Cost Report Guidelines 1.

Objective
The cost report provide teams a tool to calculate the cost of their Efficycle. The objective is to find out the actual cost of the vehicle. (For this purpose teams can assume that the same Efficycle is manufactured by a fictitious firm.) This is not required to show just the cheapest cost of the vehicle. The concept behind costing must be clear to the teams. All 1.2 manufacturing processes, assembly process etc must be taken into consideration while compiling the cost report. 1.3 Teams can practice to optimize time, cost and manpower etc in the project with the help of this cost report. 1.1

2. Cost Report Data

2.1 Definitions
2.1.1 Block: The whole vehicle can be considered to be an assembly of various subsystems (e.g. Rollcage, drivetrain, suspension, steering, brakes etc). These subsystems are defined as block in this cost report. The blocks are mentioned in the "INDEX SHEET" itself and teams must use these blocks in the BOM sheet. 2.1.2 Part Name: Parts names must be provided by teams in the Part Name Column and (if required). The description is required to identify the unique part among same category of parts. (for example: if 2 types of fasteners are used in the assembly of rollcage, bolts of M10 and M12, then the part name must be given like "Fastener" for both with their description in the Remarks Column as "Bolt M10" and "Bolt M12" respectively). In case if teams are using only part of its category then the description is not required. (for example: Motor) 2.1.3 Quantity: Quantity denotes how many times the same part is used in the block. For the same part the costs are calculated by applying quantity. (if teams are using 3 sprockets of same specification and cost, then it must be considered as the single part while quantity will be 3) 2.1.4 Procurement Cost: Procurement cost are the cost of part/material purchased. Procurement costs are considered per item only. If the parts are procured in lot or mass, then per item cost will be calculated by dividing the number of parts or amount of material to the total procurement cost of that lot. 2.1.5 Manufacturing cost: cost of all fabricated parts will be calculated by considering all number of operation used in fabricating that part or subassembly (made by joining few parts together). The cost of fabrication will be calculated by using "Cost Calculation Sheet "

2.2 Introduction to Cost Report Format

2.2.1 Sheet 1: Guidelines Teams must go through this sheet to have a complete understanding of the cost report format. All guidelines are mentioned in this sheet, in any case of discrepancy during cost calculations the teams must refer this sheet to avoid mistakes. 2.2.2 Sheet 2: Index Sheet Index sheet contains the standard rate of fabrication processes. Teams should use these rates to calculate the cost of their vehicle. If there is a case, the cost of some operation is not present in the table. Teams can use rates as per the local market. 2.2.3 Sheet 3: Main Sheet In this sheet teams will provide their Team Name, Team Number and Institute Name. Main sheet represents the summarized cost of the vehicle in terms of procurement cost, manufacturing cost, total cost of the vehicle and total number of parts used in the vehicle. 2.2.4 Sheet 4: BOM Sheet This is main BOM sheet in which the details of all parts or subassemblies used in the vehicle is to be filled. Hence teams must mention the details very carefully and accurately. (a dummy calculation is shown for example in sheet "Sample BOM" This sheet calculate the following data: 2.2.5 Number of parts in subsystem: The number of parts are calculated as per the details filled in "BOM Sheet" 2.2.6 Total Procurement Cost: This cost is the actual cost incurred in procuring the required number of parts for the vehicle. All type of parts and raw materials are included in the procurement cost 2.2.7 Total Manufacturing Cost: This is the cost incurred in manufacturing or customizing the parts or subassemblies. This included various type of fabrication processes. 2.2.8 Sheet 5: Cost Calculations Sheet There is a sheet provided to calculate the cost of subsystems with name "Cost Calculations". This sheet will be used to calculate the cost of manufactured/customized parts. Name of such part or subassemblies will be provided in the description field (a dummy calculation is shown in sheet "Sample Cost Calculation" In this sheet there are two tables for each item, namely Procurement Cost sheet and Manufacturing cost sheet. Procurement sheet can be used to calculate the cost of raw material as well as the cost of parts that can be used to fabricate customized parts.

Manufacturing cost sheet can be used to calculate the total cost of manufacturing operations used in the fabrication of a particular item. Teams must carefully understand their fabrication processes to accurately calculate the cost of manufactured part.

2.3 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.3.6

Supporting Documents

Teams will submit the supporting documents for the cost of material and parts. This is mandatory for the cost Evaluation. Supporting documents include the receipt of bills, invoices, catalogues, quotations from the manufacturers or suppliers Price tags of the parts can be used as supporting document but it must clearly show the details so as to identify the same part. Computerized invoices/bills without the retailer stamp will not be considered as supporting document. For operation carried in-house no supporting document is required. But cost must be mentioned accurately. The cost of parts must be the retail prices excluding VAT or any other tax. The labor cost are not to be mentioned separately for manufacturing operations, it is already included in the standard rates of 2.3.7 operations But in case of Vehicle assembly, labour cost will be entered separately in the BOM sheet (can be calculated from Cost Calculation 2.3.8 Sheet) The cost of resale/discounted price cannot be considered for calculation for any of the item. However teams are free to use resale 2.3.9 parts in their vehicle but the cost reflected in this report must be that of the same part purchased form the retailer. 2.3.10 For reused parts, the cost that is currently available in the market for same part must be used for calculation. 2.3.11 Cost of consumable items (like filler wire, grease, oils etc) need not to be included in the cost report.

