exam Question: DFM – Sheet Metal–
Compound Die Stamping
Use Carbon Steel for general applications or Aluminum for lightweight and corrosion-resistant needs.
Lab Exam Question: DFM – Sheet Metal–
Compound Die Stamping
Balancing initial investments with long-term savings,
enabling cost-effective high-volume manufacturing
Assumptions For Cost Effective Manufacturing
Material Selection and Costs :
1. Carbon Steel : Material Cost: Lower compared to Aluminum= 1.52 $/Lb ( given by DFM software)
Density: Higher, resulting in heavier components, which could impact shipping costs.
2. Aluminium Alloy :Material Cost: Higher = 2.110$/Lb ( given by DFM software)
Density: Lower, making the part lighter, which can reduce both shipping and handling costs
Carbon steel is selected if weight and corrosion resistance are not critical, while Aluminum is preferred if weight reduction
or corrosion resistance is important.
Assumptions For Cost Effective Manufacturing
Tool and Die Cost :
1. Initial Tooling Cost : High initial cost for compound dies, estimated at $11,430.
2. Amortization of Tooling Cost : Amortize the tooling cost over the total life volume (200,000 batches).
3. Tool Maintenance: Assume maintenance at regular intervals to maintain die precision; costs are distributed across
total production volume
The tooling cost is justified for a large batch size (12,000 pcs) due to faster production rates and lower cycle times
Assumptions For Cost Effective Manufacturing
Process Cost :
1. Cycle Time and Production Rate : Compound die stamping allows for a high production rate as per default DFM
software selection
2. Cycle Time Calculation:
A consistent production rate is achievable with periodic die maintenance.
Labor Rate and Overhead Costs :
1.
2.
Operator rate, $/hr=27$ /hr. (er hour for skilled labor required for setup, operation, and quality control.)
Overhead cost : Include utilities, administrative expenses, and equipment depreciation, -Default cost from
DFM software.
Total labor and overhead costs will scale directly with production hours, which would impact unit costs based on
efficiency improvements.
Material Utilization and Waste Reduction:
1. Material Utilization Rate: Compound die setup results in efficient material utilization; assume default utilization rate as
per DFM software.
Efficient material utilization with compound dies minimizes scrap, and recycling further reduces material cost
impact.
Assumptions For Cost Effective Manufacturing
Batch Setup Time and Changeovers:
1.
2.
Initial Setup Time: 1 hours for initial setup, die alignment, and testing.
Changeover Time :Minimal changeover for batch production, reducing overall
downtime.
Minimized setup and changeover times due to batch
production reduce idle time, enhancing cost efficiency
Quality Assurance and Defect Rate
Defect Rate: Target defect rate at 0% defects for high-quality control.
Quality Control Checks: Routine quality checks at regular intervals to detect and
correct deviations.
Quality control reduces rework costs and maintains a consistent defect rate, lowering the overall cost per unit.
Logistics and Packaging:
Packaging Cost : Not considered
shipping Costs : not considered assuming Ex- Works part
REPORTS :
DFM Concurrent Costing
Executive Summary
Monday, November 11, 2024
Exam - Sheet metal.dfmx
Analysis Name: Sheet metal-EXAM- Carbon Steel
Part name: Sheet metal Stamped part
Part number:
Material name: Generic low carbon steel
Manufacturing process: Compound die stamping
Manufacturing profile: 23A BDI North America
Product life volume
200,000
Batch size
12,000
Total cost, $
0.5272
Piece part cost, $
0.4700
Initial tooling investment, $
11,430
0.5
0.4
0.3
0.2
0.1
0
Total cost 0.5272
Process cost 0.1642
Material cost 0.2898
Setup cost 0.0083
Reject cost 0.0076
Tooling cost 0.0572
Piece part cost 0.4700
www.dfma.com
Page 1 of 1
DFM Concurrent Costing
Notes
Monday, November 11, 2024
Analysis Name: Sheet metal-EXAM- Carbon Steel
Part name: Sheet metal Stamped part
Part number:
www.dfma.com
Exam - Sheet metal.dfmx
Material name: Generic low carbon steel
Manufacturing process: Compound die stamping
Manufacturing profile: 23A BDI North America
Page 1 of 1
DFM Concurrent Costing
Pictures
Monday, November 11, 2024
Analysis Name: Sheet metal-EXAM- Carbon Steel
Part name: Sheet metal Stamped part
Part number:
www.dfma.com
Exam - Sheet metal.dfmx
Material name: Generic low carbon steel
Manufacturing process: Compound die stamping
Manufacturing profile: 23A BDI North America
Page 1 of 1
DFM Concurrent Costing
Responses
Monday, November 11, 2024
Exam - Sheet metal.dfmx
Analysis Name: Sheet metal-EXAM- Carbon Steel
Part name: Sheet metal Stamped part
Part number:
Material name: Generic low carbon steel
Manufacturing process: Compound die stamping
Manufacturing profile: 23A BDI North America
Generic low carbon steel sheet metal part
Part
Part name
Sheet metal Stamped part
Part number
Life volume
200000
Envelope shape
Stepped block
Part length, in.
