Cost Models - Powder Compaction and Sintering

Powder metallurgy comprises two independent processes (powder compaction and sintering), that can run separately from each other. However, both processes are required in order to create a finished product.

You can use the two cost models Powder Compaction and Sintering to calculate the process times and cost in metalworking for the powder compaction and sintering manufacturing processes. In FACTON, there are value rule tables, and at the cost model formulas are defined that provide you with information on:

  • The anticipated cycle time,
  • the possible process output per time and cycle,
  • the material consumption
  • the press force of the machine and
  • primary and secondary processing times.
Note

You need knowledge of the Powder Compaction and Sintering manufacturing process in order to use the cost model.

Procedure

The following example illustrates the process and structure of the Powder Compaction and Sintering 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 Production Line

Create a production line for the two cost models Powder Compaction and Sintering.

Insert Production Line

  1. In the Structure view, select the calculation element under which you want to insert the production line.
  2. Click Edit ► Insert ► Production Line (Piece) in the ribbon.

    A production line is inserted into the calculation structure.

Step 3: Insert Process for Powder Compaction

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 »Powder Compaction«.
  4. Define the following properties for the process in the Details view:
    5. Technical Descriptions
    Material Classification*
    Manufacturing Method* Primary Shaping » Sintering and Powder Compaction
    * FACTON recommends the appropriate materials and machines in the queries for the processes by allowing you to select the material classification and manufacturing process.
  5. In the Details ► General ► Valuation view, select the valuation Cost Model: Powder Compaction.

    A new Cost Model group appears with subgroups.

Note

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

Step 4: Describe Part

The part properties are required to determine the cycle time.

Describe Part

  1. In the Structure view, select the process »Powder Compaction«.
  2. Enter the following values for the part in the Details ► Cost Model ► Part view.

    These values are required in order to calculate additional values:

    3. Additional values are calculated based on the input values for the part and shown at the process »Powder Compaction« under Details ► General ► Cost Model.

Part Property Group Calculated Value
Projected Area of Part Press Force
  • Specific Press Power
  • Necessary Press Force
  • Relevant Press Force
Mechanical Requirement
Part Complexity Machine Relative Stroke Frequency

Step 5: Insert Machine for Powder Compaction

You can use the Relevant Press Force to determine the required machine and insert it.

To calculate the number of cavities, values must be entered at the machine for the Machine Type, Press Force and Stroke Frequency properties.

Note

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

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

Insert Local Machine

  1. Select the »Powder Compaction« process in the Structure view.
  2. Click Edit ► Insert ► Insert New Local Machine in the ribbon.

    A machine is inserted under the »Powder Compaction« process.

  3. Change the label to »Powder Press«.
  4. Under Details ► Technical Description ► Machine Type, select a machine type for the »Powder Press«.
    Note

    You can use the following machine type with the cost model:

    • Powder Metal Press

    The Machine Type Properties group appears under Technical Description.

  5. In the Details ► Technical Description view, enter a value for the following properties:
    • Press Force
    • Stroke Frequency
  6. Define the following properties for the machine in the Details view:
    Acquisition Costs
    Acquisition Value 100,000 EUR
    Fixed Machine Costs
    Depreciation Period6 a

Calculated values of the Powder Compaction cost model:

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
  • Is Slowest Process
  • Manufacturing Scrap Rate
  • Production Cost

Step 6: Insert Process for Sintering

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 »Sintering«.
  4. Define the following properties for the process in the Details view:
    5. Technical Descriptions
    Material Classification* Basic Materials » Metal » Steel
    Manufacturing Method* Primary Shaping » Sintering and Powder Compaction
    * FACTON recommends the appropriate materials and machines in the queries for the processes by allowing you to select the material classification and manufacturing process.
  5. In the Details ► General ► Valuation view, select the valuation Cost Model: Sintering.

    A new Cost Model group appears with subgroups.

Note

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

Step 7: Insert Material for Sintering

Values must be entered at the material for the Material Usage Weight and the Material Classification properties in order to calculate the primary processing times.

