UltraLight Steel Auto Body - Final Report - American Iron & Steel ...

5.3 Model scope
5.4 ULSAB results
ULSAB Final Report
This cost model accounts for economic and technical processes
used in the manufacture and assembly of the body structure.
Data for stamping include blanking, welding of tailored blanks
and stamping for all parts; data for hydroforming include bending,
pre-forming and final hydroforming; and data for assembly
include spot welding, MIG welding, laser welding and adhesive
bonding.
This model is limited to direct manufacturing costs, which include
fabrication and assembly of the body structure. Indirect
manufacturing costs — executive salaries, marketing and sales,
shipping and purchasing, research and development, profits - are
not considered.
Cost is assigned to each unit operation from a process flow
diagram and then those operations are separated into individual
elements. Fixed cost elements include equipment, tooling,
building maintenance, overhead labor and cost of capital;
variable cost elements include materials, labor and energy.
Manufacturing costs for the ULSAB structure are $666 for parts
fabrication and $281 for assembly. Of the 158 total parts, 94
ULSAB results
ULSAB cost in $US % of Total
PARTS FABRICATION 584 62
material 351 37
labor 36 4
energy 6 1
fixed 191 20
HYDROFORMING 41 4
PURCHASED COMPONENTS 41 4
ASSEMBLY 281 30
variable 55 6
fixed 226 24
TOTAL COST 947 100
45