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` PART NO. Front Axle Bracket ( 4 WD) DRG NO. 10070752 AC LOT SIZE 150 Nos. S. No.
Operation Description
Machin Usage Tool used e Used /tips
Cutting speed
Feed
Feed
RPM
Met/min mm / rev mm/min
DIA
LOC
No. Of passes/ stroke
Mach. time TH
PR min
mm
mm
Nos'
min
1
Rough Milling
Makino
Cutter
6
180
0.7
501.3 716
80
2000
4.00
15.96
2
Drilling
Makino
Drill
2
60
0.2
224.7 1123
17
50
4
0.89
3
Drilling
Makino
Drill
2
60
0.2
272.8 1364
14
50
18
3.299
5
Drilling
Makino
Drill
2
60
0.2
238.7 1194
16
50
2
0.419
5
Drilling
Makino
Drill
2
60
0.2
246.4 1232 15.5
50
2
0.406
6
Drilling
Makino
Drill
2
50
0.15
353.6 2358 6.75
50
1
0.141
7
Chamfer
Makino
Counter
4
20
0.3
76.38 255
25
3
30
1.178
8
Tapping
Makino
Tap
7
1.25
348.1 278
8
80
1
0.23
9
Hole Milling
Makino
Holemill
5
25
0.3
142.9 476 16.7
50
2
0.7
10 Reaming
Makino
Reamer
5
25
0.3
140.4 468
17
50
2
0.712
11 Tapping
Makino
Tap
7
2.5
309.4 124
18
80
4
1.034
12 Tapping
Makino
Tap
7
2
278.5 139
16
80
18
5.171
12
Makino
13 Rough Milling
Mazak
Cutter
8
180
0.7
3
14.96
14 Drilling
Mazak
Drill
2
60
0.2
347.2 1736
20
2
0.115
15 Drilling
Mazak
Drill
2
60
0.15
424.4 2829 6.75
20
22
1.037
16 Drilling
Mazak
Drill
2
60
0.2
381.9 1910
10
25
3
0.196
17 Counter
Mazak
Endmill
4
60
0.4
424.4 1061
18
30
6
0.424
18 Drilling
Mazak
Drill
2
60
0.15
337 2247 8.5
25
2
0.148
19 Tapping
Mazak
Tap
7
1.25
348.1 278
40
22
2.528
20 Fnish Milling
Mazak
Cutter
8
180
0.6
343.7 573
1
5.819
21 Drilling
Mazak
Drill
2
60
0.2
218.2 1091 17.5
80
4
1.466
22 Chamfer
Mazak
Counter
4
20
0.3
76.38 255
25
2
11
0.288
23 Tapping
Mazak
Tap
7
2.5
278.5 111
20
120
4
1.724
Setting, Inspection & Loading-Unloading Time
401
573
100 2000 11
8
100 2000
24 Drilling
Mazak
Drill
25 Tapping
Mazak
Tap
26 Counter
Mazak
Endmill
26
Mazak
2
4
60
0.2
318.3 1591
12
20
4
0.251
7
2
318.3 159
14
40
4
0.503
60
0.4
424.4 1061
18
30
12
0.848
Setting, Inspection & Loading-Unloading Time
Hand. Setting time time
min
min
Total time TH
PR
min
min
Concd Total . Time. Time
min
Rate
Total Cost
min
3.5
19.46
475
154.05
0.7
1.59
475
12.59
1.5
4.80
475
37.99
0.6
1.02
475
8.07
0.6
1.01
475
7.96
0.8
0.94
475
7.45
1
2.18
475
17.24
0.8
1.03
475
8.15
0.6
1.30
475
10.29
0.6
1.31
475
10.39
0.8
1.83
475
14.52
1.5
6.67
475
52.81
5.00
475
39.58
48.14
381.11
1
15.96
1050
279.33
0.4
0.52
1050
9.02
1.2
2.24
1050
39.15
0.6
0.80
1050
13.94
0.5
0.92
1050
16.17
0.5
0.65
1050
11.35
1.3
3.83
1050
66.99
0.4
6.42
1050
112.32
0.8
2.27
1050
39.66
0.6
0.89
1050
15.54
0.8
2.52
1050
44.16
0.8
1.05
1050
18.40
0.6
1.10
1050
19.30
1
1.85
1050
32.35
5.00
1050
87.50
46.01
805.17
TOTAL PROCESS SHEET Ref.No.CS109- 1 of 2
Rev. No. 0
Component: Front Axle Bracket
Drawing No.
Customer
International Tractors Ltd.
