Académique Documents
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Fixed Costs
Variable Costs
Opportunity Costs
Profits which a foregone choice of action would have
earned but which are lost because another choice is made.
Tickle-me Elmo
$1 on hand today is
worth more than $1 in future by
amount of interest it could earn
and inflation adjustments
pr present amount
i int erest decimal
n number periods
Sunk Cost
Q = F/(P-V)
Example
Q = F/(P-V)
P=$100
F=$20,000/mo
V=$80
Contribution = (P-V)
P=$100
F=$20,000/mo
V=$80
Contribution = $20
Contribution offsets fixed costs until 1000 units are sold
(break-even point).
Profit begins after break-even point.
Q = (F + desired profit) / (P - V)
In our example, if we
want to make $5000 profit:
P=$100
F=$20,000/mo
V=$80
CONTRIBUTION RATIO
CR = {(P-V) X 100} / P
P=$100
F=$20,000/mo
V=$80
Cost of Welding
($/ft) Cost
incurred to make a weld
(includes joint prep,
consumables, labor,
overhead, pre- & post-weld
treatment, etc.)
Used to compare cost
advantages of weld vs. Other
manufacturing processes
Used to decide on the most
cost effective joint design or
most cost effective welding
process to use
Used as a basis for
investment in new automated
equipment
Cost of Weldment
($/piece) Cost
incurred to make entire
structure (includes all of
above plus summation of all
the weldments and raw
material costs)
Used to bid on a welding
job
Welding Procedure
This is the starting point for cost
estimating. Procedure should include:
Joint details
Welding process
Type of filler
Type of gas/fluxes
Welding current
Position (operator factor)
Travel speed
Post weld treatment
INDIVIDUAL PART OF
ESTIMATE
Labor Costs
Power Costs
Overhead Costs
expensive)
Flame or Plasma Cut Joints
Square Butt w/o Surface Prep (least
A) Do cost analysis
on expensive)
several joint designs to minimize joint prep
cost:
Note:
If a non-prequalified joint is used, you may incur the
added cost of procedure qualification.
B) Trade off reduced costs to prepare joint with amount of weld
metal to fill joint.
Example: A submerged arc joint can be flame cut (inexpensive)
but may require a lot of weld metal to fill the joint (expensive). {see
cost of welding}
Labor Costs
Power Costs
Overhead Costs
Procedure
a)
Labor Costs
Power Costs
Overhead Costs
Calculation of Theoretical
Weight of Deposit
Labor Costs
Power Costs
Overhead Costs
Estimating Losses
Electrode Losses
(SUM)
Stub Losses
14 with 2 stub = 14% loss
18 with 2 stub = 11% loss
28 with 2 stub = 7% loss
Coating or Slag Losses
Thinner coating E6010 = 10%
loss
Heavy coating E7024 = 50%
loss
Spatter Losses
Depends on technique, usually
= 5-15% loss
or
Wt Weldment (lbs) = total wt deposit (lbs) / {filler metal yield (%) / 100}
Labor Costs
Power Costs
Overhead Costs
Calculation of Weight of
Filler Metal Actually
Consumed:
Automated Method
Determine Wire Feed Speed From Graphs
(Example at right)
Knowing type of wire
Knowing diameter of
wire
Knowing operating
current
Labor Costs
Power Costs
Overhead Costs
Calculation of
Electrode Cost
Weld Electrode Cost ($/ft) = {elect price ($/lb) * Wt Weld (lb/ft)}/filler yield (%)
Labor Costs
Power Costs
Overhead Costs
COST OF MATERIALS
(FLUX AND SHIELDING)
Labor Costs
Power Costs
Overhead Costs
COST OF LABOR
Labor Costs
Power Costs
Overhead Costs
COST OF LABOR
Deposition Rate
(function of process and current)
See graph attached, or
Deposition rate (lb/hr)={wire speed
(in/min)*60(ipm)}/{wire per wt (in/lb)*filler
yield (%)/100}
Labor Costs
Power Costs
Overhead Costs
Labor Costs
Power Costs
Overhead Costs
Final Machining
Grinding/Polishing
Heat Treating
Shot Blasting
Straightening
Inspection
OVERHEAD COSTS
Overhead costs are usually apportioned pro rata among all work
going through the plant and the overhead rate assigned.