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PER KG.

CASTING COST
(CONSIDERING 30 Kg. COKE & 1250 Nos.PER MONTH)
COST HEADS COST
RAW MATERIAL COST PER Kg 10.91
MOULD COST PER Kg 2.63
CORE COST PER Kg. 1.26
FETLING COST 1.09
PAINTING COST 0.30
FOS POWER COST PER Kg 0.28
TOTAL INDIRECT LABOUR COST 0.288
MAINTENANCE COST 0.137
CONSUMABLE COST 0.249
TOTAL DEPRECIATION COST 0.52
TOTAL INTEREST COST 0.94
FIXED OVERHEAD CHARGES 0.629
TARGETTING COST 0.141
PROFIT 1.925
TRANSPORTATION & FORWARDING 0.64
COST

TOTAL COST PER Kg. 21.951


TOTAL COST OF THE COMPONENT 1646.4

P. O . PRICE 1640
PER KG. CASTING COST

COST HEADS COST

RAW MATERIAL COST PER Kg 10.91


MOULD COST PER Kg 2.63
SAND SEIVING & DECORING 0.30
CORE COST PER Kg. 1.26
FETLING COST 1.09
PAINTING COST 0.30
FOS POWER COST PER Kg 0.28
TOTAL INDIRECT LABOUR COST 0.288
MAINTENANCE COST 0.137
CONSUMABLE COST INCLUDING LINING COST 0.249
TOTAL DEPRECIATION COST 0.52
TOTAL INTEREST COST 0.94
FIXED OVERHEAD CHARGES 0.629
TARGETTING COST 0.141
PROFIT 0.837
TRANSPORTATION & FORWARDING COST 0.64

TOTAL COST PER Kg. 21.164


TOTAL COST OF THE COMPONENT 1587.3

390206338.xlsPerKgCost 2 06/19/2018
FOUNDRY CAPACITY DETAILS

No PARAMETERS BASIS DETAILS


1 BUISNESS SHARE OF M&M % 100
2 INTEREST RATE ON INVESTMENT % 18
3 DEPRECIATION RATE ON INVESTMENTS % 10
4 CREDIT ON RAW MATERIALS Days 45
5 PROFIT % 10
6 SUPPLY PER MONTH TO M&M NUMBER 1170
7 FURNACE CAPACITY Kilo Grams 5000
8 TOTAL METAL CHARGE ADDED IN FURNACE Kilo Grams 4274.5
9 MELTING LOSS IN Kg. Kilo Grams 213.725
10 PERCENTAGE OF MELTING LOSS % 5.0
11 TOTAL MOLTEN METAL AVAILABLE FOR POURING Kilo Grams 4060.8 105580.2 114101.3
12 WEIGHT OF CASTING WITH RUNNER & RISER Kilo Grams 86 1227.676 1326.759
13 WEIGHT OF CASTING WITHOUT RUNNER & RISER Kilo Grams 75
14 SCRAP GENRATED PER CASTING Kilo Grams 11
15 TOTAL NUMBER OF CASTINGS PER HEAT Number 47
16 WEIGHT OF MOULD WITH BOX (UPPER HALF) Kilo Grams 240
17 WEIGHT OF MOULD WITH BOX (LOWER HALF) Kilo Grams 240
18 WEIGHT OF BARE BOX - UPPER BOX Kilo Grams 70
19 WEIGHT OF BARE BOX - LOWER BOX Kilo Grams 70
20 No. OF CASTINGS PER MOULD NUMBER 1
21 WEIGHT OF MOULDING SAND PER CASTING Kilo Grams 340
22 PERCENT WEIGHT OF AIR SET SAND OF MOULDING SAND % NA
23 WEIGHT OF AIR SET SAND Kilo Grams NA
24 REUSABLE MOULDING SAND % 70
25 SUPPLY PER MONTH (AVERAGE OF 3 MONTHS) GOOD CASTINGS NUMBER 1250 1321 28.0984