Part No
10071461 AA
Date : 25/09/2012
Material
1 Set Up ( Makino) S. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Process Facing Drilling Drilling Drilling Drilling Drilling Chamfering Reaming Drilling S/F Boaring F/Boaring Taping Taping Taping
Tool Type
2nd Set up (M Time
Dia 80 Milling Cutter Dia 14 Drill Carbide Dia 16 Drill Carbide Dia 17 Drill Carbide Dia 15.5 Drill Carbide Dia 6.8 Drill Carbide Dia 25 Chamfer Tool Dia 17 Rimmer Carbide Dia 37 U Drill DIA 39.7 BORING BAR Dia 40 Boaring Bar M16 X 2 Tap M18X 2.5 Tap M8 X 1.25 Setting Time
Total Cost
9.20 3.30 1.05 1.75 1.65 1.00 2.75 2.75 2.35 2.50 4.50 4.15 1.65 1.00 5.00 44.60 1050.00
780.50 1528.63
Remarks
S. No. 1 2 3 4 5 6 7 8 9 10 11
Process R/Facing F/Facing R/Milling F/Milling Drilling Drilling Drilling Chamfering Taping Taping
Casting
2nd Set up (Mazak) Tool Type Dia 100 Face Mill Cutter Dia 100 Face Mill Cutter Dia 80 Cutter Dia 40 End Mill Dia 18 End Mill Dia 6.8 Drill Carbide Dia 8.5 Drill Carbide Dia 25 X 90 Counter Shenk M8 X 1.25 Tap M10 X 1.5 Tap Setting Time
2 nd Set up Total Time Machine Hour Rate
Total Cost
Time 14.00 4.00 5.50 5.25 1.25 1.00 1.00 2.00 2.50 1.25 5.00
42.75 1050.00
748.125
` PART NO. Casing Rear Axle D RH DRG NO. D10229370 A LOT SIZE 50 Nos. S. No.
Operation Description
Machin Usage Tool used e Used /tips
Cutting speed
Feed
Feed
RPM
Met/min mm / rev mm/min
DIA
LOC
No. Of passes/ stroke
Mach. time TH
PR min
mm
mm
Nos'
min
13
23
12
0.805
469 2345 9.5
23
2
0.098
1
Drilling
VMC
Drill
2
70
0.2
2
Drilling
VMC
Drill
2
70
0.2
3
Chamfer
VMC
Counter
4
60
0.3
229.2 764
25
3
20
0.262
4
Tapping
VMC
Tap
7
1.75
324.9 186
12
23
2
0.142
5
Hole Milling
VMC
Holemill
5
20
0.3
194.9 650
9.8
23
2
0.236
6
Reaming
VMC
Reamer
5
20
0.3
191
10
23
2
0.241
7
Drilling
VMC
Drill
2
70
0.2
469 2345 9.5
23
2
0.098
8
VMC
342.8 1714
637
Setting, Inspection & Loading-Unloading Time
13 Rough Milling
Mazak
Cutter
5
180
1
909.3 909
63
2000
3
6.598
14 Drilling
Mazak
Drill
2
60
0.2
347.2 1736
11
20
2
0.115
15 Drilling
Mazak
Drill
2
60
0.15
424.4 2829 6.75
20
22
1.037
16 Drilling
Mazak
Drill
2
60
0.2
381.9 1910
10
25
3
0.196
17 Counter
Mazak
Endmill
4
60
0.4
424.4 1061
18
30
6
0.424
18 Drilling
Mazak
Drill
2
60
0.15
337 2247 8.5
25
2
0.148
19 Tapping
Mazak
Tap
7
1.25
348.1 278
40
22
2.528
20 Fnish Milling
Mazak
Cutter
8
180
0.6
343.7 573
1
5.819
21 Drilling
Mazak
Drill
2
60
0.2
218.2 1091 17.5
80
4
1.466
22 Chamfer
Mazak
Counter
4
20
0.3
76.38 255
25
2
11
0.288
23 Tapping
Mazak
Tap
7
2.5
278.5 111
20
120
4
1.724
24 Drilling
Mazak
Drill
60
0.2
318.3 1591
12
20
4
0.251
25 Tapping
Mazak
Tap
7
2
318.3 159
14
40
4
0.503
26 Counter
Mazak
Endmill
60
0.4
424.4 1061
18
30
12
0.848
26
Mazak
2
4
Setting, Inspection & Loading-Unloading Time
8
100 2000
Hand. Setting time time
min
min
Total time TH
PR
min
min
Concd Total . Time. Time
min
Rate
Total Cost
min
0.7
1.51
475
11.92
0.7
0.80
475
6.32
1
1.26
0
0.00
0.8
0.94
475
7.45
0.6
0.84
475
6.62
0.6
0.84
475
6.66
0.8
0.90
475
7.11
5.00
475
39.58
12.08
85.66
1
7.60
475
60.15
0.4
0.52
1050
9.02
1.2
2.24
1050
39.15
0.6
0.80
1050
13.94
0.5
0.92
1050
16.17
0.5
0.65
1050
11.35
1.3
3.83
1050
66.99
0.4
6.42
1050
112.32
0.8
2.27
1050
39.66
0.6
0.89
1050
15.54
0.8
2.52
1050
44.16
0.8
1.05
1050
18.40
0.6
1.10
1050
19.30
1
1.85
1050
32.35
5.00
1050
87.50
37.65
585.99
PART NO. DRG NO. LOT SIZE S. No.
