Lumax Manas Automotive Systems Limited

Gat no- 105/106, Village Ambi, Near Talegaon- Pune 410505

Costing Break up Sheet
Customer Name:- M/S Ashoka Leyland Ltd, Chennai
Customer Part no: Vehicle: - NGC
S.No

Descriptions

Part Number

Materials

Weight

Qty.

Bought out Parts

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Mtg. Pipe Lh
ERW Pipe
Mtg. Pipe Rh
ERW Pipe
Top Mtg. Bracket- Lh
M.S.
Top Mtg. Bracket - Rh
M.S.
Bottom Mtg. Bracket- Lh
Zinc(Mazak-5)
Bottom Mtg. Bracket-RLh
Zinc(Mazak-5)
Hex Bolt M8x 50
Std.
Nyloc Nut M8
Std.
Hex Bolt M8x 25
Std.
Rubber Pad- Lh
Rubber
Rubber Pad- Rh
Rubber
Coil Spring
S.S.
Nylon washer
Nylone-6
Spring Washer- M8
S.S.
Plain washer
M.S.
Bottom cap
P.P.
Forged Insert
M.S.
Packing Cost
Poly. Beg+ master carton

1.09
1.09
0.358
0.358

0.016

1
1
1
1
1
1
2
4
2
1
1
2
2
2
2
2
2

40

In House Parts
S.No
1
2
3
4
5
6

Descriptions
Part Number
Main Mirror Assembly
Wide Angle Mirror Assy.
Close Proximity Mirror
Assembly & Testing Charges
Top Mtg. Bracket Process cost
Bumper View Mirror Assy

Sub Total
ICC

400*6+5
Sh.+Bl.+Pu.+Fo.

Qty.
2
1
1
300
2
1

1.50%

Rejection
O.H.
Profit
Forwarding Costing

2%
10%
10%
Pune

Total Cost of Complete Mirror Assembly Kit

mited
- Pune 410505

Rate

Compo. Cost
70.4
70.4
42
42
65.5
65.5
1.5
1.15
0.9
3.5
3.5
4.25
0.45
0.25
0.5
1.25
24.5
40

70.4
70.4
45.78
45.78
65.5
65.5
3
4.6
1.8
3.5
3.5
8.5
0.9
0.5
1
2.5
49
40
482.16

Rate
135.27
111.71
74.21
13
6.5
201.14

Compo. Cost
270.54
111.71
74.21
13
13
201.14

683.60
1165.76
7.2324

Kit

9.6432
116.58
116.58
50

1465.78

Lumax Manas Automotive Systems Ltd.

Main Mirror Assembly (1312)
Costing Break- up sheet of Mirror Assembly.

Bought Out Parts

Part No's Descriptions

S.No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

HOUSING 'E' 1312 (CO PP)

Nyloc HEX NUT M8
Hex SCREW M8*40
SCREW M6x20 CHEESE HD BLACK
WASHER PL.OD 25mm*1.5 (Y)-1312
PVC tape
COIL SPRING -1312
(PVC) RETAINER BEADING
TOP Cover BKT. -RVM 1312
RETAINER CONE OUTRE PT. -1312
CUP WASHER SMALL-1312
SPRING RETAINER BIG-1312
MIRROR PLATE -1312 (3mm)
Air Bubble+ poly bag

Materials Weight
No off
PPCP
0.29
Std.
Std.
Std.
M.S.
PVC
SS
PVC
Nylon
0.08
Nylon
0.045
M.S.
M.S.
Imported

Rate
1
1
1
2
1
1
1
1
1
1
1
1

80
1.15
1.4
0.5
0.5
2.75
3.25
14.5
180
180
0
1
48
1.7
0.45

1
1

M-6 Nut Insert

Total BOP Cost

In House Process
S.No

Part No's Descriptions

HOUSING 'E' 1312 (CO PP)
Assembly
Retainer cone moulding
TOP Cover BKT. -RVM 1312

Process
M/C
Moulding
Assy.
Moulding
Moulding

S.Prod
180
5
150
150

408
400
816
1632

Rate
1800
500
1500
1500

Total In House Process Cost

Sub Total

Costing for Kit Ass

td.

comp. cost
23.2
1.15
1.4
1
0.5
2.75
3.25
14.5
14.4
8.1
0
1
48
1.7
0.9

121.85
Cost
4.41
6.25
1.84
0.92

13.42

135.27
Costing for Kit Assy
135.27

Lumax Manas Automotive Systems Ltd.

