Cost Model - Injection Molding

You can use the Injection Molding cost model to calculate the process times and costs for the injection molding manufacturing process in plastics processing. In FACTON, there are value rule tables, and at the cost model there are formulas defined that offer you information on:

  • The anticipated cycle time,
  • the possible process output per time and cycle,
  • the material consumption,
  • the clamping force and the machine shot volume and
  • primary and secondary processing times.

The table shows typical application scenarios of the cost model for parts and industry:

Typical Parts Typical Industries
  • Toys/Tools
  • Packaging/Containers
  • Furniture/Furnishings
  • Panel Systems in Cars
  • Automotive Sector/Aerospace Sector
  • Electrical Industry
  • Food Processing Industry
  • Consumer Goods/Everyday Items
Note

You need knowledge of the Injection Molding manufacturing process in order to use the cost model.

Procedure

The following example illustrates the process and structure of the Injection Molding 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 Manufacture of rubber and plastic products
    Production Location World » Europe » Germany
    Reference Company 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 »Injection Molding«.
  4. Define the following properties for the process in the Details view:
    5. Technical Descriptions
    Material Classification* Basic Materials » Plastic Material » Thermoplast » PA - Polyamide » PA 6 - Polyamide 6
    Manufacturing Method* Primary Shaping » Casting » Injection Molding
    * 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: Injection Molding.

    A new Cost Model group appears with subgroups.

Note

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

For more information on the Injection Molding cost model, see: Properties of the Cost Model - Injection Molding

Step 3: Insert Material

Values must be entered at the material for the Density 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:

  • Specific Clamping Force
  • Demolding Temperature
  • Tool Temperature
  • Melt Temperature
  • Cooling Factor

You can view the properties under Details ► General ► Cost Model ► Material.

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 »Injection Molding« process in the Structure view.
  2. Click on Edit ► Insert ► Insert New Local Material (Mass) in the ribbon.

    A local material is inserted under the »Injection Molding« process.

  3. Change the label to »Injection Molding Material«.
  4. In the Details ► Technical Description view, enter a value for the Density (e.g. 1.14 g/cm³).
  5. Under Details ► Technical Description ► Material Classification, select a material classification.
    Note

    You can use the following material classifications for Thermoplastics (Basic Materials » Plastic Material » Thermoplast) with the cost model:

    • PE - Polyethylene » PE-HD - Polyethylene high density
    • PE - Polyethylene » PE-HD - Polyethylene low density
    • PP - Polypropylene
    • PA - Polyamide » PA 6 - Polyamide 6
    • PA - Polyamide » PA 66 - Polyamide 66
    • PA - Polyamide » PA 11 - Polyamide 11
    • PA - Polyamide » PA 12 - Polyamide 12
    • PS - Polystyrene
    • ABS - Acrylnitrile-Buthadiene-Styrene
    • SAN - Styrene-Acrylnitrile
    • ASA - Acrylonitrile Styrene Acrylate
    • PC - Polycarbonate
    • PC / ABS - Polycarbonate/Acrylnitrile Buthadiene Styrene
    • PVC - Polyvinylchloride » PVC-U - Polyvinylchloride Unplasticized (hard)
    • PVC - Polyvinylchloride » PVC-P - Polyvinylchloride Plasticized (soft)
    • PMMA - Polymethyl methacrylate
    • PET - Polyethylene terephthalate
    • PBT - Polybutylene terephthalate
    • POM - Polyoxymethylene
    • PPE/PA - Polyphenylene ether/Polyamide
    • PSU - Polysulfone
    • PES - Polyethersulfone
    • CA - Cellulose acetate
    • CP - Cellulose proprionate
    • CAP - Cellulose acetopropionate
    • CAB - Cellulose acetobutyrate
    • PTFE - Polytetrafluoroethylene
    • ETFE - Ethylene tetrafluorethylene
    • FEP - Tetrafluorethylene/Hexafluorpropylene
    • PCTFE - Polychlortrifluorethylene

    You can use the following material classification for Elastomer (Basic Materials » Plastic Material » Elastomer) with the cost model:

    • EVA - Ethylene Vinyl Acetate

    The Material Classification Properties group appears under Technical Description.