Operation Description
Casing Rear Axle D RH
Machin Usage Tool used e Used /tips
Cutting speed
Feed
Feed
RPM
Met/min mm / rev mm/min
DIA
LOC
No. Of passes/ stroke
Mach. time TH
PR min
mm
mm
Nos'
min
1
Turning Rough
CNC
Turning
1
200
0.4
391.7 979
65
195
1
0.498
2
Turning Rough
CNC
Turning
1
200
0.2
195.9 979
65
125
1
0.638
3
Finish Turning
CNC
Turning
1
200
0.2
195.9 979
65
195
1
0.996
8
VMC
Setting, Inspection & Loading-Unloading Time
13 Rough Milling
Mazak
Cutter
5
180
1
909.3 909
63
2000
3
6.598
14 Drilling
Mazak
Drill
2
60
0.2
347.2 1736
11
20
2
0.115
15 Drilling
Mazak
Drill
2
60
0.15
424.4 2829 6.75
20
22
1.037
16 Drilling
Mazak
Drill
2
60
0.2
381.9 1910
10
25
3
0.196
17 Counter
Mazak
Endmill
4
60
0.4
424.4 1061
18
30
6
0.424
18 Drilling
Mazak
Drill
2
60
0.15
337 2247 8.5
25
2
0.148
19 Tapping
Mazak
Tap
7
1.25
348.1 278
40
22
2.528
20 Fnish Milling
Mazak
Cutter
8
180
0.6
343.7 573
1
5.819
21 Drilling
Mazak
Drill
2
60
0.2
218.2 1091 17.5
80
4
1.466
22 Chamfer
Mazak
Counter
4
20
0.3
76.38 255
25
2
11
0.288
23 Tapping
Mazak
Tap
7
2.5
278.5 111
20
120
4
1.724
24 Drilling
Mazak
Drill
60
0.2
318.3 1591
12
20
4
0.251
25 Tapping
Mazak
Tap
7
2
318.3 159
14
40
4
0.503
26 Counter
Mazak
Endmill
60
0.4
424.4 1061
18
30
12
0.848
26
Mazak
2
4
Setting, Inspection & Loading-Unloading Time
8
100 2000
Hand. Setting time time
min
min
Total time TH
PR
min
min
Concd Total . Time. Time
min
Rate
Total Cost
min
0.7
1.20
300
5.99
0.7
1.34
300
6.69
0.7
1.70
300
8.48
5.00
475
39.58
9.23
60.74
1
7.60
475
60.15
0.4
0.52
1050
9.02
1.2
2.24
1050
39.15
0.6
0.80
1050
13.94
0.5
0.92
1050
16.17
0.5
0.65
1050
11.35
1.3
3.83
1050
66.99
0.4
6.42
1050
112.32
0.8
2.27
1050
39.66
0.6
0.89
1050
15.54
0.8
2.52
1050
44.16
0.8
1.05
1050
18.40
0.6
1.10
1050
19.30
1
1.85
1050
32.35
5.00
1050
87.50
37.65
585.99
PART NO.
Front Axle Bracket
DRG NO.
10090792 FB
LOT SIZE S. No.
Operation Description
Cutting Machine Usage speed Tool used Used /tips
Feed
Feed
RPM
Met/min mm / rev mm/min
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
S. No.
1 2 3 4 5 6 7 8 9 10
Milling Drilling Chf 1x45 Drilling 17.8 Chf 1x45 Reaming 18 Milling Drilling 13.5 Chf 1x45 Tapping M16 Drilling 12 Chf 1x45 Tapping M14 Milling Drilling 13.5 Chf 1x45 Tapping M16 Drilling 12 Chf 1x45 Tapping M14 Milling Drilling 15.5 Chf 1x45 Tapping M18
Mazak Mazak Mazak Mazak Mazak Makino Mazak Mazak Mazak Mazak Mazak Mazak Mazak Mazak Mazak Mazak Mazak Mazak Mazak Mazak Mazak Mazak Mazak Mazak
Cutter Drill Drill Drill Drill Reamer Cutter Drill Drill Tap Drill Drill Tap Cutter Drill Drill Tap Drill Drill Tap Cutter Drill Drill Tap
8 2 2 2 2 5 8 2 2 4 2 2 4 8 2 2 4 2 2 4 8 2 2 4
180 60 60 60 60 25 180 60 60 7 60 60 7 180 60 60 7 60 60 7 180 60 60 7
0.6 0.2 0.2 0.15 0.2 0.3 0.6 0.2 0.2 2 0.2 0.2 2 0.6 0.2 0.2 2.5 0.2 0.2 2 0.6 0.2 0.2 2.5
343.7 198.9 173.6 160.9 191 132.6 343.7 282.9 238.7 278.5 318.3 272.8 318.3 343.7 282.9 238.7 348.1 318.3 272.8 318.3 343.7 246.4 212.2 309.4
Mazak
Operation Description Milling Drilling 6.5 Chf 1x45 Tapping Drilling 8.5 Chf 1x45 Tapping Milling Milling Holemill 29.8
Mazak Mazak Mazak Mazak Mazak Mazak Mazak Mazak Mazak
