Introductory Presentation

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

� 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 Case Study 1

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 Case Study 2

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 Exemplary Use Case

Value stream mapping

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

Reference Customers

Appendix:

Software - Screenshots

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

CALC4XL Calculators

1. Project Specification Calculator

Country Data:Footprint, Energy, imputed Interest

Overhead Factors dependent on Country, Industry, Product and Company Size

Every Dataset is rewritable

Open CALC4XL Calculators by:- Click in CALC4XL Menu (NEW calculator)- Double-Click in a linked Excel cell

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

Option 1: Use CALC4 XL Excel Calculation Templates� 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

Example for Option 1Detail Calculation in CALC4 XL Cost Breakdown

Linked Overhead Factors, Material Costs, Wage Rates, Mashine Hourly Rates and Cycle Times from

CALC4XL Database and CALC4XL Cycle Time Calculators (e.g. injection molding).

− Customizable to your needs; Secured by System of Roles and Rights

− Double-Click in linked Excel cell opens realted CALC4XL Calculator

Overheads

Wages

Machines

Cycle Times

Materials

Linked Excel Cells:

Option 2: UseYour Own Excel FilesLink CALC4XL Calculators to your own File by

� Right Mouse Click (Main Output Value) or� Button in Menu-Ribbon (Main Output Value) or� Use Link Mode of Calculators (all Values)

3: Click in an Excel cell

Usage of CALC4 XL Calculators

2

1

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?