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EXOGENOUS DATA
Annual Production Volume
Facility Production Capacity
Product Life
Direct Wages (w/ benefits)
Working Days/Yr
Downtimes
No Operations
Planned Paid
Planned Unpaid
4
800
2.00
1.60
850
100
300
5
$15.00
240
grams
mm
mm
sq cm
(000/yr)
(000/yr)
yrs
/hr
7 hrs/day
1 hrs/day
1.2 hrs/day
10%
$1,500
30
$0.080
20
35.0%
/sq m
yrs
/kWh
yrs
PROCESS INPUTS
Unplanned Downtime
1.50
Material Scrap Rate
2.0%
Reject Rate
1.0%
Direct Laborers Per Machine
1
Dedicated Equipment (1/0)
0
Number of Cavities
1
Auxiliary Equip. Cost (% mmch)
20.0%
Installation Cost (% mmch)
20.0%
Maintenance Cost (% invc)
5.0%
Tool Actions (1/0)
0
Toolmaker Shop Rate
$100.00
Baseline Mold Life 1,000,000
hrs/day
(1=y;0=n)
(1=y;0=n)
/hr
cycles
Electricity Requirement
0.75 kWh/kg
INJECTION MOLDING OVERRIDES
Molding Press & Tool Data:
Clamping Force
0 kN
Press Investment
$0
Unit Tool Investment
$0
Cycle Time & Tool Costs:
Cooling time
Total Cycle Time
0 sec
0 sec
VARIABLE COSTS
Material Cost
Energy Cost
Labor Cost
Total Variable Cost
FIXED COSTS
Main Machine
Auxiliary Equipment
Tooling
Fixed Overhead
Building
Maintenance
Total Fixed Cost
Cost
Cost
Cost
Cost
Cost
Cost
per piece
$0.80
$0.08
$0.16
$1.03
per piece
$0.18
$0.03
$0.46
$0.29
$0.17
$0.04
$1.17
$2.20
RELATED VARIABLES
Material Requirements:
Raw Material Price
Trim Scrap Rate
Gross Material per Part
Annual Material Input
Process Calculations
Effective Production Volume
Effective Capacity
Capacity and Volume are Consistent?
Available Operating Time
$0.97
2.0%
816.3
82,458
101,011
303,031
1
3,192
35
983
2,949
31%
92%
0.92
3,432
1,057
2
113
1.52
93,833
Predicted
10.4
35.0
Predicted
2,967
$136,486
$87,493
NG - COST SUMMARY
INJECT
per year
$79,776
$7,507
$15,853
$103,136
percent
36.27%
3.41%
7.21%
46.89%
per year
$17,772
$2,962
$46,161
$29,207
$16,554
$4,172
$116,829
percent
8.08%
1.35%
20.99%
13.28%
7.53%
1.90%
53.11%
$219,965
100.00%
Prod Volume
investment
$151,304
$25,217
$174,987
$156,054
$482,345
1
25
50
75
100
125
150
175
200
225
250
275
300
325
350
375
400
425
450
Var. Cost
$1.03
$1.03
$1.03
$1.03
$1.03
$1.03
$1.03
$1.03
$1.03
$1.03
$1.03
$1.03
$1.03
$1.03
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
Fixed Cost
$1.17
$116.83
$4.67
$2.34
$1.56
$1.17
$0.93
$0.78
$0.67
$0.58
$0.52
$0.47
$0.42
$0.39
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
/kg
g
kg
Unit Cost
Production
Volume
hours / year
secs / part
hours / year
hours / year
hours / year
person-hours / year
$2.20
1
25
50
75
100
125
150
175
200
225
250
275
300
325
350
375
400
Capacity
100
$49.29
$2.96
$2.00
$1.67
$1.51
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
425
450
#N/A
#N/A
sq m
Cost Breakdown @ 100,000
Unit Costs
Material
$0.80
Other Var
$0.23
Equip
$0.21
Tooling
$0.46
Other Fixed
$0.50
Total Cost
$2.20
Used
10.4
35.0
Used
2,967
$136,486
$87,493
326 tons
2500%
Fraction of Total Cost
kWh/year
0%
Total Cost
$4.00
$3.00
$2.00
$1.00
$0.00
0
50
200
300
400
500
$99.00 $117.86 $202.81 $224.59
$4.95
$5.70
$9.10
$9.97
$2.99
$3.37
$5.07
$5.50
$2.34
$2.59
$3.72
$4.01
$2.01
$2.20
$3.05
$3.27
$1.82
$1.97
$2.65
$2.82
$1.68
$1.81
$2.38
$2.52