Close Proximity Mirror Assembly
Costing Break- up sheet of Mirror Assembly.

Bought Out Parts

S.No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Part No's Descriptions

Housing
Mirror plate (Imported)
Pipe
Mtg. Bkt.
Cap
Screw M5x30 Ph.Pan Hd
Nut M5
Plain washer M5
Allen Bolt M8x30
Nyloc Nut M8
Plain Washer M8
Thermopolis Packing
Poly beg
Primary carton
Master carton

Materials Weight
No off
PPCP
0.205
Imported
1
Nylon
0.07
ADC-12
PPCP
0.01
Std.
Std.
M.S.
Std.
Std.
M.S.

Rate
1
1
1
1
1
2
2
2
1
1
1
1
1
0.5
16

80.00
40.00
155.00
18.00
80.00
0.60
0.25
0.23
3.25
1.10
0.45
1.25
1.00
8.00
50.00

Total BOP Cost

In House Process
S.No
1
2
3
4

Part No's Descriptions

Housing
Mtg. pipe
Clamp Pipe
Assembly

Total In House Process Cost

Sub Total

Machine S. Prod.
M/c rate Rate
180
408
1800
130 890.1818
1300
80 1780.364
800
3
500
500

4.41
1.46
0.45
3

comp. cost
16.40
40.00
10.85
18.00
0.80
1.20
0.50
0.46
3.25
1.10
0.45
1.25
1.00
4
3.13

102.39
Cost
4.41
1.46
0.45
3

9.32
111.71

Lumax Manas Automotive Systems Ltd.

Wide Mirror Assembly
Costing Break- up sheet of Mirror Assembly.
Bought Out Parts
S.No
1
2
3
4
5
6
7
8
9
10
14
15

Part No's Descriptions

Housing
Mtg. Stay
Cover Stay
Mirror plate
Screw M4x20
Hex Nut M4
Nut M5
Screw M5x25
Spring Washer M5
Air Bubble

Materials Weight
No off
PPCP
0.165
Nylon GF-20
0.034
Nylon GF-20
0.024
Float Glass Imported
Std.
Std.
Std.
Std.
Std.

Rate
1
1
1
1
2
2
2
2
2
1

80
180
180
37
0.4
0.2
0.2
0.5
0.2
0.75

Process
Machine Production
Moulding
180
489.6
Moulding
80
816
Moulding
80
1088
assy
4
500

1800
1000
1000
500

Total BOP Cost

In House Process
S.No

Part No's Descriptions

Housing
Mtg. Stay
Cover Stay
Assembly

Total In House Process Cost

Sub Total
Kit Pricing

d.

comp. cost
13.2
6.12
4.32
37
0.8
0.4
0.4
1
0.4
0.75

64.39
Cost
3.68
1.23
0.92
4

9.82
74.21
74.21

Lumax Manas Automotive Systems Ltd.

Gat no- 105/106, Village Ambi, Near Talegaon - Pune

TOLLING COST
S.No

Descriptions

Nos

Tolling Cost

Top Mounting Bracket

1 Blanking Tool
2 Hole Piercing Tool
3 Forming Tool

1
1
1

125,000
75,000
100,000

1
1
1
1

65,000
25,000
25,000
65,000

Top Mounting - L -Bracket

1
2
3
4

Blanking Tool
Hole Piercing Tool
L Bending Tool
Welding Fixture

Bottom Mtg. Bracket Kazak PDC Mould

1 P D C Mould- LH
2 P D C Mould- RH

1
1

285,000
285,000

35,000

Forged Insert Tool

1 Forged Insert Tool

Assembly Fixture
1 Assembly Fixture
2 Receiving Gauge
3 Testing Fixture

60,000
45,000
150,000

Homologation Charges
1 Testing Charges as per AIS
2 Testing Charges as per AIS

150,000
150,000

1,640,000

Lumax Manas Automotive Systems Ltd.