4.470
Part width, in.
2.250
Part height, in.
1.300
Average thickness, in.
0.075
Forming direction
Z
Compound die stamping process
Basic data
Batch size
12000
Overall plant efficiency, %
85.00
Material cost, $/lb
0.760
Material scrap value, $/lb
0.050
Gage thickness, in.
0.075
Stock form
Sheet
Automatic sheet size selection?
Yes
Sheet size
72 x 48 in.
Part to stock edge clearance, in.
0.150
Part to part clearance, in.
0.150
Parts per stroke
1
Parts per sheet
190
www.dfma.com
Page 1 of 6
DFM Concurrent Costing
Responses
Monday, November 11, 2024
Exam - Sheet metal.dfmx
Part basic data
Unfolded length, in.
4.470
Unfolded width, in.
3.600
Length overlap, in.
0.000
Width overlap, in.
0.000
Processing direction
Width
Additional setups
Hole punching
0
Form feature punching
0
Combination punch operation
0
Die bend forming
1
Press brake
0
Compound die operation data
Area of blank, in²
16.092
Perimeter of blank, in.
16.140
Number of holes
8
Area of holes, in²
1.262
Perimeter of holes, in.
10.053
Number of form features
0
Perimeter of form features, in.
0.000
Form bends 1 data
Number of bends
1
Length of bend lines, in.
4.470
Piranha 1/4 in. x 8 foot hydraulic power shear
Machine selection
Automatic selection?
Yes
Power shear characteristics
Maximum shear length, in.
96.000
www.dfma.com
Page 2 of 6
DFM Concurrent Costing
Responses
Monday, November 11, 2024
Exam - Sheet metal.dfmx
Maximum gage thickness, in.
0.250
Processing data
Machine rate, $/hr
20.00
Operator rate, $/hr
27.00
Process rate, $/hr
47.00
Rejects, %
0.50
Shear and stack time, s
6.50
Result
Process time per part, s
0.59
Load sheet and remove scrap
Operation result
Operation time per part, s
0.21
Machine setup data
Machine rate during setup, $/hr
16.50
Setup operator rate, $/hr
31.00
Setup rate, $/hr
47.50
Setup time, hr
0.25
Power shear operation
Operation result
Operation time per part, s
0.38
MMC CX1-450 (50 ton)
Machine selection
Automatic selection?
Yes
Press characteristics
Press force, tons
50.00
www.dfma.com
Page 3 of 6
DFM Concurrent Costing
Responses
Monday, November 11, 2024
Exam - Sheet metal.dfmx
Coil fed press speed, strokes/min
77
Press dimensions
Bed length, in.
33.460
Bed width, in.
17.320
Processing data
Machine rate, $/hr
16.00
Operator rate, $/hr
27.00
Process rate, $/hr
43.00
Rejects, %
0.50
Result
Process time per part, s
4.91
Load and advance strip
Operation result
Operation time per part, s
2.57
Machine setup data
Machine rate during setup, $/hr
13.00
Setup operator rate, $/hr
31.00
Setup rate, $/hr
44.00
Setup time, hr
1.00
Compound die tooling data
Single punch and die life
500000
Tooling material cost, $
406
Die manufacturing rate, $/hr
42.00
Design and manufacture time, hr
198.87
Compound die operation
Operation result
www.dfma.com
Page 4 of 6
DFM Concurrent Costing
Responses
Monday, November 11, 2024
Exam - Sheet metal.dfmx
Operation time per part, s
2.34
MMC CX1-450 (50 ton)
Machine selection
Automatic selection?
Yes
Press characteristics
Press force, tons
50.00
Coil fed press speed, strokes/min
77
Press dimensions
Bed length, in.
33.460
Bed width, in.
