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Manufacturing Day                                                 Page 1May 10th, 2011                        TechniQuote ...
Manufacturing Day                                               Page 2May 10th, 2011                                      ...
Manufacturing Day            The French Technological Institute   Page 3May 10th, 2011               for mechanics   Gover...
Manufacturing Day       Making Technological choices                            Page 4May 10th, 2011          for the futu...
Manufacturing Day                                                                                          Page 5May 10th,...
Manufacturing Day                                               Page 6May 10th, 2011                      Automated cost c...
Manufacturing Day                                               Page 7May 10th, 2011                        Introduction  ...
Manufacturing Day                                               Page 8May 10th, 2011                       Costing of comp...
Manufacturing Day                                                         Page 9May 10th, 2011                       What ...
Manufacturing Day                                                                  Page 10May 10th, 2011                  ...
Manufacturing Day                                                                      Page 11May 10th, 2011              ...
Manufacturing Day                                                Page 12May 10th, 2011                       Why using an ...
Manufacturing Day                                                                                           Page 13May 10t...
Manufacturing Day                                               Page 14May 10th, 2011                       Intuitive Appr...
Manufacturing Day                                                              Page 15May 10th, 2011                      ...
Manufacturing Day                                                  Page 16May 10th, 2011                       Analytical ...
Manufacturing Day                                               Page 17May 10th, 2011                       Parametrical a...
Manufacturing Day                                               Page 18May 10th, 2011                       Parametrical a...
Manufacturing Day                                                                        Page 19May 10th, 2011            ...
Manufacturing Day                                                                              Page 21May 10th, 2011      ...
Manufacturing Day                                                                                         Page 22May 10th,...
Manufacturing Day                                                                         Page 23May 10th, 2011         Ch...
Manufacturing Day                                                Page 24May 10th, 2011                       Study-case : ...
Manufacturing Day                                                    Page 25May 10th, 2011                        Costing ...
Manufacturing Day                                                          Page 26May 10th, 2011                          ...
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Sirris manufacturingday2011 automated-calculation-cetim

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Cost estimation is a critical task due to the small margins between production cost and selling price in a competitive market. For machining companies, this process is complex because of the high amount of variation occurring. An intelligent software system provides accurate cost estimation based on 3D CAD models.

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Sirris manufacturingday2011 automated-calculation-cetim

