Exercise 24: Part Cost Estimator

The Part Cost Estimator is a Synthesizer model that calculates the total cost of a component based on the material and processing costs.

Note: You will need to use an advanced Level 3 database for this exercise
  1. Use the Part Cost Estimator to compare the cost of a component when manufactured as an injection-molded polymer, or a rolled and pressed metal
    1. Click Synthesizer on the toolbar. In the dialog, select Cost – Part cost estimator.
  2. Enter the Component Details for the first component
    Material
    PP (copolymer, 20% talc)
    Value of scrap material
    10%
    Part mass
    6.4
    Part length
    10
    Batch size
    1000 - 1E6
    Number of values
    10

    For this exercise, the units of part mass and part length do not matter.

  3. Enter the Primary Shaping Process values
    Primary process
    Injection molding (thermoplastics)
    Availability
    Custom form
    Part complexity
    Standard

    Use the default values for Load factor, Overhead rate, and Capital write-off time.

  4. Set the Record Naming values
    Material
    PP
    Primary process
    molded
  5. Create the new records
    1. Click Create. Keep the Part Cost Estimator dialog open.
  6. Enter Component Details for the second component
    1. In the Part Cost Estimator dialog, click Previous and change the Component Details:
    Material
    YS170 hot rolled (a high strength, drawing quality steel)
    Part mass
    10

    Use the existing values for scrap material value, part length, batch size, and number of values (these are retained from the first material processing chain input).

  7. Enter Primary Shaping Process values
    Primary process
    Hot shape rolling

    Use the existing values for the remaining properties.

  8. Enter details for the Secondary Shaping Process
    1. Select Include secondary process, and enter the following value:
    Secondary process
    Press forming

    Use the default values for Part complexity, Amount of scrap, and Scrap recycled.

  9. Enter the Record Naming values:
    Material
    Steel
    Primary process
    rolled
    Secondary process
    pressed
  10. Click Create and then Finish to create the records and close the Part Cost Estimator

    Synthesized records created using Part Cost Estimator are appended to the MaterialUniverse browse tree under My records > Synthesized > Part cost estimator.

  11. Create a bubble chart to compare the two material processing chains
    1. Select MaterialUniverse: All bulk materials, click Chart/Index, and set the following x- and y-axis values:
    Category
    Part cost estimator
    X-Axis Attribute
    Batch size
    Y-Axis Attribute
    Part cost
  12. Change the Record color for easy comparison of the two processing chains
    1. Navigate to My records > Synthesized > Part cost estimator. Right-click the PP, molded subfolder, click Record color, and click a color to change the record color for all records in that folder.
  13. Delete the Chart Stage