1、EIA EDIBL-B 85 = 3234600 OOOLL5b 3 = - OCTOBER 1985 ENGINEERING DESIGN INTEGRATION BULLETIN NO. 1-B UNIT PRODUCTION COST TRACKING MODEL UPCTG ELECTRONIC INDUSTRIES ASSOCIATION ENQINEERINQ DEPARTMENT 2001 EYE STREET, N.W. WASHINOTON, D.C. 20006 . i - Copyright Government Electronics Cost estimates fo
2、r such components vary depending upon their maturity at the expected time of purchase. the expected cost reduction, and incorporate it into a Unit Production Cost estimate for an equipment using the component, for any time of production from the current time to the time of component maturity. Data e
3、ntry has been.simplified in the Global control file. PCT6 can consider O The Unit Production Cost Tracking bdel UPCT6 was developed by Mr. Harvey Barton of RCA as G-47 Task Leader. the members of the committee who participated and applied the model to particular pmgrams. . We extend our thanks to Mr
4、. Barton and The coinnittee particularly welcomes comments on additional applications of the model to specific programs. Comments or suggestions may be forwarded to: The G-47 Staff Fmgineer EIA Headquarters 2001 Eye Street, N.W. Washington, D.C. 20006 i Copyright Government Electronics or shop order
5、s to identify cost centers; or common components used in several assembl ies. Costs are accumulated by “process“ as well as CBS element, to -5- Copyright Government Electronics E FROM TOT “RECUR RECM 0.58 17.83 0. O0 1.10 1.30 o. 00 0. o0 3.06 0.66 11.82 2.55 33.81 0. 00 a. ia 0.00 13.12 0.00 242.01
6、 0.00 255.14 2.55 41899 2.SS 297.13 0.34 10.43 0. 00 0. 64 0. 75 0. 00 0. 00 1.79 O. 66 4.74 1.75 17.60 0.00 4877 0.00 14.88 0.00 124.98 UrrUrslL, DTUPC Statua Report With All Proecrrics - -10- NONRECUR o. O0 o. o0 -0. 12 0. 00 -0.0s -0.17 0. O0 0. 00 0. ob o. 00 -0.17 -0.17 0.13 o. 00 0.07 0. o0 0.
7、04 . 0.23 0. 00 0. 00 0. O0 RECUR 0. 64 -0.17 0. 00 -0. 18 0. 00 0, 29 1 .o5 0. 28 a. 69 8.97 1.34 10.31 -0.47 0. 00 -0. 05 -0.22 -0.82 0. 08 -0.22 39.20 -o. oe f -i. Copyright Government Electronics & Information Technology Association Reproduced by IHS under license with GEIA Not for ResaleNo repr
8、oduction or networking permitted without license from IHS-,-,-EIA EDIBL-B 85 W 3234600 0001L72 L W Y EDIB1-B DATA TESTER TAELE 1 DTUPC STATUS REPORT PAGE 2 REPORT 19 8/85 TARGET TOLERANCE +0.09,-0,09 PRODUCTION QUANTITY 10000. COST BASIS DATE 1/84 TECHNOLOGY DATE 3/86 EiEMENT/ PROCESS CURRENT COST T
9、ARGET COST VARIANCE FROM TGT NONRECUR RECUR NONREWR RECLIR NONRECUR RECUR 92 MATERIAL 0.00 178.84 0.00 139.86 0.00 38.98 92 LABOR 1.98 21.63 1.75 22.37 0.23 -0.74 99 MFG. TOTAL 1.88 200148 1.75 162.24 0.23 38.24 2. 3. 0. 01 0. 0 CHASC IS 8164312-502 1 ASSEMBLY 10.09 E15.96 10.44 85.64 -0.35 0. 32 2
10、IE8tPROD CTRL 0. 00 3.29 o. o0 3.22 0. o0 0. 07 3 PRCIDUCIBILTY 4.25 0. 00 4.43 0.00 -0.18 0. 00 4 &FIELD QA o. o0 2.03 o. o0 2.09 0.00 -0.05 7 FACTORYLAEWR 14.34 91.28 14.67 90.95 -0.53 0. 33 8 ENQINEERING 0.00 24.13 0.00 24.54 0.00 -0.42 10 OTHER MATL 3.74 57.92 3.99 52.16 -0.25 5.75 92 MATERIAL 3
11、.74 37.92 3.99 52.16 -.25 5. 75 91 WR 14.34 115.41 14.87 115.49 -0.53 -0.08 99 MFG. TOTAL 18.08 173.32 18.87 167.65 -0.78 5.67 2. o. 0. o. 0. 0 TESTER 8163302-504 1 ASSEMBLY 11.13 121.79 2 IELPROD CTRL 0. 00 5.33 3 PRODUCIBILTY 6.24 0. 00 4 QCWIELD BA 0.00 14.83 5 TEST 19.90 70.52 6 PACKWKG 0.00 5.8
12、3 7 FACTORYLABOR 37.28 218.29 8 ENGINEERING 0.00 41.43 11.36 0. O0 6.48 0. 00 20.24 0. 00 38.00 0. 00 121.34 5.52 0. 00 1s. 30 70.85 218.77 5.76 40.91 -0.23 0. 45 0.00 -0.19 -0.23 0.00 0.00 4.48 -0.34 -0.33 0.00 0.07 -0.80 -0.48 Fiaure 4. DTUPC Status Report With All Processee (con t i nu4 0. 00 0.
