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
1.Main 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
3.Other 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