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SUPPLY PER MONTH IN Kg. (AVERAGE OF 3 MONTHS) GOOD
26 Kilo Grams 93750
CASTINGS
27 EXTRA PRODUCTION PER MONTH CONSIDERING REJECTION NUMBER 71 113573.8 28.0984
28 EXTRA PRODUCTION PER MONTH CONSIDERING REJECTION Kilo Grams 5296.875 121523.9 30.06529
29 CASTING YIELD % OF FOUNDRY % 0.87
30 TOTAL CAPACITY OF No. OF MOULDS PREPARED PER MONTH 2548
31 TOTAL CAPACITY OF No. OF CORES PREPARED PER MONTH NUMBER 2548
32 FOUNDRY REJECTION % 5
33 REJECTION AFTER MACHINING % 0.65
34 TRANSPORTATION RATE PER Kg. Rs. 0.64
35 MAINTENANCE & SPARES CHARGES PER MONTH Rs. 12808.75
36 TIME REQUIRED TO MELT ONE CHARGE OF FURNACE Minutes 10
37 ELECTRIC BILL PAID PER MONTH (Actual Bill Amount) Rs. 103946.94
38 POWER CONSUMED PER MONTH FOR PRODUCTION Units 18422
39 POWER RATE PER UNIT Rs. 5.64
40 DIRECT SKILLED LABOUR RATE PER SHIFT Rs. 100
41 DIRECT UNSKILLED LABOUR RATE PER SHIFT Rs. 70
42 DIRECT LABOURS NUMBER 40
43 AVERAGE SALARY PER MONTH OF DIRECT LABOUR Rs.
44 TOTAL AMOUNT PAID PER MONTH FOR LABOUR Rs. 104000
45 TOTAL AMOUNT OF INDIRECT LABOUR PER MONTH Rs. 27000
46 ADMINISTRATION & SELLING EXPENSES PER MONTH Rs. 59005
47 No. OF WORKING DAYS PER MONTH NUMBER 26
48 No. OF HEATS PER MONTH NUMBER 28.0
49 SHIFTS PER DAY NUMBER 1
50 EFFICIENCY % 70
51 EFFECTIVE MINS. PER SHIFT mins. 360

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MELTING OPERATION

DESCRIPTION UNIT ACTUAL CONSUMPTION RATE PER UNIT IN


PER MELT(Shift) OF 4250 Rs.
Kgs.
RAW MATERIAL POURED
Pig iron Kg 1700 7.30
M.S. scrap Kg 170 7.00
C.I.Scrap Kg 1700 7.45
R/R Returns. Kg 680 0
Ferromanganese Kg 8.5 30.35
Chromium Kg 8.5 39.50
Innoculant Kg 7.50 75.0
Total raw material required per heat 4274.5
Less material available in furnace after pouring Kg 18.8 6.4
Less scrap due to foundry rejection Kg 203.0 6.4
Less scrap due to machining rejection Kg 24.8 6.4
TOTAL RAW MATERIAL COST PER HEAT
MATERIAL REQUIRED FOR FIRING THE CUPOLA FURNACE
Coke required for initial firing Kg 500
Coke required per charge of 250 Kg. Kg 50
No. of charge per heat. Nos. 17
Total coke required for one heat Kg 1350 6.7
Lime Stone required for initial firing Kg 150
Limestone required per charge of 250 Kg. Kg 12
Total Limestone required for one heat Kg 354 0.35
Firewood Kg 80 1.3
Kerosene Ltrs. 5 8.0
Total power required to run Induction furnace Units 340 5.6

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TOTAL FIRING COST REQUIRED PER HEAT
LABOUR REQUIRED PER HEAT
Time required for one heat mins. 300
Labour required for melting - Skilled Nos. 2 140
Labour required for melting - Unskilled Nos. 4 100
Time required for pouring mins. [ 210 ]
Labour required for pouring - Skilled Nos. 3 140
Labour required for pouring - Unskilled Nos. 3 100
Total labour required per heat

TOTAL COST PER HEAT Rs

TOTAL MATERIAL COST PER Kg. Rs


TOTAL MATERIAL COST PER CASTING Rs

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G OPERATION

TOTAL COST PER


MELT IN Rs.

