VARROC ENGINEERING PVT LTD.

,
E&E R&D, PUNE ENGINEERING BILL OF MATERIAL

ELECTRONICS CUSTOMER VARROC CUSTOMER PAGE 1 OF 2

ELECTRICAL √ TVSM PRODUCT NAME FLYWHEEL MAGNETO ASSY. FLYWHEEL MAGNETO ASSY. BOM NO. PL 02 XXX XXXXX PROTOTYPE √
PRODUCT CATEGORY
SWITCH APPLICABLE MODEL PRODUCT NO. 02 XXX XXXXX K6060490 BOM REV NO. COSTING DEVELOPMENT

JUPITER BS-VI PRODUCT NO. REV / DATE COSTING / 14/03/2019 29/10/2018 BOM REV DATE 14/03/20019 PRODUCTION

S.N. LEVEL SUPPLIER

PART / SAP CODE (WITH PART/ PRODUCT Basic Tool cost MATERIAL/SURFACE
DRG NO. REV N/C UOM QTY Part Cost Assy Cost Remark LEGEND/ DESIGNATOR A/I DISTRIBUTOR REMARKS
ITEM DESCRIPTION REV. NO.) CATEGORY (TYPE) in lacs TREATMENT
0 1 2 3 4 5 6 7 MAKE MAKER PART No.

1 0 FLYWHEEL MAGNETO ASSY 02 XXX XXXXX N Nos 1 - -

2 1 ROTOR ASSY. 02 XXX XXXXX N Nos 1 - -
Notching feasibility
needs to review
3 2 FLYWHEEL CUP M/C REFER SKETCH N Nos 1 57.68 57.68 17.24 - -
(feasibility submited to
R&D)

Riveting Hole & Radius

will produce thru Press
4 2 BOSS (FINISH) REFER SKETCH N Nos 1 50.82 50.82 9.20 opearation , So needs to - -
review the feasibility for
related dimn

5 2 MAGNET 02 295 40941 N Nos 4 - -

6 2 MAGNET CASE REFER SKETCH N Nos 1 11.02 11.02 3.82 - -
7 2 RIVET (DIA 5 * 14L) 01 001 10108 C Nos 6 Existing - -
8 2 ADHESIVE - ANABOND 221 01 001 60006 C gm 4.5 Existing ANABOND ANABOND 221
9 2 RUST PREVENTIVE OIL 01 001 60007 C ml 0.5 Existing - -
10 2 ELMOLUFT 1A 01 001 60021 C ml 1 Existing - -

11 1 STATOR ASSY. 02 XXX XXXXX N Nos 1 In-house - -

12 2 STATOR COIL ASSY. 02 XXX XXXXX N Nos 1 - -
13 3 CORE ASSY REFER SKETCH N Nos 1 40.01 40.01 9.15 - -
14 4 LAMINATION A REFER STAR CITY N Nos 15 - -
15 3 BOBBIN A REFER SKETCH N Nos 1 6.57 6.57 13 - -
16 3 BOBBIN B REFER STAR CITY N Nos 1 Existing - -
17 3 COPPER WIRE DIA 0.9 DCCH 01 001 30002 C gm 145 Existing - -
18 3 SILASTOMER SLEEVE DIA 1.0, BLACK 01 001 20083 C mm 100 Existing - -
19 3 TERMINAL 02 295 40945 C Nos 1 Existing - -
20 3 EARTH TERMINAL REFER STAR CITY N Nos 1 Existing - -
21 3 VARNISH FT 2001 01 001 60071 C gm 8 Existing ELANTAS BECK FT 2001
22 3 THINNER DILUENT M 01 001 60010 C gm 3 Existing ELANTAS BECK DILUTENT M
23 3 HARDNER K2 01 001 60009 C gm 0.08 Existing ELANTAS BECK K2
24 3 SOLDER STICK 63/37 01 001 30019 C gm 0.15 Existing BT SOLDER/COOKSON -
25 3 VFG SLEEVE (∅4,YELLOW) 01 001 20064 C mm 30 Existing - -
26 3 HEAT SHRINKABLE SLEEVE(DIA3.5/1.75) 01 001 20030 C mm 25 Existing - -
27 3 TETRON TAPE 01 001 20003 C mm 300 Existing - -
28 2 WIRING HARNESS ASSY. REFER SKETCH N Nos 1 23.38 23.38 - -
29 3 GROMMET REFER SKETCH N Nos 1 Existing 1.5 - -
30 2 SOLDER WIRE - 16 SWG (Sn95:Sb5) 01 001 30026 C gm 1 Existing COOKSON -
31 2 ELMOLUFT 1A 01 001 60021 C ml 0.5 Existing - -
32 2 NO CLEAN FLUX RF800 01 001 60041 C ml 0.5 Existing COOKSON -
33 2 YELLOW POWDER 5440 01 001 60078 C gm 0.04 Existing R.D.C.P.L -