3. Format
3.1 3.2 3.3 3.4 3.5

The teams must use the format provided by the Efficycle SAENIS only. No other formats will be accepted for evaluation. Cost report must be submitted in .xls or .xlsx format only. No other format like .xlsm(Macros enabled), .pdf will not be considered. Report must not contain any image, media file or digital signatures etc. For any query regarding cost report format, teams are advised to write to efficycle2012@gmail.com For preparing the hard copy of report take print of Main Sheet, BOM and Cost Calculation Sheets.

4. Report Submission
4.1 Reports will be submitted on or before the deadlines as mentioned on the website or as communicated to teams by mails etc. 4.2 No report will be considered for evaluation if submitted after the deadlines. 4.3 Teams must carry their cost report in the USB storage device at the time of main event.

All reports will be mailed to efficycle.reports@icat.in only with subject name Cost Report_<Team Name>_<Team Number>. 4.4 Teams must not mail their reports to any other ID until and unless published on the Efficycle SAENIS official website. Report sent to other IDs will not be considered for evaluation.
4.5 Teams will also carry a printed copy of report at the time of main event.

5. Evaluation Criteria
5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5

Teams will be evaluated on the basis of following criteria BOM knowledge Cost methodology BOM accuracy Cost accuracy Srategies Adopted to Minimize the cost

The evaluation of cost report will strictly not be only on the basis of lowest cost of any Efficycle. The vehicle 5.2 having minimum cost doesn't mean it will get maximum marks in the cost event. Teams must also be prepared for the above mentioned points. Teams providing fake data or tempering with the format of cost report will be penalized or can be disqualified 5.4 from the event. For not including the cost of significant part/s in the cost report, penalty will be applied in terms of adding the 5.5 cost of that part in total vehicle cost 3 times than the actual cost. The decision of judges in this regard will be final.

Operation
Lathe (per hour) CNC (per hour) TIG Welding (per 10mm) SMAW Welding (per 10mm) Gas Welding/Gas Cutting (per 10mm) Drill per hole (upto 5 mm. depth) Drill per hole(more than 5 mm. depth) Reaming (per hour) Boring (10 mm depth) Grinding (hour) Profiling (per cut) Riveting (per rivet) Shaper (per hour) Milling (per hour) Shearing (per cut) Cutting (per cut) Gear Hobbing (10 mm width per teeth) Rack Cutting (10 mm width per teeth) Labour Cost (per hour)

Cost INR
100 200 4 3 4 5 10 100 10 35 5 5 120 100 5 5 50 50 35

Blocks
Rollcage Drivetrain Steering Suspension Brake Wheel & Tyre Miscellaneous Driver Seat Aerodynamic Device Body Panel

Efficycle SAENIS 2012-Cost Report

Team Number Manufacturing Cost Procurement Cost Total Cost Total No. of Parts Team Name Institute 0 0 0 0

Block

Part Name/Description

Quantity

Procurement Cost (Per item)

Total Procurement Manufacturing Cost Total Cost (Per Item) Manufacturing Cost

Total Cost

Remarks

Total

Subassemblies and Customized Part Cost Calculation

Description: Item A Roll Cage Main Frame Procurement Cost Sheet Material Amount Alloy steel 80 ft

S. No. Part Name 1 Pipe

Unit

Rate 20.875

Total procurement Cost of Item Manufacturing Cost Sheet Amount Unit 42 cut 1 hour 2000 mm

Cost 1670 0 0 0 0 1670

S. No. 1 Cutting 2 Grinding 3 SMAW

Process

Rate 5 35 0.3

Cost 210 35 600 0 0 0 0 0 845 2515

Total Manufacturing Cost of Item Cost of Item A Description: Item B Drive Train Material Cost Sheet Material Amount 1

S. No. 1 2 3 4 5

Part Name Axle bearing Free Wheel Drive Set Chain

Unit No.

