AT 1804 Instructions
INSTRUCTIONS FOR COMPLETION OF PIECE COST BREAKDOWN WORKSHEET
Definitions for Document Header:
Daily Estimated Volume - LCR: The ATI daily requirement with a 5 day per week operating plan. Supplier is required to meet the weekly
requirement within an 80 hour work week. This value should be entered from the data provided in the RFQ package.
Daily Estimated Volume - MCR: 127.5% of LCR. Supplier is required to meet within a 120 hour work week. This value should be entered from
the data provided in the Request for Quote (RFQ) package.
Supplier Daily Capacity Rate: The quantity of parts the Supplier is capable of making per day based on their operating plan.
@ hrs / day: The hours per day scheduled in the Supplier operating plan.
@ days / week: The days per week scheduled in the Supplier operating plan.
Definitions for Sequential Items (below the document header):
1) Item Description: Identify the name of the component and part number. Outside services
(i.e. heat treat, coatings) and expendable packaging should be placed in this section also.
2) Material Type / Grade: Identify the type of material (i.e. Steel, Aluminum, etc.) & Grade (4140, A356, etc.) and be specific.
3) Base Index Cost (USD): Identify your base material index cost that you have used (i.e. 4140 @.50/lb. based on Feb 2014 economics).
4) Purch. (P) or Manuf. (M): Identify if component is purchased or manufactured in house.
5) Unit of measure: Identify the unit of measurement (i.e.: lbs./pc, gal/pc, inches/pc., each, etc.)
Can be in metric, but be consistent. Indicate if gross weight (G) or net weight (N) where applicable.
6) Net Weight: Identify the net weight of the part.
7) Quantity: Identify how much of that unit it takes for one part.
8) Base Index Cost / Unit: Extended Base Cost calculated by multiplying #3 (Base Index Cost) x #6 (Net Weight).
9) Total Material Cost (USD): Identify the cost per unit of each item. Field 9 = Field 7 x Field 8.
10) Supplier: Identify the supplier or potential supplier for the item of material.
11) Country of Origin: Identify country where part or component is manufactured or purchased.
12) Supplier DUNS Number: Identify the supplier or potential supplier's Dun & Bradstreet number, if applicable.
13) Operation/Process Description: Identify each of the processes the part must go through.
14) Set Up (USD): Identify the set up costs in USD for the operations outlined in #13.
15) Hrly Labor Rate (USD): Identify the labor rate for each operation in USD.
Please note in remarks if fringes are included in labor rate or in the burden.
16) Cycle Time: Identify the cycle time in hours to perform the operations outlined in #13.
17) Number of Operators: List the number of operators required to produce one part.
18) Labor Cost: Extension of labor rate multiplied by the standard hours or divide the labor rate by the hourly production rate.
Field 18 = Field 14 X Field 15 X Field 16 X Field 17.
19) Machine Size: List the size in tonnage or other unit of measure for any machinery involved
in this process step (i.e.: 300 Ton Injection Molding Machine).
20) Machine Type: List the type of machinery used in this process step (i.e. stamping press, etc.).
21) Variable Cost (USD): Identify the portion of the burden which varies directly with activity level in USD
(i.e. indirect material supplies, freight, etc.).
22) Fixed Cost (USD): Identify the portion of the burden which remains constant, regardless of changes in activity level in USD
(i.e.: depreciation, supervisory salaries, maintenance, etc.).
23) Total (USD): Includes all manufacturing costs except direct labor and direct material, costs associated in USD,
with operating the factory. Field 23 = Field 21 + Field 22.
24) Total Manufacturing Cost (USD): (material + labor + burden): Sum of material, labor and burden in USD.
25) Selling, General and Administration Expenses (USD):
Identify the dollar amount included for selling, general and administrative expenses in USD
(i.e.: non-manufacturing costs such as accounting, executive salaries, advertising, travel etc.).
26) Profit (USD): Identify the profit dollar amount portion of the selling price in USD.
27) Supply Chain Costs (USD): Detailed supplier costs per supply chain requirements in USD (reference AT-1700).
28) Grand Total Selling Price (USD): Identify the selling price in USD.
29) Local Currency: Identify the local quoted currency of the Selling Price.
30) Currency Exchange Rate per OANDA Website (USD to Local Currency): Identify the currency rate of exchange.
31) Date of Currency Exchange Rate: Identify the date used to determine #30.
32) Grand Total Selling Price: Identify the selling price in local currency.
33)
Is Capital Equipment Being Purchased: Identify if capital equipment is needed in order to support this program. If YES, please
provide amortization schedule.
the selling price in local currency:
34) Scrap Rate %: Identify the scrap rate as a % built into the piece cost.
