2.810 Cost Adventureweb.mit.edu/2.810/www/files/lectures/lec20-cost-2019.pdfBudget Issues •Retail...
Transcript of 2.810 Cost Adventureweb.mit.edu/2.810/www/files/lectures/lec20-cost-2019.pdfBudget Issues •Retail...
2.810 Cost AdventureJohn Lewandowski
Assumptions/constraints
- Must keep holes/locations- Must achieve approximately same strength- Cost will include material/tooling/production
How does our manufacturing process, design, and cost per part change as our company grows in size and sells higher quantity?
L-bracket LLC
First prototype: L-bracket by 3D printing
Additive X
Additive Y
Additive Z
Let’s separate production levels
• Prototyping: QTY 1-10• Demo units (design changes needed)
• Lead time: days
• Short-term manufacturing: QTY 10-1,000• Products for first-customers (functional)
• Lead time: weeks
• High-quantity production: QTY 1,000-1,000,000• Scaled mass manufacturing (throughput)
• Lead time: months
L-bracket via extrusion and machining
L-bracket by 3D printing (less material)Additive
Additive X
Additive Y
Additive Z
L-bracket via sheet metal forming or waterjet
L-bracket
Fill Pressure OK.
1,000 psi.
Number of Gates: 1.
Gate Type: Tab.
Part is too big for a multi cavity mold in a standard sized machine
L-bracket by injection molding
L-bracket via casting
Assuming each part is optimizedBreakeven between die casting and machining is at ~20,000 unitsInjection molding becomes cost effective at under ~1000 unitsMachining/waterjet/sheet metal are very competitive for low qtyAdditive has no scaling advantage, only useful for a few parts
$-
$50.00
$100.00
$150.00
$200.00
$250.00
$300.00
1 10 100 1000 10000 100000 1000000
Cavity trade-offs
1 Cavity 2 Cavity 4 Cavity 8 Cavity
Break even points
2 Cavity ~50004 Cavity ~100008 Cavity ~25000
Takeaways
• Think about the sensitivity analysis and risk: what if wages increase, material changes (quality, cost), design/function changes (more holes in the bracket, thicker part)
• Even the simplest part can have significant trade-offs between manufacturing cost and functionality
• There will be multiple iterations for every process
• All departments/skills should be involved in the discussion
• Let’s see a real life example of when not everybody was involved in the decision-making process…
Apple has machined
Aluminum, let’s cast our
computer out of magnesium
Go tell marketing to announce a magnesium
laptop
Then go talk to engineering to design it, we’re taking over this
industry
Laptop Enclosure Manufacturing Cost and Process Breakdown
Top Cover
Keyset Cover
Raw MaterialExtruded Mg billet
Anti-Corrosion TreatmentCeramic anti-corrosion coating
Top Cover
Keyset Cover
PaintSpray + Conveyor
CNC Milling7 operations, 98.3 minutes total
Step 3
80.5
min
Step 2
10.5
min
Ste
p 6
7.5
mi
n
CNC Milling6 operations, 105.3 minutes total
Step 5
16.1
min
Step 2
23.8
min
Step 3
48.1
min
Raw MaterialExtruded Mg billet
MgC
Line
Anti-Corrosion TreatmentCeramic anti-corrosion coating
MgC
Line
Logo SubassemblyAssembly + Inspection
Laser
Paint
Ablation
Logo
Inspect
ion
Secondary OperationsLaser etching + Paint touch-up
Vent Hole
Micro-
spray
Laser
Etch
PaintSpray + Conveyor
Paint
Line
Paint
Line
Post-CNC Robot deburr and wash
Was
h
LineRob
ot
Deb
urr
Wash
Line
Post-CNC Robot deburr and wash
Was
h
LineRob
ot
Deb
urr
Wash
Line
Secondary OperationsLaser etching + inspection
Laser
Inspecti
on
Logo
Asse
mbly
Material/mechanical properties
Magnesium
• Cost: $2.10/lb.
• Strength:
• Density:
• Specific strength: 158 kN*m/kg
• Embodied energy:
• Specific energy:
Aluminum
• Cost: $0.72/lb.
