Praese 201907 v16 unnecessaryDeleted en forIntroPresentation · Compare laser cutting vs....
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Transcript of Praese 201907 v16 unnecessaryDeleted en forIntroPresentation · Compare laser cutting vs....
The Excel Costing -Tool
� Keep our Excel!familiar environment
no loss of your calculations
offline/online/multiuser
interface market leader
� Install the CALC4XL
Benchmark Database
� Create your users and
rights
Let‘s go with CALC4XL!
AdminAdmin
User 1User 1 User 2User 2
User 4
User 5User 5
User 3
Project – Specification(Country Data, Overheads)
Wages
Machines
Material and Volume Calc.
Manuf. Cycle Time Calc.
File- / Template Module
and Software
The Database� 417 Country Datasets (Footprint Cost, Energy Cost, Imputed Interest)
� 70.440 Overhead Sets (Material, Manufacturing, Sales, Administration,
Logistic, Development)
� 2.520 Wage Sets (direct Wage, Employer‘s Contribution) from Industrial
Parks
� 1.500 Machines (Name, Description, Investment, Installation Cost, Footprint, Energy Cost,
Maintenance and Machine Specific Data as diameter, clamping force, …)
� Materialdatabase structure with sample data (Steel, Plastic)
� Cycle Time Calculators for usual Manufacturing Processes (e.g. injection molding, die casting,
mechanical processing, …)
� Calculation Templates and Precalculated Parts
� Database: Recommendes Values, at least 1 Update per Year
Editable and Extendable by your Own Expert Knowlwdge: smart domain
of knowledge- own (supplier) data - own calculation templates
- … etc. …- (parametrized) calculations
CALC4XL Features� CALC4XL is a stand-alone costing software with
� uniform, extendable benchmark database
� uniform, extendable calculation templates
� system of rights and roles
� Manufacturing Process Cycle Time Calculators
� Excel remains as Input/Output Interface and Customizing-Tool (incl. Office infrastr.)
� familiar environment; no loss of existing calculations and data
� Open Book: You can exchange your calculations with partners w/o CALC4XL license
� All structured in Modules:
� Use CALC4XL Templates as Ready-To-Use Complete System
� Use CALC4XL Modules in your own, existing Excel-Files
(e.g. your or supplier Excel files)
� CALC4XL software screenshots in the appendix below
CALC4XL Scope� Cost Breakdown
� Detailed calculation with supply chain management (MultiBOM)
� Target Pricing
� Benchmark (incl. Request for Quotation, Best Cost Country, ...)
� Value Stream Analysis
� Product Development Process
� Make or Buy
� Design to Cost
� Technology Transfer
� Fixed Cost Degression
� Design Change
� Etc. …
In the following slides:
CALC4XL Case Studies
CALC4XL Use Case 1
Cost Breakdown
CALC4XL-Cost Breakdowncalculate, calculate, calculate…
Overheads
Wages
Machines
Cycle Times
Materials
Linked Excel Cells:
CALC4XL Case Study 1
Request for Quotation (RFQ)
RFQ - Basisdata Should Cost Cylinder
Column 1: Supplier 1 Cost Breakdown
Column 2: Cost Engineer Analysis
Column 3: Supplier 2 Cost Breakdown
Negotiated purchase price: 68 €/pc from supplier 1
with long-term agreement: 3% price reduction per year
CALC4XL Case Study 2
Comparison of different manufacturing technologies with consideration of tool costs
Case: Compare laser cutting to progressive die stamping
Key data and process flow detail calculation progre ssive die stamping vs. laser cutting
Progressive die stamping
Painting
Check and Packaging
Company: CALC4XLLocated: Hamburg
Turnover (Trend): 18.7 Mill. €
Workers: 150
Working days/a: 240 days/a
Shiftmodel & time: 2 shifts; 7,5 hours/shift
Material: S275JR
Overheads SG & A: Database
Profit: 7 %
Volume: 30.000 Pcs/a
Tooling: estimate
Progressive die stamping from coil with a roll feed line
Example: Progressive die stamping tool from coil with strip
HINT:Painting, check and packaging are identical processes for stamping and laser cutting manufacturing.
Laser cutting
Bending
Painting
Check and Packaging
Laser cutting from a plate
Example: Bending tool
Example: Progressive die stamping tool from coil with strip
Main topics for comparison:material, cycle time, machine - , setup - , productions costs and tool cost
Process flow detail calculation progressive die sta mping vs. laser sheet metal part
Example: Bending tool
Laser cutting from a plate
HINT:
See Excel file with Cost Breakdown for laser cutting versus progressive die stamping.