34 1 PULSER COIL ASSY. 02 XXX XXXXX N Nos 1 25.96 25.96 - -

35 2 PULSER COIL ASSY & POTTING. 02 XXX XXXXX N Nos 1 - -
36 3 PULSER COIL WINDING. 02 149 20586 N Nos 1 - -
37 4 PULSER BOBBIN 02 132 40590 C Nos 1 - -
38 4 COPPER WIRE DIA 0.09,UEW 01 001 30036 C gm 8 - -
39 4 TERMINAL LH 02 146 40703 C Nos 1 - -
40 4 TERMINAL RH 02 146 40704 C Nos 1 - -
41 3 LEAD WIRE - WHITE REFER SKETCH N Nos 1 - -
42 3 LEAD WIRE - BROWN REFER SKETCH N Nos 1 - -
43 3 SOLDER WIRE - 16 SWG (Sn95:Sb5) 01 001 30026 C gm 0.2 BT SOLDER -
44 3 PULSER MAGNET 02 039 40209 C Nos 1 - -
45 3 MICA SHEET (16*4) 01 001 20040 C Nos 1 - -
46 3 PULSER CORE `A' 02 039 40202 C Nos 2 - -
47 3 P.G.PLATE REFER SKETCH N Nos 1 1.10 - -
48 3 P.G.CASE 02 101 40848 C Nos 1 - -
49 3 RESIN - DOBECKOT 5503 01 001 60033 C gm 8 ELANTAS BECK RESIN - DOBECKOT 5503
50 3 HARDNER EH408 01 001 60004 C gm 2 ELANTAS BECK HARDNER EH408

Total 215.44 215.44 55.01

SR.N
ABBREVATION Details MECHANICAL/ELECT. ELECTRONICS
O.
1 A Automotive Grade Component
PREP BY
2 I Industrial Grade Component

SIGN & DATE

3 N New Part/Component
CHKD BY
4 C Common part/component
5 NA Not Applicable
APPD BY

R&D/FR/18/03/(DATE OF REV.19/05/2017)
 Volume Details.- Monthly Volume 25K
Part No. 02 XXX XXXXX
FLYWHEEL
Sub Part Name CUP(MACHINING) Landed Cost 40
Material Specif. HRPO-1079 DD
RAW MATERIAL DETAILS
Sr.No. Description Thk. Width Length Weight
1 Sheet Size 3 1250 2500 73.688
2 Component Size 3 168 168 0.666
3 Strip Size 3 171 174.0 0.701
4 No. of Comp./ Sheet 7 14 98
5 Weight / Comp. 0.752
6 Pitch
RAW MATERIAL COSTING DETAILS
Sr.No. Description Details
1 Loading Wt. - Kg 0.752
2 Rate - Rs./ Kg 40.00
3 R.M. Input Cost - Rs./ Part 30.08
4 Finish Wt.of the Component - Actuals 0.447
5 Scrap Wt. - Kg 0.305
6 Scrap Recovery rate/ - Rs/ Kg 20.00
7 Scrap Recovery Cost - Rs/ Kg 6.10
8 Component Cost - Rs. 23.98