17.320
Processing data
Machine rate, $/hr
16.00
Operator rate, $/hr
27.00
Process rate, $/hr
43.00
Rejects, %
0.50
Result
Process time per part, s
5.59
Load and unload part
Operation result
Operation time per part, s
3.25
Machine setup data
Machine rate during setup, $/hr
13.00
Setup operator rate, $/hr
31.00
Setup rate, $/hr
44.00
Setup time, hr
1.00
Form bends tooling data
www.dfma.com
Page 5 of 6
DFM Concurrent Costing
Responses
Monday, November 11, 2024
Exam - Sheet metal.dfmx
Single punch and die life
500000
Tooling material cost, $
384
Die manufacturing rate, $/hr
42.00
Design and manufacture time, hr
54.46
Form bends
Operation result
Operation time per part, s
2.34
Inspect visually
Rejects, %
0.500
Sampling percentage, %
10.000
Inspected area, in²
37.587
Labor rate, $/hr
32.00
Part handling time, s
5.400
Inspection time, s
2.000
Operation time, s
0.7400
www.dfma.com
Page 6 of 6
DFM Concurrent Costing
Cost Breakdown
Monday, November 11, 2024
Exam - Sheet metal.dfmx
Analysis Name: Sheet metal-EXAM- Carbon Steel
Material name: Generic low carbon steel
Part name: Sheet metal Stamped part
Manufacturing process: Compound die stamping
Part number:
Manufacturing profile: 23A BDI North America
Part weight: 0.315 lb
Generic low carbon steel sheet metal part
0.2898
0.0083
0.1642
0.0076
0.4700
0.0572
0.5272
11.82
11,430
0.2898
0.0083
0.1565
0.0054
0.4601
0.0572
0.5172
11.08
11,430
Piranha 1/4 in. x 8 foot hydraulic power
shear
0.0010
0.0090
0.0014
0.0114
0.0114
0.59
Load sheet and remove scrap
0.0010
0.0032
0.0042
0.0042
0.21
0.0058
0.0058
0.0058
0.38
Compound die stamping process
12,000
Power shear operation
MMC CX1-450 (50 ton)
Load and advance strip
0.0037
0.0690
0.0037
Compound die operation
0.0744
0.0438
0.1182
4.91
8,759
0.0361
0.0398
0.0438
0.0836
2.57
8,759
0.0328
0.0328
0.0328
2.34
MMC CX1-450 (50 ton)
0.0037
0.0785
Load and unload part
0.0037
Form bends
Inspect visually
www.dfma.com
0.0018
0.0844
0.0134
0.0977
5.59
2,672
0.0457
0.0493
0.0134
0.0627
3.25
2,672
0.0328
0.0328
0.0328
2.34
0.0100
0.0100
0.74
0.0077
0.0022
0.0022
Page 1 of 1
DFMA® - Boothroyd Dewhurst, Inc.
DFM Concurrent Costing
Totals
Monday, November 11, 2024
Analysis Name
Part name
Exam - Sheet metal.dfmx
Sheet metal-EXAMCarbon Steel
Sheet metal Stamped
part
Sheet metal-EXAM- Aluminium
Sheet metal Stamped AL
Part number
Material
Generic low carbon steel Generic aluminum alloy
Manufacturing process
Compound die stamping
Compound die stamping
Manufacturing profile
23A BDI North America
23A BDI North America
Cost per part, $
Baseline
Value
Material
0.2898
0.2719
-0.02
-6%
Setup
0.0083
0.0084
0.00
1%
Process
0.1642
0.2377
0.07
45%
Rejects
0.0076
0.0073
0.00
-4%
Piece part
0.4700
0.5253
0.06
12%
Tooling
0.0572
0.0572
0
0%
Total
0.5272
0.5824
0.06
10%
Initial tooling investment
11,430
11,430
0
0%
Life volume
200,000
200,000
0
0%
Batch size
12,000
12,000
0
0%
Part weight, lb
0.315
0.11
-0.207
-66%
www.dfma.com
Difference
Page 1 of 1
DFMA® - Boothroyd Dewhurst, Inc.