Cutter Drill Drill Tap Drill Drill Tap Cutter Cutter Holemill
8 2 2 2 2 8 8 4
180 60 60 7 60 60 7 180 180 60
0.6 0.2 0.2 1.25 0.15 0.2 1.5 0.6 0.6 0.4
343.7 587.6 477.4 348.1 337 381.9 334.2 343.7 343.7 256.3
LOC
No. Of passes/ stroke
TH
PR
mm
mm
Nos'
min
min
573 100 900 2 5.237 995 19.2 30 6 0.905 868 22 1 6 0.035 1073 17.8 14 2 0.174 955 20 1 2 0.01 442 18 14 2 0.211 573 100 820 2 4.771 1415 13.5 50 5 0.884 1194 16 2 5 0.042 139 16 45 5 0.808 1591 12 55 2 0.346 1364 14 2 2 0.015 159 14 50 2 0.314 573 100 820 2 4.771 1415 13.5 50 5 0.884 1194 16 2 5 0.042 139 16 45 5 0.646 1591 12 55 2 0.346 1364 14 2 2 0.015 159 14 50 2 0.314 573 100 690 2 4.015 1232 15.5 45 4 0.731 1061 18 2.5 4 0.047 124 18 45 4 0.582 Setting, Inspection & Loading-Unloading Time
Cutting Feed Feed RPM Machine Usage speed Tool used Used /tips Met/min mm / rev mm/min Mazak
Mach. time
DIA
573 2938 2387 278 2247 1910 223 573 573 641
DIA
LOC
No. Of passes/ stroke
TH
PR
mm
mm
Nos'
min
min
2 23 23 23 4 4 4 2 2 4
8.751 0.47 0.048 0.793 0.142 0.01 0.144 1.862 1.862 0.134
100 1504 6.5 12 8 1 8 12 8.5 12 10 1 10 12 100 320 100 320 29.8 8.6
Mach. time
11 12 13 14 15 16
Chf 1x45 Reaming 30 Drilling 17.5 Chf 1x45 Tapping
Mazak Makino Mazak Mazak Mazak
Counter Reamer Drill Drill Tap
4 5 2 2
60 25 60 60 7
0.2 0.1 0.2 0.2 2.5
119.4 26.52 218.2 191 278.5
597 32 1 4 0.034 265 30 8.6 4 1.297 1091 17.5 55 4 1.008 955 20 2 4 0.042 111 20 50 4 0.718 Setting, Inspection & Loading-Unloading Time
Hand. Setting time time min
min
0.5 0.3 0.3 0.3 0.3 0.3 0.5 0.3 0.3 0.3 0.3 0.3 0.3 0.5 0.3 0.3 0.3 0.3 0.3 0.3 0.5 0.3 0.3 0.3 g-Unloading Time
0.5 0.3 0.3 0.3 0.3 0.3 0.3 0.5 0.5 0.3
TH
PR
min
min
5.74 1.20 0.33 0.47 0.31 0.51 5.27 1.18 0.34 1.11 0.65 0.31 0.61 5.27 1.18 0.34 0.95 0.65 0.31 0.61 4.51 1.03 0.35 0.88 5.00 39.14
Hand. Setting time time min
Total time
min
Rate 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100
Total Cost 105.17 22.09 6.13 8.69 5.69 9.37 96.64 21.70 6.27 20.31 11.84 5.77 11.26 96.64 21.70 6.27 17.35 11.84 5.77 11.26 82.77 18.89 6.36 16.16 91.67 717.62
Total time TH
PR
min
min
9.25 0.77 0.35 1.09 0.44 0.31 0.44 2.36 2.36 0.43
Rate
Total Cost
1100 1100 1100 1050 1100 1100 1050 1100 1100 1100
169.60 14.11 6.38 19.13 8.11 5.69 7.76 43.30 43.30 7.96
0.3 0.3 0.3 0.3 0.3 g-Unloading Time
0.33 1.60 1.31 0.34 1.02 5.00
1100 1100 1100 1100 1100 1100
27.42 Total
66.56
6.11 29.28 23.98 6.27 18.67 91.67 501.33
Rs.
1218.95
EMMBROS AUTOMOTIVE PVT. LTD. COST ESTIMATION CUSTOMER - ITL Front Axle Bracket NA
PART NAME
Sr.No
Description / Item
PART NO. ( Casting ) PART NO. ( MACHINING )
10090792 FB
NA
BLANK NO. 01 02
Material Finish weight ( Finish Part After Machining ) ( Kg )
10
Srcap genrated (Kg) after mc
11 12
Srcap Rate / Kg. (Rs )
14 18 19 20 21
Machining Process Cost
FG260
Value of Total Srcap 1248.95 10.00 124.89 249.79 120.00
Packing ( Individual or Bulk ) Detail attached Overheads @ 10% of process cost Profit @ 20% of process cost Freight @ Rs. 3/Kg on Finish wt
TOTAL COST ( Finish Part ) / Pc TOOLING COST One Time 50 % Advance & 50 % at the time of sample approval ( DIE + GAUGES )
1753.63 0.00
MACHINING COST
OPN.NO.
