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INJECTION MOLDING TECHNICAL COST MODEL

MIT - Materials Systems Laboratory


Jump to Sensitivity Analysis
PART/MATERIAL INPUTS
Material
Weight
Maximum Wall Thickness
Average Wall Thickness
Projected Area

EXOGENOUS DATA
Annual Production Volume
Facility Production Capacity
Product Life
Direct Wages (w/ benefits)
Working Days/Yr
Downtimes
No Operations
Planned Paid
Planned Unpaid

4
800
2.00
1.60
850

100
300
5
$15.00
240

grams
mm
mm
sq cm

(000/yr)
(000/yr)
yrs
/hr

7 hrs/day
1 hrs/day
1.2 hrs/day

Capital Recovery Rate

10%

Price, Building Space


Building Recovery Life
Price of Electricity
Accounting Life of Machine
Overhead Burden (% fc)

$1,500
30
$0.080
20
35.0%

/sq m
yrs
/kWh
yrs

PROCESS INPUTS
Unplanned Downtime
1.50
Material Scrap Rate
2.0%
Reject Rate
1.0%
Direct Laborers Per Machine
1
Dedicated Equipment (1/0)
0
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
Toolmaker Shop Rate
$100.00
Baseline Mold Life 1,000,000

hrs/day

(1=y;0=n)

(1=y;0=n)
/hr
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
Total Cycle Time

0 sec
0 sec

INJECTION MOLDING - COST SUMMARY

VARIABLE COSTS
Material Cost
Energy Cost
Labor Cost
Total Variable Cost
FIXED COSTS
Main Machine
Auxiliary Equipment
Tooling
Fixed Overhead
Building
Maintenance
Total Fixed Cost

Cost
Cost
Cost
Cost
Cost
Cost

Total Fabrication Cost

per piece
$0.80
$0.08
$0.16
$1.03
per piece
$0.18
$0.03
$0.46
$0.29
$0.17
$0.04
$1.17
$2.20

RELATED VARIABLES
Material Requirements:
Raw Material Price
Trim Scrap Rate
Gross Material per Part
Annual Material Input

Process Calculations
Effective Production Volume
Effective Capacity
Capacity and Volume are Consistent?
Available Operating Time

$0.97
2.0%
816.3
82,458

101,011
303,031
1
3,192

Effective Cycle Time (from below)


Required Operating Time (produced)
Required Operating Time (capacity)
Run-Time for One Machine (produced)
Run-Time for One Machine (capacity)
Number of Parallel Streams

35
983
2,949
31%
92%
0.92

Paid Operating Time (available in year)


Actual Paid Operating Time (allocated)

3,432
1,057

Number of tools required


Required Building Space
Energy Adjustment Factor
Annual Energy Consumption

2
113
1.52
93,833

Cycle Time Calculations


Cooling Time (sec)
Total Cycle Time (sec)

Predicted
10.4
35.0

Press & Tool Characteristics & Costs


Clamping Force (kN)
Press Cost
Tool Cost

Predicted
2,967
$136,486
$87,493

NG - COST SUMMARY

INJECT

per year
$79,776
$7,507
$15,853
$103,136

percent
36.27%
3.41%
7.21%
46.89%

per year
$17,772
$2,962
$46,161
$29,207
$16,554
$4,172
$116,829

percent
8.08%
1.35%
20.99%
13.28%
7.53%
1.90%
53.11%

$219,965

100.00%

Prod Volume

investment
$151,304
$25,217
$174,987
$156,054
$482,345

1
25
50
75
100
125
150
175
200
225
250
275
300
325
350
375
400
425
450

Var. Cost

$1.03
$1.03
$1.03
$1.03
$1.03
$1.03
$1.03
$1.03
$1.03
$1.03
$1.03
$1.03
$1.03
$1.03
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A

Fixed Cost

$1.17
$116.83
$4.67
$2.34
$1.56
$1.17
$0.93
$0.78
$0.67
$0.58
$0.52
$0.47
$0.42
$0.39
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A

