Want to identify the components of mold cost:
1. break down the cost components;
2. determining the formula for calculating the cost components;
3. determine the source and accuracy of the data;
4. form a model based on the previous steps.
Standardized Mold Costing Methodology:
From the mold processing From the point of view of the cost components, whether it is the design costs, material costs, profits and management costs, or debugging transportation costs and standard parts costs, as long as the patient collection of data, careful accounting, relatively easy to identify and account for; mold processing costs in the most difficult part of the processing fee, which is also the part of the manufacturers of the water is more. Processing from the initial roughing to the subsequent finishing, and then to the back of the EDM, wire cutting, polishing, etc., paid for labor and mold input, if not the relevant work experience, want to identify the corresponding cost of the difficulty is still relatively large, but can be learned from the experience of different suppliers, summarized and summarized. However, it is possible to learn from the experience of different suppliers, summarize and know the general cost composition of the parts.
Mold Supply Chain Model:
In the mold manufacturing Processing has a corresponding time cycle, through the time cycle and combined with the manufacturing process, looking for the average price on the market
Estimates can be made to get rid of certain water. For example, some positions are double shifts and some positions are single shifts, according to the breakdown given by the supplier to see if the processing time matches, so as to deduce the cost composition of the supplier.
Understand the supplier's supply chain, know his supplier's cost level in order to know the supplier's cost level. Generally speaking, the traditional mold factory has three profit points Material costs, processing costs and management costs; therefore, we must have an understanding of the price of raw materials.
Die casting mold Cost is composed of the following pieces:
- design cost;
- material costs;
- processing costs;
- management and labor costs;
- Inspection costs;
- Trial mold costs;
- Transportation costs;
- After-sales costs ;
- Taxes
Material costs and design costs are relatively visible, other costs such as manufacturing costs , debugging, transportation, validation, management costs, profits, other costs belong to the black box, should be established mold costing mechanism. Supply chain information sharing level needs to be further strengthened: such as design change information, demand forecasting etc.
A mold cost basically contains the above 9 parts of the cost, the general mold factory will also be counted on the auxiliary costs of about 5% of the mold cost, the rest is the profit part of the mold.
1. design cost:
And labor costs Closely related to the labor cost, so we need to understand the supplier's regional wage level in order to better estimate the labor cost. Mold design generally includes CAD structural design & 2D drawings, CAE flow analysis and CAM programming. However, when considering the mold design cost is usually considered only the cost of CAD and CAE.
Design Cost
Generally depending on the size of the mold, the complexity of the degree of difficulty, in fact, the mold factory quotes are different. Ningbo area generally large mold accounted for 2% of the total cost, small mold design cost 2.5% ~ 3%. General mold design engineer salary 8K ~ 12K or so, experience senior more than 10 years of large mold factory can get between 15W ~ 25W, technical minister more than 30W.
Design generally includes CAD structural design & 2D drawings, CAE mold flow analysis, CAM production department Programming.
2. material cost:
The material of die casting mold mainly includes the cost of mold frame (rack), mold core (kernel). Die frame is divided into homemade die frame and standard die frame. Due to the larger the tonnage of the mold, the greater the requirements of the mold processing equipment stroke, so most of the mold factory purchasing outsourcing The larger the tonnage of the mold, the larger the requirement for the stroke of the processing equipment, so most of the mold factories purchase outsourcing and buy standard mold frame.
The larger the tonnage of the mold, the larger the mold carrier. Generally, the larger the mold frame, the lower the cost, accounting costs in accordance with the weight of the direct accounting, but to remove the gap part of the mold feet. Mold frame material is generally 45#, 50#, 55# steel, 50# steel mold frame cost in 12~13 yuan/Kg.
According to the design life of die-casting mold
Choose the material of die frame, due to the aluminum alloy die life is generally in 8~100,000 die times, the die frame can be reused to meet the life of 30W~40W. So we need to consider the reuse of the mold frame in the daily copy of the mold.
The die times of soft mold is very low, only a few hundred die times, can not use the mold frame, directly use the core material instead.
The material cost is mainly the cost of mold frame and core. It should be noted that if the mold life has come, ready to open copy mold, need to go to identify whether the mold frame can be reused; If can be reused, then copy the mold cost can be greatly reduced. Heat treatment cost, for die casting die, heat treatment cost is also a big head, including tempering, vacuum quenching, nitriding and other steps of the cost. The specific cost of the high and low depends on the size of the supplier. SWPH13 Beilun Xingbo 8 yuan or so, a year the volume will have a preferential price of 6 ~ 6.5 yuan / Kg; Nitriding treatment of 2 ~ 3 yuan / Kg; A Shengbai's material 25 yuan or so, the agreement price of 17 yuan or so.
3. Manufacturing costs:
including machine tools, spark machines, wire cutting and other equipment costs and labor costs such as matching molds, polishing. General mold processing costs can not exceed 20% of the cost of the entire mold.
5. Inspection costs: mainly for the key dimensions of the mold, electrode, die core process inspection and subsequent factory inspection, inspection costs accounted for 1-2% of the total costs
4. Test mold transportation and packaging costs:
General mold company internal constant is 2 times trial mold index, 800T mold below trial mold cost 1-1.5%; 800T above trial mold cost 2%. Aluminum alloy die casting trial mold cost is relatively cheap, and magnesium alloy die casting trial mold cost will be higher, because magnesium alloy on the material safety performance requirements are higher; magnesium alloy material unit price is higher; plus magnesium alloy die casting furnace and aluminum alloy is not the same. It should be noted that the general trial mold
The number of times should not be more than 3 times, if more than 3 times, the cost of the trial mold should be borne by the mold factory itself, because it is due to their mold itself has a problem only led to the need for multiple trial mold. In addition, the parameters of the equipment must be debugged accurately to ensure that the trial mold smooth.
Transportation cost depends on the customer's geographical distribution, generally 0.5%, 1.5% for long distance. Moulds belong to heavy goods, a single transport may be a car can only be loaded with a mold, so the cost of transport will be higher.
5. After-sales service and taxes:
After-sales service costs generally account for 5% of the special requirements except for molds.
Taxes are generally removed from the material credits the company will have to bear 9%.
The above costs basically represent 90% of the mold company's offer status, the general gross profit at 15% -18%.
Remove equipment depreciation, bank loans, pension insurance Factors such as to ensure that 5% -8% of the net profit mold company is quite good.