1/2018. Operation Manual. How to calculate a plastic part

Transcription

1 1/2018 Operation Manual How to calculate a plastic part

2 How to Calculate a Plastic Part Step 1: Connecting to a Database... 2 Step 2: Adjust Project Specifications... 3 Step 3: Take over Project Specifications... 5 Step 3.1: Raw Material...6 Step 3.2: Production... 7 Supplement: Insert your own machines Step 4: Insert Packaging and Logistics Step 5: Investment and Tooling Step 6: Long-term Agreement Additional Information Overview and Summary The Benefits of Cost Breakdowns

3 Step 1: Connecting to a Database 1: Open Excel and start CALC4XL 2: Select change costing DB 3: Select a database from your folder 2

4 Step 2: Adjust Project Specifications 1: Open templates and select Cost_Breakdown_(CBD).xlsm 2: First insert or select input overheads (overhead costs and country data depend on country, industry, product and company size) 3

5 3: If needed, change overhead factors such as working system, general and calculation premises, picture and remarks. Confirm with OK. 1 4: The Cost Breakdown (CBD) will open, including all linked project specification data. Furthermore the new user -form will open. You can insert a password for the administrator. Confirm with OK. 1 Note: In the example, suppliers deliver parts without need for development; thus, development costs appear as 0%. 4

6 Step 3: Take over Project Specifications 1: The CBD presents various information on raw materials, components and production. If needed, you can also insert a second picture. 5

7 Step 3.1: Raw Material 1: Double click the blank field under materials to open material calculation 2: Choose PA66 in the name and number selection box 3: Insert scrap refund, net mass and charge weight. (In case of plastics produced in heating channels, these values are usually identical since no losses occur during the sprue.) 6

8 Step 3.2: Production Cycle Time 1: Double click the field below cycle time. 2: The cycle time can be either entered directly or determined by using the cycle time calculator. To open the cycle time calculator, click "C4XL: Injection Molding" in the dropdown logic. 2.1: In the cycle time calculator, insert all fields as per dropdown. (For the machine selection, the max. clamp force is needed.) 7

9 Machine rate per hour 1: Double click the field below machine to open the machine choice template. 2: Select your process group and machine group. 2 If needed, change data or add equipment and consumables on top. Furthermore, you can insert the machine hourly rate and manually set numbers. 2 Note: The injection molding machine max clamp force is of 203kN/mm² as calculated in the cycle time calculator. 8

10 Operator 1: Click the field below operator to open the wages template. 2: Select the skill level or, if desired, set the data manually. 3: Insert number of operators (e.g. 1 operator on 3 machines = 0.33 operators) Set up cost 1: Insert production batch size (normal size for 10 batches/year is 12000pc/a/10 = : Insert setup time in the field Std. Capacity Calculation. 9

11 Scrap cost 1: Scrap costs are entered as % value for the total process. Supplement: Insert your own machines 1: Click button in CBD section 2.4 below machine. Select Process group and machine group and select <new machine> (e.g. Tamponer ). 2: Insert investment, variable rates, description and machine parameters. Click insert as new machine in DB. 10

12 Step 4: Insert Packaging and Logistics Example (not with original CBD data) Calculating the packaging 11

13 Step 5: Investment and Tooling This is a pure collector; thus, there are no pay-as-you-go or project distributions. Step 6: Long-term Agreement 12

14 Additional Information Worksheet Overview and Summary 13

15 The Benefits of Cost Breakdowns Includes all common cost information in one file Number of lines per category is customizable Part mapping facilitates assignment and trackability Total sums can be displayed by number (/ pc, / 10, / 100 or, / 1000) Allows variable, supplier specific calculations of surcharges Display options for the following cost scenarios o 2 different delivery places o 2 different packaging options o 3 different Incoterms Graphics for quick and simple understanding (non-binding) o Calculation machine hourly rate o Calculation machine capacity o Detailed packaging & transport options o Incl. terms of business o Complete cost overview Summary with comparative overview for several parts or cost variants 14