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8/2/2019 A_L- NGC- cost
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Customer Name:- M/S Ashoka Leyland Ltd, Chennai
Customer Part no: -
Vehicle: - NGCS.No Descriptions Part Number Materials Weight Qty.
Bought out Parts
1 Mtg. Pipe Lh ERW Pipe 1
2 Mtg. Pipe Rh ERW Pipe 1
3 Top Mtg. Bracket- Lh M.S. 1.09 1
4 Top Mtg. Bracket - Rh M.S. 1.09 1
5 Bottom Mtg. Bracket- Lh Zinc(Mazak-5) 0.358 1
6 Bottom Mtg. Bracket-RLh Zinc(Mazak-5) 0.358 1
7 Hex Bolt M8x 50 Std. 2
8 Nyloc Nut M8 Std. 4
9 Hex Bolt M8x 25 Std. 2
10 Rubber Pad- Lh Rubber 1
11 Rubber Pad- Rh Rubber 1
12 Coil Spring S.S. 2
13 Nylon washer Nylone-6 2
14 Spring Washer- M8 S.S. 2
15 Plain washer M.S. 2
16 Bottom cap P.P. 0.016 2
17 Forged Insert M.S. 2
18 Packing Cost Poly. Beg+ master carton 40
19
20
In House PartsS.No Descriptions Part Number Qty.
1 Main Mirror Assembly 2
2 Wide Angle Mirror Assy. 1
3 Close Proximity Mirror 1
4 Assembly & Testing Charges 400*6+5 3005 Top Mtg. Bracket Process cost Sh.+Bl.+Pu.+Fo. 2
6 Bumper View Mirror Assy 1
Sub Total
ICC 1.50%
Costing Break up Sheet
Lumax Manas Automotive Systems Limited
Gat no- 105/106, Village Ambi, Near Talegaon- Pune
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Rejection 2%
O.H. 10%
Profit 10%
Forwarding Costing Pune
Total Cost of Complete Mirror Assembly Kit
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Rate Compo. Cost
70.4 70.4
70.4 70.4
42 45.78
42 45.78
65.5 65.5
65.5 65.5
1.5 3
1.15 4.6
0.9 1.8
3.5 3.5
3.5 3.5
4.25 8.5
0.45 0.9
0.25 0.5
0.5 1
1.25 2.5
24.5 49
40 40
482.16
Rate Compo. Cost
135.27 270.54
111.71 111.71
74.21 74.21
13 136.5 13
201.14 201.14
683.60
1165.76
7.2324
10505
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Bought Out PartsS.No Part No's Descriptions Materials Weight No off Rate
1 HOUSING 'E' 1312 (CO PP) PPCP 0.29 1 80
2 Nyloc HEX NUT M8 Std. 1 1.15
3 Hex SCREW M8*40 Std. 1 1.4
4 SCREW M6x20 CHEESE HD BLACK Std. 2 0.5
5 WASHER PL.OD 25mm*1.5 (Y)-1312 M.S. 1 0.5
6 PVC tape PVC 1 2.75
7 COIL SPRING -1312 SS 1 3.25
8 (PVC) RETAINER BEADING PVC 1 14.5
9 TOP Cover BKT. -RVM 1312 Nylon 0.08 1 180
10 RETAINER CONE OUTRE PT. -1312 Nylon 0.045 1 180
11 CUP WASHER SMALL-1312 M.S. 1 012 SPRING RETAINER BIG-1312 M.S. 1 1
13 MIRROR PLATE -1312 (3mm) Imported 1 48
14 Air Bubble+ poly bag 1 1.7
15 M-6 Nut Insert 2 0.45
Total BOP Cost
In House ProcessS.No Part No's Descriptions Process M/C S.Prod Rate
HOUSING 'E' 1312 (CO PP) Moulding 180 408 1800
Assembly Assy. 5 400 500
Retainer cone moulding Moulding 150 816 1500
TOP Cover BKT. -RVM 1312 Moulding 150 1632 1500
Total In House Process Cost
Sub Total
Costing
Lumax Manas Automotive Systems Ltd.Main Mirror Assembly (1312)
Costing Break- up sheet of Mirror Assembly.
