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Logged in user Name: Priyanka Date:February-15-2023

File Name: ecoayt

E-Coat Inputs
A) Part Information
Part No 34
Part Description 43
B) Volume (Number of Pieces Produced)
Annual Volume 34
Production Lot Run Sizes 34
C) Part Specific Information
Envelop Length (mm) 344
Envelop Width (mm) 342
Envelop Height (mm) 123
Thickness of Part (mm) 2
Surface Area (Sq cm) 235.30
Weight (Kilograms) 23
D) E-Coat Process Specific Information
Select Coating Process Batch - Large & Bulky Parts
Derusting / Acid Pickling? no
Assumptions & Overrides
Paint material rate ($ / Kg) 3.170
Select Paint Thickness (Microns) 25.000
Cycle Time of Load Bars Or Hooks (Mins) 5.600
Override Number of Pieces / Load Bar or Hook (Units) 157.000
Assumed Minimum Lot run Charge $ 150.000
SG&A + Profit % 30.000
Select Number of Process Tanks for Pre-treatment & E-Coat 11 Tanks having Zinc/Iron Phosphating Pre-Treatment Process

E-coat Output
Cost Breakdown USA More Competitive Cost ($) Competitive Cost ($)
Material Cost (Paint) $ 0.012 $ 0.012
Setup cost $ 0.229 $ 0.264
Process Cost $ 1.455 $ 1.673
Other Cost (Derusting / Acid Pickling + Rework) $ 4.019 $ 4.598
SG&A + Profit $ 1.714 $ 1.964
Total Cost/piece $ 7.430 $ 8.510
E-coat - Cost Breakdown for USA

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Premium Section Lot R

Global Manufacturing Costing
Country Name More Competitive Cost Competitive Cost
USA $7.43 $8.51
Material Cost $0.01 $0.01
E-coat $0.01 $0.01
Setup Cost $0.23 $0.26
E-coat $0.23 $0.26
Process Cost $1.45 $1.67
E-coat $1.45 $1.67
Other Cost $4.02 $4.02
E-coat $4.02 $4.60
SG&A + Profit $1.71 $1.71
E-coat $1.71 $1.96
China $3.57 $5.93
Material Cost $0.01 $0.01
E-coat $0.01 $0.01
Setup Cost $0.19 $0.22
E-coat $0.19 $0.22
Process Cost $0.63 $1.05
E-coat $0.63 $1.05
Other Cost $5.93 $5.93
E-coat $1.92 $3.28
SG&A + Profit $0.82 $0.82
E-coat $0.82 $1.37
Mexico $4.81 $7.36
Material Cost $0.01 $0.01
E-coat $0.01 $0.01
Setup Cost $0.19 $0.22
E-coat $0.19 $0.22
Process Cost $0.85 $1.31
E-coat $0.85 $1.31
Other Cost $8.58 $8.58
E-coat $2.65 $4.12
SG&A + Profit $1.11 $1.11
E-coat $1.11 $1.70
India $2.55 $4.76
Material Cost $0.01 $0.01
E-coat $0.01 $0.01
Setup Cost $0.18 $0.21
E-coat $0.18 $0.21
Process Cost $0.43 $0.82
E-coat $0.43 $0.82
Other Cost $9.91 $9.91
E-coat $1.33 $2.61
SG&A + Profit $0.59 $0.59
E-coat $0.59 $1.10
Brazil $5.62 $8.27
Material Cost $0.01 $0.01
E-coat $0.01 $0.01
Setup Cost $0.20 $0.23
E-coat $0.20 $0.23
Process Cost $1.03 $1.51
E-coat $1.03 $1.51
Other Cost $13.00 $13.00
E-coat $3.08 $4.61
SG&A + Profit $1.30 $1.30
E-coat $1.30 $1.91
Western Europe $8.13 $11.11
Material Cost $0.01 $0.01
E-coat $0.01 $0.01
Setup Cost $0.23 $0.27
E-coat $0.23 $0.27
Process Cost $1.59 $2.16
E-coat $1.59 $2.16
Other Cost $17.41 $17.41
E-coat $4.41 $6.11
SG&A + Profit $1.88 $1.88

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Country Name More Competitive Cost Competitive Cost