  6. Define the following property in the Details view:
    General
    Price per Unit 0.50 EUR / kg

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

  • Specific Clamping Force
  • Melt Temperature
  • Tool Temperature
  • Demolding Temperature
  • Cooling Factor

Step 4: Describe Part

The part properties are required in order to determine the cycle time.

Describe Part

  1. In the Structure view, select the process »Injection Molding«.
  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 »Injection Molding« under Details ► General ► Cost Model.

Part Property Group Calculated Value
Gating System Volume Material
  • Material Usage Weight
  • Material Usage Volume
  • Recyclable Material
Part Volume Part Part Weight
Projected Area of Part Projected Area of Gating System
Projected Area of Part Clamping Force
  • Clamping Force by Projected Area of Part
  • Required Clamping Force for Part
  • Clamping Force by Projected Area of Gating System
  • Required Total Clamping Force
Maximum Wall Thickness Primary Processing Times
  • Cooling Time

Step 5: Insert Machine

You can use the Required Total Clamping Force and the Material Usage Volume to determine and insert the required machine. The required total clamping force is the minimum amount of force a machine must supply in order to manufacture the described part.

To calculate the number of cavities, values must be entered at the machine for the Machine Type, Available Clamping Force and Machine Shot Volume 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 »Injection Molding« process in the Structure view.
  2. Click Edit ► Insert ► Insert New Local Machine in the ribbon.

    A machine is inserted under the »Injection Molding« process.

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

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

    • Injection Molding (Horizontally)
    • Injection Molding (Vertically)
    • Screw Extruder

    The Machine Type Properties group appears under Technical Description.

  5. In the Details ► Technical Description view, enter a value for the following properties:
    • Available Clamping Force
    • Machine Shot Volume
  6. Define the following properties for the machine in the Details view:
    Acquisition Costs
    Acquisition Value 50,000 EUR
    Fixed Machine Costs
    Depreciation Period6 a

Calculated values of the Injection Molding 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
  • Manufacturing Scrap Rate
  • Production Cost

Step 6: Insert Worker and Tool

Insert Worker

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

    The tool is inserted under the process.

Step 7: Additional Fine Tuning

You can continue fine tuning the settings in the Details ► General ► Cost Model view:

Group Properties
Material
  • Specific Clamping Force
  • Melt Temperature
  • Tool Temperature
  • Demolding Temperature
  • Cooling Factor
  • Tensile Strength
Clamping Force
  • Additional Clamping Force for Safety (Percentage or Absolute)
  • Additional Clamping Force for Sliders (Percentage or Absolute)
Secondary Processing Times
  • Insertion Parts Necessary
  • Parts Insertion Time
  • Additional Secondary Processing Times
Primary Processing Times
  • Cooling Time
  • Tool Open Close Time
  • Multi Component Process
  • Additional Time for Multi Component Process
  • Additional Primary Processing Times

Properties of the Cost Model - Injection Molding

Material Group

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

Material Properties Description Input
Possible		 Calculated
 Required
Density

Density of the material


This value is required and can be managed at the material (Details View ► Technical Description), or is applied when global templates are inserted.		     x
Specific Clamping Force

Specific clamping force per area for a given material
Depends on:

  • Material Classification
 with F12    
Melt Temperature

Temperature the melted material has during injection
Depends on:

  • Material Classification
 with F12    
Tool Temperature

Temperature of the tool which causes cooling of the melted material
Depends on:

  • Material Classification
 with F12    
Demolding Temperature

Target temperature when cooling is finished and demolding can be done
Depends on:

  • Material Classification
 with F12    
Cooling Factor

Cooling factor that specifies how much area of a given material can cool down per time
Depends on:

  • Material Classification
 with F12    
Material Usage Weight

Required material weight incl. gating system weight
Is calculated from:

  • Density
  • Material Usage Volume
   x  
Material Usage Volume

Required material volume incl. gating system volume
Is calculated from:

  • Part Volume
  • Cavity Count
  • Gating System Volume
   x  
Recyclable Material

Material mass of the gating system which can be recycled
Is calculated from:

  • Density
  • Gating System Volume
   x  
Tensile Strength Tensile strength of the material direct    

