Cost Model - Work Step Calculator

You can use the Work Step Calculator cost model to calculate the process times and costs of workflows that are performed by a worker or are only partially automated.

A detailed schedule helps indicate options for cost-saving measures.

The Work Step Calculator cost model lets you:

  • Enter cycle times for work steps in detail
  • Manage work steps in the master data
  • Reuse work steps you created in the master data or create new ones in the calculation.

Procedure

The following example illustrates the process and structure of the Work Step Calculator cost model.

Tip

The black triangle helps you identify values that you can enter .

The Consistency Rule Violation check is available to you when entering values. The consistency rule violations check notifies you of missing values and verifies the accuracy of the values entered.

When you hover over one of the Consistency rule violations icons with your mouse, a tooltip appears with the specific reason for the consistency rule violations.

Step 1: Create Should Cost Calculation

Create Should Cost Calculation

  • You are logged in as Calculator.
  • You are in the Calculations workspace.
  1. In the ribbon, click on Manage.
  2. Select the Should Cost Calculation.

    The created calculation opens in a new tab.

    You are the owner of the calculation that was created.

  3. Define the following properties for the Should Cost Calculation in the Details view:
    4. Reference Company*
    Industrial Sector Manufacture of fabricated metal products, except machinery and equipment
    Production Location World » Europe » Germany
    Reference Company Plant Revenue 100m EUR
    Reference Company Material Share 50%
    Reference Company Degree of Automation Medium
    Production Planning
    Production Quantity 100,000 pc / a
    Target Profit Rates
    Target Profit Rate on Raw Material 2 %
    Target Profit Rate on Purchased Material 2 %
    Target Profit Rate on Manufacturing 2 %

    * Values are determined for the following properties using value rules based on your inputs under reference companies:

    • Material Overhead Rate
    • Manufacturing Overhead Rate
    • Administrative Overhead Rate
    • Sales Overhead Rate
    • Development Overhead Rate
    • Logistics Overhead Rate

Step 2: Insert Process

Insert Process

  1. In the Structure view, select the calculation element you wish to insert under the process.
  2. Click Edit ► Insert ► Process in the ribbon.

    A process is inserted in the calculation structure.

  3. Change the label to »Work Step Calculator«.
  4. In the Details ► General ► Valuation view, select the valuation Cost Model: Work Step Calculator.

    Selecting the valuation allows you to insert work steps as global templates or locally.

Note

When changing valuations the sub-elements are grayed-out and no longer considered in the calculation.

Step 3: Insert Work Steps

A manufacturing process requires a number of individual work steps. FACTON offers you the option of breaking down a process into multiple work steps and performing a detailed cost analysis.

Note

You can insert the work step as a master data using queries (see Insert Global Calculation Element) or insert your own work step locally (see Insert Local Calculation Element).

The latter is shown in the following, because it illustrates the inputs required for calculation.

Insert Work Steps

  1. In the Structure view, select the »Work Step Calculator« process .
  2. In the ribbon, click on Edit ► Insert ► Insert New Local Work Step.

    A work step is inserted under the process.

  3. Change the label to »Pick up part«.
  4. In the Details view, enter a value for the following properties of the work step:
    General
    Name»Pick up part«
    Procedure duration *»7 TMU«
    Repetitions»2 1/cycle«
    Technical description
    TMU work step categoryBasic movement - finger, hand, arm system » Grasp
    * The procedure duration can be entered in TMU or directly in seconds.

    TMU (Time Measurement Unit) is the term used to refer to the unit of time in MTP process modules.

    One TMU is 10^-5 hours.

    These values are required in order to calculate the Total Procedure Duration.

  5. Repeat steps 1 through 2 to insert a new work step.
  6. Change the name to »Place part«.
  7. In the Details view, enter a value for the following properties of the work step:
    General
    Name»Place part«
    Procedure Duration *»30 TMU«
    Repetitions»2 1/cycle«
    Technical Description
    TMU Work Step CategoryBasic movement - finger, hand, arm system » Position
    * The procedure duration can be entered in TMU or directly in seconds.

    TMU (Time Measurement Unit) is the term used to refer to the unit of time in MTP process modules.

    One TMU is 10^-5 hours.

    These values are required in order to calculate the Total Procedure Duration.

Work step properties

General group

This group shows the general work step properties.

Properties Description Input
Possible		 Calculated
 Required
Name Work Step Name Direct   x
Relevant Quantity Displays the relevant quantity in s / cycle   x  
Procedure Duration The time needed for performing the procedure. Direct   x
Repetitions The number of repetitions of the procedure. Direct    
Total Procedure Duration

The time needed for performing the work step including all repetitions
It is calculated taking the:

  • Procedure Duration
  • Repetitions
   x  

Technical Description Group

This group displays and maintains the technical descriptions of the work step, such as label and description.

The Work Step Type property is initially defined by »TMU work step«.

Technical Description ► Subgroup Work Step Type Properties

You can assign the work step to a TMU Work Step Category in this technical description subgroup. The categorization of the TMU work step categories is based on the MTM standard time value card.

Note

In the queries for the work steps you can use the TMU Work Step Category and the Key to find the work steps.

Step 4: Insert Worker

Insert Worker

  1. In the Structure view, select the »Work Step Calculator« process.
  2. In the ribbon, click on Edit ► Insert ► Worker.

    The corresponding labor costs for the worker are determined based on the sector, the reference location, the reference date and the labor group.

Calculated values of the Work Step Calculator:

The following values are calculated using the data entered and then shown in the Details ► General ► Cost Model view:

  • Cycle Time
  • Ʃ Measure Values Cycle Time
  • Cycles per Time
  • Output per Cycle
  • Output per Time
  • Time per Unit Output
  • Manufacturing Scrap Rate
  • Production Cost