DFM Concurrent Costing
Cost Totals
Monday, November 11, 2024
Exam - Sheet metal.dfmx
Sheet metal-EXAMCarbon Steel
Cost per part, $
Life volume
www.dfma.com
Sheet metal-EXAMAluminium
Compound die stamping Compound die stamping
Generic low carbon
Generic aluminum alloy
steel
200,000
200,000
Material
0.2898
0.2719
Setup
0.0083
0.0084
Process
0.1642
0.2377
Rejects
0.0076
0.0073
Piece part
0.4700
0.5253
Tooling
0.0572
0.0572
Total
0.5272
0.5824
Initial tooling investment
11,430
11,430
Page 1 of 1
DFMA® - Boothroyd Dewhurst, Inc.
DFM Concurrent Costing
Cost Totals
Monday, November 11, 2024
Exam - Sheet metal.dfmx
1 Sheet metal-EXAMCarbon Steel
Cost per part, $
Life volume
www.dfma.com
2 Sheet metal-EXAMAluminium
Compound die stamping Compound die stamping
Generic low carbon
Generic aluminum alloy
steel
200,000
200,000
Material
0.2898
0.2719
Setup
0.0083
0.0084
Process
0.1642
0.2377
Rejects
0.0076
0.0073
Piece part
0.4700
0.5253
Tooling
0.0572
0.0572
Total
0.5272
0.5824
Initial tooling investment
11,430
11,430
Page 1 of 1
DFMA® - Boothroyd Dewhurst, Inc.
DFM Concurrent Costing
Cost Totals
Monday, November 11, 2024
Exam - Sheet metal.dfmx
1 Sheet metal-EXAMCarbon Steel
Cost per part, $
Life volume
www.dfma.com
2 Sheet metal-EXAMAluminium
Compound die stamping Compound die stamping
Generic low carbon
Generic aluminum alloy
steel
200,000
200,000
Material
0.2898
54.98%
0.2719
46.68%
Setup
0.0083
1.58%
0.0084
1.44%
Process
0.1642
31.16%
0.2377
40.81%
Rejects
0.0076
1.44%
0.0073
1.26%
Piece part
0.4700
89.16%
0.5253
90.19%
Tooling
0.0572
10.84%
0.0572
9.81%
Total
0.5272
100%
0.5824
100%
Difference
-0.0552
0.0000
Initial tooling investment
11,430
11,430
Page 1 of 1
DFM Concurrent Costing
Guide to Cost Reduction
Monday, November 11, 2024
Exam - Sheet metal.dfmx
Analysis Name: Sheet metal-EXAM- Carbon Steel
Part name: Sheet metal Stamped part
Part number:
Material name: Generic low carbon steel
Manufacturing process: Compound die stamping
Manufacturing profile: 23A BDI North America
For the product life volume of 200000 and the batch size of 12000 you have specified, the tooling costs form 10.84% of
the total cost of 0.53. The chart provides an indication of the contributions to this total cost made by various factors. Note
that, if multiple operations of the same type are required, the total contributions from all operations of that type are shown.
When considering changes to reduce cost you may wish to concentrate on the part features that affect the operations
which are the largest cost contributors.
www.dfma.com
Category
Savings, $
Bend forming setups
0.0981
Additional operations
0.0100
Rejects
0.0076
Page 1 of 1
DFM Concurrent Costing
Executive Summary
Monday, November 11, 2024
Exam - Sheet metal.dfmx
Analysis Name: Sheet metal-EXAM- Aluminium
Part name: Sheet metal Stamped AL
Part number:
Material name: Generic aluminum alloy
Manufacturing process: Compound die stamping
Manufacturing profile: 23A BDI North America
Product life volume
200,000
Batch size
12,000
Total cost, $
0.5824
Piece part cost, $
0.5253
Initial tooling investment, $
11,430
0.6
0.5
0.4
0.3
0.2
0.1
0
Total cost 0.5824
Process cost 0.2377
Material cost 0.2719
Setup cost 0.0084
Reject cost 0.0073
Tooling cost 0.0572
Piece part cost 0.5253
www.dfma.com
Page 1 of 1
DFM Concurrent Costing
Notes
Monday, November 11, 2024
Analysis Name: Sheet metal-EXAM- Aluminium
Part name: Sheet metal Stamped AL
Part number:
www.dfma.com
Exam - Sheet metal.dfmx
Material name: Generic aluminum alloy
Manufacturing process: Compound die stamping
Manufacturing profile: 23A BDI North America
Page 1 of 1
DFM Concurrent Costing
Pictures
Monday, November 11, 2024
Analysis Name: Sheet metal-EXAM- Aluminium
Part name: Sheet metal Stamped AL
Part number:
www.dfma.com
Exam - Sheet metal.dfmx
Material name: Generic aluminum alloy
Manufacturing process: Compound die stamping
Manufacturing profile: 23A BDI North America
Page 1 of 1
DFM Concurrent Costing
Responses
Monday, November 11, 2024
Exam - Sheet metal.dfmx
Analysis Name: Sheet metal-EXAM- Aluminium
Part name: Sheet metal Stamped AL
Material name: Generic aluminum alloy
Manufacturing process: Compound die stamping
Part number:
Manufacturing profile: 23A BDI North America
Generic aluminum alloy sheet metal part
Part
Part name
Sheet metal Stamped AL
Part number
Life volume
200000
Envelope shape
Stepped block
Part length, in.
