ESTIMATION OF PRODUCTION COST OF TACK WELDING COMPONENTS

1. ESTIMATION OF PRODUCTION
COST OF TACK
WELDING COMPONENTS
By:
M NAVEEN SAI ASHISH
191914089L

2. INTRODUCTION
■ In the manufacturing sector, estimating production costs is important
because it influences whether a product will be profitable. To temporarily
secure parts in place, a type of welding called tacking involves welding tiny
spots or beads of metal.
■ The price of labor, raw materials, and overhead expenses are just a few of
the variables that must be taken into account when estimating the
production cost of tack welding components.
■ The component's specifications, such as its size, shape, and material, must
be understood in order to calculate the production cost with accuracy.

3. INTRODUCTION
■ With the aid of this data, it is possible to calculate the quantity of raw
materials needed, the number of welding hours, and the labor costs involved
in the production process.
■ In order to estimate the cost of producing tack welding components, a
thorough examination of every aspect of the manufacturing process is
necessary.

4. THE ROLE OF COST MODELS IN DESIGN
FOR MANUFACTURE
■ When estimating the production costs of tack welding components, cost
models are a critical component of Design for Manufacture (DFM).
■ Manufacturers are given insightful information about the production process
through the use of cost models in DFM, which empowers them to make wise
choices regarding the design and manufacturing process.
■ When creating designs with specific cost objectives or when choosing the
best manufacturing methods for a particular part and optimizing it for those
methods, designers require information on manufacturing cost.
■ Because of this, designers need to be able to calculate the costs of various
concepts to conduct trade-off analyses.

5. THE ROLE OF COST MODELS IN DESIGN
FOR MANUFACTURE
■ Experienced designers frequently rely on unwritten rules to estimate the cost
of manufacturing designs and to maximize their ability to be manufactured.
Design experience is extremely valuable, but it also has its limitations.
■ To sum up, the use of cost models in DFM for the estimation of production
cost of tack welding components gives manufacturers useful understanding
of the production process and aids in optimizing the design and
manufacturing process to cut costs and raise product quality.

6. REQUIREMENTS FOR MANUFACTURING
COST ESTIMATION MODELS
■ Cost estimation for manufacturing will always take time and work. To make it
worthwhile, there are two crucial conditions.
■ The cost estimates must, first and foremost, be precise enough to be used in
design decisions.
■ Second, the models must only call for inputs that the designer can easily
access during the design phase in question
■ Figure 1 shows a comparison of the final estimates of fabrication time for
three assemblies performed by production cost estimators from two
different companies.

8. REQUIREMENTS FOR MANUFACTURING
COST ESTIMATION MODELS
To be effective, manufacturing cost estimation models for the estimation of
production cost of tack welding components must meet certain requirements.
Some of the key requirements for these models include:
■ Accuracy
■ Relevance
■ Flexibility
■ User-friendly
■ Scalability
■ Data reliability

9. MANUFACTURING COST ESTIMATION
FOR BATCH PRODUCTION
■ The estimation of manufacturing costs for batch production is crucial to
determining the production costs of tack welding components. Instead of
continuously producing components, batch production involves making a set
number of them at once.
■ Setup time makes up a sizable portion of the production times because the
equipment and fixtures need to be configured for each new batch.

10. MANUFACTURING COST ESTIMATION
FOR BATCH PRODUCTION
■ in order to cut costs and raise product quality, the manufacturing process for
tack welding components in batch production needs to be optimized. Waste
can be reduced, production efficiency can be increased, and cost-effective
materials can all help with this.
■ Manufacturers can make sure that their products are reasonably priced and
competitive on the market by optimizing the manufacturing process and
taking into account all pertinent factors, including the cost of labor,
overhead costs, and raw material costs.

11. MODEL DEVELOPMENT
There are several steps involved in the development of a model for the
estimation of production cost of tack welding components:
■ Data collection: The first step in model development is to gather data on the
various factors that affect the production cost of tack welding components,
such as the cost of raw materials, labor, and overhead expenses.
■ Model selection: The next step is to select an appropriate model for the
estimation of production cost. There are several types of models that can be
used for this purpose, such as regression models, simulation models, and
activity-based costing models.

12. MODEL DEVELOPMENT
■ Model validation: The selected model must be validated to ensure that it is
accurate and reliable. This can be done by comparing the results of the model
with real-world data, such as actual production costs.
■ Model refinement: Based on the results of the validation process, the model
may need to be refined to improve its accuracy. This may involve adjusting the
inputs or the methodology used to arrive at the results.
■ Model implementation: The final step is to implement the model in the
manufacturing process. This may involve integrating the model into existing
production software, or developing a custom solution specifically for the
estimation of production cost of tack welding components.

13. THE MANUFACTURING COST
ESTIMATION MODELS
■ The designer needs to be aware of the material costs, tooling costs, and
manufacturing companies' hourly rates for labour and equipment in order to
estimate the direct manufacturing cost of a component. Typically, it is simple
to find this information.
■ The models for tack welding, which express the amount of time needed for
various manufacturing processes, are shown in Tables 1 to 3.

17. THE
MANUFACTURING
COST ESTIMATION
MODELS
• As shown in Fig. 2, the cost models'
accuracy was evaluated by contrasting their
fabrication and assembly estimates with the
final production cost estimates from two
companies for two assemblies (5 parts and
40 parts, respectively), each with a batch
size of 20.
• The estimates are within the cost model's
tolerance for the smaller assembly, but
company B's estimate is outside the
tolerance range for the larger assembly.
• It should be noted that Company A data for
the cost models were gathered, but not
Company B.

18. CONCLUSIONS
■ As a result, estimating the production costs of tack welding components is a
crucial task that requires a thorough comprehension of the manufacturing
procedure and the variables that affect production costs.
■ For the manufacturing process to be profitable and to allow for informed
choices regarding pricing, production, and product design, accurate and
trustworthy cost estimation is crucial.

19. CONCLUSIONS
■ Manufacturers can ensure that they have a reliable and efficient tool for
estimating the production cost of tack welding components by carefully
evaluating the inputs and outputs of the cost models and by choosing the
model that is best suited to their needs.
■ estimating the production costs of tack welding components is an important
step in the design for manufacture process, and using cost models may give
manufacturers useful information and help in their attempts to simplify the
manufacturing process and boost profitability.