/kg
g
kg

Unit Cost
Production
Volume

hours / year
secs / part
hours / year
hours / year

hours / year
person-hours / year

$2.20
1
25
50
75
100
125
150
175
200
225
250
275
300
325
350
375
400

Capacity
100
$49.29
$2.96
$2.00
$1.67
$1.51
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A

425
450

#N/A
#N/A

sq m
Cost Breakdown @ 100,000
Unit Costs
Material
$0.80
Other Var
$0.23
Equip
$0.21
Tooling
$0.46
Other Fixed
$0.50
Total Cost
$2.20

Used
10.4
35.0

Used
2,967
$136,486
$87,493

326 tons

2500%
Fraction of Total Cost

kWh/year

0%

INJECTION MOLDING - Sensitivity Analysis

Total Cost

Effect of Production Volume


$5.00
Var. Cost
Total Cost

$4.00
$3.00
$2.00
$1.00
$0.00
0

50

200
300
400
500
$99.00 $117.86 $202.81 $224.59
$4.95
$5.70
$9.10
$9.97
$2.99
$3.37
$5.07
$5.50
$2.34
$2.59
$3.72
$4.01
$2.01
$2.20
$3.05
$3.27
$1.82
$1.97
$2.65
$2.82
$1.68
$1.81
$2.38
$2.52
$1.59
$1.70
$2.18
$2.31
$1.52
$1.62
$2.04
$2.15
#N/A
$1.55
$1.93
$2.02
#N/A
$1.50
$1.84
$1.93
#N/A
$1.46
$1.77
$1.84
#N/A
$1.42
$1.70
$1.78
#N/A
#N/A
$1.65
$1.72
#N/A
#N/A
$1.61
$1.67
#N/A
#N/A
$1.57
$1.63
#N/A
#N/A
$1.54
$1.59

100

150

200

250

300

350

400

Production Volume (thousands)

Effect of Production Vol & Capacity


$5.00
$4.50
$4.00
Unit Cost ($/part)

Unit Cost ($ / piece)

$2.20
$117.86
$5.70
$3.37
$2.59
$2.20
$1.97
$1.81
$1.70
$1.62
$1.55
$1.50
$1.46
$1.42
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A

$3.50
$3.00
$2.50
$2.00
$1.50
$1.00
$0.50
$0.00
0

50 100 150 200 250 300 350 400 450 5


Production Volume (parts/year)

$0.00
0
#N/A
#N/A

#N/A
#N/A

#N/A
#N/A

50 100 150 200 250 300 350 400 450 5

$1.56
$1.53

Production Volume (parts/year)

Cost Breakdown By Element

Fraction of Total Cost

2500%
Other Fixed
Tooling
Equip
Other Var
Material

0%

Unit Cost
Past
Mass

st

400

& Capacity

350 400 450 500

s/year)

100
200
300
400
500

$2.20
100
150
200
250
300
350
400
450
500
550
600
650
700
750
800
850
900
950
1,000

Max Wall Thickness


1
1.5
$0.84
$0.90
$0.92
$0.98
$1.00
$1.06
$1.08
$1.15
$1.16
$1.23
$1.24
$1.31
$1.32
$1.39
$1.40
$1.48
$1.48
$1.56
$1.56
$1.64
$1.65
$1.73
$1.73
$1.81
$1.81
$1.90
$1.90
$1.98
$1.98
$2.07
$2.07
$2.16
$2.15
$2.24
$2.24
$2.33
$2.32
$2.42

2
$0.99
$1.07
$1.16
$1.24
$1.33
$1.41
$1.50
$1.59
$1.67
$1.76
$1.85
$1.93
$2.02
$2.11
$2.20
$2.29
$2.38
$2.47
$2.56

350 400 450 500

s/year)

2.5
$1.10
$1.19
$1.28
$1.37
$1.46
$1.55
$1.64
$1.73
$1.82
$1.91
$2.00
$2.10
$2.19
$2.28
$2.37
$2.46
$2.56
$2.65
$2.75