35) Set Up Information: Identify the cost per set up in USD along with the parts being able to be run per this set up.
AT-1804
Rev 7/11/2014
Vuteq Canada corp.
VC-1804 Piece Cost Breakdown Worksheet (PCBW)
V: 07/15/2014
Part Number:
Part Name:
Supplier Name:
Manufacturing Location:
DUNS Number:
Prepared By:
OS Number:
Drawing Level:
Daily Estimated Volume - LCR:
Daily Estimated Volume - MCR:
Supplier Daily Capacity- SCR:
@ hrs/day:
@ days/week:
100
127.5
Date:
(80 hours / 5 days per week)
(127.5% of LCR)
Raw Material & Purchased Components:
(1)
(2)
(3)
(4)
(5)
Item Description
Material
Type/Grade
Base Index
Cost (USD)
Purch.(P)
Manuf.(M)
Unit of
measure
Kg
abs
$1.4000
(7)
(8)
(9)
Net Weight
Quantity
Base
Cost / Unit
Total
Material Cost
(USD)
0.5000
(6)
0.7000
$1.4000
0.0000
$0.0000
0.0000
$0.0000
0.0000
$0.0000
0.0000
$0.0000
0.0000
$0.0000
0.0000
$0.0000
0.0000
$0.0000
0.0000
$0.0000
0.0000
$0.0000
0.0000
$0.0000
0.0000
$0.0000
0.0000
$0.0000
0.0000
$0.0000
0.0000
$0.0000
Total
Labor & Burden:
Machine Data:
Labor Detail:
(14)
(13)
Operation
Description
OP #
Set Up (USD)
(11)
(12)
Supplier
Country
of Origin
Duns Number
$1.4000
Burden Detail:
Burden Total:
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
Hrly Labor
Rate (USD)
Hrly Cycle
Time
No. of
Oper.
Labor Cost
(USD)
Machine
Size
Machine
Type
Variable
Cost (USD)
Fixed
Cost (USD)
Total (USD)
Total Labor Cost (USD):
$0.0000
$0.0000
$0.0000
$0.0000
$0.0000
$0.0000
$0.0000
$0.0000
$0.0000
$0.0000
$0.0000
$0.0000
$0.0000
$0.0000
$0.0000
$0.0000
$0.0000
$0.0000
$0.0000
$0.0000
$0.0000
$0.0000
$0.0000
$0.0000
$0.0000
$0.0000
$0.0000
$0.0000
$0.0000
$0.0000
$0.0000
Additional Life Cycle Detail:
(33) Is Capital Equipment Being Purchased?
Yes
No
IF YES: Please provide detailed amortization schedule including monies added to piece
price and amortization schedule
(34) Scrap Rate
%:
(10)
Total Burden Cost (USD):
(24)
Total Manufacturing Cost (USD)
(Material + Labor + Burden):
$0.0000
$1.4000
(25) Selling, General & Administrative
Expenses (USD):
$0.0000
(26) Profit (USD):
$0.0000
(27) Supply Chain Costs (USD):
$0.0000
(28) Grand Total Selling Price (USD):
$1.4000
Raw
Finished
(29) Local Currency Type
(35) Set Up
Information:
Cost per set up (USD)
Currency Exchange Rate Per
(30) OANDA Website (USD to Local
Currency)
Parts ran per set up
(31) Date of Currency Exchange Rate
(32) Grand Total Selling Price In Local
Currency:
Remarks:
AT-1804
Version: 07/15/2014
0.0000
Vuteq Corp. Mold Cost Breakdown Sheet (MCBS)
RFQ #:
DOMESTIC OR LCC BUILD:
Domestic
RFQ Date:
RFQ Due Date:
Rev. Level:
DATE:
Vuteq Corp. Part Number(s):
Tool Shop Name:
Part Name(s):
Tool #:
Program Name:
Quote #:
Tool / Process Description:
Cavitation:
Base Material:
Cavity-Core Inserts Y/N:
Machine Size (Tons):
# Actions/Tool:
Cavity-Core Steel Type:
Cycle Time (Seconds):
# Hyd. Cylinders:
Manifold Make or Type:
Texture Type:
# Pressure Trans:
# Manifold Drops:
Mold Flow / Mold Cool Included Y/N:
Pressure Trans. Type:
Valve Gates Y/N:
Tool Build Duration to 1st Parts(Wks):
Gate Type:
Special Inserts Y/N:
If supplier quote differs from the Mold Matrix and RFQ, supplier must indicate the differences
Special Assumptions:
