Hands On Layout

Given Values:
1. Volume: _________
2. Surface Area: _________
3. Weight: _________
4. Thickness: _________
5. Length: _________
6. Length: _________
7. Width: _________

This is Aluminium Alloy part and the raw material form is plate. For calculation of material
cost we must take excess material.
For Plate Form,1-inch of excess taken in length direction and 0.2-inch excess considered
in width direction. In Thickness direction, we will add 0.25-inch excess then round it off to
next quarter.
Length: _____ (From Given) + 1 = _____-inch
Width: ______ (From Given) + 0.2 = _____-inch
Thickness: ______ (From Given) + 0.25 = _____-inch

Unit cost of material from database= $1.64/lb.

Reclaim price = $0.4/lb.

Volume = Length * Width * Thickness= ______*_______*_______ = ________in^3

Density for the raw material from database = 0.101 lb./in^3.
Weight = Density * Volume = 0.101*_____ = ______lb.
Reclamation weight = 90% of weight of material removed = (Stock weight -Finished weight)
*0.9 = (______-0.558) *0.9=______ lb.
Material cost = Stock Weight*Unit Cost = ______*1.64 = $_____
Reclaim cost = Reclaim Weight*Reclaim Price = ______*0.4 = $______
Final Material cost = Material Cost –Reclaim Cost = _____ - ______ = $_____

Final Material Cost = $_______

Manufacturing Cost:
1: Cut to Working Size
The first step in manufacturing is to cut the raw material to a feasible size to work on.
For the Plate form, we will be using Abrasive water jet cutting for the Cut to Working size
step.
The labor time for Cut to Working size depends on Length and Width of stock and the setup
time ranges from 10 to 15 min.
Labor Time = (Stock Length + Stock Width) / Cutting Rate.
Labor Time = (______+______)/10 = _____min.
Setup Time = 10.58 min
Wrap Rate for Abrasive water jet cutting for Turkey Region = $30.41/hour
Cost of Cut to Working size = [(Setup time (in hours)/lot size) +labor time(hours)] * Wrap
Rate
Cost of Cut to Working size = [(0.176/10) +______] *30.41 = $______.

2: Machine Run Time

In this step, we will remove the material from work piece to get required part shape using
feasible machining process.
Since it is a vertical or right-angled part and contour design is there,
we will select mill (3 or 4) axis machine.

Material to be removed = Stock Volume –Finished Volume = ______-_____ (From Given)

Material to be removed = ________ in^3.
Roughing volume = 85% of material to be removed = 0.85*Material to be removed
= _______ in^3
Roughing Time = Roughing Volume / Roughing MRR = _____/10 = _____ min
Finishing volume = 15% of material to be removed = 0.15* material to be removed
= ______ in^3.
Finishing Time = Finishing Volume / Finishing MRR = ____/1.5 = _____ min
Setup Time = 15.58 min.
*If holes are given
____ Holes to be drilled and reamed. So, the runtime of drilling and reaming also to be
added to machine runtime.
Drilling Runtime for Aluminium = 7 to 9 sec per drill
Reaming Runtime for Aluminium = 3 to 5 sec per drill
Runtime for drilling and reaming = (No. of holes*(8/60)) +(No. of Holes*(4/60))
Runtime for drilling and reaming = ____min.
Total Machine runtime = Part Loading Time + Roughing Time + Finishing Time + Drilling
& Reaming Time
Total Machine runtime/Labor Time = 1 + _____ + _____+ _____ = ____ min
Wrap Rate for Mill 4 Axis Aluminium Plate Small = $23.43 /hour.
Cost of Machining = [(Setup time (in hours)/lot size) +labor time(hours)] * Wrap Rate.
Cost of Machining = [ (0.26/10) +_______] *23.43 = ___*23.43 = $____.