OPERATION
MACHINE
010
Machining Process Cost
CNC TURNING
070
MARKING
PIN MARKING
090
FINAL INSPECTION
INSPECTION
Total Process Cost
These rate are included freight
M/C HOUR RATE
M/C TIME 66.56
125
Front Axle Bracket NA 10090792 FB
NA FG260
1248.95 10.00 124.89 249.79 120.00
1753.63 0.00 M/C COST 1218.95 30.00
1248.95
0
Operation Description
Machin Usage Tool used e Used /tips
Cutting speed
Feed
Feed
RPM
Met/min mm / rev mm/min
DIA
LOC
No. Of passes/ stroke
Mach. time TH
PR min
mm
mm
Nos'
min
1
Rough Milling
Makino
Cutter
6
180
0.7
501.3 716
80
2000
4.00
15.96
2
Drilling
Makino
Drill
2
60
0.2
224.7 1123
17
50
4
0.89
3
Drilling
Makino
Drill
2
60
0.2
272.8 1364
14
50
18
3.299
5
Drilling
Makino
Drill
2
60
0.2
238.7 1194
16
50
2
0.419
5
Drilling
Makino
Drill
2
60
0.2
246.4 1232 15.5
50
2
0.406
6
Drilling
Makino
Drill
2
50
0.15
353.6 2358 6.75
50
1
0.141
7
Chamfer
Makino
Counter
4
20
0.3
76.38 255
25
3
30
1.178
8
Tapping
Makino
Tap
7
1.25
348.1 278
8
80
1
0.23
9
Hole Milling
Makino
Holemill
5
25
0.3
142.9 476 16.7
50
2
0.7
10 Reaming
Makino
Reamer
5
25
0.3
140.4 468
17
50
2
0.712
11 Tapping
Makino
Tap
7
2.5
309.4 124
18
80
4
1.034
12 Tapping
Makino
Tap
7
2
278.5 139
16
80
18
5.171
12
Makino
13 Rough Milling
Mazak
Cutter
8
180
0.7
3
14.96
14 Drilling
Mazak
Drill
2
60
0.2
347.2 1736
20
2
0.115
15 Drilling
Mazak
Drill
2
60
0.15
424.4 2829 6.75
20
22
1.037
16 Drilling
Mazak
Drill
2
60
0.2
381.9 1910
10
25
3
0.196
17 Counter
Mazak
Endmill
4
60
0.4
424.4 1061
18
30
6
0.424
18 Drilling
Mazak
Drill
2
60
0.15
337 2247 8.5
25
2
0.148
19 Tapping
Mazak
Tap
7
1.25
348.1 278
40
22
2.528
20 Fnish Milling
Mazak
Cutter
8
180
0.6
343.7 573
1
5.819
21 Drilling
Mazak
Drill
2
60
0.2
218.2 1091 17.5
80
4
1.466
22 Chamfer
Mazak
Counter
4
20
0.3
76.38 255
25
2
11
0.288
23 Tapping
Mazak
Tap
7
2.5
278.5 111
20
120
4
1.724
Setting, Inspection & Loading-Unloading Time
401
573
100 2000 11
8
100 2000
24 Drilling
Mazak
Drill
25 Tapping
Mazak
Tap
26 Counter
Mazak
Endmill
26
Mazak
2
4
60
0.2
318.3 1591
12
20
4
0.251
7
2
318.3 159
14
40
4
0.503
60
0.4
424.4 1061
18
30
12
0.848
Setting, Inspection & Loading-Unloading Time
Hand. Setting time time
min
min
Total time TH
PR
min
min
Concd Total . Time. Time
min
Rate
Total Cost
min
3.5
19.46
475
154.05
0.7
1.59
475
12.59
1.5
4.80
475
37.99
0.6
1.02
475
8.07
0.6
1.01
475
7.96
0.8
0.94
475
7.45
1
2.18
475
17.24
0.8
1.03
475
8.15
0.6
1.30
475
10.29
0.6
1.31
475
10.39
0.8
1.83
475
14.52
1.5
6.67
475
52.81
5.00
475
39.58
48.14
381.11
1
15.96
1050
279.33
0.4
0.52
1050
9.02
1.2
2.24
1050
39.15
0.6
0.80
1050
13.94
0.5
0.92
1050
16.17
0.5
0.65
1050
11.35
1.3
3.83
1050
66.99
0.4
6.42
1050
112.32
0.8
2.27
1050
39.66
0.6
0.89
1050
15.54
0.8
2.52
1050
44.16
0.8
1.05
1050
18.40
0.6
1.10
1050
19.30
1
1.85
1050
32.35
5.00
1050
87.50
46.01
805.17
TOTAL PROCESS SHEET Ref.No.CS109- 1 of 2
Rev. No. 0
Component: Front Axle Bracket
Drawing No.
Customer
International Tractors Ltd.
