Cost Analysis totals for:

DFA index (percent)

4.4 %

Total assembly time

723

seconds

Total labor cost

$6.02

dollars/unit

Total assembly weight

0.67

lbs

Number of different parts or sub-assemblies

41

# parts & sub-assemblies assembled (inc. rpts.)

50

# reorientations & standard or user ops. (inc. rpts.)

37

Theoretical min # parts or unanalyzed sub-assemblies

11

Base Hourly labor rate

$15.00

dollars/hour

Burdened Hourly labor rate

$30.00

dollars/hour

Summary of Parts and Sub-assembly Cost

Total tooling cost

$0.95

dollars/unit

Total part and OEM sub-assembly costs

$5.14

dollars/unit

TOTAL UNIT COST

$12.11

dollars/unit

Production Volume

1,000,000

units/year

3

year production life

Table of Subassemblies for:

TOASTER

Oper.

Labor

Repeat

Assy Labor

Material

Tooling &

Item

Min

DFA

TOTAL

No.

Name

Analysis Status

Level

Time

Rate

Count

Cost

Cost

Proc. Cost

Count

Parts

Index

COST

Part Number

Comment

1

Final Assembly

Analysis complete

0

120.0

$30

1

$1.00

$0.18

$0.10

16

1

2.4

$1.28

Final Assembly

2

Packaging

Analysis complete

1

65.1

$30

1

$0.54

$1.00

$0.03

8

4

17.7

$1.57

Packaging

3

S6 Base Unit

Analysis complete

1

31.2

$30

1

$0.26

$0.08

$0.08

4

1

9.2

$0.42

S6

4

A3 Toast Cage

Analysis complete

1

371.1

$30

1

$3.09

$1.58

$0.64

43

1

0.8

$5.32

A3

6

S9 Slider Asm

Analysis complete

2

17.0

$30

1

$0.14

$0.07

$0.01

2

1

17.0

$0.22

S9

7

A4 Control Asm

Analysis complete

1

70.0

$30

1

$0.58

$2.10

$0.00

5

0

0.0

$2.68

A4

9

S7 Circuit Bd Hsng

Analysis complete

2

29.0

$30

1

$0.24

$0.08

$0.01

4

1

9.9

$0.33

S7

10

S10 Darkness Knob

Analysis complete

1

11.0

$30

1

$0.09

$0.01

$0.01

2

1

26.2

$0.11

S10

11

S5 Crumb Tray

Analysis complete

1

8.7

$30

1

$0.07

$0.03

$0.07

2

1

33.1

$0.17

S5

TOTALS

723

$6.02

$5.14

$0.95

86

11

4.4%

$12.11

Worksheet for subassembly:

Final Assembly

Repeat

Min

Tool

Item Handlg

Item Insrtn

Total Oper.

Total Oper.

Mtl

Tl & Pr

No.

Item Type

Name

Count

Parts

Acq T

/Acq Time

Time

Assy Time

Assy Cost

Cost

Cost

Weight

Description

Part Number

Comment

1

Sub

Packaging

1

1

0

2.0

1.5

3.5

$0.03

-

--

-

add

Packaging

2

Sub

S6 Base Unit

1

0

0

3.0

2.3

5.3

$0.04

-

--

-

add

S6

3

Part

020 Coil Spring

1

0

0

4.1

5.0

9.1

$0.08

$0.05

--

--

add & push fit

020

4

Sub

A3 Toast Cage

1

0

0

2.7

1.8

4.5

$0.04

-

--

-

add & snap fit

A3

5

Sub

A4 Control Asm

1

0

0

3.0

7.7

10.7

$0.09

-

--

-

add & snap fit

A4

6

Part

001 Cover

1

0

0

3.0

6.0

9.0

$0.08

$0.11

$0.08

0.18

print and add

001

7

Oper

reorientation

1

-

-

-

4.5

4.5

$0.04

-

--

-

reorient & adjust

8

Part

003 Screws

4

0

2.9

2.1

4.0

27.1

$0.23

$0.02

$0.02

--

add & thread

003

9

Oper

reorientation

1

-

-

-

4.5

4.5

$0.04

-

--

-

reorient & adjust

10

Sub

S10 Darkness Knob

1

0

0

2.0

8.7

10.7

$0.09

-

--

-

add & push fit

S10

11

Part

024 Handle

1

0

0

2.0

13.2

15.2

$0.13

$0.00

$0.00

0.00

add & push fit

024

12

Oper

reorientation

1

-

-

-

4.5

4.5

$0.04

-

--

-

reorient & adjust

13

Sub

S5 Crumb Tray

1

0

0

2.7

8.7

11.4

$0.10

-

--

-

add & push fit

S5

Worksheet for subassembly:

Packaging

Repeat

Min

Tool

Item Handlg

Item Insrtn

Total Oper.

