Equipment manufacturing cost calculation method based on production complexity

Abstract

The invention provides an equipment manufacturing cost calculation method based on production complexity, and belongs to the technical field of equipment manufacturing. The method comprises the following steps: S1, acquiring parameters for calculating production complexity; wherein the production complexity refers to a cost influence factor for producing a single product in an equipment manufacturing process; the parameters comprise the machining precision, the process maturity, the operating environment value, the machining coefficient, the part number and the utilization rate of the single product in the equipment manufacturing process; s2, calculating the production complexity based on the parameters; wherein the production complexity comprises single complexity and combined complexity; and S3, determining the equipment manufacturing cost by using the production complexity. According to the method, cost estimation of equipment manufacturing can be better completed, and meanwhile, a user can conveniently unify the standard in the equipment manufacturing process and better assess the manufacturing scheme.

Description

Technical Field

[0001] The present invention relates to the technical field of equipment manufacturing, and in particular to a method for calculating equipment manufacturing costs based on production complexity. Background Art

[0002] Equipment manufacturing cost estimation primarily relies on parametric estimation, a method widely used for its versatility, accuracy, and scientific nature as the most practical and effective cost estimation method. However, there has been no unified standard or tool for identifying the core cost parameters that influence costs.

[0003] Parametric models are becoming a trend as a direct tool for project budgeting. Currently, due to deficiencies in fundamental work such as the establishment of historical cost databases and the formulation of relevant rules, there is no authoritative, unified standard for equipment manufacturing cost estimation. This, coupled with the varying selection of estimating factors by various user organizations, leads to significant deviations in the estimated results, significantly impacting project approval and procurement. Summary of the Invention

[0004] In order to solve the above problems, the present invention designs a practical calculation tool (PCPT) based on production complexity (PCP) through practical application and summary, so as to help users better complete cost estimation, and also facilitate users to unify standards in the equipment manufacturing process and better evaluate manufacturing plans.

[0005] The present invention proposes a method for calculating equipment manufacturing costs based on production complexity, the method comprising:

[0006] Step S1: Obtain parameters for calculating production complexity; wherein:

[0007] The production complexity refers to the cost-influencing factors of producing a single product during the equipment manufacturing process;

[0008] The parameters include processing accuracy, process maturity, operating environment value, machining coefficient, number of parts, and utilization rate for the single product during the equipment manufacturing process;

[0009] Step S2: Calculating the production complexity based on the parameters; wherein:

[0010] The production complexity includes single complexity and combined complexity;

[0011] Step S3: Determine the equipment manufacturing cost using the production complexity.

[0012] In step S2, the calculation formula of the single complexity is:

[0013] 1-PCP=(sp*u) / (p*m*i)*Z

[0014] Among them, 1-PCP represents single complexity, sp represents the operating environment value, u represents utilization rate, p represents processing accuracy, m represents process maturity, i represents machining coefficient, and Z represents adjustment parameter.

[0015] In step S2, the calculation formula of the combination complexity is:

[0016] N-PCP=PCP1*w1+PCP2*w2+…+PCPn*w n

[0017] Among them, N-PCP represents the combination complexity, n represents the number of parts, PCPn represents the production complexity of the nth part, and w n Indicates the weight percentage of the nth component.

[0018] In step S3, the calculation formula for equipment manufacturing cost is:

[0019] C=a*W*e pcp

[0020] Among them, C represents the equipment manufacturing cost, a represents the adjustment coefficient, W represents the weight, and pcp represents the production complexity.

[0021] The processing accuracy refers to the manufacturing tolerance for the single product during the equipment manufacturing process, and the unit is decimal centimeters or millimeters. The lower the processing accuracy, the higher the production complexity.

[0022] The process maturity indicates the impact of production difficulty caused by different process types and the labor intensity of the manufacturer on production complexity. The process types include forging, composite lamination, machining, welding, and casting. The higher the process maturity, the higher the production complexity. The process maturity value ranges from 1 to 5.5.

[0023] The operating environment value describes the reliability requirements of the equipment in the expected working environment. The operating environment value ranges from 1.0 to 7.0, among which the operating environment value of military ground equipment is 2.0 and the operating environment value of military aviation equipment is 6.5.

[0024] The machining coefficient describes the difficulty of processing different materials. The higher the difficulty of material processing, the smaller the machining coefficient. The machining coefficient of carbon alloy steel with the grade C1214 is set to 100, and this is used as a benchmark. Materials that are easier to process than C1214 have a machining coefficient less than 100, and materials that are more difficult to process than C1214 have a machining coefficient greater than 100.

[0025] The number of parts refers to the number of parts contained in the single product during the equipment manufacturing process, excluding fasteners. The fasteners refer to bolts, nuts, rivets, and gaskets. A part includes several components. The production complexity of a part is determined by calculating the production complexity of each component, and the production complexity of each component is integrated to determine the production complexity of the single product during the equipment manufacturing process.

[0026] The utilization rate indicates the ratio of the weight of available material to the weight of the blank material during the machining or milling process of the blank material in the equipment manufacturing process. The lower the utilization rate, the higher the production complexity.

[0027] In summary, the present invention regards production complexity as the most important cost driving factor, which is composed of multiple quantifiable indicators; constructs multiple parameter indicators into a stable hybrid indicator through a mathematical regression algorithm and applies it to the cost estimation model; further unifies the indicators of the equipment manufacturing cost estimation system and reasonably establishes a structural production complexity calculation tool, which is of great significance to the equipment manufacturing cost estimation work. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the specific embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0029] Figure 1 The figure is a flowchart of a method for calculating equipment manufacturing cost based on production complexity according to an embodiment of the present invention. DETAILED DESCRIPTION

[0030] To make the objectives, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts shall fall within the scope of protection of the present invention.

[0031] like Figure 1 As shown, a method for calculating equipment manufacturing costs based on production complexity includes:

[0032] Step S1: Obtain parameters for calculating production complexity; wherein:

[0033] The production complexity refers to the cost-influencing factors of producing a single product during the equipment manufacturing process;

[0034] The parameters include processing accuracy, process maturity, operating environment value, machining coefficient, number of parts, and utilization rate for the single product during the equipment manufacturing process;

[0035] Step S2: Calculating the production complexity based on the parameters; wherein:

[0036] The production complexity includes single complexity and combined complexity;

[0037] Step S3: Determine the equipment manufacturing cost using the production complexity.

[0038] In step S2, the calculation formula of the single complexity is:

[0039] 1-PCP=(sp*u) / (p*m*i)*Z

[0040] Among them, 1-PCP represents single complexity, sp represents the operating environment value, u represents utilization rate, p represents processing accuracy, m represents process maturity, i represents machining coefficient, and Z represents adjustment parameter.

[0041] In step S2, the calculation formula of the combination complexity is:

[0042] N-PCP=PCP1*w1+PCP2*w2+…+PCPn*w n

[0043] Among them, N-PCP represents the combination complexity, n represents the number of parts, PCPn represents the production complexity of the nth part, and w n Indicates the weight percentage of the nth component.

[0044] In step S3, the calculation formula for equipment manufacturing cost is:

[0045] C=a*W*e pcp

[0046] Among them, C represents the equipment manufacturing cost, a represents the adjustment coefficient, W represents the weight, and pcp represents the production complexity.

[0047] The processing accuracy refers to the manufacturing tolerance for the single product during the equipment manufacturing process, and the unit is decimal centimeters or millimeters. The lower the processing accuracy, the higher the production complexity.

[0048] The process maturity indicates the impact of production difficulty caused by different process types and the labor intensity of the manufacturer on production complexity. The process types include forging, composite lamination, machining, welding, and casting. The higher the process maturity, the higher the production complexity. The process maturity value ranges from 1 to 5.5.

[0049] The operating environment value describes the reliability requirements of the equipment in the expected working environment. The operating environment value ranges from 10. to 7.0, among which the operating environment value of military ground equipment is 2.0 and the operating environment value of military aviation equipment is 6.5.

[0050] The machining coefficient describes the difficulty of processing different materials. The higher the difficulty of material processing, the smaller the machining coefficient. The machining coefficient of carbon alloy steel with the grade C1214 is set to 100, and this is used as a benchmark. Materials that are easier to process than C1214 have a machining coefficient less than 100, and materials that are more difficult to process than C1214 have a machining coefficient greater than 100.

[0051] The number of parts refers to the number of parts contained in the single product during the equipment manufacturing process, excluding fasteners. The fasteners refer to bolts, nuts, rivets, and gaskets. A part includes several components. The production complexity of a part is determined by calculating the production complexity of each component, and the production complexity of each component is integrated to determine the production complexity of the single product during the equipment manufacturing process.

[0052] The utilization rate indicates the ratio of the weight of available material to the weight of the blank material during the machining or milling process of the blank material in the equipment manufacturing process. The lower the utilization rate, the higher the production complexity.

[0053] In some embodiments, the PCPT (Practical Calculation Tool) provides a suite of complexity algorithms and calculation tools. Users can input data based on the detailed requirements of actual product production, including quantifiable data. This data is processed using the calculation algorithm provided by the present invention to generate a complexity factor (PCP) that influences production costs. The resulting PCP factor can be adjusted based on actual circumstances, such as technological progress, process optimization, and worker proficiency, ensuring that parameter-based cost estimation methods are more scientific, intuitive, and convenient.

[0054] In some embodiments, production complexity is mainly composed of six necessary input parameters: processing accuracy, process maturity, operating environment value, machining coefficient and component quantity, and utilization rate.

[0055] In some embodiments, machining accuracy describes the manufacturing tolerance of a component. Its units are decimal centimeters, or millimeters when using the International System of Units. A tolerance of + / - 0.2 mm results in a machining accuracy of 0.4 mm. Machining accuracy is a highly sensitive input; smaller machining values result in more labor hours and higher costs, resulting in higher PCP.

[0056] In some embodiments, the machining coefficient describes the difficulty of machining different materials. The machining coefficient is expressed as a machining coefficient. The more difficult the material is to machine, the smaller the machining coefficient. The machining coefficient of carbon alloy steel grade C1214 is set to 100 and used as a benchmark. Materials that are easier to machine than C1214 have a machining coefficient less than 100, while materials that are more difficult to machine than C1214 have a machining coefficient greater than 100.

[0057] In some cases, the number of parts refers to the number of parts contained in the product, excluding fasteners (bolts, nuts, rivets, washers, etc.). A produced part may consist of multiple components, and the tool can calculate the PCP of each component and then add them together to form the PCP of the whole part.

[0058] In some embodiments, the operating environment reflects the requirements of the equipment in terms of reliability under the expected final working environment. The present invention specifies that the operating environment represents the operating environment parameters. The operating environment value is used to evaluate the portability, reliability, structuring, testability and documentation requirements related to the contract. The higher the operating environment value, the more demanding the expected working environment of the equipment, and the higher the requirements for the reliability of the equipment. The operating environment value for military ground equipment is 2.0, and the operating environment value for military aviation equipment is 6.5. As the operating environment value increases, the rigor, verification materials, and documentation required for the design will increase accordingly. Therefore, different operating environment values will cause corresponding changes in manufacturing complexity and engineering complexity, which will have a significant impact on research and development costs. The operating environment is widely used in the generation process of production complexity (structure or electronics). The operating environment value ranges from 0.6 to 3.0, and 10 operating environment values within the interval are taken as hypothetical values for analysis and research.

[0059] Table 1: Description of the operating environment

[0060] Serial number describe Value 1 Commercial-Consumer Products 1.0 2 High-quality commercial supplies 1.5 3 Military Ground Systems 2.0 4 Ground System-Commercial 2.5 5 Ground Systems-Military 3.0 6 Water System-Passenger Ship 4.0 7 Water systems-naval vessels 4.5 8 underwater system 5.5 9 Aviation Systems-Commercial 6.0 10 Aviation Systems-Military 6.5 11 Aerospace Systems-High Reliability 7.0

[0061] In some embodiments, process maturity represents the combined impact of the difficulty of different process types and the manufacturer's labor intensity on manufacturing complexity. Process types include forging, composite lamination, machining or welding, casting, and others. Generally, more complete processes, i.e., higher process maturity values, result in lower PCP and lower costs. The process maturity value ranges from 1 to 5.5, with 10 process maturity values within this range used as hypothetical values for analysis and research.

[0062] In some embodiments, the utilization rate represents the percentage of the weight of a part of the blank material in the process of machining or milling. The utilization rate is an influencing factor that is highly sensitive to manufacturing complexity.

[0063] Table 2: Correlation between various parameters and PCP

[0064]

[0065]

[0066] In some embodiments, production includes all inputs incurred during the production process to manufacture a product or provide a service. This includes raw materials, labor, equipment use and maintenance, and any directly or indirectly related processes and operating hours.

[0067] 1. Direct costs.

[0068] 2. Material cost: The cost of raw materials and components required to produce each unit of product.

[0069] 3. Direct labor costs: wages and benefits of workers directly involved in production.

[0070] 4. Indirect costs (manufacturing indirect costs or manufacturing expenses).

[0071] 5. Equipment depreciation: The value of production equipment decreases over time.

[0072] 6. Maintenance and repair: Maintenance costs of equipment and plants.

[0073] 7. Factory Management and Employee Benefits: Salaries and benefits of factory management.

[0074] 8. Energy costs: electricity, water, fuel, etc. consumed during the production process.

[0075] 9. Other manufacturing costs: such as quality control, warehousing, logistics, etc.

[0076] In some embodiments, the algorithm core of the present invention is mainly to calculate direct labor costs, describe the cost impact factor of producing a unit of product as production complexity (PCP), and then add other factors to solve the overall cost during cost estimation.

[0077] In some embodiments, the use environment is sp, the machining coefficient is i, the material is m, the component ratio is r, the precision is p, and the utilization rate is u. Of course, different cost characteristics can also be selected according to different products.

[0078] Single complexity (PCP) = (environment * utilization) / (precision * material type * machining coefficient) * adjustment parameter Z;

[0079] Combinatorial complexity (nPCP) = PCP1*(n1%)*PCP2(n2%)*…

[0080] Complexity is a representation of cost characteristics, then:

[0081] PCP=f(sp,p,m,u,i) (1)

[0082]

[0083] C=a*w*e PCP (3)

[0084] (1) is a function of computational complexity, with input parameters including cost characteristics such as environment, material, precision, processing coefficient, and utilization rate. f is the core function of computational complexity.

[0085] (2) The formula for calculating composite complexity when a product consists of multiple subcomponents. n It is the weight ratio of the component in the unit product.

[0086] In (3), a represents the adjustment coefficient, w represents the weight, and C is a natural increase function relative to the PCP. The natural exponent expresses the cost characteristic with respect to the rate of increase of the cost, and has the characteristics of monotony, continuity, and differentiability.

[0087] In some embodiments, manufacturing complexity is a measure of the technical difficulty of a component (processing, machining accuracy, ease of machining, and surface treatment, etc.) and the level of organizational productivity. Manufacturing complexity is a primary driver of cost and schedule. Manufacturing complexity can be derived through this tool by describing the product's design to obtain this key parameter. The manufacturing complexity value can be derived starting from a top-level description, then gradually decomposing and calculating the complexity of each component to ultimately determine the overall manufacturing complexity of the product.

[0088] As can be seen, the present invention, through the functionality provided by PCPT, can derive a computational mixing factor, which is also the core factor in parametric cost estimation. The generation complexity estimation tool constructed by this invention not only provides a standard for equipment manufacturing cost estimation but also offers more intuitive tool support for estimating equipment manufacturing costs in practical application models. Equipment manufacturing cost estimation is a highly complex issue, and unified standards, methods, and tools are the foundation of all estimation work.

[0089] In summary, the present invention regards production complexity as the most important cost driving factor, which is composed of multiple quantifiable indicators; constructs multiple parameter indicators into a stable hybrid indicator through a mathematical regression algorithm and applies it to the cost estimation model; further unifies the indicators of the equipment manufacturing cost estimation system and reasonably establishes a structural production complexity calculation tool, which is of great significance to the equipment manufacturing cost estimation work.

[0090] Please note that the various technical features of the above embodiments can be combined arbitrarily. In order to make the description concise, not all possible combinations of the various technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification. The above-mentioned embodiments only express several implementation methods of the present application. The description is relatively specific and detailed, but it cannot be understood as a limitation on the scope of the invention patent. It should be pointed out that for ordinary technicians in this field, without departing from the concept of this application, several variations and improvements can be made, which all fall within the scope of protection of this application. Therefore, the scope of protection of the patent in this application shall be based on the attached claims.

Claims

1. A method for calculating equipment manufacturing costs based on production complexity, characterized in that: The method comprises: Step S1: Obtain parameters for calculating production complexity; wherein: The production complexity refers to the factors that affect the cost of producing a single product during the equipment manufacturing process; The parameters include processing accuracy, process maturity, operating environment value, machining coefficient, number of parts, and utilization rate for the single product during the equipment manufacturing process; Step S2: Calculating the production complexity based on the parameters; wherein: The production complexity includes single complexity and combined complexity; Step S3: Determine the equipment manufacturing cost using the production complexity.

2. The equipment manufacturing cost calculation method based on production complexity according to claim 1, characterized in that: In step S2, the calculation formula of the single complexity is: 1-PCP=(sp*u) / (p*m*i)*Z Among them, 1-PCP represents single complexity, sp represents the operating environment value, u represents utilization rate, p represents processing accuracy, m represents process maturity, i represents machining coefficient, and Z represents adjustment parameter.

3. The equipment manufacturing cost calculation method based on production complexity according to claim 2, characterized in that: In step S2, the calculation formula of the combination complexity is: N-PCP=PCP1*w1+PCP2*w2+…+PCPn*w n Among them, N-PCP represents the combination complexity, n represents the number of parts, PCPn represents the production complexity of the nth part, and w n Indicates the weight percentage of the nth component.

4. The method for calculating equipment manufacturing cost based on production complexity according to claim 2, characterized in that: In step S3, the calculation formula for equipment manufacturing cost is: C=a*W*e pcp Among them, C represents the equipment manufacturing cost, a represents the adjustment coefficient, W represents the weight, and pcp represents the production complexity.

5. The method for calculating equipment manufacturing cost based on production complexity according to claim 4, characterized in that: The processing accuracy refers to the manufacturing tolerance for the single product during the equipment manufacturing process, and the unit is decimal centimeters or millimeters. The lower the processing accuracy, the higher the production complexity.

6. The method for calculating equipment manufacturing cost based on production complexity according to claim 4, characterized in that: The process maturity indicates the impact of production difficulty caused by different process types and the labor intensity of the manufacturer on production complexity. The process types include forging, composite lamination, machining, welding, and casting. The higher the process maturity, the higher the production complexity. The process maturity value ranges from 1 to 5.

5.

7. The method for calculating equipment manufacturing cost based on production complexity according to claim 4, characterized in that: The operating environment value describes the reliability requirements of the equipment in the expected working environment. The operating environment value ranges from 1.0 to 7.0, among which the operating environment value of military ground equipment is 2.0 and the operating environment value of military aviation equipment is 6.

5.

8. The method for calculating equipment manufacturing cost based on production complexity according to claim 4, characterized in that: The machining coefficient describes the difficulty of processing different materials. The higher the difficulty of material processing, the smaller the machining coefficient. The machining coefficient of carbon alloy steel with the grade C1214 is set to 100, and this is used as a benchmark. Materials that are easier to process than C1214 have a machining coefficient less than 100, and materials that are more difficult to process than C1214 have a machining coefficient greater than 100.

9. The method for calculating equipment manufacturing cost based on production complexity according to claim 4, characterized in that: The number of parts refers to the number of parts contained in the single product during the equipment manufacturing process, excluding fasteners. The fasteners refer to bolts, nuts, rivets, and gaskets. A part includes several components. The production complexity of a part is determined by calculating the production complexity of each component, and the production complexity of each component is integrated to determine the production complexity of the single product during the equipment manufacturing process.

10. The method for calculating equipment manufacturing cost based on production complexity according to claim 4, characterized in that: The utilization rate indicates the ratio of the weight of available material to the weight of the blank material during the machining or milling process of the blank material in the equipment manufacturing process. The lower the utilization rate, the higher the production complexity.

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