Cost Report Guidelines1. Objective

1.1

1.2

1.3 Teams can practice to optimize time, cost and manpower etc in the project with the help of this cost report.

2. Cost Report Data2.1 Definitions

2.1.1 Block:

2.1.2 Part Name:

2.1.3 Quantity:

2.1.4 Procurement Cost:

2.1.5 Manufacturing cost:

The cost report provide teams a tool to calculate the cost of their Efficycle. The objective is to find out the actual cost of the vehicle. (For this purpose teams can assume that the same Efficycle is manufactured by a fictitious firm.)

This is not required to show just the cheapest cost of the vehicle. The concept behind costing must be clear to the teams. All manufacturing processes, assembly process etc must be taken into consideration while compiling the cost report.

The whole vehicle can be considered to be an assembly of various subsystems (e.g. Rollcage, drivetrain, suspension, steering, brakes etc). These subsystems are defined as block in this cost report. The blocks are mentioned in the "INDEX SHEET" itself and teams must use these blocks in the BOM sheet.

Parts names must be provided by teams in the Part Name Column and (if required). The description is required to identify the unique part among same category of parts. (for example: if 2 types of fasteners are used in the assembly of rollcage, bolts of M10 and M12, then the part name must be given like "Fastener" for both with their description in the Remarks Column as "Bolt M10" and "Bolt M12" respectively). In case if teams are using only part of its category then the description is not required. (for example: Motor)

Quantity denotes how many times the same part is used in the block. For the same part the costs are calculated by applying quantity. (if teams are using 3 sprockets of same specification and cost, then it must be considered as the single part while quantity will be 3)

Procurement cost are the cost of part/material purchased. Procurement costs are considered per item only. If the parts are procured in lot or mass, then per item cost will be calculated by dividing the number of parts or amount of material to the total procurement cost of that lot.

cost of all fabricated parts will be calculated by considering all number of operation used in fabricating that part or subassembly (made by joining few parts together). The cost of fabrication will be calculated by using "Cost Calculation Sheet"

2.2 Introduction to Cost Report Format2.2.1 Sheet 1: Guidelines

2.2.2 Sheet 2: Index Sheet

2.2.3 Sheet 3: Main SheetIn this sheet teams will provide their Team Name, Team Number and Institute Name.

2.2.4 Sheet 4: BOM Sheet

This sheet calculate the following data:2.2.5 Number of parts in subsystem:

2.2.6 Total Procurement Cost:

2.2.7 Total Manufacturing Cost:

2.2.8 Sheet 5: Cost Calculations Sheet

In this sheet there are two tables for each item, namely Procurement Cost sheet and Manufacturing cost sheet.

Teams must go through this sheet to have a complete understanding of the cost report format. All guidelines are mentioned in this sheet, in any case of discrepancy during cost calculations the teams must refer this sheet to avoid mistakes.

Index sheet contains the standard rate of fabrication processes. Teams should use these rates to calculate the cost of their vehicle. If there is a case, the cost of some operation is not present in the table. Teams can use rates as per the local market.

Main sheet represents the summarized cost of the vehicle in terms of procurement cost, manufacturing cost, total cost of the vehicle and total number of parts used in the vehicle.

This is main BOM sheet in which the details of all parts or subassemblies used in the vehicle is to be filled. Hence teams must mention the details very carefully and accurately. (a dummy calculation is shown for example in sheet "Sample BOM"

The number of parts are calculated as per the details filled in "BOM Sheet"

This cost is the actual cost incurred in procuring the required number of parts for the vehicle. All type of parts and raw materials are included in the procurement cost

This is the cost incurred in manufacturing or customizing the parts or subassemblies. This included various type of fabrication processes.

There is a sheet provided to calculate the cost of subsystems with name "Cost Calculations". This sheet will be used to calculate the cost of manufactured/customized parts.

Name of such part or subassemblies will be provided in the description field (a dummy calculation is shown in sheet "Sample Cost Calculation"

Procurement sheet can be used to calculate the cost of raw material as well as the cost of parts that can be used to fabricate customized parts.

Manufacturing cost sheet can be used to calculate the total cost of manufacturing operations used in the fabrication of a particular item. Teams must carefully understand their fabrication processes to accurately calculate the cost of manufactured part.

2.3 Supporting Documents2.3.1 Teams will submit the supporting documents for the cost of material and parts. This is mandatory for the cost Evaluation.2.3.2 Supporting documents include the receipt of bills, invoices, catalogues, quotations from the manufacturers or suppliers2.3.3 Price tags of the parts can be used as supporting document but it must clearly show the details so as to identify the same part.2.3.4 Computerized invoices/bills without the retailer stamp will not be considered as supporting document.2.3.5 For operation carried in-house no supporting document is required. But cost must be mentioned accurately.2.3.6 The cost of parts must be the retail prices excluding VAT or any other tax.