Close Proximity Mirror Assembly
Costing Break- up sheet of Mirror Assembly.

Bought Out Parts

S.No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Part No's Descriptions

Housing
Mirror plate (Imported)
Pipe
Mtg. Bkt. Febricated
Cap
Screw M5x30 Ph.Pan Hd
Nut M5
Plain washer M5
Allen Bolt M8x30
Nyloc Nut M8
Plain Washer M8
Thermopolis Packing
Poly beg
Primary carton
Master carton

Materials Weight
No off
PPCP
0.205
Imported
1
Nylon
0.07
M.S.
PPCP
0.01
Std.
Std.
M.S.
Std.
Std.
M.S.

Rate
1
1
1
1
1
2
2
2
1
1
1
1
1
0.5
8

80.00
50.00
155.00
90.56
80.00
0.60
0.25
0.23
3.25
1.10
0.45
1.25
2.00
16.00
40.00

Total BOP Cost

In House Process
S.No
1
2
3
4

Part No's Descriptions

Housing
Mtg. pipe
Clamp Pipe
Assembly

Total In House Process Cost

Sub Total

Machine S. Prod.
M/c rate Rate
180
408
1800
4.41
130 890.1818
1300
1.46
80 1780.364
800
0.45
3
500
500
3

comp. cost
16.40
50.00
10.85
90.56
0.80
1.20
0.50
0.46
3.25
1.10
0.45
1.25
2.00
8
5.00

191.82
Cost
4.41
1.46
0.45
3

9.32
201.14

Tool Cost

Ashok Leyland, Chennai.

Part Details
Part No / Issue
Part Description
Tool Type
Tool Size (mm)
Tonnage
No. off Per Vehicle

MOULDING

Date
Model
Unit
Tool Life

390 x 350 x 300

Mtrl thick

Material Cost Details (A)

S. No

Item Description

Material Dia in Length Breath Thick in

Wt. in Kgs
No. off
Grade
mm in mm in mm
mm
+ 5%Extra

Top Main Mounting Bracket Blanking Die

1 Pillar base plate
M.S.
2 Side support Plate
M.S.
3 Stepper plate
M.S.
4 Cavity block
HcHCr
5 Support Block
M.S.
6 Guide Pillar
16MnCr5
7 Locking Bush
M.S.
8 Pillar Top Plate
M.S.
9 Guide Bush
16MnCr5
10 Core Block
HcHCr
11 Front Stopper Plate
OHNS
12 Side Stopper Plate
OHNS
13 Core Back Plate
OHNS
14 Cavity Back Plate
OHNS

425
425
350
500
230
300
50
425
90
500
100
425
500
500

50
25
55

375
90
300
400
110

45
45
30
150
45

375

38

400
100
90
400
400

150
25
38
25
25

1
2
1
1
1
4
16
1
4
1
1
2
1
1

59.19
28.41
26.00
247.59
9.40
18.51
3.09
49.98
6.72
247.59
2.06
23.99
41.27
41.27

RM Cost
Standard Elements
Qty

UOM

Rate / no

1 P.U. Bush / Spring

15

OD 50 , ID 15 X 60

500

2 Dowel

25

10 x 60

60

40
40
40

BSW1/2x100
BSW1/2x60
BSW1/2x30

50
50
50

S. No

Element Desc

3
4
5
6

Sco. Head Screw

Sco. Head Screw
Sco. Head Screw

Misc.

