sirris manufacturingday2011 automated-calculation-cetim
DESCRIPTION
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.TRANSCRIPT
Manufacturing Day May 10th, 2011
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Automated cost calculation of complex parts – L. Berteloot
TechniQuote
Automated cost calculation of complex parts
L. BertelootSoftware Department manager
Cetim - France
Manufacturing Day May 10th, 2011
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Automated cost calculation of complex parts – L. Berteloot 0706
-05-
GB
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Automated cost calculation of complex parts – L. Berteloot
Governed by Articles L342.1 to L342.13of the Code of Research
Steered by mechanical industrialistsunder the State’s supervision
Founded in 1965
700 people with 56% engineers
The French Technological Institute for mechanics
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Automated cost calculation of complex parts – L. Berteloot
MechatronicsInspection
Measurement
Sustainable development
Materials - Processes
Design SimulationTests
4 Technological
axes
Making Technological choices for the future
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Automated cost calculation of complex parts – L. Berteloot
Permanent information
15 technical days60 mechanical mondays
2 international congresses
More than 30 000technical calls/year
800 participants to flash Midest lectures
30,000 visitors every month
30 new performance reports10 new issues/year
Catalogues: Training, Publishing, Software
Transfering of Technology to mechanical Small and Medium Companies
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Automated cost calculation of complex parts – L. Berteloot
Automated cost calculation for complex parts
Manufacturing Day May 10th, 2011
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Automated cost calculation of complex parts – L. Berteloot
Introduction
TIME, COST and PRICE • 3 different terms for a single concept COSTING
Remark : Time will be also used for Delay
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Automated cost calculation of complex parts – L. Berteloot
Costing of complex parts
A part is complex by: Geometry Precision Quantity of detailsManufacturing 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
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Automated cost calculation of complex parts – L. Berteloot
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
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Automated cost calculation of complex parts – L. Berteloot
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
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Automated cost calculation of complex parts – L. Berteloot
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)
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Automated cost calculation of complex parts – L. Berteloot
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)
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Automated cost calculation of complex parts – L. Berteloot
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,…)
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Automated cost calculation of complex parts – L. Berteloot
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
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Automated cost calculation of complex parts – L. Berteloot
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
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Automated cost calculation of complex parts – L. Berteloot
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.
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Automated cost calculation of complex parts – L. Berteloot
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
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Automated cost calculation of complex parts – L. Berteloot
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
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Automated cost calculation of complex parts – L. Berteloot
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
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Automated cost calculation of complex parts – L. Berteloot
How to choose your approach ?
Projects
Parts
Process
Operations
X 10Analogical
X50 StatisticalFew information
Maxi of information
Analytical
X 1
Parametrical
Risk reduction
Setting-up
Change control
Parametrical
IntuitiveX 1
X50X 1
X 1
Analytical
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Automated cost calculation of complex parts – L. Berteloot
Advantages / disadvantages
Intuitive Analogical Analytical Parametrical Statistical
Precise evaluationReliability
SensitivenessRight price
Implementation
Set-up easiness
Automation
Technical Level
Budget and resources
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Automated cost calculation of complex parts – L. Berteloot
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
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Automated cost calculation of complex parts – L. Berteloot
Study-case : automated cost calculation
from CAD file to Costing in few clicks !
• Cetim TechniQuote analytical automatic/interactive
Video
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Automated cost calculation of complex parts – L. Berteloot
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
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Automated cost calculation of complex parts – L. Berteloot
Thank you for your attention
Cetim52, Avenue Félix-Louat
France - 60 304 Senlis Cedex
Laurent BERTELOOTTel : (+33) 3 44 67 47 79
Mail : [email protected]