Rate 500

Cost 500 100 150 400 750 1900

2 50 3 50 2 200 3 250 Total procurement Cost of Item Manufacturing Cost Sheet Amount Unit 2 cut 1 hr

S. No. 1 2

Process Cutting Lathe

Rate 5 100

Cost 10 100 0 0 0 0 0

Total Manufacturing Cost of Item Cost of Item B Description: Item C Steering Material Cost Sheet Material Amount 1 1 5 ft

0 110 2010

S. No. Part Name 1 Hook' joint 2 Steering handle 3 Round bar

Unit -

Rate 200 200 40

Cost 200 200 200 0 0 600

Total procurement Cost of Item Manufacturing Cost Sheet Amount Unit 4 cut 0.3 hour 100 mm

S. No. 1 Cutting 2 Grinding 3 SMAW

Process

Rate 5 35 0.3

Cost 20 10.5 30 0 0 0 0 0 60.5 660.5

Total Manufacturing Cost of Item Cost of Item C Description: Item D Suspention Procurement Cost Sheet Material Amount 1 2

S. No. Part Name 1 Front Fork 2 Rear Suspention

Unit -

Rate 650 500

Cost 650 1000 0 0 0 1650

Total procurement Cost of Item Manufacturing Cost Sheet Amount Unit

S. No.

Process

Rate

Cost 0 0 0 0 0 0

Total Manufacturing Cost of Item Cost of Item A Description: Item E Brake Material Cost Sheet Material Amount 3 3

0 0 0 1650

S. No. Part Name 1 Disc Brake Set 2 Brake lever

Unit No. No.

Rate 450 15

Total procurement Cost of Item Manufacturing Cost Sheet Amount Unit

Cost 1350 45 0 0 0 1395

S. No.

Process

Rate

Cost 0 0 0 0 0 0 0 0 0 1395

Total Manufacturing Cost of Item Cost of Item B Description: Item F Wheel & tyre Material Cost Sheet Material Amount 3 3 3 3

S. No. 1 2 3 4

Part Name Wheel tyre tube misc

Unit -

Rate 200 180 100 60

Cost 600 540 300 180 0 1620

Total procurement Cost of Item Manufacturing Cost Sheet Amount Unit

S. No.

Process

Rate

Cost 0 0 0 0 0

Total Manufacturing Cost of Item Cost of Item C Description: Item G Driver Seat Procurement Cost Sheet Material Amount 2

0 0 0 0 1620

S. No. Part Name 1 Seats

Unit

Rate 500

Total procurement Cost of Item Manufacturing Cost Sheet Amount Unit

Cost 1000 0 0 0 0 1000

S. No.

Process

Rate

Cost 0 0 0 0 0 0 0 0 0 1000

Total Manufacturing Cost of Item Cost of Item A Description: Item H Miscellenous Material Cost Sheet Material Amount 2 4 4

S. No. Part Name 1 Motor 2 Battery 3 Painting

Unit No.

Rate 4000 2000 150

Total procurement Cost of Item Manufacturing Cost Sheet Amount Unit 6 hour

Cost 8000 8000 600 0 0 16600

S. No. 1

Process Labour cost

Rate 35

Cost 210 0 0 0

Total Manufacturing Cost of Item Cost of Item B

0 0 0 0 210 16810

Block Rollcage Rollcage Drivetrain Drivetrain Drivetrain Drivetrain Driver Seat Wheel & Tyre

Part Name/Description Main Frame Mounting Points Battery Motor Sprockets Drive Axle Seat Wheels

Quantity 1 20 1 1 3 1 2 3

Procurement Cost (Per item) 3000 0 600 1500 200 900 800 800

Total Procurement Manufacturing Cost Total Cost (Per Item) Manufacturing Cost 3000 0 600 1500 600 900 1600 2400 740 28 0 0 0 38 0 0 740 560 0 0 0 38 0 0

Total Cost

Remarks

3740 560 600 1500 600 938 1600 2400 Rim & Tyres

Read Comments at B2, B7

Total

10600

1338

11938

Subassemblies and Customized Part Cost Calculation

Description: Item A Rollcage Main Frame Procurement Cost Sheet Material Amount Unit Rate Mild Steel-1020 50 ft 60 Total procurement Cost of Item Manufacturing Cost Sheet Amount Unit Rate 24 cut 5 3 hour 35 14 bend 10 1250 mm 0.3 Total Manufacturing Cost of Item Cost of Item A Drive Axle Material Cost Sheet Material Amount Unit Rate 2 No. 450 Total procurement Cost of Item Manufacturing Cost Sheet Amount 2 70

S. No. Part Name 1 Pipe

Cost 3000 3000

S. No. 1 2 3 4

Process Cutting Grinding Pipe Bending SMAW

Cost 120 105 140 375 740 3740

Description: Item B

S. No. Part Name 1 Axle

Cost 900 900

S. No. Process 1 Cutting 2 TIG Welding

Unit cut mm

Rate 5 0.4

Cost 10 28 38 938

Total Manufacturing Cost of Item Cost of Item B Description: Item C Material Cost Sheet Amount

S. No. Part Name

Material

Unit

Rate

Total procurement Cost of Item Manufacturing Cost Sheet Amount

Cost 0 0 0 0 0 0

S. No. Process

Unit

Rate

Cost

Total Manufacturing Cost of Item Cost of Item C

0 0 0 0 0 0 0 0 0 0

Read comments on G8, F12, F14, D15, G16, C23.