13、53 -1 1- PXoULEfil HARD COPY Copyright Government Electronics & Information Technology Association Reproduced by IHS under license with GEIA Not for ResaleNo reproduction or networking permitted without license from IHS-,-,-EbIB1-B EIA EDIBL-B 5 m 3234600 0001L73 3 m DATA TESTER TABLE 1 DTUPC STATUS
14、 REPORT PME 3 REWRT 19 8/85 TARGET TOLERANCE +0.09,-0.09 PRODUCTICNJ QUANTITY 1. ELEMENT/ PR3CESS 9 CAPACITORS 10 OTHER MATPL 92 MATERIAL 91 LABOR 99 MFG. TOTAL 25.02 LOAD DTUPC TOTAL CURRENT COST NONRECUR RECIJR 0.00 28.06 3.74 472.80 3.74 30&07 37.28 259.73 41.02 760.59 10. 190. 51 351. TOTAL DTUP
15、C ESTIMATE 1002. COST BASIS DATE 1/84 TECHNOLOY DATE 3/86 TARGET COST VARIANCE FROM TOT NONRECUR RECUR 0.00 28.00 3.99 419.16 3.99 447.16 38.68 259.67 42.07 706.84 11. 177. 53 884 936. ur+ 4. DTWC Status Rwort With All Processes CConeludrd) -12- NQNRECltR RECUR 0. o0 0. o6 -0.25 53.65 -0.25 53.70 -0
16、.80 o. 05 -1.05 53.76 -0. 13. -i. 67. 66. Copyright Government Electronics & Information Technology Association Reproduced by IHS under license with GEIA Not for ResaleNo reproduction or networking permitted without license from IHS-,-,-EIA EDIBL-B 85 m 3234b00 OOOLL74 5 m EDIB-B DATA TESTER TAELE 1
17、 DTUPC STATUS REPORT PAGE 1 REPORT 19 8/85 TAROET TOLERANCE +0.09,-0.09 PRODUCTIC3N QUANTITY 10000. COST BASIS DATE 1/84 TECHNOLOOY DATE 3/86 ELEMENT/ PROCESS CURRENT COST TAROET COST VARIANCE FROM TGT NONRECUR RECUR NONRECUR RECUR NONRECUR RECUR 2. 2. 1. 0. 0. 0 CAPACITMIS CKR06 9 CAPACITORS 0.00 1
18、4.66 0.00 14.88 0.00 -0.22 2. 2. 2. 0. 0. 0 DIODES 10 OTHER MATL 0. 00 5.64 0. 00 5.73 0.00 -0.09 2. 2. 3. 0. 0. O CONNECTOR WTB30PR7SY 10 OTHER MATL 0. 00 7.86 0. 00 7.40 0. 00 0. 47 2. 2. 4. 0. 0. 0 INTERATED CKTS. 10 OTHER MAT L 0.00 138.67 0.00 101.69 0.00 36.98 2. 2. 5. o. 0. o PC BOARD 10 OTHE
19、R MATL 0.00 12.02 0.00 10.17 0. 00 1 .84 2. 2. o. 0. o. o CONVERTER 8164311-503 i ASSEMBLY 0. 46 9.96 0.34 10.43 0.13 -0.47 2 IE8tPROD CTRL 0.00 0. s6 0. 00 0. 64 0.00 -0.08 3 PRODUCIBILTY 0. 82 0. 00 0. 75 0. 00 0.07 , 0.00 . 4 QC&FIELD GIA 0. 00 1.74 0. 00 1.79 0.00 -0.05 5 TEST 0. 70 4.52 0. 66 4
20、.74 0.04 -0.22 7 FACTORYLABOR 1.98 16.78 1.75 17.60 0.23 -0.82 ENQINEERIN 0. 00 4.85 0. 00 4.77 0. 00 0. 08 9 CAPACITORS 0.00 14.66 0.00 14.88 0.00 -0.22 10 OTHER MATL 0.00 164.19 0.00 124.98 0.00 39.20 92 MATERIAL 0.00 178.84 0.00 139.86 0.00 38.98 91 LABOR 1.98 21.63 1.75 22.37 0.23 -0.74 99 MFG.
21、TOTAL 1.98 200.48 1.75 162.24 0.23 38.24 mre 5, DTUPC 8t at us Report With Al 1 Pu ocesses Limited to Branch 2.2. -13- Copyright Government Electronics & Information Technology Association Reproduced by IHS under license with GEIA Not for ResaleNo reproduction or networking permitted without license
22、 from IHS-,-,-I- - EDIB1-B EIA EDIB1-B 5 = 3234600 0001175 7 DATA TESTER DTUPC TRACKING CHART REPMZT 19 8/85 TARBET TMERANCE +0.09,-0.09 PROWCTION QblANfITY 10000. COST BASIS DATE 1/84 ?TECHNOLOGY DATE 3/86 .30 . S . . . . . . . . -.30 . e DTUPC Tracking Chart Copyright Government Electronics & Info
23、rmation Technology Association Reproduced by IHS under license with GEIA Not for ResaleNo reproduction or networking permitted without license from IHS-,-,-EIA EDIBL-B 85 = 3234b00 0001176 9 . EDIBl-B TABLE 4. DTUPC PROBLEM ANALYSIS REPORT REPORT 19 8/85 TARGET TOLERANCE +0.09,-0.09 PRODUCTION QUANT
24、ITY 10000. COST BASIS DATE 1/84 TECHNOLOl3Y DATE 3/86 ITEM TESTER CBS ELEMENT 2. O. O. O. O. O OTHER MATL RECUfZRINO NONRECURRING TOTAL BASELINE COST TARBET 419.16 3.99 42% 15 CURRENT COST PROJECTION 472.80 3.74 476 55 TOTAL VARIAWE 53.65 -0.25 53.40 REASON IMPACT ON OTHER ITEMS CORRECTIVE ACTIONAMT
25、E ITEM MANAGER DTC CHAIRMAN FROORAM MANAGER Eiciure 7% DTUPC Problem Analysis Report -15- Copyright Government Electronics & Information Technology Association Reproduced by IHS under license with GEIA Not for ResaleNo reproduction or networking permitted without license from IHS-,-,-EIA EDIBL-B 85
26、M 3234600 OOOLL77 O M EDIB1-B MODEL INPUTS The Unit Production Cost Tracking computer program derives its inputs from three source data files. Two of these files contain nonrecurring and recurring cost estimates or allocations associated with specific CBS elements. A tinte period index is included w
27、ith each cost estimate, indicating when the estimate or allocation was made. The production quantity basis is included, also. The index number of the CBS element manager is indicated for use in Problem Analysis Reports. The third data file contains “system level“ information such as program beginnin
28、g and ending.dates, report date, cost basis date, technology basis date, tolerance limits for beginning and end of the program, desired production quantity, identification of processes, escalation factors, managers names, and report request information. It may include process learning factors, labor
29、 rates, and burden rates. Copyright Government Electronics & Information Technology Association Reproduced by IHS under license with GEIA Not for ResaleNo reproduction or networking permitted without license from IHS-,-,- EIA EDIBL-B 5 The computer program is written in FORTRAN 668 for time-shared o
30、peration on an IBM mainframe computer, with the VM/CMS operating system. The FORTRAN is standard, without use of any proprietary language extensions. The program requires assignment of approximately lOO,OOO memory bytes, independent of complexity of the equipment being analyzed. Execution time depen
31、ds upon the lengths of Target and Current Cost files, as well as CBS limits of analysis established in the Global File. Minimum execution time is assured by limiting analysis to branches of immediate interest. The program executes upon a single pair of file lines at a time, reading and writing on li
32、ne. Most efficient operation reads inputs from resident disks and writes outputs similarly. This mode can create extensive reports very rapidly. Creation of an executive file facilitates operation. The Executive file assigns library functions if necessary, and defines input and output files. Program
33、 loading and execution can be accomplished in the Executive file, also. A typical example of an Executive file follows as implemented in VM /CMS . FILEDEF 05 DISK UPCT6 GLOBAL FILEDEF 11 DISK UPCT6 BASELINE FILEDEF 12 DISK UPCT6 TARGET FILEDEF 13 DISK UPCTG PROBLEM FILEDEF 99 DISK UPCT6 REPORT Note
34、that the program reads GLOBAL FILE from data set 058 BASELINE FILE from data set 11 and TARGET FILE from data set 12. The DTUPC Status Report and Tracking Chart are written to data set 99. These may be written to the line printer by changing the designation “DISK UPCTG REPORT“ to “PRINTER (RECFM FA)
35、“. The “(RECFM FA)“ option causes the printer to * recognize the first character of a FORMAT as a carriage control character. The DTUPC Problem Analysis Report is written to data set 13 when initiated by excessive cost deviation. The Problem Analysis Reports may be written to the line printer by the
36、 “PRINT“ command as shown: PRINT UPCT6 PROBLEM (CC. The option CC causes the printer to recognize the control characters in the file. This will result in page separation of PAR reports. Following is a listing of the current version of the computer program. Copyright Government Electronics & Informat
37、ion Technology Association Reproduced by IHS under license with GEIA Not for ResaleNo reproduction or networking permitted without license from IHS-,-,-e O O EIA EDIBL-B 5 E 3234600 0001L9 4 E EDIB1-B c C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C
38、 C C PRORAM UPCT6 AUOUST 15, 1985 REVISED 9/12/85 He R. BARTON, JR. VERNMENT COMMUNICATIONS SYSTEMS RCA CMPORATION CAMDEN, NEW JERSEY TELEPHONE: (609)338-2442 UNIT PRODUCTION COST TRACKIN MODEL WITH CAPABILITY OF VARYIN0 PRODUCTION QUANTITY, CHANGIffi UNIT PRODUCTION COST BY LEARNING CURVE COMPUTATI
39、ON. LEARNING CURVE SLOPES ARE ASSOCIATED WITH MAY BE USED. IF NONRECURRIN LEARNIW CURVE PERCENTAOES ARE PRODUCTION QUANTITY. A NONZERO LEARNXNO VALUE LESS THAN 80 CAUSES COST INPUTS TO BE TREATED AS FIXED UNIT COSTS, WITHOUT LEARNING. PROCESS NONRECURRIM AND RECURRING COSTS, SO UP TO 196 VALUES ENTE
40、RED AS ZEROES, THEY ARE TREATED AS FIXED COSTS DIVIDED BY PRODUCTION QUANTITY IS ASSOCIATED WITH EACH COST ELEMENT, IN TARGET AND CURRENT COST FILE. A PROGRAM QUANTITY TOLERANCE INITIATES LEARNING CURVE APPLICATION WHEN THE INPUT FILE QUAN- TITY DIFFERS FROM THE DESIRED PRODUCTION QUANTITY BY MORE T
41、HAN THE QUANTITY TOLERANCE. DESIRED PRODUCTION QUANTITY IS ENTERED VIA THE CONTROL. OR GLOBAL FILE. UPCOO01O UPCO02O UPCO003O UPCOO04O UPCOOO50 UPCoO06O UPCOOO7O U P 6: O O O 8 O UPCOO090 UPCOO 1 00 UPCOO 1 1 O UPCOO 120 UPCOO1 30 UPCOO d 40 UPCOO1 SO UPCO 16O UPCOO 170 UPCOO 180 UFCOOl9 UPC02OO. UP
42、COO2 1 o UPC00220 UPCOO230 UPCOO246 U P C O O 2 5 0 UPC0026O UPCOO270 UPCOO280 UPCOO290 DESIRED PRODUCTION QUANTITY MAY VARY FROM ONE TO 99,9)9,999 UNITS.UPCOOOO UPCOO31O CONSIDERATION MAY BE GIVEN TO ANTICIPATED COST REDUCTIONS DUE TO UPCOO320 TECHNOLOGY IMPROVEMENT. THE MODEL ASSUMES A LINEAR REDU
43、CTION UPCOO330 TOWARD A SPECIFIED GOAL. U P C 0 O 3 4 0 UPCOO350 UPCT6 PROVIDES THE CAPABILITY TO ENTER CURRENT COSTS IN TERMS UFC0360 OF LABOR HOURS AND BASIC MATERIAL COSTS, IF DESIRED. LABOR CAN UPCOO370 BE WEIGIHTED BY A UNIQUE LABOR RATE AND OVERHEAD RATE FOR EACH UPCO030O PROCESS. UPCOO390 UPC
44、OO400 PROCESSES HAVE BEEN ORGANIZED INTO PROCESS GROUPS, PROCESSES, UPCOO410 AND SUBPROCESSES, EACH OF WHICH MAY USE A UNIQUE LABOR RATE, UFCOO42O AND OVERHEAD RATE. PROCESS GROUPS, PROCESSES, AND SUBPROCESSES UPCOO430 ARE RELATED TO EACH OTHER BY GLOBAL FILE DATA. ANY INPUT PROCESS UPCOO440 MAY HAV
45、E AN ASSOCIATU) MAXIMUM PROCUREMENT QUANTITY BEYOND. WHICH UFC00450 NO ADDITIONAL UNIT COST REDUCTIONS ARE POSSIBLE. UPCOO460 SUBPROCESS COSTS ARE SUMMED INTO PROCESSES, AND PROCESS COSTS UPCOO470 ARE SUtlMED INTO PROCESS GROUPS, AND THENCE TO TOTAL MANUFACTURING UPC00480 COST. TOTAL MANUFACTURING C
46、OST IS LOADED BY U&A OR OTHER UPCOO490 DESIRED LOADINU. UPCOO500 UPCOOS 1 0 UPCOO520 - Copyright Government Electronics & Information Technology Association Reproduced by IHS under license with GEIA Not for ResaleNo reproduction or networking permitted without license from IHS-,-,-EIA EDIBL-B 5 m 32
47、34b00 0001LO O m EDIB1-B C UPCOO53O CbttttXXXttXttXXtXXSPECIFICATIOSECTItXXttXXXXttXttXXtXtXtXttXXUPC6OS4O C UPCOO550 INTEERt2 FI/O/,RP/O/,NPRINT/O/,POI/I/,PAGEL/8/,N/88/ UPCOO560 INTEQEWP BR(7)/7tO/,TR(7)/7tO/,PN/O/,MkrXWBC/O/IN/ UFCS7O INTEGER$2 SAVWBS(7)/72O/,EFMO/I/,EFYR/l/,CMATM/O/,CMATY/O/ UPC
48、OOSO INTEERX4 IDSl/5/IDS2/11/,IDS3/12/ UP C O O 6 O O INTEERt2 BEMON/I/,BEGYR/75/,ENDMON/l/,ENDYR/9O/,YRLTH/i/ UPCOO610 INTEGERt2 COSTMO/i/,COSTYR/8O/,REPMON/i/,REPYR/85/,MOLGTH/i/ UPCOO620 INTEGERX2 IC/B/,IT/O/,LCURVN(99)/9*O/,LCURVR(99/99t0/ UFCO0630 INTEERtZ WBCH(7)/7tO/,LVL/O/ UPCOO640 INTEGER*2
49、 PMUE/O/ UPC65O INTEGERt2 NMO/O/,NDA/O/,NYR/O/,MO/O/,NQ/I/ UPC0066O INTEERX2 MCRC/O/,YCRC/O/,MTRC/O/,YTRC/O/,LCI/99/ UPCOO670 INTEER*2 FIPT/O/,PLOTM/O/,TMRNO,TECHMO/O/,TECHYR/O/ UPCOG80 INTEER*2 NSUB(40)/4010/,NREL(9)S9*S9/,PNSUB(99)/9*0/ UFCOO69O INTEQERt2 PRQRP UPCOO700 REALP4 HR(SS)/S9PO.O/,EURDEN(9S)/S*O.0/,MAXQ(S9)/9t./ UFCO7 I O REALt4 TNIT4,
