Static Event

Cost for Manufacturing Event

1- Cost for Manufacturing Event Objective-

The objectives of the Cost and Manufacturing Event are:

To teach the participants that cost and budget are significant factors that must be considered in any engineering exercise.

  • For teams to make trade-off decisions between content and cost based on the performance advantage of each part and assembly.

  • To gain experience with creating and maintaining a Bill of Material (BOM).

  • For the participants to learn and understand the principles of Design for Manufacture and Assembly, lean manufacturing and Minimum Constraint Design.

2- Rules Objective The objectives of the Cost and Manufacturing Event rules are:

  • To provide a logical, simple and time-efficient rule set enabling students to achieve the event's objectives.

  • To improve fairness by providing consistent pricing guidelines independent of team geographical location by using standardized Cost Tables.

  • To require the minimal burden of supporting documentation such as receipts or catalog pages. However, in order to convey design information to cost judges engineering documentation (drawings, process descriptions, etc.) are required.

3- Event Requirements This event is comprised of three (3) parts

Part 1 "Cost Report Document"-The preparation and submission of a report (the "Cost Report Document"), which is to be sent which is to be submitted.

Part 2 "Discussion" -A discussion at the Competition with the Cost Judges around the team's kart. This evaluates not only the cost of the car but also the team's ability to prepare accurate engineering and manufacturing cost estimates.

Part 3 "Real Case" -A "real case" scenario where students will have to respond to a challenge related to the cost or manufacturing of the student vehicle.

4- Definitions The following definitions will apply throughout the Cost Event rules:

  • Adjusted Cost – The final cost for the vehicle including penalties.

  • Amended Cost – The cost of the vehicle after modification by the competition addendum.

  • Bill of Material – A hierarchical list of all parts of the vehicle.

  • Cost Report – All materials, including electronic and hard copy, submitted for judging.

  • Cost Score – Refers to the total number of points out of 100 earned in the Cost Event.

  • Cost Tables – All tables that list costs for objects and processes.

  • Design for Manufacture and Assembly (DFMA) – The process where parts are designed for ease of manufacture and assembly, resulting in lower cost.

  • Fixed Cost – Costs associated with production that is independent of volume produced. Fixed cost items, such as tooling, are converted to variable costs when included in the Cost Report.

  • Initial Cost – The cost of the vehicle submitted for initial judging in the Cost Report.

  • Lean Manufacture – A methodology for producing goods that emphasizes the elimination of waste and improvement in process flow with the goal of optimizing the cost and quality of goods.

  • Minimum Constraint Design (MCD) – A design methodology emphasizing the elimination of redundant constraints in the attachment of parts. Each part requires constraint in six degrees of freedom and additional constraints can make assembly difficult, force tight tolerances and increase the cost of manufactured goods.

  • Purchased Parts – Also called bought parts; these items are listed in the Cost Tables in a near - installed condition. For example, wheels, engines, and motors are purchased parts. In some cases, purchased parts may still require additional processing before they can be assembled to the car. Wheels, for example, do not include the machined features for mounting to the hub. Purchased parts do not include fasteners unless specifically noted in the Cost Tables.

  • Quantity – The amount of the item

  • Raw Materials – Materials used for manufacturing parts, such as aluminum, steel and rubber hose.

  • Tools – Tools refer to hand or power tools used to assemble the vehicle. The costs of these tools are not included in the Cost Report. The effects of the tools used for assembly are captured in the process tables for labor as different costs are given based on the tools used for assembly.

  • Variable Cost – This is a cost associated with production that is proportional to the vehicle volume produced. All costs submitted with the Cost Report will be variable costs.

5- General Requirements- The Cost Report Document Must:

a- Use the standardized Cost Tables available in your account.

b- List and cost every part of the prototype vehicle. This includes any equipment fitted on the vehicle at any time during the competition. The cost of any onboard fire suppression system, rain tires, video or radio system, and transponder does not need to be included in the Cost Report Document.

c- Be based on the estimated costs of materials, fabrication purchased parts, and assembly of the kart. The costs must be calculated as defined in these rules.

d- Be based on the actual manufacturing technique used on the prototype.

e- Include tooling (e.g. welding jigs, molds, patterns, and dies) for processes requiring it.

f- Exclude R & D and capital expenditures (e.g. plant, machinery, hand tools, and power tools). There is no maximum cost. Receipts are not required for any items.

The Cost Tables have been designed to:

  • Be verifiable at the event. Differentiating between different types of materials (for example different alloys of steel) is not possible so no differentiation is made in the table cost.

  • Minimize influence on safety equipment content. For example, driver harnesses are cost independent of the style chosen.

  • Higher costs of some goods must reflect actually higher value of those goods. However, the costs must still allow for team innovation and vehicle content, with some reduction in cost score.

Note: Additional information about the Cost and Manufacturing Event including Cost Tables and other information may be obtained from the team account.