2.3.7

2.3.8

2.3.9

2.3.10 For reused parts, the cost that is currently available in the market for same part must be used for calculation.2.3.11 Cost of consumable items (like filler wire, grease, oils etc) need not to be included in the cost report.

3. Format3.1 The teams must use the format provided by the Efficycle SAENIS only. No other formats will be accepted for evaluation.3.2

3.3 Report must not contain any image, media file or digital signatures etc.3.4

3.5 For preparing the hard copy of report take print of Main Sheet, BOM and Cost Calculation Sheets.

4. Report Submission4.1 Reports will be submitted on or before the deadlines as mentioned on the website or as communicated to teams by mails etc.4.2 No report will be considered for evaluation if submitted after the deadlines.4.3 Teams must carry their cost report in the USB storage device at the time of main event.

4.4

4.5 Teams will also carry a printed copy of report at the time of main event.

The labor cost are not to be mentioned separately for manufacturing operations, it is already included in the standard rates of operations

But in case of Vehicle assembly, labour cost will be entered separately in the BOM sheet (can be calculated from Cost Calculation Sheet)

The cost of resale/discounted price cannot be considered for calculation for any of the item. However teams are free to use resale parts in their vehicle but the cost reflected in this report must be that of the same part purchased form the retailer.

Cost report must be submitted in .xls or .xlsx format only. No other format like .xlsm(Macros enabled), .pdf will not be considered.

For any query regarding cost report format, teams are advised to write to efficycle2012@gmail.com

All reports will be mailed to efficycle.reports@icat.in only with subject name Cost Report_<Team Name>_<Team Number>. Teams must not mail their reports to any other ID until and unless published on the Efficycle SAENIS official website. Report sent to other IDs will not be considered for evaluation.

5. Evaluation Criteria5.1 Teams will be evaluated on the basis of following criteria

5.1.1 BOM knowledge5.1.2 Cost methodology5.1.3 BOM accuracy5.1.4 Cost accuracy5.1.5 Srategies Adopted to Minimize the cost

5.2

5.4

5.5

The evaluation of cost report will strictly not be only on the basis of lowest cost of any Efficycle. The vehicle having minimum cost doesn't mean it will get maximum marks in the cost event. Teams must also be prepared for the above mentioned points.

Teams providing fake data or tempering with the format of cost report will be penalized or can be disqualified from the event.

For not including the cost of significant part/s in the cost report, penalty will be applied in terms of adding the cost of that part in total vehicle cost 3 times than the actual cost. The decision of judges in this regard will be final.

Operation Cost INR100200

TIG Welding (per 10mm) 4SMAW Welding (per 10mm) 3Gas Welding/Gas Cutting (per 10mm) 4Drill per hole (upto 5 mm. depth) 5Drill per hole(more than 5 mm. depth) 10Reaming (per hour) 100Boring (10 mm depth) 10Grinding (hour) 35Profiling (per cut) 5Riveting (per rivet) 5Shaper (per hour) 120

100Shearing (per cut) 5Cutting (per cut) 5Gear Hobbing (10 mm width per teeth) 50Rack Cutting (10 mm width per teeth) 50Labour Cost (per hour) 35

Lathe (per hour)CNC (per hour)

Milling (per hour)

BlocksRollcageDrivetrainSteeringSuspensionBrakeWheel & TyreMiscellaneousDriver SeatAerodynamic DeviceBody Panel

Efficycle SAENIS 2012-Cost Report

Team Number Team Name Institute

Manufacturing Cost 0

Procurement Cost 0

Total Cost 0

Total No. of Parts 0

Block Part Name/Description Quantity Total Cost Remarks

Total 0 0 0 0

Procurement Cost (Per item)

Total Procurement Cost

Manufacturing Cost (Per Item)

