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Molding Should
Cost Model
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Definitions
Plastics
Plastic Injection Molding
Part Description
Costing Process By First Principle
Part Should Cost (Ex-W / FOB / CIF)
Definitions
Customer XXX
PN# 093D0209 (IR Housing Bottom)
Material - GE Noryl PX0840, 039A0289, BK 1A497, Black - Noryl is a blend
of polyphenylene oxide (PPO) and polystyrene (PS) which was developed in
1966 by General Electric Plastics (now owned by SABIC). Specific Gravity -
1.06. g/cm
Part Net Weight - 0.0093 KG
Wall Thickness - 0.08 IN
Part Vol. 0.530 Cu. In
EAU - 4864110
Part Description Cont.
Costing First Principle
A. Raw Mtrl. Cost Calculation
Raw Mtrl. Cost per pc. = Part Gross Weight (KG)* Landed RM cost per KG =
0.0097 * 5.15 ~ $ 0.05
Costing First Principle
B. Process Cost Calculation
Process involved will only be PI Molding (No Pre Heating or De-flashing Rqrd. in
Automatic Molding machines with Hot runner systems)
Machine Tonnage (clamp force) - The Clamp Unit of an injection molding machine is
rated by the maximum amount of clamp force that the machine is capable of
producing. This force is required in order to keep the mold closed during the injection
process, which is the primary purpose of the clamp unit. Normally, the force rating is
stated in tons. So, a specific machine having a rating of 200 tons is capable of
producing a maximum clamping force equivalent to a total of 200 tons.
Machine Tonnage (clamp force) Calculation = Part Projection Area * no. of cavities *
Flow constant * Clamping factor = 2.84 sq. in * 4 * 5 (Noryl is low flow) = 57 T ~ 60
T.
Note: Metal Flow Index varies from 5 to 20 (low flow to high low) & is directly related to clamp factor ranging from 2 to 8 (low
flow to high flow). To understand more on Metal Flow Index, pls visit http://www.iplas.com/clamptonnage.html
Costing First Principle
B. Process Cost Calculation
Cost of 60 T L&T (Now Toshiba Machine) ~ 1.86 Million INR ~ 35700 USD
Costing First Principle
B. Process Cost Calculation
Cycle time (Sec) - With centerline cooling. W. Thick=0.08, Inj. Temp=605 F/318 C,
Mold Temp.=250 F/121 C, Ejection temp.=280 F/137 C; 18 Seconds ~ 200 Shots
per Hour
Productivity per Hour No. of shots * no. of cavities = 200 * 4 = 800 ~ 720 pcs per
hour
Source:
http://www.downloadmanagerapp.com/gb/sg/?adnm=18409097082&i=s&grid=B&lg=EN&cc=IN&clg=en&c=1&d=0&cid=_223244601&kw=download%20free%20
software&mn=sourceforge.net&Network=D&expr=&agid=_2463981735
Costing First Principle
B. Process Cost Calculation
1 60 Ton 18.6 52.31 28.44 16.4 69.29 7.75 7.75 15.50 25 206.0
Inventory
1.5% of Material Cost 0.040
Carrying Cost
Total FOB India cost per pc. (With packaging) = $ 0.058 + $ 0.005 = $ 0.063
Total CIF USA cost per pc. (With packaging) = FOB + 8% of FOB = 0.063 + 0.08 *
0.063 = $ 0.068
Questions??..
Thank You