INJECTION MOLDING TECHNICAL COST MODEL

MIT - Materials Systems Laboratory

Jump to Sensitivity Analysis

PART/MATERIAL INPUTS
Material 4
Weight 800 grams
Maximum Wall Thickness 2.00 mm
Average Wall Thickness 1.60 mm
Projected Area 850 sq cm

EXOGENOUS DATA
Annual Production Volume 100 (000/yr)
Facility Production Capacity 300 (000/yr)
Product Life 5 yrs
Direct Wages (w/ benefits) $15.00 /hr
Working Days/Yr 240
Downtimes
No Operations 7 hrs/day
Planned Paid 1 hrs/day
Planned Unpaid 1.2 hrs/day

Capital Recovery Rate 10%

Price, Building Space $1,500 /sq m

Building Recovery Life 30 yrs
Price of Electricity $0.080 /kWh
Accounting Life of Machine 20 yrs
Overhead Burden (% fc) 35.0%

PROCESS INPUTS
Unplanned Downtime 1.50 hrs/day
Material Scrap Rate 2.0%
Reject Rate 1.0%
Direct Laborers Per Machine 1
Dedicated Equipment (1/0) 0 (1=y;0=n)
Number of Cavities 1
Auxiliary Equip. Cost (% mmch) 20.0%
Installation Cost (% mmch) 20.0%
Maintenance Cost (% invc) 5.0%
Tool Actions (1/0) 0 (1=y;0=n)
Toolmaker Shop Rate $100.00 /hr
Baseline Mold Life 1,000,000 cycles
 Electricity Requirement 0.75 kWh/kg
INJECTION MOLDING OVERRIDES
Molding Press & Tool Data:
Clamping Force 0 kN
Press Investment $0
Unit Tool Investment $0

Cycle Time & Tool Costs:

Cooling time 0 sec
Total Cycle Time 0 sec
 INJECTION MOLDING - COST SUMMARY

VARIABLE COSTS per piece per year percent

Material Cost $0.80 $79,776 36.27%
Energy Cost $0.08 $7,507 3.41%
Labor Cost $0.16 $15,853 7.21%
Total Variable Cost $1.03 $103,136 46.89%

FIXED COSTS per piece per year percent investment

Main Machine Cost $0.18 $17,772 8.08% $151,304
Auxiliary Equipment Cost $0.03 $2,962 1.35% $25,217
Tooling Cost $0.46 $46,161 20.99% $174,987
Fixed Overhead Cost $0.29 $29,207 13.28%
Building Cost $0.17 $16,554 7.53% $156,054
Maintenance Cost $0.04 $4,172 1.90%
Total Fixed Cost $1.17 $116,829 53.11% $482,345

Total Fabrication Cost $2.20 $219,965 100.00%

RELATED VARIABLES

Material Requirements:
Raw Material Price $0.97 /kg
Trim Scrap Rate 2.0%
Gross Material per Part 816.3 g
Annual Material Input 82,458 kg
Production

Process Calculations
Effective Production Volume 101,011
Effective Capacity 303,031
Capacity and Volume are Consistent? 1
Available Operating Time 3,192 hours / year

Effective Cycle Time (from below) 35 secs / part

Required Operating Time (produced) 983 hours / year
Required Operating Time (capacity) 2,949 hours / year
Run-Time for One Machine (produced) 31%
Run-Time for One Machine (capacity) 92%
Number of Parallel Streams 0.92

Paid Operating Time (available in year) 3,432 hours / year

Actual Paid Operating Time (allocated) 1,057 person-hours / year
Number of tools required 2
Required Building Space 113 sq m
Energy Adjustment Factor 1.52
Annual Energy Consumption 93,833 kWh/year

Cycle Time Calculations

Predicted Used Other Var
Cooling Time (sec) 10.4 10.4
Total Cycle Time (sec) 35.0 35.0
Other Fixed

Press & Tool Characteristics & Costs

Predicted Used
Clamping Force (kN) 2,967 2,967 326 tons
Press Cost $136,486 $136,486
Tool Cost $87,493 $87,493
 INJECTION MOLDING - Sensitivity Analysis

Unit Cost ($ / piece)