Total Standard Element Cost

Total Material Cost (A)
Other Cost Details
S. No

Category
2 Assembly,polishing Cost

Time in Hours

Cost Per Hour

40

450

Total Other Cost ( C )

Sub Total Cost (A+B+C-D)
A

B
C
D
Mould Cost (E)
Homologation Charges (E)
Final Mould Cost (E)

Note : - Rs 150000 / - are the homologation charges for the bumper Mirror Assembly.

Tool Cost Estimation Sheet

Supplier Details
Lumax Manas Automotive Systems Ltd. Pune
Supplier Name
Development Referred by
SS Buyer

100000

Conversion Cost Details (Time in Hours) (B)

Rate/kg Material Cost

65
65
65
160
65
200
65
65
200
160
100
100
100
100

Rough
Coordina
Surface
Machinin
te
Grinding
g
Drilling

3847.32
1846.71
1689.80
39614.40
610.74
3702.06
200.53
3248.85
1343.85
39614.40
206.33
2399.15
4126.50
4126.50

6.00
5.00
6.00
15.00
5.00
3.00
5.00
5.00
3.00
15.00
5.00
5.00
9.00
9.00

7.00
5.00
6.00
12.00
3.00
1.00
1.00
5.00
1.00
12.00
2.00
2.00
7.00
7.00

Bench
work

7.00
6.00
6.00
12.00
3.00
0.00
2.00
5.00
0.00
12.00
2.00
2.00
10.00
10.00

7.00
7.00
7.00
15.00
2.00
0.00
0.00
6.00
0.00
15.00
1.00
1.00
7.00
7.00

Heat
Treatme
nt
0.00
6.00
6.00
7.00
0.00
4.00
2.00
0.00
4.00
7.00
1.00
1.00
6.00
6.00

Cutting

6.00
6.00
6.00
12.00
2.00
3.00
2.00
5.00
3.00
12.00
2.00
2.00
4.00
4.00

CG

0.00
7.00
7.00
12.00
3.00
4.00
3.00
0.00
4.00
12.00
1.00
1.00
4.00
4.00

106577.13

Cost Per Hour

Rate / no

Cost

500

7500.00

60

1500.00

50
50
50

2000.00
2000.00
2000.00
9000.00

160

170

220

150

120

250

250

FS

15360.00 12070.00 16940.00 11250.00 6000.00 17250.00 15500.00

24000.00

Total Conversion Cost (B)

Recovery Cost Details (Applicable for Obsolescence / Modific

130577.13
Cost Per Hour
450

Cost

Category

S.No
1 Recovery of RM Cost
2 Recovery of Other items

18000.00

Total Recovery Cost (D)

18000.00
Supplier
130577.13

Quote By

Lumax Manas Automotive Systems Ltd. Pune

Date:

189120.00
18000.00
1000.00

338697.13
150000.00
488697.13

e bumper Mirror Assembly.

Sign/Date

Supplier Details

omotive Systems Ltd. Pune

Cost Details (Time in Hours) (B)

EDM

4.00
5.00
4.00
17.00
0.00
0.00
0.00
0.00
0.00
17.00
0.00
0.00
0.00
0.00

WEDM

5.00
5.00
8.00
11.00
0.00
0.00
0.00
5.00
0.00
11.00
0.00
0.00
5.00
5.00

CNC
Milling

Surface
Finishing

0.00
0.00
0.00
25.00
0.00
0.00
0.00
0.00
0.00
25.00
0.00
0.00
4.00
4.00

Jig Boring

7.00
6.00
6.00
13.00
1.00
1.00
1.00
5.00
1.00
13.00
1.00
1.00
10.00
10.00

5.00
0.00
0.00
0.00
0.00
0.00
0.00
5.00
0.00
0.00
0.00
0.00
0.00
0.00

Cost Per Hour

350

400

500

300

450

FS

16450.00 22000.00 29000.00 22800.00

version Cost (B)

icable for Obsolescence / Modification Tool) (D)
Category

4500.00

189120.00
Cost
1000

overy Cost (D)

1000
Settled by
Date:

Sign/Date