Note

Values are determined for the following properties using value rules by selecting the material classification:

  • Unwaxing Time
  • Sintering Time
  • Cooling Time

You can view the properties at the »Sintering« process under Details ► General ► Cost Model ► Primary Processing Times.

Note

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

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

Insert Local Material

  1. Select the »Sintering« process in the Structure view.
  2. Click Edit ► Insert ► Insert New Local Material (Mass).

    A local material is inserted under the »Sintering« process.

  3. Change the label to »Sintering material«.
  4. Under Details ► Technical Description ► Material Classification, select a material classification.
    Note

    You can use the following material classification with the cost model:

    • Steel
    • Heavy Metal
    • Copper
    • Alnico
    • Ferrite
    • Molybdenum
    • Tantalum
    • Tungsten
    • Tungsten Carbide
    • Light Metal
    • Titanium Alloy

    The Material Classification Properties group appears under Technical Description.

  5. Define the following properties for the material in the Details view:
    General
    Price per Unit 1.50 EUR / kg
  6. Select the »Sintering« process in the Structure view.
  7. Enter a value (e.g. 0.50 kg) in the Details ► Cost Model ► Material ► Material Usage Weight view.
  8. Activate the value for Details ► Cost Model ► Primary Processing Times ► Requires Unwaxing.

Values are determined at the process in the Cost Model ► Primary Processing Times group for the following properties using value rules based on the material classification:

  • Unwaxing Time
  • Sintering Time
  • Cooling Time

Step 8: Insert Machine for Sintering

You can use the Material Usage Weight to determine and insert the required machine.

Values must be entered at the machine for the Machine Type and Furnace Capacity properties.

Note

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

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

Insert Local Machine

  1. Select the »Sintering« process in the Structure view.
  2. Click Edit ► Insert ► Insert New Local Machine in the ribbon.

    A machine is inserted under the »Sintering« process.

  3. Change the label to »Sintering Furnace«.
  4. Under Details ► Technical Description ► Machine Type, select a machine type for the »Sintering Furnace«.
    Note

    You can use the following machine type with the cost model:

    • Sintering Furnace

    The Machine Type Properties group appears under Technical Description.

  5. In the Details ► Technical Description view, enter a value for the following property:
    • Furnace Capacity
  6. Define the following properties for the machine in the Details view:
    Acquisition Costs
    Acquisition Value 400,000 EUR
    Fixed Machine Costs
    Depreciation Period6 a

Calculated values of the Sintering cost model:

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
  • Is Slowest Process
  • Manufacturing Scrap Rate
  • Production Cost

Step 9: Insert Worker and Tool

Insert Worker

  1. In the Structure view, select the »Sintering« 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.

Insert Tool

  1. In the Structure view, select the process »Sintering«.
  2. Click Edit ► Insert ► Insert New Local Tool.

    The tool is inserted under the process.

Properties of the Cost Model - Powder Compaction

Part Group

The part properties used to calculate the cost model are shown in this group.

Part Properties Description Input
Possible		 Calculated
 Required
Projected Area of Part The area of the part projected in the mold parting surface Direct   x
Mechanical Requirement Selection of the mechanical requirement of the part Direct   x
Part Complexity Selection of the complexity of the geometry and shape of the part Direct   x

Press Force Group

The press force properties used to calculate the cost model are shown in this group.

Pressure Properties Description Input
Possible		 Calculated
 Required
Specific Press Power

Necessary press power depending on the mechanical requirements of the part
Depends on the selection of:

  • Mechanical Requirement

with F12

    
Necessary Press Force

Necessary press force without surcharges
Is calculated from:

  • Specific Press Power
  • Projected Area of Part
   x  
% Additional Press Force Percentaged additional press force
Calculated when entering a value for the surcharge for press force		 Direct    
Additional Press Force Absolute additional press force
Calculated when entering a value for the percentaged additional press force

Direct

    
Relevant Press Force

Necessary press force including all surcharges
Is calculated from:

  • Necessary Press Force
  • Additional Press Force
   x  

Machine

The machine properties used to calculate the cost model are shown in this group.