Total Oper.

Mtl

Tl & Pr

No.

Item Type

Name

Count

Parts

Acq T

/Acq Time

Time

Assy Time

Assy Cost

Cost

Cost

Weight

Description

Part Number

Comment

Part

X1 Box

1

1

0

2.0

-

-

-

$0.30

--

--

X1

1

Part

X2 Documents

3

3

0

5.6

2.3

23.7

$0.20

$0.10

--

--

add

X2

2

Part

X3 Cardboard insert

1

0

0

5.6

5.0

10.6

$0.09

$0.05

--

--

add & push fit

X3

3

Oper

place Assm in Bag

1

-

0

-

-

12.5

$0.10

$0.05

--

--

library operation

plastic bag

4

Part

X4 Styrofm End Cap

1

0

0

1.8

5.0

6.8

$0.06

$0.25

$0.01

--

add & push fit

X4

5

Oper

reorientation

1

-

-

-

4.5

4.5

$0.04

-

--

-

reorient & adjust

6

Part

X5 Styrofm End Cap

1

0

0

2.0

5.0

7.0

$0.06

$0.25

$0.01

--

add & push fit

X5

Worksheet for subassembly:

S6 Base Unit

Repeat

Min

Tool

Item Handlg

Item Insrtn

Total Oper.

Total Oper.

Mtl

Tl & Pr

No.

Item Type

Name

Count

Parts

Acq T

/Acq Time

Time

Assy Time

Assy Cost

Cost

Cost

Weight

Description

Part Number

Comment

1

Part

002 Base

1

1

0

2.0

1.5

3.5

$0.03

$0.04

$0.03

0.06

add

002

2

Part

002-1 Rubber Foot

2

0

0

1.4

6.5

15.9

$0.13

$0.02

$0.00

--

add & intrfrnce fit

002-1

3

Part

002-2 Label

1

0

0

6.4

5.5

11.9

$0.10

$0.02

$0.05

--

add & self-stick

002-2

Worksheet for subassembly:

A3 Toast Cage

Repeat

Min

Tool

Item Handlg

Item Insrtn

Total Oper.

Total Oper.

Mtl

Tl & Pr

No.

Item Type

Name

Count

Parts

Acq T

/Acq Time

Time

Assy Time

Assy Cost

Cost

Cost

Weight

Description

Part Number

Comment

1

Part

005 Top Plate

1

1

0

2.3

3.7

6.0

$0.05

$0.05

$0.11

0.03

add

005

2

Oper

tab twisting

4

-

2.9

-

1.1

7.3

$0.06

--

--

--

standard operation

3

Part

007 Front Plate

1

0

0

1.8

5.2

7.0

$0.06

$0.15

$0.05

0.08

add

007

4

Oper

tab twisting

6

-

2.9

-

1.1

9.5

$0.08

--

--

--

standard operation

5

Oper

reorientation

1

-

-

-

4.5

4.5

$0.04

-

--

-

reorient & adjust

6

Part

007 Front Plate

1

0

0

2.7

5.2

7.9

$0.07

$0.15

0.05

0.08

add

7

Oper

tab twisting

6

-

2.9

-

1.1

9.5

$0.08

--

--

--

standard operation

8

Sub

S8 Heat Tubes

1

0

0

6.4

8.7

15.1

$0.13

$1.00

--

--

add & press fit

S8

9

Oper

reorientation

1

-

-

-

4.5

4.5

$0.04

-

--

-

reorient & adjust

10

Oper

complex adjust, Tube

1

-

0

-

-

162.0

$1.35

--

--

--

library operation

11

Part

008 Side Plate

1

0

0

2.7

5.2

7.9

$0.07

$0.02

0.05

0.02

add

008

12

Oper

tab twisting

2

-

2.9

-

1.1

5.1

$0.04

--

--

--

standard operation

13

Part

017 Carriage

1

0

0

2.7

8.9

11.6

$0.10

$0.03

$0.11

0.03

add

017

14

Oper

tab twisting

1

-

2.9

-

1.1

4.0

$0.03

--

--

--

standard operation

15

Part

021 Wire

1

0

0

6.4

12.7

19.1

$0.16

$0.01

--

--

add

021

16

Oper

bending

1

-

2.9

-

1.1

4.0

$0.03

--

--

--

standard operation

17

Oper

assem end of spring

1

-

2.8

-

-

2.8

$0.02

--

--

--

library operation

with Pliers

18

Part

019 Extension Spring

1

0

0

4.1

5.5

9.6

$0.08

$0.05

--

--

add & snap fit

019

19

Sub

S9 Slider Asm

1

0

0

3.0

10.9

13.9

$0.12

-

--

-

add & push fit

S9

20

Part

008 Side Plate

2

0

0

2.7

5.2

15.9

$0.13

$0.02

$0.05

0.02

add

21

Oper

tab twisting

1

-

2.9

-

1.1

4.0

$0.03

--

--

--

standard operation

22

Part

016 Grill

2

0

0

2.7

11.9

29.3

$0.24

$0.02

$0.11

0.02

add

016

23

Oper

bending

4

-

2.9

-

1.1

7.3

$0.06

--

--

--

standard operation

24

Part

006 Bottom Plate

1

0

0

2.0

1.5

3.5

$0.03

$0.08

$0.11

0.08

add

006

Worksheet for subassembly:

S9 Slider Asm

Repeat

Min

Tool

Item Handlg

Item Insrtn

Total Oper.

Total Oper.

Mtl

Tl & Pr

No.

Item Type

Name

Count

Parts

Acq T

/Acq Time

Time

Assy Time

Assy Cost

Cost

Cost

Weight

Description

Part Number

Comment

1

Part

022 Slider

1

1

0

3.0

8.7

11.7

$0.10

$0.07

$0.01

0.01

add & push fit

022

2

Part

023 Lever Extender

1

0

0

2.0

3.3

5.3

$0.04

$0.00

$0.00

0.00

add & snap fit

023

Worksheet for subassembly:

A4 Control Asm

Repeat

Min

Tool

Item Handlg

Item Insrtn

Total Oper.

Total Oper.

Mtl

Tl & Pr

No.

Item Type

Name

Count

Parts

Acq T

/Acq Time

Time

Assy Time

Assy Cost

Cost

Cost

Weight

Description

Part Number

Comment

Part

011 Cord

1

--

0

4.0

5.0

9.0

$0.08

$0.10

--

--

add

011

1

Oper

plug in connector

2

-

0

-

-

24.0

$0.20

--

--

--

library operation

Harness or Device

2

Oper

route wire harness

1

-

0

-

-

26.1

$0.22

--

--

--

library operation

Regrasp required every 6 inch.

3

Pcb

026 Circuit Board

1

0

0

2.0

5.5

7.5

$0.06

$2.00

--

--

add & snap fit

026

4

Sub

S7 Circuit Bd Housing

1

0

0

2.0

1.5

3.5

$0.03

-

--

-

add

S7

Worksheet for subassembly:

S7 Circuit Bd Hsng

Repeat

Min

Tool

Item Handlg

Item Insrtn

Total Oper.

Total Oper.

Mtl

Tl & Pr

No.

Item Type

Name

Count

Parts

Acq T

/Acq Time

Time

Assy Time

Assy Cost

Cost

Cost

Weight

Description

Part Number

Comment

1

Part

031,032 defr/heat

1

1

0

2.0

10.0

12.0

$0.10

$0.00

$0.00

--

add & snap fit

031, 032

2

Part

030 Button Leg

2

0

0

2.7

3.3

12.1

$0.10

$0.02

$0.00

0.00

add & snap fit

030

3

Part

025 CB Enclosure

1

0

0

2.0

3.0

5.0

$0.04

$0.06

$0.01

0.01

add

025

Worksheet for subassembly:

S10 Darkness Knob

Repeat

Min

Tool

Item Handlg

Item Insrtn

Total Oper.

Total Oper.

Mtl

Tl & Pr

No.

Item Type

Name

Count

Parts

Acq T

/Acq Time

Time

Assy Time

Assy Cost

Cost

Cost

Weight

Description

Part Number

Comment

1

Part

029 Knob Transmitter

1

1

0

1.5

6.5

8.0

$0.07

$0.01

$0.00

0.00

add & press fit

029

2

Part

028 Darkness knob

1

0

0

1.5

1.5

3.0

$0.03

$0.00

$0.00

0.00

add

028

Worksheet for subassembly:

S5 Crumb Tray

Repeat

Min

Tool

Item Handlg

Item Insrtn

Total Oper.

Total Oper.

Mtl

Tl & Pr

No.

Item Type

Name

Count

Parts

Acq T

/Acq Time

Time

Assy Time

Assy Cost

Cost

Cost

Weight

Description

Part Number

Comment

1

Part

015 Crumb Tray Hndle

1

1

0

2.0

3.3

5.3

$0.04

$0.00

$0.00

0.00

add & snap fit

015

2

Part

014 Crumb tray

1

0

0

2.0

1.5

3.5

$0.03

$0.03

$0.07

0.03

add

014