CostTable Processes 2017

Process Table.
Posted Version 1, 10-May-17

Process ID Process Unit Cost Unit
None ₹ -
Die Casting ₹ 260.00 kg
Investment Casting ₹ 520.00 kg
Plastic injection molding ₹ 178.75 kg
Powder Metal Forming ₹ 195.00 kg
Rapid Prototype - Metal ₹ 21,450.00 kg
Rapid Prototype - Plastic ₹ 2,080.00 kg
Sand Casting ₹ 195.00 kg
Vacuum Form ₹ 650.00 m^2
Exhaust System Ceramic Coating ₹ 1,625.00 m
Cure, Autoclave ₹ 3,250.00 m^2
Cure, Oven ₹ 1,300.00 m^2
Cure, Room Temperature ₹ 650.00 m^2
Lamination, Fillament Winding ₹ 1,625.00 kg
Lamination, Manual ₹ 2,275.00 m^2
Potting ₹ 32.50 cm
Resin application, Infusion Molding ₹ 162.50 m^2
Resin application, Manual ₹ 325.00 m^2
Attach Wire, Fork ₹ 16.25 unit
Attach Wire, Quick connect terminal ₹ 6.77 unit
Attach Wire, Ring ₹ 31.15 unit
Attach Wire, Solder wire, bent ₹ 23.02 unit
Attach Wire, Solder wire, not bent ₹ 33.85 unit
Attach Wire, Terminated wire with screw ₹ 23.02 unit

Attach Wire, Terminated wire with screw
and nut ₹ 33.85 unit
Attach Wire, Wire to screw ₹ 31.15 unit
Attach Wire, Wire to screw with nut ₹ 41.98 unit
Attach Wire, Wire to terminal block ₹ 23.02 unit
Attach Wire, Wire wrap around terminal
post ₹ 17.60 unit
Install Tie Wrap (Zip Tie, Cable Clamp) ₹ 6.09 unit

Wire Dressing (Install and route) ₹ 65.00 m
Insert Bundle Into Tube or Sleeve ₹ 1.30 m
Install Adhesive Cable Clamp ₹ 12.19 unit
Lace ₹ 9.48 unit
Shrink Tube ₹ 9.75 cm
Taping Wire Bundle ₹ 2.60 cm
Connector Install, Circular, Bayonet ₹ 7.04 unit
Connector Install, Circular, Friction ₹ 9.07 unit
Connector Install, Circular, Screw Thread ₹ 15.30 unit
Connector Install, Square, Friction ₹ 9.07 unit
Connector Install, Square, Latch/Snap-on
Type ₹ 10.97 unit
Connector Install, Square, Screw (x2) ₹ 32.50 unit
Connector Install, Square, Spring Clip ₹ 13.27 unit
Lay Wire - Control ₹ 1.30 m
Lay Wire - Power ₹ 1.95 m
Lay Wire - Signal ₹ 1.30 m
Crimp Wire ₹ 10.83 unit
Cut wire ₹ 5.42 unit
Strip Multi-Conductor ₹ 8.45 wire(s)
Strip Wire ₹ 5.42 unit
Tin Wire ₹ 8.13 unit
Connector Assembley, Crimp ₹ 23.40 contacts
Connector Assembley, Solder ₹ 15.60 contacts
Hand - Start Only ₹ 7.80 unit
Hand, Loose <= 25.4 mm ₹ 32.50 unit
Hand, Loose <= 6.35 mm ₹ 16.25 unit
Hand, Loose > 25.4 mm ₹ 48.75 unit
Hand, Tight <= 6.35 mm ₹ 32.50 unit
Power Tool <= 25.4 mm ₹ 16.25 unit
Power Tool <= 6.35 mm ₹ 16.25 unit
Power Tool > 25.4 mm ₹ 32.50 unit
Ratchet <= 25.4 mm ₹ 48.75 unit
Ratchet <= 6.35 mm ₹ 32.50 unit
Ratchet > 25.4 mm ₹ 97.50 unit
Reaction Tool <= 25.4 mm ₹ 16.25 unit
Reaction Tool <= 6.35 mm ₹ 16.25 unit
Reaction Tool > 25.4 mm ₹ 32.50 unit
Screwdriver < 1 Turn ₹ 7.80 unit
Screwdriver > 1 Turn ₹ 32.50 unit
Wrench <= 25.4 mm ₹ 97.50 unit
Wrench <= 6.35 mm ₹ 65.00 unit
Wrench > 25.4 mm ₹ 130.00 unit
Braze ₹ 9.75 cm
Sewing ₹ 5.20 cm
Weld ₹ 9.75 cm
Adjustment - Misc. ₹ 325.00 unit
Aerosol Apply ₹ 341.25 m^2
Annodize ₹ - unit
Assemble, >20 kg, Interference ₹ 365.63 unit
Assemble, >20 kg, Line-on-Line ₹ 243.75 unit
Assemble, >20 kg, Loose ₹ 121.88 unit
Assemble, 1 kg, Interference ₹ 12.19 unit
Assemble, 1 kg, Line-on-Line ₹ 8.13 unit
Assemble, 1 kg, Loose ₹ 4.06 unit
Brake Bleed - Per Bleeder Valve ₹ 162.50 unit
Brush Apply ₹ 1.30 cm^2
Cut (scissors, knife) ₹ 3.90 cm
Engine first start, includes fuel ₹ 3,250.00 unit
Heat Treatment ₹ - unit
Liquid Applicator Gun ₹ 1.30 cm
Liquid Apply - Pour Expanding Foam ₹ 130.00 m^3