  1. 1. Manufacturing Day Page 1May 10th, 2011 TechniQuote Automated cost calculation of complex parts L. Berteloot Software Department manager Cetim - France Automated cost calculation of complex parts – L. Berteloot
  2. 2. Manufacturing Day Page 2May 10th, 2011 0706-05-GB Automated cost calculation of complex parts – L. Berteloot
  3. 3. Manufacturing Day The French Technological Institute Page 3May 10th, 2011 for mechanics Governed by Articles L342.1 to L342.13 of the Code of Research Steered by mechanical industrialists under the State’s supervision Founded in 1965 700 people with 56% engineers Automated cost calculation of complex parts – L. Berteloot
  4. 4. Manufacturing Day Making Technological choices Page 4May 10th, 2011 for the future Mechatronics Design Simulation 4 Inspection Tests Measurement Technological axes Materials - Processes Sustainable development Automated cost calculation of complex parts – L. Berteloot
  5. 5. Manufacturing Day Page 5May 10th, 2011 Transfering of Technology to mechanical Small and Medium Companies Permanent information 30,000 visitors 15 technical days 2 international 800 participants to every month  60 mechanical mondays congresses flash Midest lectures More than 30 000 30 new performance reports technical calls/year 10 new issues/year Catalogues: Training, Publishing, Software Automated cost calculation of complex parts – L. Berteloot
  6. 6. Manufacturing Day Page 6May 10th, 2011 Automated cost calculation for complex parts Automated cost calculation of complex parts – L. Berteloot
  7. 7. Manufacturing Day Page 7May 10th, 2011 Introduction TIME, COST and PRICE • 3 different terms for a single concept COSTING Remark : Time will be also used for Delay Automated cost calculation of complex parts – L. Berteloot
  8. 8. Manufacturing Day Page 8May 10th, 2011 Costing of complex parts A part is complex by:  Geometry  Precision  Quantity of details  Manufacturing process  Assembly (number of parts and their types)  Standards Costing can become complex with informal aspects :  Importance for company (stakes and risks)  Delay to cost Automated cost calculation of complex parts – L. Berteloot
  9. 9. Manufacturing Day Page 9May 10th, 2011 What is in Technical Cost ? Technical Cost = Supply Cost + Manufacturing Cost • Cost = f(Quantity, Machine and Tools, Process, Labour Rate) Supply Cost  preparation (bar, forged, casted)  Losses (cutting mark, clamping, off cut) Manufacturing Cost :  O&M department  Prep. (machine / tools), Mounting  Machining + Tool Cost  Subcontracting (painting, treatment, …)  Controlling, Assembling, Logistics Automated cost calculation of complex parts – L. Berteloot
  10. 10. Manufacturing Day Page 10May 10th, 2011 What is NOT in Technical Cost ? Margins problem are complex and multiple : • Real margins : price = cost (1+ margin)  Manufacturing, Supplying, Subcontracting, • Hided costs  Commercial or organization costs,  Machine occupation rate, return on invest  Non estimated activities (logistics, transportation, controlling, …) • Risk coverage percentage Automated cost calculation of complex parts – L. Berteloot
  11. 11. Manufacturing Day Page 11May 10th, 2011 Costing : a global concept for company • Engineering : COST  Design to cost  Value engineering • Manufacturing : TIME* and COST  Process optimization  Anticipation of working load  Data Flow optimization  Best practices • Sales/Procurement : COST and PRICE  Shorten delay for quotation  Increase precision and reliability of tenders  Argue a quotation • Management : COST  Decision making aids (delocalization, investment, politics and strategy) Automated cost calculation of complex parts – L. Berteloot
  12. 12. Manufacturing Day Page 12May 10th, 2011 Why using an automated cost calculation ? What is the job of a Cost expert ?  Analyse and consultation  Optimize process  Estimate Time and Cost Remark : Delay  and Risk  First reasons :  Faster and more precise  One solution  Optimization by simulation  The solution Main reasons:  Repetitiveness, Reliability, Simulation tool  Customizable (Costing know-how capitalization)  Integration in the numerical chain (CAD-Costing-ERP) Automated cost calculation of complex parts – L. Berteloot
  13. 13. Manufacturing Day Page 13May 10th, 2011 Costing : different approaches • Qualitative  Intuitive or empirical  From personal experience  Analogical  Search tool • Quantitative (calculation tool)  Analytical  Exhaustive description of all the process operations  Parametrical  Parameterization of analytical approach  Statistical  “Black box” system with variables  ex : pomp (flow rate, power, efficiency, rotation,…) Automated cost calculation of complex parts – L. Berteloot
  14. 14. Manufacturing Day Page 14May 10th, 2011 Intuitive Approach • Unformal analogical approach • No real tool aids (sometime : excel file)  cross-multiplication  extrapolation  direct costing without feedback loops • Implementation  Based on personal experience and feeling Automated cost calculation of complex parts – L. Berteloot
  15. 15. Manufacturing Day Page 15May 10th, 2011 Analogical approach • Concept  Database of part references with specific description and cost  Search engine or multicriteria request to find closest references  Interpolation to estimate Cost • Problem : how do you valorize differences ?  dimension, material  serie • Implementation  Collect data on part description with associated cost  Formalize of part description  Determinate cost drivers Automated cost calculation of complex parts – L. Berteloot
  16. 16. Manufacturing Day Page 16May 10th, 2011 Analytical Approach • Description of the operational process  “Exhaustive” list of all the required operations  Calculation of TIME (Raw material, Machine)  COST  Estimation of TIME (technological data)  COST  Sum up to get global COST• Implementation  Customize cost database  Add-on specific ops. Automated cost calculation of complex parts – L. Berteloot
  17. 17. Manufacturing Day Page 17May 10th, 2011 Parametrical approach (1) • Plain parametrical formula :  Cost = Cost (material+drilling+machining+controlling)  Raw Material = Vol (L*l*H) * C1  Drilling = (Nb of drills)*C2+(Nb of taps)*C3  Machining = (Vraw-Vfinish)*C4  Controlling = (50 ch) * C5  Implementation  Quite close from intuitive approach Automated cost calculation of complex parts – L. Berteloot
  18. 18. Manufacturing Day Page 18May 10th, 2011 Parametrical approach (2) • Parametrical based on analytical approach  Identification of the relevant process  Change parameters  Validate for cost calculation • Implementation  Collect data on process  Realize initial estimates with analytical approach Automated cost calculation of complex parts – L. Berteloot
  19. 19. Manufacturing Day Page 19May 10th, 2011 Statistical approach • No access to analytical approach / Few information / Complex project • Early phase in the Product Life Cycle  Parametrical approach based on statistical laws (Cost Estimation Relationship) extracted from large ERP database • Implementation  Collect input data on project  Determine cost drivers  Identify stat. laws :  Regression  Main composant analyse  Difference Automated cost calculation of complex parts – L. Berteloot
  20. 20. Manufacturing Day Page 21May 10th, 2011 How to choose your approach ? Few information Projects Intuitive Analogical Statistical X1 X 10 X50 Parametrical Analytical Risk Parts X1 Analytical reduction X50 Process X1 Parametrical Maxi of information Operations X1 Change control Setting-up Automated cost calculation of complex parts – L. Berteloot
  21. 21. Manufacturing Day Page 22May 10th, 2011 Advantages / disadvantages Intuitive Analogical Analytical Parametrical Statistical Precise evaluation Reliability      Sensitiveness      Right price      Implementation      Set-up easiness      Automation      Technical Level      Budget and resources      Automated cost calculation of complex parts – L. Berteloot
  22. 22. Manufacturing Day Page 23May 10th, 2011 Challenges for a company implementing a costing solution 1. Correlation cost estimation and manufacturing cost (feedback loop) 2. Update data (technical and economical) 3. Training and customization 4. Integration with ERP system (input and/or output) 5. Implementation in a group with subsidiaries 6. Vulgarization of Costing tool 7. Education of “ordering party” and “sub/contractors” in exchanging 3D model files Automated cost calculation of complex parts – L. Berteloot
  23. 23. Manufacturing Day Page 24May 10th, 2011 Study-case : automated cost calculation from CAD file to Costing in few clicks ! • Cetim TechniQuote  analytical  automatic/interactive Video Automated cost calculation of complex parts – L. Berteloot
  24. 24. Manufacturing Day Page 25May 10th, 2011 Costing : perspectives - Enlarge Costing to multi-technology : - Sheet metal - Tooling - Forging - Composites - Mix performant approaches - Statistical and analytical - Costing orientations - Introduce as a major phase in the Product Life Cycle - Feed back to engineering - Optimization of process for O&M department Automated cost calculation of complex parts – L. Berteloot
  25. 25. Manufacturing Day Page 26May 10th, 2011 Thank you for your attention Cetim 52, Avenue Félix-Louat France - 60 304 Senlis Cedex Laurent BERTELOOT Tel : (+33) 3 44 67 47 79 Mail : laurent.berteloot@cetim.fr Automated cost calculation of complex parts – L. Berteloot

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