Part No
10071461 AA
Date : 25/09/2012
Material
1 Set Up ( Makino) S. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Process Facing Drilling Drilling Drilling Drilling Drilling Chamfering Reaming Drilling S/F Boaring F/Boaring Taping Taping Taping
Tool Type
2nd Set up (M Time
Dia 80 Milling Cutter Dia 14 Drill Carbide Dia 16 Drill Carbide Dia 17 Drill Carbide Dia 15.5 Drill Carbide Dia 6.8 Drill Carbide Dia 25 Chamfer Tool Dia 17 Rimmer Carbide Dia 37 U Drill DIA 39.7 BORING BAR Dia 40 Boaring Bar M16 X 2 Tap M18X 2.5 Tap M8 X 1.25 Setting Time
Total Cost
9.20 3.30 1.05 1.75 1.65 1.00 2.75 2.75 2.35 2.50 4.50 4.15 1.65 1.00 5.00 44.60 1050.00
780.50 1528.63
Remarks
S. No. 1 2 3 4 5 6 7 8 9 10 11
Process R/Facing F/Facing R/Milling F/Milling Drilling Drilling Drilling Chamfering Taping Taping
Casting
2nd Set up (Mazak) Tool Type Dia 100 Face Mill Cutter Dia 100 Face Mill Cutter Dia 80 Cutter Dia 40 End Mill Dia 18 End Mill Dia 6.8 Drill Carbide Dia 8.5 Drill Carbide Dia 25 X 90 Counter Shenk M8 X 1.25 Tap M10 X 1.5 Tap Setting Time
2 nd Set up Total Time Machine Hour Rate
Total Cost
Time 14.00 4.00 5.50 5.25 1.25 1.00 1.00 2.00 2.50 1.25 5.00
42.75 1050.00
748.125
` PART NO. Casing Rear Axle D RH DRG NO. D10229370 A LOT SIZE 50 Nos. S. No.
Operation Description
Machin Usage Tool used e Used /tips
Cutting speed
Feed
Feed
RPM
Met/min mm / rev mm/min
DIA
LOC
No. Of passes/ stroke
Mach. time TH
PR min
mm
mm
Nos'
min
13
23
12
0.805
469 2345 9.5
23
2
0.098
1
Drilling
VMC
Drill
2
70
0.2
2
Drilling
VMC
Drill
2
70
0.2
3
Chamfer
VMC
Counter
4
60
0.3
229.2 764
25
3
20
0.262
4
Tapping
VMC
Tap
7
1.75
324.9 186
12
23
2
0.142
5
Hole Milling
VMC
Holemill
5
20
0.3
194.9 650
9.8
23
2
0.236
6
Reaming
VMC
Reamer
5
20
0.3
191
10
23
2
0.241
7
Drilling
VMC
Drill
2
70
0.2
469 2345 9.5
23
2
0.098
8
VMC
342.8 1714
637
Setting, Inspection & Loading-Unloading Time
13 Rough Milling
Mazak
Cutter
5
180
1
909.3 909
63
2000
3
6.598
14 Drilling
Mazak
Drill
2
60
0.2
347.2 1736
11
20
2
0.115
15 Drilling
Mazak
Drill
2
60
0.15
424.4 2829 6.75
20
22
1.037
16 Drilling
Mazak
Drill
2
60
0.2
381.9 1910
10
25
3
0.196
17 Counter
Mazak
Endmill
4
60
0.4
424.4 1061
18
30
6
0.424
18 Drilling
Mazak
Drill
2
60
0.15
337 2247 8.5
25
2
0.148
19 Tapping
Mazak
Tap
7
1.25
348.1 278
40
22
2.528
20 Fnish Milling
Mazak
Cutter
8
180
0.6
343.7 573
1
5.819
21 Drilling
Mazak
Drill
2
60
0.2
218.2 1091 17.5
80
4
1.466
22 Chamfer
Mazak
Counter
4
20
0.3
76.38 255
25
2
11
0.288
23 Tapping
Mazak
Tap
7
2.5
278.5 111
20
120
4
1.724
24 Drilling
Mazak
Drill
60
0.2
318.3 1591
12
20
4
0.251
25 Tapping
Mazak
Tap
7
2
318.3 159
14
40
4
0.503
26 Counter
Mazak
Endmill
60
0.4
424.4 1061
18
30
12
0.848
26
Mazak
2
4
Setting, Inspection & Loading-Unloading Time
8
100 2000
Hand. Setting time time
min
min
Total time TH
PR
min
min
Concd Total . Time. Time
min
Rate
Total Cost
min
0.7
1.51
475
11.92
0.7
0.80
475
6.32
1
1.26
0
0.00
0.8
0.94
475
7.45
0.6
0.84
475
6.62
0.6
0.84
475
6.66
0.8
0.90
475
7.11
5.00
475
39.58
12.08
85.66
1
7.60
475
60.15
0.4
0.52
1050
9.02
1.2
2.24
1050
39.15
0.6
0.80
1050
13.94
0.5
0.92
1050
16.17
0.5
0.65
1050
11.35
1.3
3.83
1050
66.99
0.4
6.42
1050
112.32
0.8
2.27
1050
39.66
0.6
0.89
1050
15.54
0.8
2.52
1050
44.16
0.8
1.05
1050
18.40
0.6
1.10
1050
19.30
1
1.85
1050
32.35
5.00
1050
87.50
37.65
585.99
PART NO. DRG NO. LOT SIZE S. No.