E-coat $1.88 $2.56
Eastern Europe $5.18 $7.76
Material Cost $0.01 $0.01
E-coat $0.01 $0.01
Setup Cost $0.21 $0.24
E-coat $0.21 $0.24
Process Cost $0.99 $1.46
E-coat $0.99 $1.46
Other Cost $20.18 $20.18
E-coat $2.77 $4.25
SG&A + Profit $1.20 $1.20
E-coat $1.20 $1.79

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Volume Impact To Costing

Cost For Lot Run Sizes

Country 10 25 50 100 250 500 1000 5000 50000
USA $8.14 $7.54 $7.33 $7.23 $7.17 $7.15 $7.14 $7.13 $7.13
Material Cost $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01
E-coat $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01
Setup Cost $0.78 $0.31 $0.16 $0.08 $0.03 $0.02 $0.01 $0.00 $0.00
E-coat $0.78 $0.31 $0.16 $0.08 $0.03 $0.02 $0.01 $0.00 $0.00
Process Cost $1.45 $1.45 $1.45 $1.45 $1.45 $1.45 $1.45 $1.45 $1.45
E-coat $1.45 $1.45 $1.45 $1.45 $1.45 $1.45 $1.45 $1.45 $1.45
Secondary Process Cost $4.02 $4.02 $4.02 $4.02 $4.02 $4.02 $4.02 $4.02 $4.02
E-coat $4.02 $4.02 $4.02 $4.02 $4.02 $4.02 $4.02 $4.02 $4.02
SG&A + Profit $1.88 $1.74 $1.69 $1.67 $1.65 $1.65 $1.65 $1.65 $1.65
E-coat $1.88 $1.74 $1.69 $1.67 $1.65 $1.65 $1.65 $1.65 $1.65
China $3.77 $3.50 $3.42 $3.37 $3.35 $3.34 $3.33 $3.33 $3.33
Material Cost $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01
E-coat $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01
Setup Cost $0.34 $0.14 $0.07 $0.03 $0.01 $0.01 $0.00 $0.00 $0.00
E-coat $0.34 $0.14 $0.07 $0.03 $0.01 $0.01 $0.00 $0.00 $0.00
Process Cost $0.63 $0.63 $0.63 $0.63 $0.63 $0.63 $0.63 $0.63 $0.63
E-coat $0.63 $0.63 $0.63 $0.63 $0.63 $0.63 $0.63 $0.63 $0.63
Secondary Process Cost $1.92 $1.92 $1.92 $1.92 $1.92 $1.92 $1.92 $1.92 $1.92
E-coat $1.92 $1.92 $1.92 $1.92 $1.92 $1.92 $1.92 $1.92 $1.92
SG&A + Profit $0.87 $0.81 $0.79 $0.78 $0.77 $0.77 $0.77 $0.77 $0.77
E-coat $0.87 $0.81 $0.79 $0.78 $0.77 $0.77 $0.77 $0.77 $0.77
Mexico $5.16 $4.81 $4.69 $4.63 $4.59 $4.58 $4.58 $4.57 $4.57
Material Cost $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01
E-coat $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01
Setup Cost $0.46 $0.18 $0.09 $0.05 $0.02 $0.01 $0.00 $0.00 $0.00
E-coat $0.46 $0.18 $0.09 $0.05 $0.02 $0.01 $0.00 $0.00 $0.00
Process Cost $0.85 $0.85 $0.85 $0.85 $0.85 $0.85 $0.85 $0.85 $0.85
E-coat $0.85 $0.85 $0.85 $0.85 $0.85 $0.85 $0.85 $0.85 $0.85
Secondary Process Cost $2.65 $2.65 $2.65 $2.65 $2.65 $2.65 $2.65 $2.65 $2.65
E-coat $2.65 $2.65 $2.65 $2.65 $2.65 $2.65 $2.65 $2.65 $2.65
SG&A + Profit $1.19 $1.11 $1.08 $1.07 $1.06 $1.06 $1.06 $1.05 $1.05
E-coat $1.19 $1.11 $1.08 $1.07 $1.06 $1.06 $1.06 $1.05 $1.05
India $2.61 $2.43 $2.37 $2.34 $2.32 $2.31 $2.31 $2.31 $2.31
Material Cost $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01
E-coat $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01
Setup Cost $0.23 $0.09 $0.05 $0.02 $0.01 $0.00 $0.00 $0.00 $0.00
E-coat $0.23 $0.09 $0.05 $0.02 $0.01 $0.00 $0.00 $0.00 $0.00
Process Cost $0.43 $0.43 $0.43 $0.43 $0.43 $0.43 $0.43 $0.43 $0.43
E-coat $0.43 $0.43 $0.43 $0.43 $0.43 $0.43 $0.43 $0.43 $0.43
Secondary Process Cost $1.33 $1.33 $1.33 $1.33 $1.33 $1.33 $1.33 $1.33 $1.33
E-coat $1.33 $1.33 $1.33 $1.33 $1.33 $1.33 $1.33 $1.33 $1.33
SG&A + Profit $0.60 $0.56 $0.55 $0.54 $0.54 $0.53 $0.53 $0.53 $0.53
E-coat $0.60 $0.56 $0.55 $0.54 $0.54 $0.53 $0.53 $0.53 $0.53
Brazil $6.08 $5.65 $5.50 $5.43 $5.39 $5.37 $5.37 $5.36 $5.36
Material Cost $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01
E-coat $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01