Part Group

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

Part Properties Description Input
Possible		 Calculated
 Required
Part Weight Weight of the part
Is calculated when entering a value for the part volume		 direct    
Part Volume Volume of the part
Is calculated when enteringr a value for the part weight		 direct   x
Gating System Volume Volume of the gating system direct   x
Projected Area of Part The area of the part projected in the mold parting surface direct   x
Projected Area of Gating System

The area of the gating system projected in the mold parting surface
Is calculated when entering a value for the projected area of the part
Is calculated from:

  • Ratio of area to volume (cm²/cm³)
  • Gating System Volume
 with F12    
Maximum Wall Thickness Maximum wall thickness of the part direct   x

Clamping Force Group

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

Clamping Force Properties Description Input
Possible		 Calculated
 Required
Clamping Force by Projected Area of Part

Clamping force by projected area of part in the mold parting surface
Is calculated from:

  • Specific Clamping Force
  • Projected Area of Part

 

 x  
% Additional Clamping Force for Safety Percentaged additional clamping force for safety ratio by projected area
Is calculated when entering a value for the additional clamping force for safety		 direct    
Additional Clamping Force for Safety Absolute additional clamping force for safety ratio by projected area
Is calculated when entering a value for the % additional clamping force for safety		 direct    
% Additional Clamping Force for Sliders Percentaged additional clamping force for sliders by projected area
Is calculated when entering a value for the additional clamping force for sliders		 direct    
Additional Clamping Force for Sliders Ratio Absolute additional clamping force for sliders by projected area
Is calculated when entering a value for the additional clamping force for sliders		 direct    
Required Clamping Force for Part

Required clamping force for the part with additional clamping forces
Is calculated from:

  • Clamping Force by Projected Area of Part
  • Additional Clamping Force for Safety
  • Additional Clamping Force for Sliders Ratio
   x  
Clamping Force by Projected Area of Gating System

Clamping force by projected area of the gating system in the mold parting surface
Is calculated from:

  • Specific Clamping Force
  • Projected Area of Gating System
   x  
Required Total Clamping Force

Required total clamping force for all cavities and the gating system
Is calculated from:

  • Required Clamping Force for Part
  • Cavity Count
  • Clamping Force by Projected Area of Gating System
   x  

Machine Group

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

Machine Properties Description Input
Possible		 Calculated
 Required
Clamping Force of the Machine

Maximum clamping force 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
Machine Shot Volume

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
Possible Cavity Count
by Clamping Force

The possible count of cavities determined with respect to the available clamping force
Is calculated from:

  • Clamping Force of the Machine
  • Clamping Force by Projected Area of Gating System
  • Required Clamping Force for Part
   x  
Possible Cavity Count
by Shot Volume

The possible count of cavities determined with respect to the available shot volume
Is calculated from:

  • Machine Shot Volume
  • Gating System Volume
  • Part Volume
   x  
Cavity Count

Number of cavities
Is c from:

  • Possible Cavity Count
    by Clamping Force
  • Possible Cavity Count
    by Shot Volume
 with F12    

Secondary Processing Times Group

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

Secondary Processing Times Description Input
Possible		 Calculated
 Required
Insertion Parts Necessary Selection, whether insertion parts are necessary direct    
Parts Insertion Time Time for inserting the parts into the machine.
Calculated when the selection for necessary insertion parts is activated		 direct    
Additional Secondary Processing Times Chance to add secondary processing times that have not been considered yet direct    
Secondary Processing Time

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

  • Parts Insertion Time
  • Additional Secondary Processing Times
   x  

Primary Processing Times Group

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

Primary Processing Times Description Input
Possible		 Calculated
 Required
Cooling Time

Time for cooling down the part for removal and further usage
Is calculated from:

  • Maximum Wall Thickness
  • Melt Temperature
  • Tool Temperature
  • Demolding temperature
  • Cooling Factor
   x  
Tool Open Close Time

Time for opening and closing the tool
Depends on:

  • Machine Size (Available Clamping Force)
 with F12    
Multi Component Process Selection, whether it is a multi component process direct    
Additional Time for Multi Component Process Additional time required for a multi component injection molding process
Calculated when the selection for a multi component process is activated		   x  
Additional Primary Processing Times Chance to add primary processing times that have not been considered yet direct    
Primary Processing Time

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

  • Cooling Time
  • Tool Open Close Time
  • Additional Time for Multi Component Process
  • Additional Primary Processing Times
   x