CONVERSION COST DETAILS

Sr.No. Operation Press Type Press Ton. Rate / Stroke Tool Cost
1 Shearing @ 750 / MT 0.56
2 Blank MECHNICAL 150 0.50 125000
3 Draw Hyd 250 1.25 411000
4 Draw Oil And its applic Manual 0.75
5 Piercing MECHNICAL 110 0.35 115000
6 Notching MECHNICAL 110 0.35 290000
7 Embossing MECHNICAL 50 0.17 85000
8 Pip Forming
Chamfer 22 Pip
for tapping MECHNICAL 50 3.74 635000
9 hole and Tooling Hole Drill Machine 1.60 0
10 both Side3 nos
Tapping Tapping machine 1.20 18000
Dia 32 Chamfer and Total Lathe Machine
11 Ht.ID/OD Chamf. 2.00
12 Vibro Finishing Vibro Machine 1.00
13 PLATING ZINC 7.97
14 Inspection 0.25 45000
CONVERSION COST - Rs. 21.69 1724000

COST OF THE COMPONENT

Sr.No. DESCRIPTION COST
1 Raw Material Cost - Rs. 23.98
2 Conversion Cost - Rs. 21.69
3
4 Profit on 7.0% R.M. + 10% Convers 3.85
5 Rejection on R.M. + Conversion - 1 0.46
6 Sub Total (Sr.1+2+3+4+5+6) 49.97
7 Tool Maint.Cost 2% 0.91
8 Packing In Plastic crates 0.35
9 Transport 1.25
10 Component Cost - Rs./ Part 52.49
Part Cost For M/s.VEL-PUNE PLANT III

49.75 9.75 7.331154

27 7 2.134393
5.196761
57.68
Quote

Specifications BOSS 0229540938

Material S45C
RM Rate / Kg + Unloading 55.25
Scrap Rate / Kg 18.00
Description BOSS TVS JUPITER

Operations Machine Norms Time ( S ) Eff% Cost

Gross Wt 0.323
Cut Wt. 0.300
Forging Wt. 0.279
S/F Wt. 0.220
Job Finish Wt. 0.115
Scrap Wt 0.208
Net Scrap Wt. 85% scrap recovery 85% 0.177
Scrap Rate / KG 18.00
RM Rate / KG 55.25
Gr. RM Cost 17.85
Net Scrap Cost 3.18
RM Cost 14.66
Value Addition cost 29.69
Bar Dia
Cutting Band Saw 0.06 0.81
Forging - PRESS FORGING 14 0.300 7.00
Pre Machining Lathe 45 220 85% 2.75
Heat Treatment Hardening & Tempering 14 0.220 3.08
CNC - 1 CNC 165 60 85% 3.24
CNC - 2 CNC 165 70 85% 3.77

Pcd hole drill& slot PRESS 5.50

Phospeting 0.75
Debubring Drill 45 40 85% 0.59
Chamfer both side. Drill 45 40 85% 0.59
Cnc -3 CNC 165 30 85% 1.62
0.00
Value Addition 29.69
Sub total 44.36
Rej 1% 0.44
Profit on Rm 7% 1.03
Profit on VA 10% 2.97
Transportaton cost ht ,bothside 1.5 0.33
Transportaton with bin return 0.50
Inspection & Hardeness Testing 50 50 0.69
Oiling 0.25
Packing cost 0.25
RM Cost 14.66
Total VA 36.16

Rate for Jupiter 50.8

Development cost in Lacs

1) Tapper Finish Auto Guaging cost 7.5
2) Air Gauge for tapper angle 0.7
3) Press Tool 1.0
Total 9.20
 Remark

Wt provided by R&D

Needs to review the feasibility for face out &

other parameter.
To optimise the cost , out radius & hole
consider thru piercing opearation
To :-Varroc Engineering Ltd.

