TML Norms for existing supplier
Sl No
1
2
3
4
5
6
7
8
9
Part Name
Validity
Material
1
1
1
1
E34
E34
E34
E34
Outer Link
Inner Link
Damper Bracket
Spring Seat
Tube - OD 51 x 4.5 mm
THK
Reinf outer
Reinf Inner
Reinf plate
Bracket Br Hose Mtg
CEW
1
1
1
1
E34-1.60
E34-1.60
E34-1.60
DD1079
Thk
3.15
2.50
2.50
2.50
1.60
1.60
1.60
2.00
Scrap Rate
Net RM
Cost
36.30
36.30
36.30
36.30
2.302
1.897
0.564
1.881
1.480
1.199
0.330
0.960
18.00
18.00
18.00
18.00
68.77
56.30
16.26
51.70
65.03
0.262
0.274
0.275
0.198
0.049
0.215
0.180
0.210
0.191
0.030
18.00
18.00
18.00
18.00
18.00
32.38
RM Rate
36.30
36.30
36.30
36.30
I/p wt
F wt
8.25
8.81
7.06
1.44
250.97
[Link] Process details
Sl No
M/c T
No of
strokes
Rate/
stroke
Cost
Blank & Piercing
Forming I
250.00
250.00
1.00
1.00
1.00
1.00
1.65
1.65
Forming II
250.00
1.00
1.00
1.65
Restrike
250.00
1.00
1.00
1.65
Piercing
200.00
0.50
0.75
0.38
Drain hole piercing
200.00
0.50
0.75
0.38
Blank
Blank
Forming I
200.00
200.00
250.00
0.50
0.50
1.00
0.75
0.75
1.00
0.38
0.38
1.65
Forming II
250.00
0.50
1.00
0.83
Restrike
Cam trimming
Restriking
200.00
200.00
200.00
1.00
1.00
1.00
0.75
0.75
0.75
0.76
0.76
0.76
Blanking
200
200
1.00
1.00
0.75
0.75
Notching
100
1.00
Forming I
100
1.00
-ve forming
100
Forming II
100
Restriking
Cam piercing
Part Name
Outer Link
Process
7.36
Inner Link
5.14
Damper Bracket
0.76
0.76
0.25
0.25
0.25
1.00
0.25
0.25
0.50
0.25
0.13
100
0.50
0.25
0.13
100
0.50
0.25
0.13
0.25
1.89
Spring Seat
Parting
Draw-1
100.00
160.00
1.00
0.50
0.25
0.48
0.25
0.24
Draw-2
200.00
0.50
0.75
0.38
Draw-3
200.00
0.50
0.75
0.38
Piercing
160.00
0.24
200.00
200.00
100.00
200.00
0.50
0.50
0.50
0.50
1.00
0.48
Trimming
Collar Forming
Notching
U-Forming
0.75
0.75
0.25
0.75
0.38
0.38
0.13
0.76
3.14
Tube
3.37
Blank & Pierce
Blank & Pierce
Forming
160.00
160.00
Restrike
160.00
100.00
160.00
1.00
1.00
0.50
0.48
0.48
0.50
0.48
0.25
0.48
0.48
0.24
0.48
Reinf outer
Notching
0.50
0.24
0.13
4.94
Blank & Pierce
Forming
160.00
160.00
160.00
1.00
1.00
0.50
0.48
0.48
0.48
0.48
0.48
0.24
Restrike
Notching
160.00
0.50
0.48
0.24
160.00
0.50
0.48
0.24
Blanking & Piercing
75.00
75.00
1.00
1.00
0.19
0.19
0.19
0.19
Forming
75.00
1.00
0.19
0.19
Blanking & Piercing
Forming
50.00
50.00
50.00
1.00
1.00
0.13
0.13
0.13
Reinf Inner
1.20
Reinf plate
0.38
Bracket Br Hose Mtg
1.00
0.13
0.13
0.13
0.26
Total Main Process cost
2. Welding Details
Sl no
Process
No of Tacks/Length
1
2
Tack welding - Spring seat
Tack welding - Assy links welded
3
5
5
Robo welding - Spring seat
Robo welding - Assy Links welded
Assy STA
Rate/Tack
Cost
34.00
1,530.00
0.08
0.0165
2.72
25.25
34.00
18.00
0.15
0.15
5.10
2.70
7.65
43.41
[Link] Process cost
Sl no
1
Process
Powder coating
Unit
Sq m
Values
0.472
Rates
90.00
Cost
42.48
42.48
Conversion
108.62
Total RM+Conversion
359.59
Overhead & Profit will be added as per norms
Packing & Transportation as actual will be added
Bigger Dia
Investment For Project "NANO STA (Petrol)
Sr.
