1/2018

Operation Manual
How to calculate a plastic part
How to Calculate a Plastic Part
Step 1: Connecting to a Database ....................................................................................................2

Step 2: Adjust Project Specifications...............................................................................................3

Step 3: Take over Project Specifications ......................................................................................... 5

Step 3.1: Raw Material ..................................................................................................................6

Step 3.2: Production...................................................................................................................... 7

Supplement: Insert your own machines ..................................................................................... 10

Step 4: Insert Packaging and Logistics.......................................................................................... 11

Step 5: Investment and Tooling .................................................................................................... 12

Step 6: Long-term Agreement ....................................................................................................... 12

Additional Information ................................................................................................................. 13

Overview and Summary ................................................................................................................ 13

The Benefits of Cost Breakdowns .................................................................................................. 14

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Step 1: Connecting to a Database
1: Open Excel and start CALC4XL

2: Select “change costing DB“

3: Select a database from your folder

2
Step 2: Adjust Project Specifications
1: Open “templates” and select Cost_Breakdown_(CBD).xlsm

2: First insert or select input overheads (overhead costs and country data depend on country,
industry, product and company size)

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3: If needed, change overhead factors such as working system, general and calculation premises,
picture and remarks. Confirm with “OK”.1

4: The Cost Breakdown (CBD) will open, including all linked project specification data.
Furthermore the “new user”-form will open. You can insert a password for the administrator.
Confirm with “OK”.

1 Note: In the example, suppliers deliver parts without need for development; thus, development costs appear as 0%.

4
Step 3: Take over Project Specifications
1: The CBD presents various information on raw materials, components and production. If
needed, you can also insert a second picture.

5
Step 3.1: Raw Material
1: Double click the blank field under materials to open material calculation
2: Choose “PA66” in the name and number selection box
3: Insert scrap refund, net mass and charge weight. (In case of plastics produced in heating
channels, these values are usually identical since no losses occur during the sprue.)

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Step 3.2: Production
Cycle Time
1: Double click the field below cycle time.

2: The cycle time can be either entered directly or determined by using the cycle time calculator.
To open the cycle time calculator, click "C4XL: Injection Molding" in the dropdown logic.

2.1: In the cycle time calculator, insert all fields as per dropdown. (For the machine selection, the
max. clamp force is needed.)

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Machine rate per hour
1: Double click the field below machine to open the machine choice template.

2: Select your process group and machine group.2 If needed, change data or add equipment and
consumables on top. Furthermore, you can insert the machine hourly rate and manually set
numbers.

2 Note: The injection molding machine max clamp force is of 203kN/mm² as calculated in the cycle time calculator.

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Operator
1: Click the field below operator to open the wages template.

2: Select the skill level or, if desired, set the data manually.

3: Insert number of operators (e.g. 1 operator on 3 machines = 0.33 operators)

Set up cost
1: Insert production batch size (normal size for 10 batches/year is 12000pc/a/10 = 1200.

2: Insert setup time in the field “Std. Capacity Calculation.”

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Scrap cost
1: Scrap costs are entered as % value for the total process.

Supplement: Insert your own machines

2: Insert investment, variable rates, description and machine parameters. Click “insert as new
machine in DB”.

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Step 4: Insert Packaging and Logistics
Example (not with original CBD data)

Calculating the packaging

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Step 5: Investment and Tooling
This is a pure collector; thus, there are no pay-as-you-go or project distributions.

Step 6: Long-term Agreement

12
Additional Information

Worksheet „Overview and Summary“

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The Benefits of Cost Breakdowns
■ Includes all common cost information in one file

■ Number of lines per category is customizable

■ Part mapping facilitates assignment and trackability

■ Total sums can be displayed by number (/ pc, / 10, / 100 or, / 1000)

■ Allows variable, supplier specific calculations of surcharges

■ Display options for the following cost scenarios

o 2 different delivery places

o 2 different packaging options

o 3 different Incoterms

■ Graphics for quick and simple understanding (non-binding)

o Calculation machine hourly rate

o Calculation machine capacity

o Detailed packaging & transport options

o Incl. terms of business

o Complete cost overview

■ Summary with comparative overview for several parts or cost variants

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