Dear Sir ,
Volume Details.- Monthly Volume 25K
Part No. X2 XXX XXXXX Date
Sub Part Name Magnet Case
Landed Cost 253
Material Specif. J1 Jindal Steel

RAW MATERIAL DETAILS

Sr.No. Description Thk. Width Length Weight
1 Sheet Size 0.15 162 162 0.031
2 Component Size 0.15 160 160 0.030
3 Strip Size 0.15 162 162 0.031
4 No. of Comp./ Sheet 1 1 1
5 Weight / Comp. 0.031
6 Pitch
RAW MATERIAL COSTING DETAILS
Sr.No. Description Details
1 Loading Wt. - Kg 0.031
2 Rate - Rs./ Kg 253.00
3 R.M. Input Cost - Rs./ Part 7.83
4 Finish Wt.of the Component - Actuals 0.014
5 Scrap Wt. - Kg 0.017
6 Scrap Recovery rate/ - Rs/ Kg 25.00
7 Scrap Recovery Cost - Rs/ Kg 0.42
8 Component Cost - Rs. 7.40

CONVERSION COST DETAILS

Sr.No. Operation Press Type Press Ton. Rate / Stroke Tool Cost
1 Blank MECHNICAL 63 0.21 90000
2 Draw 1 Hyd 63 0.32 85000
3 Poliithin Sheet for Draw 0.55 0
4 Draw 2 Hyd 63 0.32 85000
5 Trimming MECHNICAL 63 0.21 90000
6 Inspection 0.20 32000
CONVERSION COST - Rs. 1.81 382000.00

COST OF THE COMPONENT

Sr.No. DESCRIPTION COST
1 Raw Material Cost - Rs. 7.40
2 Conversion Cost - Rs. 1.81
3 ICC on R. M. Cost - 2% 0.15
4 Over Head 5%Conversion 0.09
5 Profit on 7.5% R.M. + 10% Convers 0.74
6 Rejection on R.M. + Conversion - 1 0.09
7 Sub Total (Sr.1+2+3+4+5+6) 10.28
8 Tool Maint.Cost 2% 0.18
9 Packing In Box 0.25
10 Transport 0.30
11 Component Cost - Rs./ Part 11.02
Part Cost For M/s.VEL-III
 CRCA Grade
MATERIALS DETAILS 12 mm
1 Raw Mtls CRNO DOUBLE Row
2 Thickness 0.80
3 Width 176.00
4 pitch 96.00
5 density 7.85
6 WEIGHTS DETAILS
7 gross wt/Lamination KGS 0.0531
8 No.of Lamination 15.00
9 Net wt/Lamination KGS 0.0192
Scrap wt/lamination KGS 0.0339
Gross wt / core pack KGS 0.7958
Net wt/core pack KGS 0.2880
Scrap wt/ core pack KGS 0.5078
R.M.COST DETAILS
Raw Mtls Price/kgs RS 55.75
Scrap Price/kgs 27.00
Gross Raw Matls cost/pack 44.366
Scrap cost/pack 13.711
Net Raw Mtls Cost/pack 30.655
Other Matl cost
Rivet price 0.14
No.of Rivet required 4.00
Rivet cost/pack 0.560
Total R.M.Cost / Pack 31.22
Process Cost Deatls
Blanking /Lamination up to 0.5mm 0.2
Blanking /Lamination from 0.6 to 0.9mm 0.125 1.88
Blanking / Lamination for 1- 1.6mm 0.2
Bending price/Lamination 0.12
Additional Piercing RS
Riveting Process cost/pack 0.500
Rivet Insersion & Lug stratning fix 0.018 0.108
Restacking process cost fix 0.150
Phospeting cost 10
Tapping 0.3
Total Process cost/pack 2.63
Other cost/pack
Rejection cost/pack Fix 1% 0.338
Packing cost 1.752
Inspection cost fix 0.200
Die maint. Cost Fix 0.250
inventory carring cost 1.5% 0.460
Total other cost Pack
Profit cost details
Profit on R.M. fix 7.0% 2.15
Profit on Process cost fix 10% 0.2633
Tool Amortosation
Tapping cost - M 3 x 10 mm deep
Ultrasonic Washing 0.7500
Core Pack Cost 40.01
Core pack Cost
 Core pack Cost
Tool cost for Main Lamination A 885000
Rivetting fixture 30000
Total 915000
COSTING LANXES
PARTICULAR
HEAD S RM
Costing Date -------->
PLANT --------> 2200
Plant & CUSTOMER -------->
Cutome
Item Type (2W - 4W) --------> 2W
r
RM Commodity --------> Nylon
Details
Freeze Profit Margine Price/Kg--------> 150.00
Costing Status ("T"/"F") --------> T
Supplie Supplier Code -------->
r& Supplier Name -------->
Item Item Code -------->
Details Item Description --------> Bobbin A
RM Code -------->
RM Description -------->
RM Supplier --------> LANXESS
RM Rates as on --------> 27.02.2019
RM
Jul'18 RM Base
Details
Further RM increase ,
RM Landed Rate --------> 302.00 So Actual RM rate
needs to consider
during SOP
Net Wt in gms --------> 10.18 Wt provided by R&D
Runner Wt in gms --------> 6.00
RM Gross Wt in gms --------> 13.18
Cost Rejection % --------> 0.030
Reconciliation Wt --------> 13.58
Net RM Cost --------> 4.10
BOP Code --------> XYZ
BOP Description --------> Insert
BOP
No of BOP --------> 0.00
Cost
Rate -------->
BOP Cost --------> 0.00
M/c Tonnage --------> 150
M/c Shift Rate --------> 1365
Cavity per Mould --------> 2
Conver Cycle Time in secs --------> 60
sion
Efficiency @ 95% --------> 0.95
Details
Shots per Shift --------> 456
Production per Shift --------> 912
Final Conversion Cost --------> 1.50
Profit on Conversion 8.0% 0.12
Profit On RM 6.0% 0.25
Profits Profit on BOP (Inserts Etc) 3.0% 0.00
Rejection on RM % 2.0% 0.11
Total Profit --------> 0.48
Post Open Cost if any --------> 0.10
Packing Cost With Details --------> 0.15
Transportation cost with
--------> 0.15
details
Total Other Charges --------> 0.40
Scrap Recovery --------> 0.15
Final
Annealing --------> 0.25
Rate
Final PO Rate --------> 6.57
s.r no CABLE:: Unit Qty. Rate Cost