Compare laser cutting vs. progressive die stamping pa rt
Summary technology change
Saving by 30.000 pc/a and lifetime 7 years• 7 x 30.000 x (5,62-2,848) = 582.120 EUR • reduced by the difference in tool costs• 582.120 - (85.000-15.000) = 512.120 €• Lifetime saving: 512.120 €• without dynamic return on investment
How to: Compare laser cutting vs. progressive die stam ping • Save the initial calculation for laser cutting by „copy sheet“.• Change the calculation, e.g. here: manufacturing process laser
cutting to progressive die stamping, as well as tool costs• … and save the new version by „copy sheet“.• Compare versions in worksheet „Summary“.• Compare laser cutting vs. progressive die stamping and decide for
the right technology.
CALC4XL Use Case 2
MultiBOM
CALC4XL MultiBOM
Detailed calculation for any complex bill of materials with supply chain management
Show/hide cost details
Add a part / assembly
Show / hide
Assembly Level
- Assembly
- Purchased part
- Manufactured part
- Process
- Material
- In-house production
- External production
Reference Customers
Trainings:
� CALC4XL-Software and Overhead Calculation
� Manufacturing Technologies, e.g. mechan. processing, injection molding, casting, a.s.o.
� Which machine for which process?
� How to determine the cycle time? Which following processes are needed?
CALC4XL Consulting Group – Excerpt:
� Tool Cost Calculation
� Product Cost Calculation on basis of Should Cost Analysis /
Purchase Cost Analysis
� Competitor Analysis / Product-Tear-Down
� Product- and Process-Potential-Analysis
� CALC4XL FULL COST Engineering
� Implementation of a Cost Engineering Team
� Introducing of Costing-Tools like Cost-Breakdown, Linear Price Performance, Value
Stream Mapping, Measurables, etc.
� … ETC …
CALC4XL Consulting Group
Central, editable, extendable Template Module
Multilingual, User Administration
System of Rights and Roles
Central, editable, extendable Database
Help Panel
incl. 30min Introduction
In Detail:
CALC4XL Menu Excel
Show CALC4XL Data in the File and Prepare File for User w/o CALC4XL
Modular CALC4XL calculators
Open the CALC4XL calculators by :
� Click in the CALC4XL menu bar
or
� Double click into a linked EXCEL cell
CALC4XL includes the following calculators:
� Project-Specification
� Machine Calculator
� Wage Calculator
� Manufacturing Processes
� Material
1. Project Specification Calculator
Country Data:Footprint, Energy, imputed Interest
Overhead Factors dependent on Country, Industry, Product and Company Size
Every Dataset is rewritable
2. Machine Calculator
75 Machinegroups
Approx. 1500 Machines
Push Own Machines into Database
3. Wage Calculator
4. Material Calculator (with)
Put own Materials in Database
Determination of Cycle Time and Machine Size by our Cycle Time Calculators
For Example
5. Cycle Time Calculator (Expert Knowledge „To Go“)
Die Casting
Mechanical Machining
Usage of CALC4 XL Calculators
� All CALC4XL Calculators are linked automatically (Project Specification, Machines, Wages, Materials, Cycle Time)
� Open Calculators by Double-Click in linked Excel cell
� User can adjust links individually
� Structure, Cells, and Formulas are editable/customizable in Excel Application according to System of Rights and Roles
CALC4XL Cost Breakdown
Use the integrated Cost Breakdown...
Overheads
Wages
Machines
Cycle Times
Materials
Linked Excel Cells:
CALC4XL MultiBOM
… or the integrated detailed calculation with supply management…
Own EXCEL files
… or use your own EXCEL spreadsheets and transfer the values from the
CALC4XL calculators by linking.
Template Module
Upload arbitrary Files to Database for your Colleagues, e.g.� Customized CALC4XL Templates� Your Own Excel Files (with or w/o CALC4XL-Modules)� Files of arbitrary Type like Powerpoint, PDF, even full Softwares (exe)=> Cross-Departmental Files always up-to-date
Company-Wide, Extendabel Templates
Precalculated Parts
• Quickly familiarize yourself with the CALC4XL system using the pre-calculated parts (assemblies/components)
• Each assembly/component comes with an explanation PDF and a calculation file.
• Use the pre-calculated assemblies/components as a parameterized calculation.
CALC4XL Software Introductory Workshop
1 hour: Introduction
• Getting to know each other
• Discussion of the customer-specific use case
• Overview of the CALC4XL modules
4 hours: The Basics
• Calculation of 2-3 components in the CALC4XL system
• The parts are selected according to the manufacturing techniques to be primarily
applied or prepared according to your CAD files.
2 hours: Going Further
• Customizinig
• CALC4XL modules in your own Excel files and templates
• Further applications: CALC4XL Cost Engineering
1 hour: Feedback
• Does this meet all the requirements of the initial discussion?
• Best Practice for requirements of the initial discussion
• What's missing? How can we solve this together?
CALC4XL GmbH
CALC4XL.com