$1.59
$1.70
$2.18
$2.31
$1.52
$1.62
$2.04
$2.15
#N/A
$1.55
$1.93
$2.02
#N/A
$1.50
$1.84
$1.93
#N/A
$1.46
$1.77
$1.84
#N/A
$1.42
$1.70
$1.78
#N/A
#N/A
$1.65
$1.72
#N/A
#N/A
$1.61
$1.67
#N/A
#N/A
$1.57
$1.63
#N/A
#N/A
$1.54
$1.59
100
150
200
250
300
350
400
$2.20
$117.86
$5.70
$3.37
$2.59
$2.20
$1.97
$1.81
$1.70
$1.62
$1.55
$1.50
$1.46
$1.42
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
$3.50
$3.00
$2.50
$2.00
$1.50
$1.00
$0.50
$0.00
0
$0.00
0
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
$1.56
$1.53
2500%
Other Fixed
Tooling
Equip
Other Var
Material
0%
Unit Cost
Past
Mass
st
400
& Capacity
s/year)
100
200
300
400
500
$2.20
100
150
200
250
300
350
400
450
500
550
600
650
700
750
800
850
900
950
1,000
2
$0.99
$1.07
$1.16
$1.24
$1.33
$1.41
$1.50
$1.59
$1.67
$1.76
$1.85
$1.93
$2.02
$2.11
$2.20
$2.29
$2.38
$2.47
$2.56
s/year)
2.5
$1.10
$1.19
$1.28
$1.37
$1.46
$1.55
$1.64
$1.73
$1.82
$1.91
$2.00
$2.10
$2.19
$2.28
$2.37
$2.46
$2.56
$2.65
$2.75
3
$1.25
$1.34
$1.44
$1.54
$1.63
$1.73
$1.82
$1.92
$2.01
$2.11
$2.20
$2.30
$2.40
$2.49
$2.59
$2.69
$2.79
$2.89
$2.99
100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950
1
1.5
2
2.5
Part M ass (g)
3
M ax Wall
3
2.5
2
1.5
1
Material Cost
Energy Cost
Labor Cost
Total Variable Cost
Main Machine Cost
Auxiliary Equipment Cost
Tooling Cost
Fixed Overhead Cost
Building Cost
Maintenance Cost
Total Fixed Cost
Total Fabrication Cost
Resin
Unit Costs
$0.80
$0.08
$0.16
$1.03
$0.18
$0.03
$0.46
$0.29
$0.17
$0.04
$1.17
$2.20
4
Material
Other Variable
Equipment
Tooling
Other Fixed
Total Cost
Unit Costs
$0.80
$0.23
$0.21
$0.46
$0.50
$2.20
MATERIAL DATABASE
Type
POLYSTYRENE
PVC (RIGID)
ABS
POLYPROPYLENE (HOMO)
NYLON 6
POLYCARBONATE
ACETAL (HOMO)
HDPE
POLYPHENYLENE ETHER
PET
THERMOPLASTIC POLYIMIDE
EVA
NYLON 6/30% GLASS
POLYCARBONATE/30% GLASS
ABS/20% GLASS
ACETAL/25% GLASS
PBT Alloy
PC/PBT
PC/PBT
PC
PPE
Blend
PA
PA
EVA CoPA
PA
Ionomer
LDPE
LDPE
LDPE
HDPE
HDPE
HDPE
PP CoPP CoPP CoEMPP
EMPP
EMPP
R-EMPP
ABS
Tradename
Valox
Xenoy
Xenoy
Lexan
Noryl
Noryl
Zytel
Zytel
Elvax
Bexloy
Bexloy
Suryln
Stamylan-LD
Stamylan-LD
Stamylan-LD
Stamylan-HD
Stamylan-HD
Stamylan-HD
Stamylan-P
Stamylan-P
Stamylan-P
Keltan TP
Keltan TP
Keltan TP
Kelburon
Ronfalin
Grade
830
1200
1101
141
844
GTX
ST-801
ST-901
960
2138GW00
2322GL00
2538EL00
7249
7058
5119
83MF10
412MN40
48M10
0603
0505
2607
90594
FX
#
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
ABS
ABS
ABS
ABS/PVC
PPE
PPE
PPE
PPE
ABS
ABS
ABS
ABS
ABS
ABS
TPO
TPO
TPE ester
TPE ester
TPU
Ronfalin
Ronfalin
Ronfalin
Ronfalin
Prevex
Prevex
Prevex
Prevex
Cycolac
Cycolac
Cycolac
Cycolac
Cycolac
Cycolac
Ontex
Dexflex
Lomod
Bexloy
Estane
TX
HX
VE
RN-03
PMA
PQA
VJA
W30
T
GSM
L
DFAR
DH
KJB
111BX
850
521
V
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
Price
($/kg)
$2.33
$0.84
$2.22
$0.97
$4.38
$3.96
$3.43
$0.81
$2.93
$3.52
$11.88
$2.09
$4.27
$5.21
$2.38
$4.07
$3.26
$3.96
$3.74
$4.64
$2.66
$3.63
$5.06
$5.41
$1.50
$4.07
$4.40
$2.97
$0.73
$0.73
$0.73
$0.81
$0.81
$0.81
$0.93
$0.87
$0.87
$1.83
$1.93
$1.73
$1.89
$2.13
$2.24
$2.24
$2.72
$2.64
$3.43
$4.29
$3.76
$3.76
$2.50
$2.53
$2.60
$2.35
$2.42
$2.99
$2.97
$2.09
$3.74
$3.63
$4.62