3: Blending & Deburring

This step is required to remove machining marks and burrs created during machining process.
Blending time = Surface area / Blending Speed = ______ (From Given) /150 = __ min
If it is less than 0.5 min, we will consider blending time as 0.5 min.
Deburring time = Deburring Edge Length / Deburring speed = ______ (if not given assume
Value around + or – 100) /50 = _____ min.
Setup Time of Blending and Deburring = 2.9 min (Setup time range: 2 –6 min).
Total Blending & Deburring Runtime (also called as Labor time) = Blending Time +
Deburring Time
= _____ + ______ = _______min.
Wrap Rate for Blending & Deburring = $9.13
Cost of Blending & Deburring = [(Setup time (in hours)/lot size) +labor time(hours)] * Wrap
Rate
Cost of Blending & Deburring = [ (0.048/10) + ______] * 9.13 = $______.
4: Visual Inspection
Time for visual inspection depends on part size. For our part length, 1 min is enough for
visual inspection.
Cost of Visual Inspection = [(Setup time (in hours)/lot size) +labor time(hours)] * Wrap Rate
Cost of Visual Inspection = [ 0+0.0166] * 9.13 = $0.15.

5: Fab Inspection
Fab inspection time is 10% of the summation of all runtimes in manufacturing section
excluding inspections.
Fab Inspection time = (Cut to Working size time + Machining time + Blending & Deburring
time) *0.1.
Fab Inspection time = (_______+_______+______) *0.1 = _____ min.
Cost of Fab Inspection = [(Setup time (in hours)/lot size) +labor time(hours)] * Wrap Rate.
Cost of Fab Inspection = (0+______) *9.13 = $______.
Total Manufacturing Cost = Cut to Working size Cost + Machining Cost + Blending &
Deburring Cost + Visual Inspection Cost + Fab Inspection Cost.

Total Manufacturing Cost = _____+______+______+______+______

Total Manufacturing Cost = $______

6: Processing Cost
This Processing section includes cost of all finishing operations. All other processes apart
from machining process done over the finished product will be included here.

a) Penetrant Inspection
This process is to detect surface defects on the finished part
Setup time = 15.58 min
Wrap Rate = $21.13/hour
Labor time or Runtime = 1min
Labor time for penetrant inspection depends on surface area of part
Cost of Penetrant Inspection = [(Setup time (in hours)/lot size) +labor time(hours)] *
Wrap Rate
Cost of Penetrant Inspection = [(0.26/10) +0.0167] *21.13 = $0.9

b) Chromic Acid Anodizing

Setup time = 5.58 min
Wrap Rate = $19.13/hour
Labor time or Runtime = 1.08min
Consumable cost = Surface area * unit cost = ______ * 0.001 = $______
 Cost of Chromic Acid Anodizing = {[(Setup time (in hours)/lot size) +labor
time(hours)] * Wrap Rate} + Consumable cost.

Cost of Chromic Acid Anodizing = {[(0.093/10) +0.018] *19.13} +____ = $___.

c) Primer Coatings: 2 Coats

Setup time = 5.58 min

Wrap Rate = $9.13/hour
Labor time or Runtime = 1.58min
Consumable cost = Surface area * unit cost per coat*no. of coats= ______ * 0.0001*2
= $______.
Cost of primer coating= {[(Setup time (in hours)/part) +labor time(hours)] * Wrap
Rate} + Consumable cost
Cost of primer coating = {[(0.093/10) +0.0263] *9.13} +____= $____.

d) Part Making
Setup time = 0
Wrap Rate = $9.13/hour
Labor time = 0.08 min
Cost of Part marking = [(Setup time (in hours)/lot size) +labor time(hours)] * Wrap
Rate
Cost of Part marking = (0+0.0013) *9.13 = $0.01

Total Processing Cost = Penetrant inspection cost + Chromic acid anodizing cost +
primer coating cost+ part marking cost

Total Processing Cost = 0.9+_____+_____+0.01 = $______

Total Processing Cost = $______

Total Cost = Material Cost + Manufacturing Cost + Processing Cost

Total Cost = _____+_____+_____= $______

SG&A Cost:
Selling, General and Administrative costs are the expenses required to manage the company.
It is 6% of the total cost.
SG&A = _____*0.06 = $_____

Profit:
Profit is 10% on total cost and SG&A cost
Profit= (_____+____) *0.1 = $______

Total Price of the Part = Total Cost + SG&A + Profit

Total Price = _____ + ______+ _____

Total Price = $________