Operation Description
Casing Rear Axle D RH
Machin Usage Tool used e Used /tips
Cutting speed
Feed
Feed
RPM
Met/min mm / rev mm/min
DIA
LOC
No. Of passes/ stroke
Mach. time TH
PR min
mm
mm
Nos'
min
1
Turning Rough
CNC
Turning
1
200
0.4
391.7 979
65
195
1
0.498
2
Turning Rough
CNC
Turning
1
200
0.2
195.9 979
65
125
1
0.638
3
Finish Turning
CNC
Turning
1
200
0.2
195.9 979
65
195
1
0.996
8
VMC
Setting, Inspection & Loading-Unloading Time
13 Rough Milling
Mazak
Cutter
5
180
1
909.3 909
63
2000
3
6.598
14 Drilling
Mazak
Drill
2
60
0.2
347.2 1736
11
20
2
0.115
15 Drilling
Mazak
Drill
2
60
0.15
424.4 2829 6.75
20
22
1.037
16 Drilling
Mazak
Drill
2
60
0.2
381.9 1910
10
25
3
0.196
17 Counter
Mazak
Endmill
4
60
0.4
424.4 1061
18
30
6
0.424
18 Drilling
Mazak
Drill
2
60
0.15
337 2247 8.5
25
2
0.148
19 Tapping
Mazak
Tap
7
1.25
348.1 278
40
22
2.528
20 Fnish Milling
Mazak
Cutter
8
180
0.6
343.7 573
1
5.819
21 Drilling
Mazak
Drill
2
60
0.2
218.2 1091 17.5
80
4
1.466
22 Chamfer
Mazak
Counter
4
20
0.3
76.38 255
25
2
11
0.288
23 Tapping
Mazak
Tap
7
2.5
278.5 111
20
120
4
1.724
24 Drilling
Mazak
Drill
60
0.2
318.3 1591
12
20
4
0.251
25 Tapping
Mazak
Tap
7
2
318.3 159
14
40
4
0.503
26 Counter
Mazak
Endmill
60
0.4
424.4 1061
18
30
12
0.848
26
Mazak
2
4
Setting, Inspection & Loading-Unloading Time
8
100 2000
Hand. Setting time time
min
min
Total time TH
PR
min
min
Concd Total . Time. Time
min
Rate
Total Cost
min
0.7
1.20
300
5.99
0.7
1.34
300
6.69
0.7
1.70
300
8.48
5.00
475
39.58
9.23
60.74
1
7.60
475
60.15
0.4
0.52
1050
9.02
1.2
2.24
1050
39.15
0.6
0.80
1050
13.94
0.5
0.92
1050
16.17
0.5
0.65
1050
11.35
1.3
3.83
1050
66.99
0.4
6.42
1050
112.32
0.8
2.27
1050
39.66
0.6
0.89
1050
15.54
0.8
2.52
1050
44.16
0.8
1.05
1050
18.40
0.6
1.10
1050
19.30
1
1.85
1050
32.35
5.00
1050
87.50
37.65
585.99
PART NO.
Front Axle Bracket
DRG NO.
10090792 FB
LOT SIZE S. No.
Operation Description
Cutting Machine Usage speed Tool used Used /tips
Feed
Feed
RPM
Met/min mm / rev mm/min
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
S. No.
1 2 3 4 5 6 7 8 9 10
Milling Drilling Chf 1x45 Drilling 17.8 Chf 1x45 Reaming 18 Milling Drilling 13.5 Chf 1x45 Tapping M16 Drilling 12 Chf 1x45 Tapping M14 Milling Drilling 13.5 Chf 1x45 Tapping M16 Drilling 12 Chf 1x45 Tapping M14 Milling Drilling 15.5 Chf 1x45 Tapping M18
Mazak Mazak Mazak Mazak Mazak Makino Mazak Mazak Mazak Mazak Mazak Mazak Mazak Mazak Mazak Mazak Mazak Mazak Mazak Mazak Mazak Mazak Mazak Mazak
Cutter Drill Drill Drill Drill Reamer Cutter Drill Drill Tap Drill Drill Tap Cutter Drill Drill Tap Drill Drill Tap Cutter Drill Drill Tap
8 2 2 2 2 5 8 2 2 4 2 2 4 8 2 2 4 2 2 4 8 2 2 4
180 60 60 60 60 25 180 60 60 7 60 60 7 180 60 60 7 60 60 7 180 60 60 7
0.6 0.2 0.2 0.15 0.2 0.3 0.6 0.2 0.2 2 0.2 0.2 2 0.6 0.2 0.2 2.5 0.2 0.2 2 0.6 0.2 0.2 2.5
343.7 198.9 173.6 160.9 191 132.6 343.7 282.9 238.7 278.5 318.3 272.8 318.3 343.7 282.9 238.7 348.1 318.3 272.8 318.3 343.7 246.4 212.2 309.4
Mazak
Operation Description Milling Drilling 6.5 Chf 1x45 Tapping Drilling 8.5 Chf 1x45 Tapping Milling Milling Holemill 29.8
Mazak Mazak Mazak Mazak Mazak Mazak Mazak Mazak Mazak
Cutter Drill Drill Tap Drill Drill Tap Cutter Cutter Holemill
8 2 2 2 2 8 8 4
180 60 60 7 60 60 7 180 180 60
0.6 0.2 0.2 1.25 0.15 0.2 1.5 0.6 0.6 0.4
343.7 587.6 477.4 348.1 337 381.9 334.2 343.7 343.7 256.3