Prod Volume Var. Cost Fixed Cost Total Cost
$1.03 $1.17 $2.20
1 $1.03 $116.83 $117.86 Effect of Production Volume
25 $1.03 $4.67 $5.70
50 $1.03 $2.34 $3.37 $5.00
75 $1.03 $1.56 $2.59
100 $1.03 $1.17 $2.20 Var. Cost
125 $1.03 $0.93 $1.97 $4.00 Total
Cost
150 $1.03 $0.78 $1.81
175 $1.03 $0.67 $1.70 $3.00
200 $1.03 $0.58 $1.62
225 $1.03 $0.52 $1.55
250 $1.03 $0.47 $1.50 $2.00
275 $1.03 $0.42 $1.46
300 $1.03 $0.39 $1.42
$1.00
325 #N/A #N/A #N/A
350 #N/A #N/A #N/A
375 #N/A #N/A #N/A $0.00
400 #N/A #N/A #N/A 0 50 100 150 200 250 300 350 400
425 #N/A #N/A #N/A Production Volume (thousands)
450 #N/A #N/A #N/A

Unit Cost Capacity

$2.20 100 200 300 400 500
Production 1 $49.29 $99.00 $117.86 $202.81 $224.59
Unit Cost ($/part)

Effect of Production Vol & C

Volume 25 $2.96 $4.95 $5.70 $9.10 $9.97
50 $2.00 $2.99 $3.37 $5.07 $5.50 $5.00
75 $1.67 $2.34 $2.59 $3.72 $4.01
$4.50
100 $1.51 $2.01 $2.20 $3.05 $3.27
125 #N/A $1.82 $1.97 $2.65 $2.82 $4.00
150 #N/A $1.68 $1.81 $2.38 $2.52 $3.50
175 #N/A $1.59 $1.70 $2.18 $2.31
$3.00
200 #N/A $1.52 $1.62 $2.04 $2.15
225 #N/A #N/A $1.55 $1.93 $2.02 $2.50
250 #N/A #N/A $1.50 $1.84 $1.93 $2.00
275 #N/A #N/A $1.46 $1.77 $1.84
$1.50
300 #N/A #N/A $1.42 $1.70 $1.78
325 #N/A #N/A #N/A $1.65 $1.72 $1.00
350 #N/A #N/A #N/A $1.61 $1.67 $0.50
375 #N/A #N/A #N/A $1.57 $1.63
400 #N/A #N/A #N/A $1.54 $1.59 $0.00
0 100 200 300 400
Production Volume (parts/ye
 $0.50
$0.00
0 100 200 300 400
425 #N/A #N/A #N/A #N/A $1.56
Production Volume (parts/ye
450 #N/A #N/A #N/A #N/A $1.53

Cost Breakdown @ 100,000

Fraction of Total C ost

Unit Costs
Material $0.80
Other Var $0.23
Equip $0.21
Cost Breakdown By Element
Tooling $0.46
Other Fixed $0.50 2500%
Total Cost $2.20

Other Fixed
Tooling
Equip
Other Var
Material

0%
 Unit Cost Max Wall Thickness
$2.20 1 1.5 2 2.5
ume Past 100 $0.84 $0.90 $0.99 $1.10
Mass 150 $0.92 $0.98 $1.07 $1.19
200 $1.00 $1.06 $1.16 $1.28
250 $1.08 $1.15 $1.24 $1.37
Var. Cost 300 $1.16 $1.23 $1.33 $1.46
Total 350 $1.24 $1.31 $1.41 $1.55
Cost
400 $1.32 $1.39 $1.50 $1.64
450 $1.40 $1.48 $1.59 $1.73
500 $1.48 $1.56 $1.67 $1.82
550 $1.56 $1.64 $1.76 $1.91
600 $1.65 $1.73 $1.85 $2.00
650 $1.73 $1.81 $1.93 $2.10
700 $1.81 $1.90 $2.02 $2.19
750 $1.90 $1.98 $2.11 $2.28
800 $1.98 $2.07 $2.20 $2.37
850 $2.07 $2.16 $2.29 $2.46
0 300 350 400 900 $2.15 $2.24 $2.38 $2.56
housands)
950 $2.24 $2.33 $2.47 $2.65
1,000 $2.32 $2.42 $2.56 $2.75

oduction Vol & Capacity

100
200
300
400
500

200 300 400 500

ion Volume (parts/year)
 200 300 400 500
ion Volume (parts/year)
 3 Exploring the impact of design
$1.25
$1.34
$1.44
$1.54
$1.63
$1.73 3
$1.82
2
$1.92 Max Wall Thick (mm)
$2.01 Unit Cost 1
$2.11 ($/part) 600