Liquid Apply - Spot ₹ 6.50 unit
Machining Setup, Change ₹ 42.25 unit
Machining Setup, Install and remove ₹ 84.50 unit
Riveting ₹ 16.25 unit
Safety Wire, Install ₹ 39.00 unit
Suspension Setup - Solid Axle (per corner) ₹ 292.50 unit

Suspension Setup-Independent Susp. (per
corner) ₹ 568.75 unit
Tape ₹ 52.00 m
Broach, External ₹ 32.50 cm
Broach, Internal ₹ 32.50 cm
Drilled hole < 50.8 mm dia. ₹ 45.50 hole
Drilled holes < 25.4 mm dia. ₹ 22.75 hole
EDM - Plunge ₹ 19.50 cm^3
EDM - Wire ₹ 13.00 cm
Gear Shaping (hobbing) ₹ 32.50 cm
Grind, Cylindrical ₹ 9.75 cm^2
Grind, Flat ₹ 9.75 cm^2
Grind, Profile ₹ 9.75 cm^2
Hand Finish - Material Removal ₹ 13.00 cm^3
Hand Finish - Surface Preperation ₹ 1.30 cm^2
Knurling ₹ 6.50 cm
Laser Cut ₹ 0.65 cm
Machining ₹ 2.60 cm^3

Mill - Form Cutter ₹ 6.50 cm
Non-metallic cutting <= 25.4 mm ₹ 22.75 cut
Non-metallic cutting > 76.2 mm ₹ 91.00 cut
Plasma Cutting ₹ 6.50 cm
Reemed hole ₹ 22.75 hole
Saw or tubing cuts ₹ 26.00 cm
Tapping holes ₹ 22.75 hole
Threading, External (machining) ₹ 6.50 cm
Threading, Internal (machining) ₹ 6.50 cm
Waterjet Cut ₹ 0.65 cm
Spinning, Metal ₹ 1.30 cm^3
Sheet metal bends ₹ 16.25 bend
Sheet metal punching ₹ 1.95 cm^2
Sheet Metal Saw Cut ₹ 13.00 cm
Sheet metal shearing ₹ 16.25 cut
Sheet metal stamping ₹ 1.95 cm^2
Tube bends ₹ 48.75 bend
Tube cut ₹ 9.75 cm
Tube end preperation for welding ₹ 48.75 end
Tube Flare/Bead ₹ 29.25 end
Weld - Round Tubing ₹ 24.70 cm
Category Tooling Required Near Net Shape Multiplier Type Used
Basic Forming Yes Yes

Basic Forming Yes
Basic Forming Yes
Basic Forming Yes
Basic Forming Yes
Basic Forming Yes
Coating
Composite Yes
Composite Yes
Composite Yes
Composite
Composite
Composite
Composite
Composite
Electrical - Attach Wires

Electrical - Bundle Install

Electrical - Bundle Install
Electrical - Bundle Processing
Electrical - Connections
Electrical - Layout
Electrical - Layout
Electrical - Layout
Electrical - Prep
Electrical - Prep
Electrical - Prep
Electrical - Prep
Electrical - Prep
Electrical - Wire in Connector
Electrical - Wire in Connector
Fasteners
Fasteners
Fasteners
Fasteners
Fasteners
Fasteners Fastener Installation
Fasteners
Fasteners
Fasteners
Joining Yes
Joining
Joining Yes
Labor
Labor
Labor
Labor Assembly
Labor Assembly
Labor Assembly
Labor Assembly
Labor Assembly
Labor Assembly
Labor Assembly
Labor Assembly
Labor Assembly
Labor Assembly
Labor Assembly
Labor Assembly
Labor Assembly
Labor Assembly
Labor Assembly
Labor Assembly
Labor Assembly
Labor Assembly
Labor Assembly
Labor Assembly
Labor Assembly
Labor
Labor
Labor
Labor
Labor
Labor
Labor Yes - if not fully captured