4.470
Part width, in.
2.250
Part height, in.
1.300
Average thickness, in.
0.075
Forming direction
Z
Compound die stamping process
Basic data
Batch size
12000
Overall plant efficiency, %
85.00
Material cost, $/lb
2.110
Material scrap value, $/lb
0.300
Gage thickness, in.
0.075
Stock form
Sheet
Automatic sheet size selection?
Yes
Sheet size
72 x 48 in.
Part to stock edge clearance, in.
0.150
Part to part clearance, in.
0.150
Parts per stroke
1
Parts per sheet
190
www.dfma.com
Page 1 of 6
DFM Concurrent Costing
Responses
Monday, November 11, 2024
Exam - Sheet metal.dfmx
Part basic data
Unfolded length, in.
4.470
Unfolded width, in.
3.600
Length overlap, in.
0.000
Width overlap, in.
0.000
Processing direction
Width
Additional setups
Hole punching
0
Form feature punching
0
Combination punch operation
0
Die bend forming
1
Press brake
0
Compound die operation data
Area of blank, in²
16.092
Perimeter of blank, in.
16.140
Number of holes
8
Area of holes, in²
1.262
Perimeter of holes, in.
10.053
Number of form features
0
Perimeter of form features, in.
0.000
Form bends 1 data
Number of bends
1
Length of bend lines, in.
4.470
Piranha 1/4 in. x 8 foot hydraulic power shear
Machine selection
Automatic selection?
Yes
Power shear characteristics
Maximum shear length, in.
96.000
www.dfma.com
Page 2 of 6
DFM Concurrent Costing
Responses
Monday, November 11, 2024
Exam - Sheet metal.dfmx
Maximum gage thickness, in.
0.250
Processing data
Machine rate, $/hr
20.00
Operator rate, $/hr
30.00
Process rate, $/hr
50.00
Rejects, %
0.50
Shear and stack time, s
6.50
Result
Process time per part, s
0.59
Load sheet and remove scrap
Operation result
Operation time per part, s
0.21
Machine setup data
Machine rate during setup, $/hr
17.50
Setup operator rate, $/hr
33.00
Setup rate, $/hr
50.50
Setup time, hr
0.25
Power shear operation
Operation result
Operation time per part, s
0.38
MMC CX1-450 (50 ton)
Machine selection
Automatic selection?
Yes
Press characteristics
Press force, tons
50.00
www.dfma.com
Page 3 of 6
DFM Concurrent Costing
Responses
Monday, November 11, 2024
Exam - Sheet metal.dfmx
Coil fed press speed, strokes/min
77
Press dimensions
Bed length, in.
33.460
Bed width, in.
17.320
Processing data
Machine rate, $/hr
18.00
Operator rate, $/hr
27.00
Process rate, $/hr
45.00
Rejects, %
0.50
Result
Process time per part, s
4.91
Load and advance strip
Operation result
Operation time per part, s
2.57
Machine setup data
Machine rate during setup, $/hr
13.00
Setup operator rate, $/hr
31.00
Setup rate, $/hr
44.00
Setup time, hr
1.00
Compound die tooling data
Single punch and die life
400000
Tooling material cost, $
406
Die manufacturing rate, $/hr
42.00
Design and manufacture time, hr
198.87
Compound die operation
Operation result
www.dfma.com
Page 4 of 6
DFM Concurrent Costing
Responses
Monday, November 11, 2024
Exam - Sheet metal.dfmx
Operation time per part, s
2.34
MMC CX1-450 (50 ton)
Machine selection
Automatic selection?
Yes
Press characteristics
Press force, tons
50.00
Coil fed press speed, strokes/min
77
Press dimensions
Bed length, in.
33.460
Bed width, in.