FUNCTION
HOURS
RATE
TOTAL
COMMENTS
1 DATA MANAGEMENT
2 MOLD DESIGN
3 COMPUTER SIMULATIONS (Mold Flow, Cool, FEA, etc.)
4 PROGRAM MANAGEMENT (Outsource Only)
5 ADVANCED ENGINEERING & FEASIBILITY
6 CNC MACHINING
7 GENERAL SHOP LABOR
8 CMM PARTS
9 RECEIVE, TEAR-DOWN, & INSPECT (Outsource Only)
10 STEEL VALIDATION
11 MOLD PURCHASE PRICE (Outsource Only)
12 MOLD SHIP COST (Outsource Only)
13 MOLD U.S. DUTY COST (Outsource Only)
14 TRAVEL COST (Outsource Only)
15 MOLD BASE
16 CARBON (Electrodes)
17 CAVITY-CORE STEEL (Specify Type)
18 HEAT TREATING OR PLATING
19 MANIFOLD / HOT DROP
20 COMPONENTS
21 TEXTURE
22 OTHER (Specify)
23 SAMPLE COST (Performed Domestically Only)
24 SAMPLE MATERIAL
25 TOOL DELIVERY
26 SG&A / PROFIT (Outsource Only)
27 ONTRAX
SUB TOTAL MATERIALS & SERVICES: $
TOTAL TOOL COST: $
SUB TOTAL (LABOR):
MATERIALS
Vuteq Corp. Die Cost Breakdown Sheet
RFQ #
RFQ Date
RFQ Due Date
DATE:
Vuteq Corp. Part Number(s):
Tool Shop Name:
Part Name(s):
Tool #:
Program Name:
Quote #:
Tool / Process Description:
Parts Per Stroke:
Material:
Machine Size (Tons):
Base Type (Cast or Plate):
Strokes per Minute:
# Stations:
Tool Type:
# Idle Stations:
Domestic or LCC Build:
Pitch X Width:
Tool Build Duration to 1st Parts(Wks):
Tool Size:
Hi Tensile Steel
Rev. Level:
If supplier quote differs from the Die Matrix and RFQ, supplier must indicate the differences
Special Assumptions & Station Descriptions:
FUNCTION
HOURS
RATE
TOTAL
COMMENTS
1 DATA MANAGEMENT
2 DIE DESIGN
3 COMPUTER SIMULATIONS
4 PROGRAM MANAGEMENT (LCC ONLY)
5 ADVANCED ENG. & FEAS (LCC ONLY)
6 WELD
7 CNC PROGRAMMING
8 LAYOUT
9 MACHINE, ROUGH/FINISH CAVITY
10 MACHINE, ROUGH/FINISH CORE
11 MANUAL MACHINING
12 MACHINE ELECTRODES
13 EDM
14 BOX WORK/BUILDUP
15 MAKE / FIT INSERTS, CORES, ETC.
16 HANDWORK
17 TUNING
18 ASSEMBLE
19 CMM PARTS AND STEEL
20 TRANSPORTATION (EC ONLY)
21 DISASSEMBLE (EC ONLY)
22 DIE BUY COST (LCC ONLY) (SEPARATE COST DETAIL REQUIRED)
23 DIE SAMPLE COST (LCC ONLY)
24 DIE SHIP COST (LCC ONLY)
25 DIE U.S. DUTY COST (LCC ONLY)
26 TRAVEL COST (LCC ONLY)
27 DIE BASE
28 CARBON (ELECTRODES)
29 STEEL (SPECIFY TYPE)
30 HEAT TREAT OR PLATING
32 COMPONENTS
34 OTHER (SPECIFY)
35 SAMPLE COST (DOMESTIC ONLY)
36 SAMPLE MATERIAL
37 TOOL QUALIFICATION
SUB TOTAL (LABOR):
MATERIALS
38 PART OBSOLESCENCE (EC ONLY)
SUB TOTAL MATERIALS & SERVICES: $
TOTAL TOOL COST: $
Vuteq Corp. General Tool & Equipment Cost Breakdown Sheet
RFQ #:
RFQ Date:
RFQ Due Date:
Vuteq Corp. Part Number(s):
Tool Shop Name:
Part Name(s):
Tool #:
Program Name / Model Year:
Quote #:
Type of Tool / Equipment (Welder, Trim Die, Etc.):
Build Time (Weeks):
Tool / Process Description:
Describe Tool / Equipment in detail. Include sequence of operations, number of operators, cycle time, pieces per cycle, etc. Respondent may submit a separate
quote sheet on own letterhead with as much detail as necessary, but basic details must appear here as well.