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Setup Cost $0.55 $0.22 $0.11 $0.06 $0.02 $0.01 $0.01 $0.00 $0.00
E-coat $0.55 $0.22 $0.11 $0.06 $0.02 $0.01 $0.01 $0.00 $0.00
Process Cost $1.03 $1.03 $1.03 $1.03 $1.03 $1.03 $1.03 $1.03 $1.03
E-coat $1.03 $1.03 $1.03 $1.03 $1.03 $1.03 $1.03 $1.03 $1.03
Secondary Process Cost $3.08 $3.08 $3.08 $3.08 $3.08 $3.08 $3.08 $3.08 $3.08
E-coat $3.08 $3.08 $3.08 $3.08 $3.08 $3.08 $3.08 $3.08 $3.08
SG&A + Profit $1.40 $1.30 $1.27 $1.25 $1.24 $1.24 $1.24 $1.24 $1.24
E-coat $1.40 $1.30 $1.27 $1.25 $1.24 $1.24 $1.24 $1.24 $1.24
Western Europe $8.93 $8.27 $8.05 $7.93 $7.87 $7.85 $7.83 $7.83 $7.82
Material Cost $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01
E-coat $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01
Setup Cost $0.85 $0.34 $0.17 $0.09 $0.03 $0.02 $0.01 $0.00 $0.00
E-coat $0.85 $0.34 $0.17 $0.09 $0.03 $0.02 $0.01 $0.00 $0.00
Process Cost $1.59 $1.59 $1.59 $1.59 $1.59 $1.59 $1.59 $1.59 $1.59
E-coat $1.59 $1.59 $1.59 $1.59 $1.59 $1.59 $1.59 $1.59 $1.59
Secondary Process Cost $4.41 $4.41 $4.41 $4.41 $4.41 $4.41 $4.41 $4.41 $4.41
E-coat $4.41 $4.41 $4.41 $4.41 $4.41 $4.41 $4.41 $4.41 $4.41
SG&A + Profit $2.06 $1.91 $1.86 $1.83 $1.82 $1.81 $1.81 $1.81 $1.81
E-coat $2.06 $1.91 $1.86 $1.83 $1.82 $1.81 $1.81 $1.81 $1.81
Eastern Europe $5.60 $5.19 $5.05 $4.98 $4.94 $4.92 $4.92 $4.91 $4.91
Material Cost $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01
E-coat $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01 $0.01
Setup Cost $0.53 $0.21 $0.11 $0.05 $0.02 $0.01 $0.01 $0.00 $0.00
E-coat $0.53 $0.21 $0.11 $0.05 $0.02 $0.01 $0.01 $0.00 $0.00
Process Cost $0.99 $0.99 $0.99 $0.99 $0.99 $0.99 $0.99 $0.99 $0.99
E-coat $0.99 $0.99 $0.99 $0.99 $0.99 $0.99 $0.99 $0.99 $0.99
Secondary Process Cost $2.77 $2.77 $2.77 $2.77 $2.77 $2.77 $2.77 $2.77 $2.77
E-coat $2.77 $2.77 $2.77 $2.77 $2.77 $2.77 $2.77 $2.77 $2.77
SG&A + Profit $1.29 $1.20 $1.16 $1.15 $1.14 $1.14 $1.13 $1.13 $1.13
E-coat $1.29 $1.20 $1.16 $1.15 $1.14 $1.14 $1.13 $1.13 $1.13
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