12410
1190
12665
0
257.98
335.75
562.5
27421.23
-120.44
-1302.51
-159.10
25839.18

9045.0

123.9
104.0
40.0
1918.5

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11231.4

280.00
400.00

420.00
300.00
1400.00
CONVERSION
38470.5 12631.36

10.91 3.58

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MOULDING OPERATION

DESCRIPTION UNIT ACTUAL RATE PER TOTAL COST


CONSUMPTION PER UNIT IN Rs. PER MOULD
MOULD IN Rs.
MOULDING CONSUMABLE Moulding sand- Kg 50.00 0.24 12.00
New
Mollases Kg 15 4.00 60.00
Bentonite Kg 28 0.84 23.52
Graphite Kg 0.4 15.00 6.00
French chalk Kg 0.5 1.50 0.75
Oil SAE 220 Kg 0.004 50.00 0.20
Kerosene Ltrs. 0.4 8.00 3.20
Chaplets Nos. 6 0.60 3.60
Wire nails Nos. 2 1160 / 50 Kgs. 0.74
Total consumable required per mould 110.01

SAND MIXING
Labour required for sand mixing 5 105 11.7
No. of sand mixers No. 2
Time required for sand mixing per mould per mixer mins. 12.1
Power of sand plant hp 26
Power per sand mixers hp 10
Total units of power required for sand mixing Units 4.356 5.64 24.6

MOULDING
Moulding machines used No. 2
Power per m/c (Utilised from compressor) hp 10
Diversity factor 0.6
Tme required for making one mould mins. 7
Total units of power required for moulding Units 1.4 5.64 7.9

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Total labour cost per mould 43.0

TOTAL COST PER MOULD Rs 197.2

MOULDING COST PER Kg. Rs 2.63

SAND SEIVING & DECORING 0.3

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CONVERSION
87.15

1.16

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CORE MAKING

ACTUAL
RATE PER TOTAL COST PER
DESCRIPTION UNIT CONSUMPTION
UNIT IN Rs. CORE IN Rs.
PER CORE
CORE CONSUMABLES Chotila sand Kg 45 0.38 17.1
Kheda sand Kg 45 0.1 4.5
Mollasses Kg 7 5.5 38.5
Bentonite Kg 1 0.84 0.84
Total consumable required per core 60.94
BAKING MATERIAL Coke Kg 2.22 6.1 13.542
Firewood Kg 1.66 1.3 2.158
Kerosene ltr. 0.22 8.0 1.76
Total baking material required per
17.46
core

Tme required for one core mins. 8


Labour - Skilled Nos. 3 140 9.3
Labour - Unskilled Nos. 3 105 7.0
Total labour required per core 16.33

TOTAL COST PER CORE Rs 94.7 33.8


TOTAL CORE COST PER Kg. Rs 1.26 0.45

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CONSUMABLE DETAILS

DESCRIPTION UNIT ACTUAL LANDED COST TOTAL COST IN


CONSUMPTION (Rs. / UNIT) Rs.
PER MONTH
CONSUMABLES-MELTING Meta cups No. 104 23 2392
CONSUMABLES-CUPOLA
LINING D36 Fire bricks No. 167 15.5 2583
Fire clay Bags 116 22.5 2603
Std. Bricks. No. 813 7.25 5897
Fire wood Kg. 33 1.3 43
Kerosene Ltrs. 3 8 27
Coke Kg. 67 6.1 407
Bentonite Bags 26 42 1092
Labour cost Rs. 500
TOTAL 15543
CONSUMABLES-FURNACE
LINING Ramming mass Kg. 200 2.2 440
Boric acid Kg. 4 70 280
Former No. 1 450 450
Asbestos sheet No. 2 130 260
Coil coat Kg. 10 50
Silicates Kg. 10 50
Labour cost Rs. 500
TOTAL 2030
CONSUMABLES-FURNACE
LINING Sand Kg. 2600 0.25 650
Bentonite Bags 26 42 1092
Fire wood Kg. 260 1.3 338
Kerosene Ltrs. 26 8 208
TOTAL 2288
CONSUMABLE-GENERAL Hand gloves No. 10 27 270
Goggles No. 5 25 125
Showels No. 2 90 180