LOC
No. Of passes/ stroke
TH
PR
mm
mm
Nos'
min
min
573 100 900 2 5.237 995 19.2 30 6 0.905 868 22 1 6 0.035 1073 17.8 14 2 0.174 955 20 1 2 0.01 442 18 14 2 0.211 573 100 820 2 4.771 1415 13.5 50 5 0.884 1194 16 2 5 0.042 139 16 45 5 0.808 1591 12 55 2 0.346 1364 14 2 2 0.015 159 14 50 2 0.314 573 100 820 2 4.771 1415 13.5 50 5 0.884 1194 16 2 5 0.042 139 16 45 5 0.646 1591 12 55 2 0.346 1364 14 2 2 0.015 159 14 50 2 0.314 573 100 690 2 4.015 1232 15.5 45 4 0.731 1061 18 2.5 4 0.047 124 18 45 4 0.582 Setting, Inspection & Loading-Unloading Time
Cutting Feed Feed RPM Machine Usage speed Tool used Used /tips Met/min mm / rev mm/min Mazak
Mach. time
DIA
573 2938 2387 278 2247 1910 223 573 573 641
DIA
LOC
No. Of passes/ stroke
TH
PR
mm
mm
Nos'
min
min
2 23 23 23 4 4 4 2 2 4
8.751 0.47 0.048 0.793 0.142 0.01 0.144 1.862 1.862 0.134
100 1504 6.5 12 8 1 8 12 8.5 12 10 1 10 12 100 320 100 320 29.8 8.6
Mach. time
11 12 13 14 15 16
Chf 1x45 Reaming 30 Drilling 17.5 Chf 1x45 Tapping
Mazak Makino Mazak Mazak Mazak
Counter Reamer Drill Drill Tap
4 5 2 2
60 25 60 60 7
0.2 0.1 0.2 0.2 2.5
119.4 26.52 218.2 191 278.5
597 32 1 4 0.034 265 30 8.6 4 1.297 1091 17.5 55 4 1.008 955 20 2 4 0.042 111 20 50 4 0.718 Setting, Inspection & Loading-Unloading Time
Hand. Setting time time min
min
0.5 0.3 0.3 0.3 0.3 0.3 0.5 0.3 0.3 0.3 0.3 0.3 0.3 0.5 0.3 0.3 0.3 0.3 0.3 0.3 0.5 0.3 0.3 0.3 g-Unloading Time
0.5 0.3 0.3 0.3 0.3 0.3 0.3 0.5 0.5 0.3
TH
PR
min
min
5.74 1.20 0.33 0.47 0.31 0.51 5.27 1.18 0.34 1.11 0.65 0.31 0.61 5.27 1.18 0.34 0.95 0.65 0.31 0.61 4.51 1.03 0.35 0.88 5.00 39.14
Hand. Setting time time min
Total time
min
Rate 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100
Total Cost 105.17 22.09 6.13 8.69 5.69 9.37 96.64 21.70 6.27 20.31 11.84 5.77 11.26 96.64 21.70 6.27 17.35 11.84 5.77 11.26 82.77 18.89 6.36 16.16 91.67 717.62
Total time TH
PR
min
min
9.25 0.77 0.35 1.09 0.44 0.31 0.44 2.36 2.36 0.43
Rate
Total Cost
1100 1100 1100 1050 1100 1100 1050 1100 1100 1100
169.60 14.11 6.38 19.13 8.11 5.69 7.76 43.30 43.30 7.96
0.3 0.3 0.3 0.3 0.3 g-Unloading Time
0.33 1.60 1.31 0.34 1.02 5.00
1100 1100 1100 1100 1100 1100
27.42 Total
66.56
6.11 29.28 23.98 6.27 18.67 91.67 501.33
Rs.
1218.95
EMMBROS AUTOMOTIVE PVT. LTD. COST ESTIMATION CUSTOMER - ITL Front Axle Bracket NA
PART NAME
Sr.No
Description / Item
PART NO. ( Casting ) PART NO. ( MACHINING )
10090792 FB
NA
BLANK NO. 01 02
Material Finish weight ( Finish Part After Machining ) ( Kg )
10
Srcap genrated (Kg) after mc
11 12
Srcap Rate / Kg. (Rs )
14 18 19 20 21
Machining Process Cost
FG260
Value of Total Srcap 1248.95 10.00 124.89 249.79 120.00
Packing ( Individual or Bulk ) Detail attached Overheads @ 10% of process cost Profit @ 20% of process cost Freight @ Rs. 3/Kg on Finish wt
TOTAL COST ( Finish Part ) / Pc TOOLING COST One Time 50 % Advance & 50 % at the time of sample approval ( DIE + GAUGES )
1753.63 0.00
MACHINING COST
OPN.NO.
OPERATION
MACHINE
010
Machining Process Cost
CNC TURNING
070
MARKING
PIN MARKING
090
FINAL INSPECTION
INSPECTION
Total Process Cost
These rate are included freight
M/C HOUR RATE
M/C TIME 66.56
125
Front Axle Bracket NA 10090792 FB
NA FG260
1248.95 10.00 124.89 249.79 120.00
1753.63 0.00 M/C COST 1218.95 30.00
1248.95
0
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