A
Description
Land & Building
1 Building
Land & Building A
Machineries & Other Equipment
1 Machineries & Equipment
1 Welding Robot with synchronisation
2 MIG welding Machines (500 KVA)
3 Spot Welding Guns (IT)
5 Material Handling trolleys & Bins (Internal, dispatch & CED)
Building and Machinary
Tooling Cost
Total Project Cost
Total Project Cost Rs. In Lacs
Qty / Dimn.
500 SQ. MTS
Qty / Dimn.
1 nos
5 nos
2 nos
rol)
Rate
4976500
Rate
2800000
110000
325000
Amount Amortisation
4976500
4976500
Amount
2800000
550000
650000
1350000
5350000
Sub-Total 10326500
22472287 22472287
22472287
17.92 Proj. cost interest and depreciation.
112.36 Tool Amortisation on 1 lakhs sets
32798787
327.99
130.28
Investment in Toolings and Fixtures.
Part Number: 2834 3240 0167 / 0168
Part Name: Assy Semi Trailing Arm RH/LH
2834 3240 8242 / 8243
Reinf Outer link RH / LH
1 Blank & Pierce (Common for LH/RH)
2 Form I (LH/RH together)
3 Form II (LH/RH together)
4 Bend & Restrike (LH/RH together)
5 Notch (LH/RH together)
6 Panel Checking Fixture (LH / RH together)
TOTAL
2834 4230 8203
Brake hose mounting bracket
1 Blank
2 Notch / Pierce & Bend (2 Stage)
3 Panel Checking Fixture
TOTAL
148513
137712
156073
156073
100295
60000
758666
37803
43204
10000
91007.29
Closing Plate LH / RH
1 Blank & Pierce
2 Form
3 Panel Checking Fixture
TOTAL
86794
86794
30000
203587
2834 3240 3318 / 3319
Damper Mounting Bracket LH / RH
1 Blank & Pierce (Common for LH/RH)
2 Form I (LH/RH together)
3 Form II (LH/RH together)
4 Restrike (LH/RH together)
5 Horn Pierce (LH / RH together)
6 Panel Checking Fixture (LH / RH together)
TOTAL
135784
191267
191267
151889
84865
40000
795072
Reinforcement Inner Link LH/RH
1 Blank & Pierce (Common for LH/RH)
2 Form I (LH/RH together)
3 Form II (LH/RH together)
4 Restrike (LH/RH together)
5 Notch (LH/RH together)
6 Panel checking fixture (LH/RH together)
TOTAL
2834 3240 8240 / 8241
STA Outer Link LH/RH
1 Blank & Pierce (Common for LH/RH)
205733
306028
459041
459041
313421
60000
1803264
381892
2 Form I (LH/RH together)
3 Form II (LH/RH together)
4 Restrike LH
5 Restrike RH
6 Notch & Pierce (LH/RH together)
7 Horn Pierce (LH/RH together)
8 Panel Checking Fixture (LH/RH together)
TOTAL
541013
601126
385749
385749
413716
306028
80000
3095271
Spring Seat Rear LH/RH
1 Draw 1 (LH/RH together)
2 Draw 2 (LH/RH together)
3 Trim & Pierce LH
4 Trim & Pierce RH
5 Form I (LH/RH together)
6 Form II (LH/RH together)
7 Restrike LH
8 Restrike RH
9 Panel Checking Fixture (LH/RH together)
TOTAL
360032
1440130
338495
338495
433968
433968
238682
238682
70000
3892451
2834 3240 8244 / 8245
STA Inner Link LH/RH
1 Blank & Pierce (Common for LH/RH)
2 Form I (LH/RH together)
3 Form II (LH/RH together)
4 Restrike LH
5 Restrike RH
6 End Trim & Notch (LH/RH together)
7 Panel Checking Fixture (LH/RH together)
TOTAL
668632
822931
925798
720065
720065
555479
90000
4502969
ASSLY RELATION GAUGE FOR STA LH
ASSLY RELATION GAUGE FOR STA RH
Total Cost of Press Tools & Panel checking fixtures
WELDING FIXTURE COST (12 welding fixtures)
ROBOT & WELDING FIXTURE INTEGRATION
TOTAL TOOL
COST
415000
415000
758666
91007.29
203587
795072
1803264
3095271
3892451
4502969
830000
15972287.08
5500000
1000000
22472287.08