• Strength:
• Density:
• Specific strength: 115 kN*m/kg
• Embodied energy:
• Specific energy:
Laptop Top Cover Mfg ProcessStarting Weight: 1165 g Final Weight: 115 gMaterial Waste: 90.1%
Laptop Top Cover Cost Breakdown
Top Cover Process StepsProjected
Yield %
Raw Material Billet (Mg) 100%
CNC Milling 92%
Deburr 99%
Cleaning 99%
Anti-corrosion Treatment 98%
Painting 90%
Secondary Operations 99%
Logo Subassembly 98%
Packing and Logistics /
TOTAL 77%
Top Cover Cost Structure
Total Cost: $33.73Material + Machining: $18.21
Cost (w/ defect): $43.80
Laptop Keyset Cover Mfg ProcessStarting Weight: 1225 g Final Weight: 176 gMaterial Waste: 85.6%
Laptop Keyset Cover Cost Breakdown
Keyset Process StepsProjected
Yield %
Raw Material Billet (Mg) 100%
CNC Milling 91%
Deburr 99%
Cleaning 99%
Anti-corrosion Treatment 98%
Painting 90%
Secondary Operations 96%
Packing and Logistics /
TOTAL 75%
Keyset Cost Structure
Total Cost: $37.80Material + Machining: $21.55
Cost (w/ defect): $50.40
Budget Issues• Retail Cost: $1000 (assuming 50% markup to customer)
• Wholesale Cost: $500 (assuming 50% markup to Best Buy)
• Cost out the door: $250 (all-in cost)
• Laptop cover + Keyboard cover: $43.80 + $50.40 = $94.20
• …
• Max budget for the rest of the computer: $155.80
• Already burned ~40% of the budget on two parts of the BOM
• Think about how many computers they make and sell (1M/year)
• Production rate also becomes an issue, at 90 minutes on the CNC per part, this would mean they would have to buy >100 CNC’s and run 24/7
• Total disaster: Laptop discontinued
This is a long time for each part to be on the CNC!
The interior finishing and vents make up ~70%
Look at all the tool changes
So many side vent holes
Just these 5 features make up 25% of the of the total CNC timeHow important are those, really?
This design is in big trouble, not even that much opportunity for cycle time reduction, only 10-15 minutes each
What about material savings? Or energy savings?
Takeaways
• Design + Engineering + Marketing + Management
• Build a process plan before making decisions
• Think about both cost as well as production rate issues
• Consider sensitivities as well as opportunities for cost optimization
Poly board pre-cast concrete
BAAM pre-cast concrete mold
What if the tool was ½ or ¼ of the size?
What if material rates for plastic doubled/tripled?
What if labor costs decreased by ¼?
Summary
• The additional benefits of the technique will always maintain
• Shipping costs ½ for long hauls
• Higher qty, getting 4 parts for every 3 of the lay-up method
• Every part will be different (size, material) but immune to labor changes
Mat: $24.65Tool:Prod:
Mat: $1.38Tool:Prod:
Mat: $95.37Tool:Prod:
Mat: $6.84Tool:Prod:
Mat: $0.52Tool:Prod:
Mat: $0.99Tool:Prod:
Mat: $2.48Tool:Prod:
Mat: $0.14Tool:Prod:
Mat: $0.37Tool:Prod:
Mat: $25.05Tool:Prod:
Mat: $0.24Tool:Prod:
Mat: $242.97Tool:Prod:
Mat: $0.14Tool:Prod:
Mat: $242.97Tool:Prod:
Mat: $2.37Tool:Prod:
Mat: $0.29Tool:Prod:
Mat: $4.20Tool:Prod:
Mat: $7.80Tool:Prod:
Mat: $1.19Tool:Prod:
Mat: $7.20Tool:Prod:
Mat: $3.48Tool:Prod:
Mat: $263.90Tool:Prod:
Mat: $7.82Tool:Prod:
Mat: $0.37Tool:Prod:
Mat: $7.82Tool:Prod:
Mat: $16.69Tool:Prod:
Mat: $1.15Tool:Prod:
Mat: $22.38Tool:Prod:
Mat: $31.20Tool:Prod:
Mat: $2.45Tool:Prod: