1 F-SAE Australasia 2020saeaustralasia.wildapricot.org/resources/Documents/Cost... · 2020. 10....

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F-SAE Australasia 2020Online Cost Event (OCE)

Formula SAE Australasia 2020Cost Event Information & Training for Competitors

1

Presenter Information

S Mario Cappola (Ford Australia)

S FSAE-A – Cost Judge (2011-present)

S FSAE-A – Cost Event Captain (2012-present)

S Team Swinburne Formula SAE Petrol (2010-2011)

S Financial Controller

S Cost Report Focal

S David Ford (SAE Australasia)

S Ford Motor Company [retired]

S FSAE-A – Cost Judge (2004-present)

2

Acknowledgements

S SAE Australasia

S Norbert Drage (Curtin University)

S SAE Detroit Section

S Bill Riley – SpaceX, Cornell University

S Michael Royce – Albion Associates LLC, Detroit Region SCCA

N. Drage B. Riley M. Royce

3

Presentation Overview

SECTION 1 – 2020 Event Overview

S 2020 Objectives

S Industry Focus

S Point Structure

S Section Overview

S Event Day Running

S System Cost Review

S Addenda

S Penalties

S Cost Engineering Principles

S Real Case Scenario

S Important Considerations

SECTION 2 – Cost Essentials

S Rules, Tables & Templates

S Where to find materials

S List of Published materials

S What to submit

S Cover Sheet

S EBOM

S Assembly Detail

S Part Detail

S Supplementary Material

S Addenda

S The report

4

S

Cost Event Overview for 20202020 Objectives

Industry Focus

Point Structure

Section Overview

Event Day Running

System Cost Review Detail

Cost Engineering Principles Detail

Real Case Scenario Detail

Important Considerations

Interim Q&A

5

2020 Objectives

“Due to the on-line nature of the event, total cost of Vehicle or System will not be considered for scoring purposes, as it cannot be robustly managed or judged without physical evaluation.”

Realigned focus:

S Align Cost and Presentation events with Design concepts and revisions

S Greater alignment to industry practice

S Applying Cost Engineering principles that align to industry practice:

S Setting cost targets and tracking design to these targets

S Change management

S Cost control & accountability

S BoD/BoP/BoM (Bill of Design, Process, Materials)

S Clear, sharp delivery of key criteria

S And more

What hasn’t changed:

S Teams will still be scored based on the knowledge of:

S Their Nominated System (used to be full vehicle)

S Understanding of FSAE Cost Tables and EBOM COST ESTIMATION TECHNIQUES

6

Industry Focus

Why is cost control so important?

S Product or Service must deliver healthy margins to the company

S What would the target customer be willing to pay for the product?

S What features/functions does the target customer value the most?

Added Cost Engineering Principles driven by industry experience:

S Cost estimation techniques and its importance in design (increased focus)

S Setting cost targets

S Tracking design progression to these targets – including any tools used

S Change management

S Cost control & accountability

S BoD/BoP/BoM (Bill of Design, Process, Materials)

S Assumptions of vehicle/system/component life

S Clear, sharp responses by teams

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Industry Focus

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Ranger XL – “Traffic Controller Spec”4x2 Lo-Rider 2.2L Diesel

D/A: AUD 33,105 (Postcode 3429)

Ranger Raptor – Halo ModelAWD BiT Diesel w Baha Mode

D/A: AUD 86,329 (Postcode 3429)

“Bandwidth”

Thales Bushmaster (L) & Thales Hawkei (R)Sold to ADF and other countries’ defence forces

Sale price is Classified – but it’s a LOT of money!!Sensitive to defence budget constraints

Design changes/upgrades heavily cost controlled

Point Structure – 2009-2019

Cost Report(80 Points)

Vehicle Cost(40 Points)

Report Accuracy(40 Points)

“Real Case” Scenario(20 Points)

Cost Event(100 Points)

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Point Structure – 2020

“Real Case” Scenario(30 Points)

Cost Event(100 Points)

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Cost Engineering Principles

(35 Points)

System Cost Review(35 Points)

Section Overview – 2020

System Cost Review:

S Much the same feeling as previous years, but focused on one system

S Judges will review reports before the event for feedback

Cost Engineering Principles:

S Judges will guide teams along a path where students will demonstrate their knowledge of Cost Engineering principles as outlined in 2020 Objectives and Industry Focus slides

Cost Real Case Scenario:

S Much the same feeling as previous years

S Focused on how Cost Targets are set

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Event Day Running – 2020

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Introductions – 5 minutes:

S Judges will introduce themselves

S All students presenting to introduce themselves, with a brief explanation of their contribution to the 2020 program

System Cost Review – 10-15 minutes:

S Review/feedback your costs as submitted from 30th October and any addenda

S Much the same feeling as previous years, but focused on one system

S Judges will review reports before the event to drive this part of the event

13


Cost Engineering Principles – 10-15 minutes:

S Judges will lead teams along a path where students will demonstrate their knowledge of Cost Engineering principles as outlined in 2020 Objectives

S “Quick Fire Question and Answer” between judges and students SPEED ROUND!

Cost Real Case Scenario – 10 minutes:

S No change to previous years, in terms of how this will run

S Lead into this section should include a “Cost Waterfall” to be shown by students

S This should compare 2019 system cost vs. current estimation for 2021 vehicle

Two-way Feedback – 5 minutes:

S Opportunity for judges to provide feedback to students, and vice-versa

14

System Cost Review

Duration – 10-15 minutes

The judges have reviewed the submitted cost report prior to the event

S Any issues and/or feedback for the teams will be presented at this point

S This review is done to make sure that the cost estimates as submitted are to an appropriate standard – that nothing seems to be missed and that appropriate steps have been made

Key considerations:

S The quality in which you conduct yourself and respond to questions counts. Be professional!

S Use the Cost Report as submitted to SAE-A

S You will need to show judges that you are opening your files as submitted in Google Drive –have the window open in your browser!

S Be open to feedback and discussion on areas for improvement

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System Cost ReviewAddenda

To assess how a team performs with regard to Change Management… The team may elect to submit an addendum (per FSAE rules) to reflect any changes to the vehicle design that were made between when the

cost report was submitted, and one week before the event.

The addenda:

S MUST be submitted by 7th December 2020

S This allows judges to review before the event day IMPORTANT

S MUST be in the format prescribed by the rules refer FSAE Online website for template

S MUST have supporting evidence for all amended costs attached, in the same format as the Cost Report

S IS NOT compulsory – but you will be asked by the judges why there have been no changes between report submission and the event – BE PREPARED!

S WILL NOT directly influence your final score – used as a tool to assess how the team manages change only

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System Cost ReviewAddenda

Why is the Addendum important?

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System Cost ReviewPenalties

S Penalties regarding report ‘errors’ are not applied until after they are verified at the visual inspection

S Two methods to calculate penalties per the FSAE rules:

S Fixed Point – carries over unchanged to 2020 event

S Adjusted Cost – not used in FSAE-A 2020

S No penalty applied when values are over-estimated

S Self-penalising!

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FIXED POINT PENALTIES:

S Points deducted from Accuracy score

S All penalties will be of the Fixed Point method

DescriptionPenalty

Value

Missing/InaccurateMaterial, Process, Fastener, Tooling

1 point each

Missing/Inaccurate Part3 points

each

Missing/Inaccurate Assembly5 points

each

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ADJUSTED COST PENALTIES:

This method will not be used in 2020 – as there is no scaling factor based on total cost

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System Cost Review

S The secret is to know your cost report and your design well

S Treat this as an explanation/justification exercise

S Avoid flicking between tabs/pages!!

S Practice before the event

“So it is said if you know the tables and know your car, you will do well in Cost.

If you know your design, but not the tables, you may or may not do well.

If you know neither your design nor the tables, you will do quite badly.”

Adapted from Sun Tzu’s ‘The Art of War’

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Cost Engineering Principles:“A Journey” -M. Cappola 2020

Example of how judges will guide the conversation:

S How does the team hold its members accountable to meet cost targets?

S What means do the team use to control costs, if the actual design status exceeds targets?

S How does the team manage design changes before & after releasing ‘frozen’ Cost/Design data?

S What are some factors that influenced the design decision-making process, regarding cost?

S What considerations were given regarding incremental revenue in Cost decision making?

S i.e. would the “Weekend Racer” pay more for an added feature/updated design?

S How was cost considered in the base design of a system/assembly/component?

S What design optimisation tools were used?

S What is the assumption of vehicle/system/assembly/component life?

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Real Case Scenario

Premise of the Real Case Scenario:

Senior management wishes to deep-dive the team’s approach to setting cost targets, specifically for

your team’s 2021 design.

S What is your baseline design and cost?

S What are the feature/content additions versus your baseline design?

S The above two points should be evident from your waterfall…

S How is cost broken down/allocated to different systems?

S How is cost broken down/allocated to the four cost reporting areas? (Material, Process, Fasteners, Tooling)

S Who made the decision(s) to add/remove these items?

S How was the target customer considered during the cost target setting process?

S What consideration was given to R&D effort to implement these changes?

S Did your targets consider any Design Efficiencies or Optimisations?

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Real Case Scenario

Note

S The Real Case Scenario is not a discretionary low-value activity

S It should be regarded as an integral and major part of the event

S It is an opportunity for teams to demonstrate their critical thinking abilities and approach to cost minimisation or other special activity

Additionally, it provides an insight to real problems you’ll encounter

in industry, including what management will expect you to consider

when making a recommendation!

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Important Considerations – 2020

S Keep all responses in System Cost Review and Cost Engineering Principles sections to “elevator pitch” timing

S No more than 30 seconds unless absolutely required

S Industry management do not have time to listen to long responses – nor do the cost judges!

S Judges may (and will!) cut presenters off if they are take too long to respond

S Real Case Scenario initial explanation should take no more than 3-4 minutes

S Again, judges may interject if they feel a response is taking too long

S This allows more “quick-fire” questions from the judges – these responses should be no more than 30 seconds per above

S Think about what the judges may ask

S All teams have been provided with the high-level talking points the judges will use as framework for the event

S This means there won’t be any big surprises to anyone!

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Questions & Answers2020 Cost Event Format


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Cost Event EssentialsRules, Tables & Templates

Where to find cost materials

List of published cost materials

What to Submit

The Report

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Rules, Tables & Templates

S Standardised across all FS/FSAE competitions worldwide

S Same baseline rules

S Same cost tables*

S Same part/assembly templates*

S Same Cover Page & EBOM template

S The car design drives final cost

S Engineering design is about trade-off analysis

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Where to Find Cost Materials

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Resource Where to find Hyperlink

FSAE EBOM TemplateIncludes:• Cover Page• EBOM

FSAE Online & FSAE-A

https://www.fsaeonline.com/cdsweb/gen/DocumentResources.aspxORhttp://www.saea.com.au/Resources_2020

Assembly Detail Sheet Template FSAE-A“Cost Event Assembly and Part Cost Templates” File

http://www.saea.com.au/Resources_2020

Part Detail Sheet Template

Supplementary Material Up to team’s discretion

Cost TablesIncludes:• Materials• Processes• Process Multipliers• Fasteners• Tooling

FSAE-A http://www.saea.com.au/Resources_2020

Addendum FSAE Onlinehttps://www.fsaeonline.com/cdsweb/gen/DocumentResources.aspx

Add Item Request (AIR) FSAE Onlinehttps://www.fsaeonline.com/cdsweb/gen/DocumentResources.aspx

Other Useful Resources

S Example of how to build Assembly/Part detail sheets

S Appendix of this presentation!

S Cost Event Rules Supplement – FSAE Online

S Details to help you build a report

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What to Submit – 2020 Summary

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Excel Document PDF Document

FSAE EBOM Template

(Ref: FSAE Online)Fully Completed Fully Completed

Summary Tab Fully Completed Fully Completed

BOM Tab (EBOM) Fully Completed Fully Completed

Assembly Cost Detail Sheets Nominated System Only Nominated System Only

Part Cost Detail Sheets Nominated System Only Nominated System Only

Drawings, Photos & Supporting Material Nominated System Only Nominated System Only

AddendaAs required

Submit by Monday 7th December

As required

Submit by Monday 7th December

What to Submit – 2020

Summary Tab – Fully Populated

S Must display rolled-up costs for every system

S This needs to feed your business plan!

S Teams that have entered FSAE-A prior years may (should!) carry over their EBOM costs for their non-Nominated System

S For new teams, contact cost judges before event if completing the whole EBOM is untenable

S Template will auto-generate pie chart for area totals (blank shown)

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BOM Tab (EBOM) – Fully Populated

S Must be fully populated; again:

S Will still need to show rolled-up cost for every system & total vehicle this needs to feed your business plan!

S Teams that have entered FSAE-A prior years may (should!) carry over their EBOM costs for their non-Nominated System

S For new teams, contact cost judges before event if completing the whole EBOM is untenable

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Assy Detail Cost Sheets – Nominated System

S Must be fully populated for every assembly within your nominated system

S No change versus previous years

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Part Detail Cost Sheets – Nominated System

S Must be fully populated for every part within your nominated system


35


Drawings, Photos, Supplementary Material – Nominated System

S Must be fully provided for your nominated system

S Exploded views of assemblies key to understanding how everything comes together

S Part drawings do not need to be comprehensive engineering drawings, but should show key dimensions and feature callouts

S Photos (where used) should show a scale (e.g. ruler)


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What to Submit – 2020Addenda

Key considerations:

S Addenda cost changes are notpenalised like previous years

S Must be filled out to the same standard of previous years

S Shown here is cover page only – must include all:

S Assembly Detail sheets

S Part Detail sheets

S Supporting Documents (Exploded view, drawings, photos, etc)

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The Report

Soft Copy

S Excel Format

S One file only

S Use templates available from FSAE-A website

S PDF Format

S Judges prefer one file only

S May be two files – Drawings, Photos, Supplementary Material may be broken out to one single separate file if works better for the team

NOTE: Drawings, Photos, Supplementary Material can be omitted from Excel copy if it is too difficult to integrate

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Questions & AnswersCost Event Essentials


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In ClosingEvent Preparation Summary

Questions & Answers

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S Practice using Zoom Meetings to ensure smooth running – free access! (with limitations)

S Test audio, video and presentation visuals before the event

S If all team members are in the same room;

S Ensure everyone can be picked up by the microphone

S Ensure all active participants are seen by the webcam

S Use the screen sharing function to share any presentation material prepared

S Place yourself on Mute if not actively participating

S Have your team’s Google Drive directory open so judges can verify you are opening the controlled copy

S Be ready and able to open cost tables and other relevant materials on request

S Use the chat function to share any supporting documentation.

Event Preparation

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Questions & Answers2020 Online Cost Event


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Thank you.


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APPENDIX


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Building a Better Cost ReportExplanations / Clarity

BOM (Bill of Materials) Structure

Cost Templates

Cost Tables

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Report StructureExplanations/Clarity

Clarity of reports presented varies significantly between teams

S Break down each line in the material/process/fastener/tooling sections as much as possible

S Covered later in the presentation

S Number all pages logically and clearly; this will help both your own tracking and the judges

S Utilise the “use” column as much as possible

S Just a few words in each line helps to follow along!

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Report StructureExplanations/Clarity

Drawings and other supplementary ‘visual’ materials provide the judge with a method to piece together the car, as they review the material presented to them.

In lieu of full engineering drawing/data pack, consider the following:

S Parts: 2D third-angle-projection drawing, dimensioning the overall envelope space and any key features

S Assemblies: 3D exploded-view of assembly, with BOM

S Where photo(s) are used, place a ruler with the part/assembly (to give a sense of scale)

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BOM Structure

S Some teams struggle with a clear BOM breakdown

S MUST follow parent “Systems” as specified in Appendix S-3 or EV-3

S Issues present at the assembly level, and cascade down

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BOM Structure

S Suggest using Appendix S-3 assembly list as a ‘baseline’ BOM breakdown

S Provides an appropriate level of breakdown at the assembly level

S Where an assembly is bundled into one costed elsewhere, DO NOT DELETE THE

LINE ITEM! Use description column to direct judge to new location

S Some concessions will be made to suit individual vehicle applications

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BOM StructureExample Only!

S Suspension Used as an example (excerpt from S-3 included to the right)

S Custom part numbering used, for operator’s clarity, would require ‘decoding’ page at start of report

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Cost Report Templates

Assembly Template Part Template

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Cost Tables

S Cost Tables previously available on the SAE-I website, but format has changed for SAE North America events.

S Each tables’ items have been put into online catalogues

S Old tables have been removed

S Notice sent to FSAE-A teams (http://www.saea.com.au/resources/ Documents/FSAE-A%202018%20Cost%20Event%20Update.pdf) approving the use of 2017 cost tables for this year; updated parts/materials/processes/fasteners (as listed in the 2018 online catalogue) can be used as needed though.

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Cost Tables

S Materials - the list of purchasable ‘finished parts’ and ‘raw materials’ used by teams to construct the car

S Process - operations that alter the form of the materials

S Process Multipliers - modifiers that alter the standard cost of various operations to account for physical differences (i.e. material used, geometric size)

S Fasteners - various components that are used to fasten components (i.e. bolts, nuts, washers, rivets, hose clamps, safety wire)

S Tooling - the rigging/infrastructure required for processes to be achievable (i.e. die for die casting, welding fixtures for welding, etc.)

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Cost Tables – Materials

S General categories:

Bearings Brake System Chassis Composite

Control Module Controls Damper Drivetrain

Electronics Engine EV – CM/Elec/TD Fluid

Miscellaneous Raw Material Safety Sensors

Springs Steering Tire Wheel

S Examples include:

S Raw Material – Steel, Aluminium, Titanium

S Composite – Carbon Fibre (include material weight!), Foam

S Engine – Dry Sump Pump, Overflow Bottle

S Control Module – ECU, Datalogger

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Cost Tables – Process


Basic Forming Composite Electrical – Attach Wires

Electrical – Bundle Install Electrical – Bundle Processing Electrical – Connections

Electrical – Layout Electrical – Prep Electrical – Wire in Connector

Fasteners Joining Labour

Material Removal Sheet Materials Tubing

S Examples include:

S Basic Forming – Die Casting, Sand Casting, Powder Metal

S Composite – Lamination, Oven Cure, Autoclave Cure

S Joining – Sewing, Welding

S Material Removal – Turning, Milling, Facing, EDM

S Process table tells you which processes require tooling

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Cost Tables – Process Multipliers


Assembly Fastener Installation

Drill, Tap Machining

S Examples include:

S Assembly – Length, Disassemble

S Fastener Installation – Engagement Length

S Drill, Tap – Hole Length

S Machining – Material Type

S Foam is easier to machine than Aluminium, therefore 0.33x multiplier

S Steel is harder to machine than Aluminium, therefore 3x multiplier

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Cost Tables – Fasteners


Bolts Dzus Fasteners Hose Clamps

Loop Straps Nuts Pins

Retaining Rings Studs Washers

S Points to note:

S Many fasteners are equation-driven

S Only required for components on the vehicle, not for fixtures/jigging

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Cost Tables – Tooling

S General categories driven by process(es) used

S Points to note:

S Tooling is equation-driven based on process

S Black-and-white – if the process needs tooling, then you need to calculate tooling.

S Judges will not accept “self-jigging” claims!

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Example – Welding

How many points does the jig pick up?

S

Further Cost Report InformationMaking vs. Buying

Add Item Requests

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Making vs. Buying

S Car components are classified as either bought or made

S Bought parts appear in tables

S Typically organised by: 1) part type, 2) manufacturer, and 3) model

S Can be modified as the team requiresS BUT modifications must be costed!

S Any disassembly from OEM part must be captured

S Not to be confused with tuning

S If you’re not sure – ask the FSAE-A cost team!

S Made parts can appear in tables

S Parts designated as ‘Student Built’ must be ‘made’ within the CR

S Unlisted parts must be ‘made’ or an ‘add item request’ is needed

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Making vs. Buying

Made Parts

S Start as raw materials (Steel, Alloy; Aluminium, Normal; Iron; etc.)

S Undergo various processes (Machining; Spinning, Metal; Tube cut; etc.)