Total Manufacturing Cost

Subassemblies and Customized Part Cost Calculation

Description: Item A Roll Cage Main Frame

Procurement Cost SheetS. No. Part Name Material Amount Unit Rate Cost

1 Pipe Alloy steel 80 ft 20.875 16700000

Total procurement Cost of Item 1670

Manufacturing Cost SheetS. No. Process Amount Unit Rate Cost

1 Cutting 42 cut 5 2102 Grinding 1 hour 35 353 SMAW 2000 mm 0.3 600

00000

Total Manufacturing Cost of Item 845Cost of Item A 2515

Description: Item B Drive Train

Material Cost SheetS. No. Part Name Material Amount Unit Rate Cost

1 Axle - 1 No. 500 5002 bearing 2 50 1003 Free Wheel 3 50 1504 Drive Set 2 200 4005 Chain 3 250 750

Total procurement Cost of Item 1900

Manufacturing Cost SheetS. No. Process Amount Unit Rate Cost

1 Cutting 2 cut 5 102 Lathe 1 hr 100 100

0000

00

Total Manufacturing Cost of Item 110Cost of Item B 2010

Description: Item C Steering

Material Cost SheetS. No. Part Name Material Amount Unit Rate Cost

1 Hook' joint - 1 - 200 2002 Steering handle - 1 - 200 2003 Round bar - 5 ft 40 200

00

Total procurement Cost of Item 600

Manufacturing Cost SheetS. No. Process Amount Unit Rate Cost

1 Cutting 4 cut 5 202 Grinding 0.3 hour 35 10.53 SMAW 100 mm 0.3 30

00000

Total Manufacturing Cost of Item 60.5Cost of Item C 660.5

Description: Item D Suspention

Procurement Cost SheetS. No. Part Name Material Amount Unit Rate Cost

1 Front Fork - 1 - 650 6502 Rear Suspention - 2 - 500 1000

000

Total procurement Cost of Item 1650

Manufacturing Cost SheetS. No. Process Amount Unit Rate Cost

000

00000

Total Manufacturing Cost of Item 0Cost of Item A 1650

Description: Item E Brake

Material Cost SheetS. No. Part Name Material Amount Unit Rate Cost

1 Disc Brake Set - 3 No. 450 13502 Brake lever - 3 No. 15 45

000

Total procurement Cost of Item 1395

Manufacturing Cost SheetS. No. Process Amount Unit Rate Cost

00000000

Total Manufacturing Cost of Item 0Cost of Item B 1395

Description: Item F Wheel & tyre

Material Cost SheetS. No. Part Name Material Amount Unit Rate Cost

1 Wheel - 3 - 200 6002 tyre 3 180 5403 tube 3 100 3004 misc 3 60 180

0Total procurement Cost of Item 1620

Manufacturing Cost SheetS. No. Process Amount Unit Rate Cost

00000000

Total Manufacturing Cost of Item 0Cost of Item C 1620

Description: Item G Driver Seat

Procurement Cost SheetS. No. Part Name Material Amount Unit Rate Cost

1 Seats 2 500 10000000

Total procurement Cost of Item 1000

Manufacturing Cost SheetS. No. Process Amount Unit Rate Cost

00000000

Total Manufacturing Cost of Item 0Cost of Item A 1000

Description: Item H Miscellenous

Material Cost SheetS. No. Part Name Material Amount Unit Rate Cost

1 Motor - 2 No. 4000 80002 Battery 4 2000 80003 Painting 4 150 600

00

Total procurement Cost of Item 16600

Manufacturing Cost SheetS. No. Process Amount Unit Rate Cost

1 Labour cost 6 hour 35 2100000000

Total Manufacturing Cost of Item 210Cost of Item B 16810

Block Part Name/Description Quantity Total Cost Remarks

Rollcage Main Frame 1 3000 3000 740 740 3740Rollcage Mounting Points 20 0 0 28 560 560Drivetrain Battery 1 600 600 0 0 600Drivetrain Motor 1 1500 1500 0 0 1500Drivetrain Sprockets 3 200 600 0 0 600Drivetrain Drive Axle 1 900 900 38 38 938Driver Seat Seat 2 800 1600 0 0 1600Wheel & Tyre Wheels 3 800 2400 0 0 2400 Rim & Tyres

Read Comments at B2, B7

Total 8 10600 1338 11938

Procurement Cost (Per item)

Total Procurement Cost

Manufacturing Cost (Per Item)

Total Manufacturing Cost

Subassemblies and Customized Part Cost Calculation

Description: Item A Rollcage Main Frame

Procurement Cost SheetS. No. Part Name Material Amount Unit Rate Cost

1 Pipe Mild Steel-1020 50 ft 60 3000Total procurement Cost of Item 3000

Manufacturing Cost SheetS. No. Process Amount Unit Rate Cost

1 Cutting 24 cut 5 1202 Grinding 3 hour 35 1053 Pipe Bending 14 bend 10 1404 SMAW 1250 mm 0.3 375

Total Manufacturing Cost of Item 740Cost of Item A 3740

Description: Item B Drive Axle

Material Cost SheetS. No. Part Name Material Amount Unit Rate Cost

1 Axle - 2 No. 450 900Total procurement Cost of Item 900

Manufacturing Cost SheetS. No. Process Amount Unit Rate Cost

1 Cutting 2 cut 5 102 TIG Welding 70 mm 0.4 28

Total Manufacturing Cost of Item 38Cost of Item B 938

Description: Item C

Material Cost SheetS. No. Part Name Material Amount Unit Rate Cost

00000

Total procurement Cost of Item 0

Manufacturing Cost Sheet

S. No. Process Amount Unit Rate Cost00000000

Total Manufacturing Cost of Item 0Cost of Item C 0

Read comments on G8, F12, F14, D15, G16, C23.