If supplier quote differs from the Tool Description and RFQ, supplier must indicate the differences
Special Assumptions:
FUNCTION
HOURS
RATE
TOTAL
COMMENTS
1 DATA MANAGEMENT
2 DESIGN
3 ADVANCED ENGINEERING, FEASIBILITY, SIMULATIONS
4 PROGRAM MANAGEMENT
5 CNC OR SPECIALTY MACHINING
6 GENERAL SHOP LABOR
7 CMM / CERTIFICATION
8 RUN-OFF, EVALUATION, PROVEOUT
9 MANUFACTURING PLANT SUPPORT
10 OTHER (Specify)
11 PURCHASED COMPONENTS (Electrical, Mechanical, Pneumatic, Etc.)
12 PURCHASED AUXILIAR EQUIPMENT (Robots, Dispensors, Welders, Etc.)
13 PURCHASED MATERIAL FOR FABRICATION
14 CONSUMABLE MATERIALS (Electrodes, Molds, Etc.)
15 MODEL MATERIALS
16 PATTERN MATERIALS
17 TEMPLATE MATERIALS
18 OTHER (Specify)
19 OTHER (Specify)
20 SAMPLE COST
21 SAMPLE MATERIAL
22 SG&A / PROFIT
SUB TOTAL MATERIALS & SERVICES: $
TOTAL TOOL COST: $
SUB TOTAL (LABOR):
MATERIALS
Directed Supplier Kick-off Meeting Checklist
Reference: Directed Supplier Kick-Off Meeting Work Instruction
Kick-off meeting date:
List Meeting Attendees:
Name
Title
Company
Signature
Program tooling (prototype & production):
Will directed suppliers tooling be paid by JCI or the OEM?
Prototype
Production
If JCI is paying tooling, has the directed supplier provided a tooling quotation?
YES
NO
JCI documentation required for payment of tooling to directed suppliers
__________________________________________________________________________________
What are the OEM/JCI volume requirements? ___________________________________________
What are the tooling capacities for each part ____________________________________________
Is the tooling dedicated or shared? ____________________________________________________
If shared, what are the other volume requirements? _______________________________________
Follow up action required
__________________________________________________________________________________
__________________________________________________________________________________
Owner:
Target date:
Piece price:
What type of commercial relationship is this (buy/sell, consignment)?
Has the directed supplier provided pricing for prototype and production?
What currency will the directed supplier be paid in?
When does production pricing take effect?
Who negotiates pricing and targets for directed supplier?
Under what payment terms will JCI pay the directed supplier?
What documentation is needed to change?
WW-PLUS-FR-06-10-E / Rev 01 (01-April-2004)
Page 6 of 9
What is the agreement between the OEM and directed supplier in regards to service part pricing?
__________________________________________________________________________________
Follow up action required
__________________________________________________________________________________
__________________________________________________________________________________
Owner:
Target date:
Long term commercial commitments:
What is the long term commercial agreement between the directed supplier and the OEM ?
(JCI should receive a supplier quote documenting LTA over life of program)
How will cost reductions be passed through the tier 1?
Follow up action required
__________________________________________________________________________________
__________________________________________________________________________________
Owner:
Target date:
Product change coordination / communication.
Who is responsible from JCI?
Who is responsible from directed supplier?
Identify documentation required for change to be made at JCI
Identify documentation required for change to be made by supplier
Follow up action required
Owner:
Target date:
Logistics / production control:
What is the release commitment from JCI? (number of weeks)
___________________________
What is the Directed supplier lead-time? (number of weeks)
___________________________
How are schedule increases handled?
___________________________
Who pays for premium freight?
___________________________
WW-PLUS-FR-06-10-E / Rev 01 (01-April-2004)
Page 7 of 9
What are the directed suppliers material authorizations?
Raw
___________________________
Fabricated
What are the minimum order quantities?
_____________________________________________
What are the Inco Terms?
_____________________________________________
Who is paying for packaging?
_____________________________________________
How is obsolescence handled?
_____________________________________________
Follow up action required
_____________________________________________
__________________________________________________________________________________
Owner:
Target date:
Releases:
What is JCIs system & frequency of releases during pre-production?
__________________________________________________________________________________
What is JCIs system & frequency of releases during production?
__________________________________________________________________________________
Follow up action required
__________________________________________________________________________________
__________________________________________________________________________________
Owner:
Target date:
Pre-production support:
Describe Support required from supplier during pre-production phase
Follow up action required
__________________________________________________________________________________
__________________________________________________________________________________
Owner:
Target date:
Ongoing production field support:
What are the commitments from the directed supplier? ____________________________________
Follow up action required
__________________________________________________________________________________
__________________________________________________________________________________
Owner:
WW-PLUS-FR-06-10-E / Rev 01 (01-April-2004)
Target date:
Page 8 of 9