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comp. cost
23.2
1.15
1.4
1
0.5
2.75
3.25
14.5
14.4
8.1
01
48
1.7
0.9
121.85
Cost
4.41
6.25
1.84
0.92
13.42
135.27
or Kit Assy 135.27
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Bought Out PartsS.No Part No's Descriptions Materials Weight No off Rate
1 Housing PPCP 0.205 1 80.00
2 Mirror plate (Imported) Imported 1 1 40.00
3 Pipe Nylon 0.07 1 155.00
4 Mtg. Bkt. ADC-12 1 18.00
5 Cap PPCP 0.01 1 80.00
6 Screw M5x30 Ph.Pan Hd Std. 2 0.60
7 Nut M5 Std. 2 0.25
8 Plain washer M5 M.S. 2 0.23
9 Allen Bolt M8x30 Std. 1 3.25
10 Nyloc Nut M8 Std. 1 1.10
11 Plain Washer M8 M.S. 1 0.4512 Thermopolis Packing 1 1.25
13 Poly beg 1 1.00
14 Primary carton 0.5 8.00
15 Master carton 1 16 50.00
Total BOP Cost
In House ProcessS.No Part No's Descriptions Machine S. Prod. M/c rate Rate
1 Housing 180 408 1800 4.41
2 Mtg. pipe 130 890.1818 1300 1.46
3 Clamp Pipe 80 1780.364 800 0.454 Assembly 3 500 500 3
Total In House Process Cost
Sub Total
Lumax Manas Automotive Systems Ltd.Close Proximity Mirror Assembly
Costing Break- up sheet of Mirror Assembly.
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comp. cost
16.40
40.00
10.85
18.00
0.80
1.20
0.50
0.46
3.25
1.10
0.451.25
1.00
4
3.13
102.39
Cost
4.41
1.46
0.453
9.32
111.71
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Bought Out PartsS.No Part No's Descriptions Materials Weight No off Rate
1 Housing PPCP 0.165 1 80
2 Mtg. Stay Nylon GF-2 0.034 1 180
3 Cover Stay Nylon GF-2 0.024 1 180
4 Mirror plate Float Glass Imported 1 37
5 Screw M4x20 Std. 2 0.4
6 Hex Nut M4 Std. 2 0.2
7 Nut M5 Std. 2 0.2
8 Screw M5x25 Std. 2 0.5
9 Spring Washer M5 Std. 2 0.2
10 Air Bubble 1 0.75
1415
Total BOP Cost
In House ProcessS.No Part No's Descriptions Process Machine Production
Housing Moulding 180 489.6 1800
Mtg. Stay Moulding 80 816 1000
Cover Stay Moulding 80 1088 1000
Assembly assy 4 500 500
Total In House Process Cost
Sub Total
Kit Pricing
Lumax Manas Automotive Systems Ltd.Wide Mirror Assembly
Costing Break- up sheet of Mirror Assembly.
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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
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Bought Out PartsS.No Part No's Descriptions Materials Weight No off Rate
1 Housing PPCP 0.205 1 80.00
2 Mirror plate (Imported) Imported 1 1 50.00
3 Pipe Nylon 0.07 1 155.00
4 Mtg. Bkt. Febricated M.S. 1 90.56
5 Cap PPCP 0.01 1 80.00
6 Screw M5x30 Ph.Pan Hd Std. 2 0.60
7 Nut M5 Std. 2 0.25
8 Plain washer M5 M.S. 2 0.23
9 Allen Bolt M8x30 Std. 1 3.25
10 Nyloc Nut M8 Std. 1 1.10
11 Plain Washer M8 M.S. 1 0.4512 Thermopolis Packing 1 1.25
13 Poly beg 1 2.00
14 Primary carton 0.5 16.00
15 Master carton 1 8 40.00
Total BOP Cost
In House ProcessS.No Part No's Descriptions Machine S. Prod. M/c rate Rate
1 Housing 180 408 1800 4.41
2 Mtg. pipe 130 890.1818 1300 1.46
3 Clamp Pipe 80 1780.364 800 0.454 Assembly 3 500 500 3
Total In House Process Cost
Sub Total
Lumax Manas Automotive Systems Ltd.Close Proximity Mirror Assembly
Costing Break- up sheet of Mirror Assembly.
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comp. cost
16.40
50.00
10.85
90.56
0.80
1.20
0.50
0.46
3.25
1.10
0.451.25
2.00
8
5.00
191.82
Cost
4.41
1.46
0.453
9.32
201.14
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Date
Model
Unit
Tool Life
Mtrl thick
S. No Item DescriptionMaterial
Grade
Dia in
mm
Length
in mm
Breath
in mm
Thick in
mmNo. off
Wt. in Kgs
+ 5%Extra
1 Pillar base plate M.S. 425 375 45 1 59.19
2 Side support Plate M.S. 425 90 45 2 28.41
3 Stepper plate M.S. 350 300 30 1 26.00
4 Cavity block HcHCr 500 400 150 1 247.59
5 Support Block M.S. 230 110 45 1 9.40
6 Guide Pillar 16MnCr5 50 300 4 18.51
7 Locking Bush M.S. 25 50 16 3.09
8 Pillar Top Plate M.S. 425 375 38 1 49.98
9 Guide Bush 16MnCr5 55 90 4 6.72
10 Core Block HcHCr 500 400 150 1 247.59
11 Front Stopper Plate OHNS 100 100 25 1 2.06
12 Side Stopper Plate OHNS 425 90 38 2 23.99
13 Core Back Plate OHNS 500 400 25 1 41.27
14 Cavity Back Plate OHNS 500 400 25 1 41.27
S. No Element Desc
1 P.U. Bush / Spring
2 Dowel
3 Sco. Head Screw4 Sco. Head Screw5 Sco. Head Screw
6 Misc.
S. No Category
2 Assembly,polishing Cost
E
Ashok Leyland, Chennai.