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Chisels No. 10 50 500
TOTAL 1075

GRAND TOTAL 23328

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PAINTING OPERATION

DESCRIPTION UNIT ACTUAL RATE TOTAL COST


CONSUMPTION PER UNIT PER MOULD
PER PART IN Rs. IN Rs.

PAINTING CONSUMABLE Red oxide ltrs. 0.55 33.35 18.34


Turpentine No. 0.1 17.00 1.70
Total consumable required per casting 20.04

PAINTING LABOUR
Unskilled labour No. 1 105 2.2
CONVERSION
PAINTING COST PER CASTING 22.3 2.23

PAINTING COST PER Kg. Rs 0.30 0.03

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FETLING OPERATION

DESCRIPTION UNIT ACTUAL RATE TOTAL COST


CONSUMPTION PER UNIT PER MOULD
PER PART IN Rs. IN Rs.

FETTLING CONSUMABLE Steel shots Kg 0.43 29 12.47


Depressed No. 0.07 130.00 9.10
Centre wheel
6" Wheel No. 0.085 88 7.48
Buffing wheel No. 0.04 43.00 1.72
16" Wheel No. 0.0032 2600.00 8.32
Total consumable required per casting 39.09

FETTLING LABOUR
Skilled labour No. 7 140 16.33
Unskilled labour No. 4 100 6.67
FETTLING POWER
Shot blasting (Indabrator) hp 22
Swing frame grinder hp 10
Flexible grinders. ( 2Nos.) hp 3
Average time required for fetling mins. 7
Diversity factor 0.6
Total units of power consumed Units 3.5 5.64 19.7

FETLING COST PER CASTING 81.8 42.75

FETLING COST PER Kg. Rs 1.09 0.57

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FOS POWER
Unit Cons.Per Month Units Rate Cost
Monthly Power Consumption 18422 5.64 103946.94
Power Required For Melting Per Heat 340 9509.29 5.64 53656.57
Power Required For Mold Preparition Per Mold 1.4 36.4 5.64 205.39
Power Required For Core Preparition Per Core 0 0 5.64 0.00
Monthly Power Consumption For Sand Plant 4.356 113.256 5.64 639.05
Monthly Power Consumption For Fetling 3.5 4095 5.64 23106.22
Power for non Production 4668.0569796652 5.64 26339.72
Power for non Production per Kg.of Good castings 0.28
Power for non Production per casting

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INVESTMENT DETAILS IN FOUNDRY

POWER
BUSINESS VALUE IN
Sr No PROCESS SEQUENCE DESCRIPTION OF MACHINARY OR EQUIPMENT RATING VALUE IN Rs.
SHARE Rs.
HP

MELTING Induction furnace 335 1389000


Cupola furnace 15 30000
Laddle ( 2 Nos. ) 30000

PATTERN MAKING Pattern & Core box. 35000

MOULDING Sand plant 26 575000


Moulding machine (2 -machines ) 1057000
Sand mixer ( 2 Nos. ) 20 210000
Moulding boxes ( 100 sets ) 425000

FETTLING Shot blasting machine ( Indabrator ) 22 569000


Grinders 13 55000

LABORATORY FerroLab 81500


Hardness testing machine 76000
Sand testing machine 46000

TARGETTING Radial drilling (Universal - Rajkot) 5 200000

GENERAL Compressor 50 275000


Compressor 10
Transformer 500 kva 70000

GRAND TOTAL 5123500


ADDITIONAL INVESTMENT 776500
TOTAL INVESTMENT 5900000

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