3
$1.25
$1.34
$1.44
$1.54
$1.63
$1.73
$1.82
$1.92
$2.01
$2.11
$2.20
$2.30
$2.40
$2.49
$2.59
$2.69
$2.79
$2.89
$2.99

Exploring the impact of design

Unit Cost ($/part)

100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950
1
1.5
2
2.5
Part M ass (g)

3
M ax Wall

3
2.5
2
1.5
1

0 800 850 900 950 1,00


0
1
1.5
2
2.5
3
M ax Wall Thick (m m )

Material Cost
Energy Cost
Labor Cost
Total Variable Cost
Main Machine Cost
Auxiliary Equipment Cost
Tooling Cost
Fixed Overhead Cost
Building Cost
Maintenance Cost
Total Fixed Cost
Total Fabrication Cost
Resin

Unit Costs
$0.80
$0.08
$0.16
$1.03
$0.18
$0.03
$0.46
$0.29
$0.17
$0.04
$1.17
$2.20
4

Material
Other Variable
Equipment
Tooling
Other Fixed
Total Cost

Unit Costs
$0.80
$0.23
$0.21
$0.46
$0.50
$2.20

MATERIAL DATABASE

Type
POLYSTYRENE
PVC (RIGID)
ABS
POLYPROPYLENE (HOMO)
NYLON 6
POLYCARBONATE
ACETAL (HOMO)
HDPE
POLYPHENYLENE ETHER
PET
THERMOPLASTIC POLYIMIDE
EVA
NYLON 6/30% GLASS
POLYCARBONATE/30% GLASS
ABS/20% GLASS
ACETAL/25% GLASS
PBT Alloy
PC/PBT
PC/PBT
PC
PPE
Blend
PA
PA
EVA CoPA
PA
Ionomer
LDPE
LDPE
LDPE
HDPE
HDPE
HDPE
PP CoPP CoPP CoEMPP
EMPP
EMPP
R-EMPP
ABS

Tradename

Valox
Xenoy
Xenoy
Lexan
Noryl
Noryl
Zytel
Zytel
Elvax
Bexloy
Bexloy
Suryln
Stamylan-LD
Stamylan-LD
Stamylan-LD
Stamylan-HD
Stamylan-HD
Stamylan-HD
Stamylan-P
Stamylan-P
Stamylan-P
Keltan TP
Keltan TP
Keltan TP
Kelburon
Ronfalin

Grade

830
1200
1101
141
844
GTX
ST-801
ST-901
960

2138GW00
2322GL00
2538EL00
7249
7058
5119
83MF10
412MN40
48M10
0603
0505
2607
90594
FX

#
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
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42

ABS
ABS
ABS
ABS/PVC
PPE
PPE
PPE
PPE
ABS
ABS
ABS
ABS
ABS
ABS
TPO
TPO
TPE ester
TPE ester
TPU

Ronfalin
Ronfalin
Ronfalin
Ronfalin
Prevex
Prevex
Prevex
Prevex
Cycolac
Cycolac
Cycolac
Cycolac
Cycolac
Cycolac
Ontex
Dexflex
Lomod
Bexloy
Estane

TX
HX
VE
RN-03
PMA
PQA
VJA
W30
T
GSM
L
DFAR
DH
KJB
111BX
850
521
V

43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
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

Price
($/kg)
$2.33
$0.84
$2.22
$0.97
$4.38
$3.96
$3.43
$0.81
$2.93
$3.52
$11.88
$2.09
$4.27
$5.21
$2.38
$4.07
$3.26
$3.96
$3.74
$4.64
$2.66
$3.63
$5.06
$5.41
$1.50
$4.07
$4.40
$2.97
$0.73
$0.73
$0.73
$0.81
$0.81
$0.81
$0.93
$0.87
$0.87
$1.83
$1.93
$1.73
$1.89
$2.13

$2.24
$2.24
$2.72
$2.64
$3.43
$4.29
$3.76
$3.76
$2.50
$2.53
$2.60
$2.35
$2.42
$2.99
$2.97
$2.09
$3.74
$3.63
$4.62