Part Details
Part No / Issue
Part Description
Tool Type MOULDING
No. off Per Vehicle
Material Cost Details (A)
Tool Size (mm) 390 x 350 x 300
Tonnage -
Top Main Mounting Bracket Blanking Die
RM Cost
Standard ElementsQty UOM Rate / no15 D 50 , ID 15 X 60 500
25 10 x 60 60
40 BSW1/2x100 50
Total Standard Element Cost
Total Material Cost (A)
Other Cost Details
40 BSW1/2x60 50
40 BSW1/2x30 50
40 450
Time in Hours Cost Per Hour
Total Other Cost ( C )
Sub Total Cost (A+B+C-D)
A
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Note : - Rs 150000 / - are the homologation charges for the bumper Mir
Homologation Charges (E)
Final Mould Cost (E)
B
C
D
Mould Cost (E)
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Rate/kg Material Cost
Rough
Machinin
g
Surface
Grinding
Coordina
te
Drilling
Bench
work
Heat
Treatme
nt
Cutting CG
65 3847.32 6.00 7.00 7.00 7.00 0.00 6.00 0.00
65 1846.71 5.00 5.00 6.00 7.00 6.00 6.00 7.00
65 1689.80 6.00 6.00 6.00 7.00 6.00 6.00 7.00
160 39614.40 15.00 12.00 12.00 15.00 7.00 12.00 12.00
65 610.74 5.00 3.00 3.00 2.00 0.00 2.00 3.00
200 3702.06 3.00 1.00 0.00 0.00 4.00 3.00 4.00
65 200.53 5.00 1.00 2.00 0.00 2.00 2.00 3.00
65 3248.85 5.00 5.00 5.00 6.00 0.00 5.00 0.00
200 1343.85 3.00 1.00 0.00 0.00 4.00 3.00 4.00
160 39614.40 15.00 12.00 12.00 15.00 7.00 12.00 12.00
100 206.33 5.00 2.00 2.00 1.00 1.00 2.00 1.00
100 2399.15 5.00 2.00 2.00 1.00 1.00 2.00 1.00
100 4126.50 9.00 7.00 10.00 7.00 6.00 4.00 4.00
100 4126.50 9.00 7.00 10.00 7.00 6.00 4.00 4.00
106577.13
Cost
7500.00
1500.00
2000.00
2000.00
2000.00
9000.00
24000.00
130577.13
Cost S.No
1
18000.00 2
18000.00
Supplier
130577.13 Quote By Date:
Tool Cost Estimation Sheet
Supplier Deta
Supplier Name Lumax Manas Automotive System
Development Referred by
100000 SS Buyer
Conversion Cost Details (Ti
Cost Per Ho160 170 220 150 120 250 250
FS
15360.00 12070.00 16940.00
Total Conversion Cost (B)
Recovery Cost Details (Applicable for Obsol
11250.00 6000.00 17250.00 15500.00
Recovery of Other items
Category
Recovery of RM Cost
Total Recovery Cost (D)
Lumax Manas Automotive Systems Ltd. Pune
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17/19
189120.00
18000.00
1000.00
338697.13
150000.00
488697.13
or Assembly.
Sign/Date
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EDM WEDMCNC
Milling
Surface
FinishingJig Boring
4.00 5.00 0.00 7.00 5.00
5.00 5.00 0.00 6.00 0.00
4.00 8.00 0.00 6.00 0.00
17.00 11.00 25.00 13.00 0.00
0.00 0.00 0.00 1.00 0.00
0.00 0.00 0.00 1.00 0.00
0.00 0.00 0.00 1.00 0.00
0.00 5.00 0.00 5.00 5.00
0.00 0.00 0.00 1.00 0.00
17.00 11.00 25.00 13.00 0.00
0.00 0.00 0.00 1.00 0.00
0.00 0.00 0.00 1.00 0.00
0.00 5.00 4.00 10.00 0.00
0.00 5.00 4.00 10.00 0.00
189120.00
Cost
1000
1000
Date:
ils
s Ltd. Pune
e in Hours) (B)
r400 500 300 450350
escence / Modification Tool) (D)
29000.00 22800.00 4500.0016450.00 22000.00
Settled by
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8/2/2019 A_L- NGC- cost
19/19
Sign/Date
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