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

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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
46 5.4.1 Fabrication breakdown 5.4.2 Assembly breakdown Total fabrication costs can be broken down further. Major stamped components account for $584. Fabrication breakdown Breakdown for stamped parts Cost per structure in $US material 351 labor 36 energy 6 TOTAL VARIABLE 393 equipment 89 tooling 51 overhead labor 27 building 8 maintenance 15 working capital 1 TOTAL FIXED 191 TOTAL COST 584 Assembly accounts for about one-third of the overall cost. The largest single items are labor and assembly line equipment. Assembly breakdown Breakdown for assembly cost per vehicle in $US material 0 labor 45 energy 10 TOTAL VARIABLE 55 equipment 50 tooling 23 overhead labor 125 building 18 maintenance 9 working capital 1 TOTAL FIXED 226 TOTAL COST 281 ULSAB Final Report
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UltraLight Steel Auto Body Final Re
Page 4 and 5:
Contents Preface v Introduction vii
Page 6: Preface One of the challenges in re
Page 9 and 10: viii Validation Results During the
Page 12 and 13: 1.1 Benchmarking ULSAB Final Report
Page 14 and 15: 1.2 Design philosophy and architect
Page 16 and 17: ULSAB package drawing front view UL
Page 18 and 19: 1.5 Material selection The selectio
Page 20 and 21: Steel sandwich material was chose f
Page 22 and 23: ULSAB parts list Material Material
Page 24 and 25: ULSAB parts list (cont.) Material M
Page 26 and 27: 280 MPa 2.1 Materials 210 MPa ULSAB
Page 28 and 29: Tailored blank usage Tailored blank
Page 30 and 31: 2.2 Processes 2.1.3 Steel sandwich
Page 32 and 33: 2.2.2 Assembly laser welding Sheet
Page 34 and 35: 3.1 Early involvement 3.2 Tooling 3
Page 36 and 37: Floor complete assembly: the rear r
Page 38 and 39: ULSAB Final Report 3.5.2 Adhesive b
Page 40 and 41: 4.1 Validation 4.2 CAE Analysis 4.
Page 42 and 43: ULSAB Final Report All simulations
Page 44 and 45: ULSAB Final Report The offset barri
Page 46 and 47: ULSAB Final Report Analysis was set
Page 48 and 49: ULSAB Final Report Side impact set
Page 50 and 51: 4.3 Physical testing ULSAB Final Re
Page 52 and 53: Frequency Hz Model Analysis ULSAB S
Page 54 and 55: 5. Economic Analysis Although light
Page 58 and 59: 5.4.3 Investments 5.5 Sensitivity a
Page 60 and 61: Comparison of ULSAB with Year 2000
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UltraLight Steel Auto Body - Final Report - American Iron & Steel ...

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