80_Pandit Deendayal Petroleum University_Baja SAE India 2015_CostReport

Cost Documentation

Costing Overview

We Team CZAR have designed, manufactured and fabricated ATV named Destello

for BAJA-2015. During this project, cost factor was considered as one of the

important criteria which we had emphasised. This year all the departments had an

objective to not only optimize the ATV but also make it cheaper.

During design phase:

Whole ATV was designed keeping in mind manufacturing processes required. So

during design phase only we have tried to minimize bends, welds and labour costs,

material without sacrificing factor of safety, design aesthetics.

During Manufacturing Phase:

For cost cutting we had worked efficiently, considering “Time = Money”. So our

labour cost was minimized by working in an organized manner. Also we had taken

care that no extra material is procured. Waste of material after machining was also

minimized as all the material were procured keeping in mind particular need of

material for any individual part.

The following are the areas where the parts were optimized so as to use less amount

of material:

The team noticed that primary pipes which are heavier and expensive were

used in the last year’s ATV and so after careful analysis the team replaced

some of the primary pipes with secondary pipes in the design this lead to

lowering the cost of the raw material used in the roll cage and hence the

overall cost of the vehicle was reduced. Weight was reduced by 10kg.

Unnecessarily keeping a higher factor of safety in the wishbones upper and

lower both led to escalation in the cost and so this time the factor of safety

was lowered to an acceptable value and the wishbones were redesigned with

pipes of lesser diameter(16mm OD) which not only made the car lighter but

also reduced the cost.

This time the seat that has been mounted in the ATV was custom by the

students itself from cheap materials instead of buying an expensive seats that

are available in the market and this also led to lowered cost by 8300/- INR.

Without sacrificing driver’s safety and comfort.

The bolts used were of smaller size and were of the grade that was required

and bolts of higher grade were not used.

Cheaper auxiliary parts were used in the ATV instead of expensive heavy

duty components.

The battery used to power up the electrical systems was of smaller size and

less Ampere hour and so price reduced by 2500/- INR

We finally made an ATV in 3 lakhs INR which when compared to other ATV’s

available in the market is almost 3 lakhs cheaper. Here is a comparison shown

between last year’s “The Terrano” and this year’s “Destello”.

Departments BAJA-2014 “The Terrano”(INR)

BAJA-2015 “Destello” (INR)

Engine 26102.73 32709.84 Transmission 24843.17 51671.25 Drive Train 66988.04 58495.92 Steering 3030.69 5997.98 Suspension 56567.24 76277.30 Frame 20585.32 30604.22 Body 13300.49 14475.00 Brakes 11972.63 9270.10 Safety 20532.17 13388.80 Electricals 5478.66 1935.00 Fastners 5013.01 2054.88 Miscellaneous 4333.00 1912.22 Labour Cost 30453.65 24250.66 Total Cost 289200.80 299403.35

Destello is expensive than Terrano because in Destello “FOX racing SHOX” and

CVTech CVT is used which enhanced the performance a lot. Our weight was also

reduced by 125 kg.

Engine A , Line 1

Transmission B ,

Line 1

Transmission B , Line 1(item 2)

Transmission B , Line 1(item 3)

Transmission B , Line 4

1(item 4

Total Rs:39437.68

Transmission A , Line 3

=329.99 x58= 19139.42 (INR)

=199.99 x 58 = 11599.42(INR)

= 69.99 x 58 =4059.42(INR)

= 79.99 x 58 = 4639.42(INR)

Transmission A , Line 6

Drive A , Line 1

Drive A ,Line 2

Drive A , Line 3 & 4

Drive A , Line 5 & 6

Aluminium Material For

Hub & Knuckle

Drive A , Line 3 & 4

Drive A , Line 7

Steering A , Line 1

Steering A , Line 2

Steering A , Line 3

Steering A ,

Line 4

=569.4*60INR

=17070.00 INR

Suspension A ,

Line 1

=569.4 * 60 INR

=17070.00 INR

Suspension A , Line 2

Frame B , Line 1(item 1)

Frame B , Line (item 2)

Frame A , Line 2

Frame A , Line 3 & 4

Body A , Line 1

Body A , Line 2

Brake A , Line 1

Brake A , Line 3

Brake A , Line 2

Brake A , Line 4

Brake A , Line 5

Safety A , Line 1

= 28.99 x 60

= 1739.4 INR

Safety A , Line 2

Safety A , Line 3

Electrical A , Line 1

Electrical A , Line 3

Fastners A

Fastners A