1 Endura 0.75 sq mm mtr 0.47 7.49 3.48

2 Endura 1.0 sq mm mtr 0.44 9.87 4.29
TERMINAL
2 6.3 Male lock no 2 0.66 1.32
3 3.2 DF no 2 0.37 0.74
4 Bullet Male no 2 0.65 1.30
CONNECTORS
4 2pole male 250srs Natural no 1 2.10 2.10
5 2PF natural no 1 0.71 0.71
SLEEVE
6 PVC Sleeve 6x7 mtr 0.255 1.70 0.43
7 VFG 4x5 Natural mtr 0.03 6.90 0.21
8 VFG 6x7 Natural mtr 0.105 9.50 1.00
9 PVC Sleeve 3X4 mtr 0.22 1.70 0.37
10 PVC Sleeve 4X5 mtr 0.115 1.70 0.20
RUBBER PARTS
8 Rubber Grommet 0229540946 No 1 2.59 2.59
9 Tinning no 2 0.07 0.14
10 PVC Boot mtr 2 0.30 0.60

RM 19.48
VA 20.00% 3.90
Final Price 23.38
A General Data GROMMET
Part Name
Part No
Mod no GROMMET
B Raw Material Details
Raw Material Type EPDM
Raw Material code EPDM
Raw Material Rate / Kg 180.00
Net Wt 4.00
Gross Weight in gms 5.20
Raw Material Value 0.94
Sub Total B 0.94
C Metal part details
D Moulding Details
Moulding method TRANSFER
Machine capacity 150
M/c Shift Rate 800.00
Cavity Details 25
Cycle Time 12
Preformaing cost 0
Efficiency 90%
Shots per shift 40.0
Production per shift 900
Moulding Cost 0.89
Deflashing cost 0.10
Post Curing 0.00
Inspection 0.1
Std pk box 500
Packing 0.10
Forwarding Cost 0.00
Sub Total D 1.19
Total Cost ( B+C+D) 2.12
E Transportation Details
Transportation 0.10
ICC cost 0.00
Rejection 2 % 0.04
Profit 15 0.32
Sub Cost ( E) 0.46
Total Cost ( B+C+D+E) 2.59