700

900
100

200

300

400

500

800

1,000
$2.20
$2.30
Part Mass (g)
$2.40
$2.49
1 1.5 2
$2.59
$2.69 2.5 3

$2.79
$2.89
$2.99
 Unit Costs Unit Costs
Material Cost $0.80 Material $0.80
Energy Cost $0.08 Other Variable $0.23
Labor Cost $0.16 Equipment $0.21
Total Variable Cost $1.03 Tooling $0.46
Main Machine Cost $0.18 Other Fixed $0.50
Auxiliary Equipment Cost $0.03 Total Cost $2.20
Tooling Cost $0.46
Fixed Overhead Cost $0.29
Building Cost $0.17
Maintenance Cost $0.04
Total Fixed Cost $1.17
Total Fabrication Cost $2.20

Resin 4
MATERIAL DATABASE

Price
Type Tradename Grade # ($/kg)
POLYSTYRENE 1 $2.33
PVC (RIGID) 2 $0.84
ABS 3 $2.22
POLYPROPYLENE (HOMO) 4 $0.97
NYLON 6 5 $4.38
POLYCARBONATE 6 $3.96
ACETAL (HOMO) 7 $3.43
HDPE 8 $0.81
POLYPHENYLENE ETHER 9 $2.93
PET 10 $3.52
THERMOPLASTIC POLYIMIDE 11 $11.88
EVA 12 $2.09
NYLON 6/30% GLASS 13 $4.27
POLYCARBONATE/30% GLASS 14 $5.21
ABS/20% GLASS 15 $2.38
ACETAL/25% GLASS 16 $4.07
PBT Alloy Valox 830 17 $3.26
PC/PBT Xenoy 1200 18 $3.96
PC/PBT Xenoy 1101 19 $3.74
PC Lexan 141 20 $4.64
PPE Noryl 844 21 $2.66
Blend Noryl GTX 22 $3.63
PA Zytel ST-801 23 $5.06
PA Zytel ST-901 24 $5.41
EVA Co- Elvax 960 25 $1.50
PA Bexloy 26 $4.07
PA Bexloy 27 $4.40
Ionomer Suryln 28 $2.97
LDPE Stamylan-LD 2138GW00 29 $0.73
LDPE Stamylan-LD 2322GL00 30 $0.73
LDPE Stamylan-LD 2538EL00 31 $0.73
HDPE Stamylan-HD 7249 32 $0.81
HDPE Stamylan-HD 7058 33 $0.81
HDPE Stamylan-HD 5119 34 $0.81
PP Co- Stamylan-P 83MF10 35 $0.93
PP Co- Stamylan-P 412MN40 36 $0.87
PP Co- Stamylan-P 48M10 37 $0.87
EMPP Keltan TP 0603 38 $1.83
EMPP Keltan TP 0505 39 $1.93
EMPP Keltan TP 2607 40 $1.73
R-EMPP Kelburon 90594 41 $1.89
ABS Ronfalin FX 42 $2.13
ABS Ronfalin TX 43 $2.24
ABS Ronfalin HX 44 $2.24
ABS Ronfalin VE 45 $2.72
ABS/PVC Ronfalin RN-03 46 $2.64
PPE Prevex PMA 47 $3.43
PPE Prevex PQA 48 $4.29
PPE Prevex VJA 49 $3.76
PPE Prevex W30 50 $3.76
ABS Cycolac T 51 $2.50
ABS Cycolac GSM 52 $2.53
ABS Cycolac L 53 $2.60
ABS Cycolac DFAR 54 $2.35
ABS Cycolac DH 55 $2.42
ABS Cycolac KJB 56 $2.99
TPO Ontex 111BX 57 $2.97
TPO Dexflex 850 58 $2.09
TPE ester Lomod 521 59 $3.74
TPE ester Bexloy V 60 $3.63
TPU Estane 61 $4.62
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92