Solution:TocalculateProcessloss

Materialcost
Yield
Castingwt
Processscrap
CastingWtwithRiser
Rejection+MetalSpillage8%

550 RsperKg
50 %
1.32 Kg
1.320 Kg
2.640 Kg
0.211 Kg

Totalmaterialrequired
Totalreturns
Meltloss+Cutting+Grindingloss10%
Totalmaterialrequiredincludingmeltloss
Metalconsumption
TotalProcessLoss
Solution:Tocalculatematerialcost:
Materialcost/piece
Processreturn
Processloss
Netmaterialcostperpiece
Administrativeoverheadcharges
Theotherexpendituredetailsare:
Process
Melting,Moldsetupandpouring
RiserCutting(BandSaw)
Contactgrinding&Handgrinding
Inspection&Packing
(ii)CalculateLabourCostandOverheads
Process
Melting,Moldsetupandpouring
RiserCutting(BandSaw).
Contactgrinding&HandGrinding
Inspection&Packing
Total
Labourcharges
Shopoverheads
MeltingandfettlingConsumablesperKg

2.851 Kg
1.531 Kg
0.285 Kg
3.136 Kg
1.605 Kg
17.76 %

Timeperpieceinmin
2
2.25
2
2
Timeper
pieceinmin
2
2.25
2
2

Labourchargesperhr Shopoverheadsperhrin
inRs
Rs
400
400
300
400
300
400
300
400

Labourcharges
perpiece(Rs.)
13.33
11.25
10.00
10.00
44.58
44.58 Rs.perpiece
55.00 Rs.perpiece
85.69 Rs.perKg
113.12 Rs.perpiece

Totalfactorycostw/omaterial
Totalfactorycostwithmaterial

212.70 Rs.perpiece
1067.66 Rs.perpiece

Administrativeoverheads10%ofFactorycost
Profit15%offactorycost
Totalcostperpiece

21.27 Rs.perpiece
31.90 Rs.perpiece
1120.83 Rs.perpiece

Total Cost per pc

Castwt+Meltloss

1452.00 Rs.
726.00 Rs.
128.96 Rs.
854.96 Rs.
85.69 Rs.perkgofmetalpoured.

MeltingandfettlingConsumablesperpiece

InterestandDepriciation25%

Remark
Material cost including Tax + Transportation
Casting Yield
Raw casting wt
100.00% Ingate+Riser wt
Total casting wt inclusing ingate and riser
8% Rejection+Spillagemetalwhilepouring8%
Totalmaterialrequiredtogetcastingwtincluding8%
rejectionloss
Totalreturnincludingrejection
10%

280.208

1401.04 Rs/pc

Shopoverheads
perpiece(Rs.)
13.33
15.00
13.33
13.33
55.00

10%
15%

Melting Over heads per Kg

Cost per
unit

Melting Consumables
Crucible
Heating element
Furnace lining
Pouring spoon
Graphite Coating
Albral
Hand gloves
Temperature Tip
Core pins
Accessories
Loboratory charges per Kg melt
Total consumable cost per Kg molten metal

Nos
Capacit Consumable
Required y in KG cost per Kg

26000
3800
175000
500
100
200
125
80
0
1000

1
12
1
2
100
1
6
3
0
1

12000
20000
30000
300
30000
300
600
300
600
300

Consider 50% yield conumable cost per Kgs

2.17
2.28
5.83
3.33
0.33
0.67
1.25
0.8
0.0
3.3
2.6
22.60

45.19

Rs/Kg

Fettling cost per Kgs

Cost per
unit

Melting Consumables
Band saw Blade
Grinding Belt for contact grinding
Grinding Belt for Hand grinding
Hand gloves

Nos
Capacit Consumable
Required y in KG cost per Kg

2000
380
40
25

1
1
1
2

200
100
50
100

10.00
3.80
0.80
0.50
15.10

Energy Cost
Energy consumption for melting
Units consumed per day
550 Unit
Cost per unit
6.35 Rs
Cost for 150 kg output per day
3492.5 Rs
Melting Energy consumption per Kg
23.28 Rs/Kg
Energy consumption fettling
Cost for 150 kg output per day
317.5 Rs
Fettling Energy consumption per Kg
2.12 Rs/Kg
Total Energy consumption per Kg's
25.40 Rs/Kg

Total Over Heads

85.69 Rs/Kg
Labour cost per Hr

Melting and Mold setting and pouring

NO of operator required for pouring mold, setting
and Mold maintanence
Operator Cost per day
Total Cost per day
Operator cost/Hr
Operator Cost per min
Band saw Grinding and inspection(Fettling)
NO of operator required for pouring mold, setting
and Mold maintanence
Operator Cost per day
Total operator Cost per day
Total operator Cost per Hr
Operator Cost per min

Operator

Staf

4 No
800 Rs/Day
3200 Rs/Day
400 Rs/Hr
6.67 Rs/Min

2 No
1200 Rs/Day
2400 Rs/Day
300 Rs/Hr
5.00 Rs/Min

4 No
600 Rs/Day
2400 Rs/Day
300 Rs/Hr
5.00 Rs/Min

2 No
1200 Rs/Day
2400 Rs/Day
300 Rs/Hr
5.00 Rs/Min

Total
6
5600
11.67

6
4800
10.00

Sl no

Part no

1
2
3
4

2740561R
2740561L
2749061R
2749061L

Part description
Cam
Cam
Cam
Cam

handle
handle
handle
handle

561 Right
561 Left
9061 Right
9061 Left

Material
ASTM
ASTM
ASTM
ASTM

B62,C83600
B62,C83600
B62,C83600
B62,C83600

Bronze
Bronze
Bronze
Bronze

Casting GDC Process

wt
cost in Rs

Die Cost
in rs

Machining Cost

1.25 1335.00
1.25 1335.00
1.32 1401.04
1.32 1401.04

81750.0
81750.0
98437.5
98437.5

yet
yet
yet
yet

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be
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received
received
received
received