S May require subassembly (Assemble, 1kg, Loose; Weld; Hand - Start Only)

S Examples: oil tank, uprights, A-arms

Bought Parts

S Purchased in ready state

S *Can* be modified as per team requirements

S Examples: suspension dampers, engine control units, brake master cylinders

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Rule Covering ‘Made vs. Bought’

How Team Actually Acquired the Part

How Cost Table Lists Part Team Made Team Bought

Table lists the part as“Made”

Cost as “Made” Cost as “Made”e.g. Steering Wheel quick release

Table lists the partas “Bought”

Cost as “Made”e.g. Spun Wheel Shells vs. Bought

Cost as “Bought”

Cost Table not clear if should be costed as made or bought or is not listed

Contact FSAE-A Cost Judges

2018 Formula SAE Rules, S4.13.3 (p.138)

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Add Item Requests

S Non-existent items that teams want to see in future cost tables

S Details in ‘Add Item Request Online’ on fsaeonline.com

S Use the ‘Excel format AIR’ and e-mail to [email protected]

S Don’t forget to provide the item’s/items’ critical details

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Add Item Requests

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S

Cost Report ExampleA-Arm Case Study

Part Manufacture

Parts & Tooling

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IntroductionA-Arm Case Study

This example covers

• Individual Part Manufacture

• Assembly Manufacture

• Fasteners & Tooling

Based on the example created by Bill Riley (mentioned at the start of the presentation)

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Cost Report ExamplePart Manufacture

S Example in case is the spherical bearing cup

S Manufactured from steel round bar

S *ALL* processes to be stepped

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Process Steps

Working from initial steel round bar

S Rough machine outside

S Finish machine outside

S Rough machine inside

S Finish machine inside

S Part material from round bar

Visualisation

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Parting Cut3.0mm

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Design/Process Rev. Level (Optional)

Part Cost

Material

Process

Fastener

Tooling

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Missing Steel Multiplier

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No Parting Operation


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No Parting Operation


No Machining –Install/Setup/Remove

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Cost Report ExampleParts & Tooling

Assembly Layout Assembly Parts

S Leg 1 Tube

S Leg 2 Tube

S Tube Inserts (machined & tapped)

S Spherical Bearing Cup

S Sheet Metal Gusset

S Spherical Bearing

S C-clip-type Retaining Ring

S Rod End w/Jam Nut

1

2

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Cost ReportAssembly Layout

1

2

3

3

4

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Assembly Report – MaterialsAssembly Layout

1

2

3

3

4

56

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12

3

45

3

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Assembly Report – ProcessesAssembly Layout

1

2

3

3

4

56

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5

1 2

4

1 32 3

1 42 4

5

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Assembly Report – Fasteners/ToolingAssembly Layout

1

2

3

3

4

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86

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1010

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Assembly Report – Fasteners/ToolingAssembly Layout

1

2

3 4

5

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Cost Report Example

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A-arm is complete, removed from fixture, but not yet installed onto the vehicle

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Assembly ReportCompleted Assembly

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Errors in the Costed Assembly

S Jam nuts do not include installation steps

S Hand – Start Only

S Hand, Loose <=6.35 mm

S Ratchet <=6.35 mm

S Bearing cup and threaded inserts require setup costs for the machining operations

S Machining Setup, Install and remove

S If continuous feed is used (a-la-machining centre), this needs to be included as a note

Completed Assembly

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Review Points

S Are the materials, processes, multipliers, tooling, etc. correct?

S Were any elements forgotten?

S What assumptions have been made?

S Do we have these written down to backup/explain the flow?

S Can any further evidence (visual or otherwise) complement our work?

S Engineering drawings, photos, sketches

Completed Assembly

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S Consider the legibility of the report

S Know the published materials (rules, supp. regs., cost tables, templates)

S Break down every step as far as possible

S Consider your BOM breakdown and how it cascades at each step

S Include as many supplementary ‘visual’ aids as possible

S Submit addenda by Monday 7th

December

S Lose track of submission deadlines

S Forget to use Process Multipliers, Machining Install/Remove, etc.

S Oversimplify steps in part/assembly breakdown

Dos and Don’ts - Report

DO DON’T

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And Last But Not Least

DO START EARLY!

There is *BARELY* enough time for cost report if you start early!

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Questions & Answers


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1 F-SAE Australasia 2020saeaustralasia.wildapricot.org/resources/Documents/Cost... · 2020. 10....

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Transcript of 1 F-SAE Australasia 2020saeaustralasia.wildapricot.org/resources/Documents/Cost... · 2020. 10....