17.320
Processing data
Machine rate, $/hr
16.00
Operator rate, $/hr
27.00
Process rate, $/hr
43.00
Rejects, %
0.50
Result
Process time per part, s
5.59
Load and unload part
Operation result
Operation time per part, s
3.25
Machine setup data
Machine rate during setup, $/hr
13.00
Setup operator rate, $/hr
31.00
Setup rate, $/hr
44.00
Setup time, hr
1.00
Form bends tooling data
www.dfma.com
Page 5 of 6
DFM Concurrent Costing
Responses
Monday, November 11, 2024
Exam - Sheet metal.dfmx
Single punch and die life
600000
Tooling material cost, $
384
Die manufacturing rate, $/hr
42.00
Design and manufacture time, hr
54.46
Form bends
Operation result
Operation time per part, s
2.34
Inspect visually
Rejects, %
0.500
Sampling percentage, %
100.000
Inspected area, in²
37.587
Labor rate, $/hr
32.00
Part handling time, s
5.400
Inspection time, s
2.000
Operation time, s
7.4000
www.dfma.com
Page 6 of 6
DFM Concurrent Costing
Cost Breakdown
Monday, November 11, 2024
Exam - Sheet metal.dfmx
Analysis Name: Sheet metal-EXAM- Aluminium
Material name: Generic aluminum alloy
Part name: Sheet metal Stamped AL
Manufacturing process: Compound die stamping
Part number:
Manufacturing profile: 23A BDI North America
Part weight: 0.108 lb
Generic aluminum alloy sheet metal part
0.2719
0.0084
0.2377
0.0073
0.5253
0.0572
0.5824
18.48
11,430
0.2719
0.0084
0.1603
0.0049
0.4454
0.0572
0.5026
11.08
11,430
Piranha 1/4 in. x 8 foot hydraulic power
shear
0.0011
0.0096
0.0013
0.0119
0.0119
0.59
Load sheet and remove scrap
0.0011
0.0034
0.0045
0.0045
0.21
0.0061
0.0061
0.0061
0.38
Compound die stamping process
12,000
Power shear operation
MMC CX1-450 (50 ton)
Load and advance strip
0.0037
0.0722
0.0037
Compound die operation
0.0775
0.0438
0.1213
4.91
8,759
0.0378
0.0415
0.0438
0.0853
2.57
8,759
0.0344
0.0344
0.0344
2.34
MMC CX1-450 (50 ton)
0.0037
0.0785
Load and unload part
0.0037
Form bends
Inspect visually
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0.0016
0.0842
0.0134
0.0976
5.59
2,672
0.0457
0.0493
0.0134
0.0627
3.25
2,672
0.0328
0.0328
0.0328
2.34
0.0798
0.0798
7.40
0.0774
0.0020
0.0024
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DFMA® - Boothroyd Dewhurst, Inc.
DFM Concurrent Costing
Cost vs. Life Volume
Monday, November 11, 2024
Exam - Sheet metal.dfmx
Sheet metal-EXAMCarbon Steel
Cost per part, $
Life volume
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Sheet metal-EXAMAluminium
Compound die stamping Compound die stamping
Generic low carbon
Generic aluminum alloy
steel
200,000
200,000
Material
0.2898
0.2719
Setup
0.0083
0.0084
Process
0.1642
0.2377
Rejects
0.0076
0.0073
Piece part
0.4700
0.5253
Tooling
0.0572
0.0572
Total
0.5272
0.5824
Initial tooling investment
11,430
11,430
Page 1 of 1
DFM Concurrent Costing
Guide to Cost Reduction
Monday, November 11, 2024
Exam - Sheet metal.dfmx
Analysis Name: Sheet metal-EXAM- Aluminium
Part name: Sheet metal Stamped AL
Part number:
Material name: Generic aluminum alloy
Manufacturing process: Compound die stamping
Manufacturing profile: 23A BDI North America
For the product life volume of 200000 and the batch size of 12000 you have specified, the tooling costs form 9.81% of the
total cost of 0.58. The chart provides an indication of the contributions to this total cost made by various factors. Note that,
if multiple operations of the same type are required, the total contributions from all operations of that type are shown.
When considering changes to reduce cost you may wish to concentrate on the part features that affect the operations
which are the largest cost contributors.
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Category
Savings, $
Bend forming setups
0.0980
Additional operations
0.0798
Rejects
0.0073
Page 1 of 1