Machine Properties Description Input
Possible		 Calculated
 Required
Machine Type Assignment of a machine to a specific group with the corresponding properties
This value is required in order to manage additional machine type properties. It can be managed at the machine (Details view ► Technical Description), or is applied when global templates are inserted.

 

 

 x
Press Force of the Machine

Maximum shot volume of the machine that is available

This value is required and can be managed at the machine (Details View ► Technical Description ► Machine Type Properties), or is applied when global templates are inserted.

     x
Stroke Frequency of the Machine

Maximum stroke frequency of the machine that is available

This value is required and can be managed at the machine (Details View ► Technical Description ► Machine Type Properties), or is applied when global templates are inserted.

 

   x
Relative Stroke Frequency

Share of the stroke frequency that is actually used
Depends on the selection of:

  • Part Complexity
 Direct    
Relevant Stroke Frequency

Stroke frequency that is actually used
Is calculated from:

  • Stroke Frequency of the Machine
  • Relative Stroke Frequency
 with F12    
Time per Stroke

Time required for a machine stroke
Is calculated from:

  • Stroke Frequency of the Machine
  • Relative Stroke Frequency
   x  

Secondary Processing Times

The secondary processing times used to calculate the cost model are shown in this group.

Secondary Processing Times Description Input
Possible		 Calculated
 Required
Loading Time Time for loading the machine with a part Direct    
Unloading Time Time for unloading the machine with a part Direct    
Secondary Processing Time

Necessary idle times of a process in which the actual activity of a process are not performed
Is calculated from:

  • Loading Time
  • Unloading Time

 

 x  

Primary Processing Times

The primary processing times used to calculate the cost model are shown in this group.

Primary Processing Times Description Input
Possible		 Calculated
 Required
Press Time

Press time for a process
Is calculated from:

  • Number of Strokes
  • Time per Stroke

 

 x  
Additional Press Time Surcharge for Additional Press Force Direct    
Primary Processing Time

Time in which the actual activity of a process is performed.
Is calculated from:

  • Press Time
  • Additional Press Time
   x  

Properties of the Cost Model - Sintering

Material Group

The material properties used to calculate the cost model are shown in this group.

Material Properties Description Input
Possible		 Calculated
Material Usage Weight Weight of the Blank Part Direct x

Machine

The machine properties used to calculate the cost model are shown in this group.

Machine Properties Description Input
Possible		 Calculated
 Required
Machine Type Assignment of a machine to a specific group with the corresponding properties
This value is required in order to manage additional machine type properties. It can be managed at the machine (Details view ► Technical Description), or is applied when global templates are inserted.

 

 

 x
Furnace Capacity

Maximum loading capacity of the furnace that is available

This value is required and can be managed at the machine (Details View ► Technical Description ► Machine Type Properties), or is applied when global templates are inserted.

     x

Secondary Processing Times

The secondary processing times used to calculate the cost model are shown in this group.

Secondary Processing Times Description Input
Possible		 Calculated
 Required
Loading Time Time for loading the machine with a part Direct    
Unloading Time Time for unloading the machine with a part Direct    
Secondary Processing Time

Necessary idle times of a process in which the actual activity of a process are not performed
Is calculated from:

  • Loading Time
  • Unloading Time

 

 x  

Primary Processing Times

The primary processing times used to calculate the cost model are shown in this group.

Primary Processing Times Description Input
Possible		 Calculated
 Required
Requires Unwaxing

Selection of the process of unwaxing the parts


The default setting is »no«.

Direct

    
Unwaxing Time

Time for opening and closing the tool
Depends on:

  • Material Classification
 with F12   x

Sintering Time

Required time for the sintering process
Depends on:

  • Material Classification

with F12

 

 x
Cooling Time

Time for cooling down the part for removal and further usage
Depends on:

  • Material Classification
 with F12   x

Furnace Time

Time required to complete one whole furnace cycle

Is calculated from:

  • Unwaxing Time
  • Sintering Time
  • Cooling Time

 

x

  
Additional Furnace Time Surcharge for Additional Furnace Time Direct    
Primary Processing Time

Time in which the actual activity of a process is performed.
Is calculated from:

  • Furnace Time
  • Additional Furnace Time
   x