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Title:Feature based costing of extruded parts
Author(s):Torre Nieto, Jose
Advisor(s):Philpott, Michael L.
Department / Program:Mechanical Sci & Engineering
Discipline:Mechanical Engineering
Degree Granting Institution:University of Illinois at Urbana-Champaign
Subject(s):Feature Based Costing
Design for Manufacture (DFM)
Manufacturing Cost Estimation
Abstract:This thesis presents the creation of a model to predict the manufacturing cost of parts made by the extrusion process. Feature Based Costing (FBC) techniques have been used to develop the cost model, which is intended to be used early in the design phase of a part, when the geometry and the material are being defined in a Computer Aided Design (CAD) software by the designer. The cost model was developed specifically for hot extruded parts made of aluminum alloys, extruded in the forward direction using single-hole dies, as this was found to be the case for the majority of extrusion work in the industry. As the cost model is developed, the main Geometric Cost Drivers (GCDs) and Non-Geometric Cost Drivers (NGCDs) of a part made by the hot extrusion process are identified. The main outputs of the model include the Piece Part Cost (broken down into its various recurring costs components), the Amortized Investment (i.e. Amortized Tooling Cost) and ultimately the Manufacturing Cost. The Piece Part Cost estimation includes an algorithm for selecting the optimal combination of press and billet size to extrude a given shape. Extrusion speed, cycle time and yield are all calculated by the model as well. The Piece Part Cost Model was validated against actual quotes data from extruders in the US for a number of different designs. The model predictions were shown to correlate within 3% to the actual quotes. Unlike the Piece Part Cost, the Tooling Cost part of the model is of empirical nature, obtained by Multivariate Regression techniques from actual quotes data provided by extruders in the US. The Tooling Cost Model was validated statistically, and it was shown to explain 84% of the variance observed in the actual quotes. Finally, the complete Manufacturing Cost Model developed herein was successfully implemented in a Computer Spreadsheet, which is included as a supplemental file for this thesis, representing a fantastic tool for design engineers, manufacturing engineers and any other Design for Manufacture (DFM) practitioners in general.
Issue Date:2010-06-22
Rights Information:Copyright 2010 Jose Torre Nieto
Date Available in IDEALS:2010-06-22
Date Deposited:May 2010

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