Labor
Labor
Labor
Labor
Labor
Labor
Labor
Labor
Material Removal
Material Removal
Material Removal Drill & Tap
Material Removal Machining

Material Removal
Material Removal
Shaping
Sheet Materials
Sheet Materials
Sheet Materials
Sheet Materials
Sheet Materials
Tubing
Tubing
Tubing
Tubing
Tubing
Comments
Updated terminology for clarity

Updated terminology for clarity
Linear distance of coating on exhaust header and tubing including all runners, etc. Material included.
Includes all consumable materials and labor.
Cost based on finished part mass of composite fibers and resin.
Cost based on perimeter of insert. Includes potting compund material cost
If prepreg composites are used do not included the resin application step.
Chain tension, etc.
It is not necessary to include any cost for annodizing. Included for reference only.
For use with glue, adhesives, paint, resin, etc.
Includes Fuel
It is not necessary to include any cost for heat treatment. Included for reference only.
Cost based on volume of fully expanded final part before trimming. Added note explaining that if final part is foam (not fully c
The quantity for this process may be used to scale the cost to the number of parts yielded from each setup. For example if 4 p
The quantity for this process may be used to scale the cost to the number of parts yielded from each setup. For example if 4 p
Unit includes each item or hole included in safety wire path. One item could include bolt, nut, hole in an axle, hub, etc.
Linear distance of broach

Linear distance of broach
Holes >= 50.8 mm must be machined
Linear travel of gear shaping. A half-shaft end 5cm long would cost Rupees 162.5
0.25mm machine stock
Hand sanding, grinding, shaping. Any manual material removal process.
Hand sanding, cleaning or other operations used to prepare the surface, such as for bonding.
Linear distance of knurl on part (length of knurl, not diameter)
Revised cost for 2011 Competition Years
Machining can include roughing (1.5mm machine stock min., Tol +/- 0.5mm) and/or finishing
(0.5mm machine stock min.). All parts should include the minimum 1.5mm material stock except
parts produced by "near net shaped" basic forming processes. It is not necessary to break down
rough and finish cuts, only use the correct minimum stock in the calculation of material removed.
0.5mm machine stock min. Linear distance of cutter motion.
Reemed holes must first be drilled or machined
Linear distance of thread (length of bolt thread, not diameter)

Linear distance of thread (length of bolt thread, not diameter)
Cost based on the total volume created between the metal starting position and final position.
Includes linear saw cuts and hole saw cuts. Linear cuts by linear distance and hole saw cuts by hole circumference.
Use diameter of tube

Includes mitering, nothing, sanding, wire wheeling and surface prep. All steps necessary for welding of one tube end except cu
Form flare or bead for brake lines, cooling lines, etc. in hard lines
Use diameter for dimension. Ratio of pi included.
terial included.
ning that if final part is foam (not fully contained in something else) than tooling is required and added tooling for liquid pour operations to
ded from each setup. For example if 4 parts can be machined from a single plate then the quantity per part may be set to 0.25 to spread th
ded from each setup. For example if 4 parts can be machined from a single plate then the quantity per part may be 0.25 to spread the cost
olt, nut, hole in an axle, hub, etc.

cuts by hole circumference.
ry for welding of one tube end except cutting and welding.

tooling for liquid pour operations to tooling table.
part may be set to 0.25 to spread the cost out over each part.
part may be 0.25 to spread the cost out over each part.
Brake Rotor 10 31.41593 linear in
0.25 4.712389 linear in
36.12832 linear in
91.76592 linear cm
9.176592

CostTable Processes 2017

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Process Table.

Posted Version 1, 10-May-17

Attach Wire, Terminated wire with screw ₹ 23.02 unit

Install Tie Wrap (Zip Tie, Cable Clamp) ₹ 6.09 unit

Liquid Apply - Pour Expanding Foam ₹ 130.00 m^3

Suspension Setup - Solid Axle (per corner) ₹ 292.50 unit

Machining ₹ 2.60 cm^3

Basic Forming Yes Yes

Electrical - Attach Wires

Electrical - Attach Wires

Electrical - Attach Wires

Electrical - Bundle Install

Labor Yes - if not fully captured

Material Removal Machining

Updated terminology for clarity

Cost based on perimeter of insert. Includes potting compund material cost

Linear distance of broach

Reemed holes must first be drilled or machined

Linear distance of thread (length of bolt thread, not diameter)

Use diameter of tube

olt, nut, hole in an axle, hub, etc.

ry for welding of one tube end except cutting and welding.

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