User Guide - zf.com · the entire production process provides useful starting points for optimizing the process and reducing waste. Technical modifications The detailed depiction

User Guidefor the Quotation Analysis Form (QAF) V3.0and Tooling Analysis Form (TAF) V3.0

3

Content

Working together as partners

05 Benefit of QAF and TAF06 Structure of the QAF 07 Using the QAF08 Structure and use of the TAF

Cost Engineering

11 The ZF cost model16 How ZF structures overhead

Fill out the QAF

21 How to correctly fill out the QAF22 Data sheet „Summary“31 Additional data sheets 32 The „Material“ data sheet40 The „Manufacturing“ data sheet48 The „SME_R&D“ data sheet

How to correctly fill out the TAF

55 Detailed description of structure and use 59 What you need to fill out in the TAF

01 0203

04

Annex

61 Annex62 Notes

05

54 Working together as partnersUser guide for QAF and TAF

01Working together as partners

Benefits of QAF and TAF

The key issue is cost transparency. In order for the ZF Group to work together with suppliers as partners, it is essential that the costs of purchased parts and the associated special manufacturing equipment (SME) should be presented transparently. The partner-ship depends on this information, because only by maintaining a very high degree of transparency is it possible for both sides to identify cost-driving factors and improve future structures. We make our decisions based on competitiveness, so we always take total coststhroughout the supply chain into account.

You may already be aware that ZF and itssuppliers collaborate on existing productsthrough interdisciplinary value analysis teams. This approach is intended to transform annual, one-off price negotiations into ongoing, open cost discussions. The aim of this approach is not to question supplier profits. Instead, it is all about identifying cost-driving factors for which both sides are responsible during product and process design so that cost-efficient solutions can be found. Our top priority is to work together to achieve an optimal cost level that benefits both parties.

When we choose suppliers for Early Supplier Involvement, it is important that we become familiar with and gain a precise understanding of the cost structures of both the suppliers and their entire supply chain. Only if there is a suit-able degree of cost transparency is it possible for us to assess which suppliers can achieve our target costs. For this, we need suppliers to be both willing and able to engage – as part of a team – in open discussions of existing andpotential cost structures, and to create newcost structures where appropriate. As for the ZF Group, we are prepared to further pool our

future requirements into families of parts, and make a long-term commitment to a single sup-plier for each family. We are ready to make such a commitment because it is also our intention to enable our suppliers to be highly profitable while maintaining global market cost levels.

The following forms are used to present thespecific cost components involved:

• Quotation Analysis Form (QAF) for purchased parts

• Tooling Analysis Form (TAF) for special manufacturing equipment

What do we hope to achieve with these two forms?

Joint understanding of the costs involved The standardized, detailed breakdown allows us to analyze and evaluate quotations systematically and consistently.

Starting point The analysis of the entire production process provides useful starting points for optimizing the process and reducing waste.

Technical modifications The detailed depiction of cost structures means that there is a trans-parent cost audit trail in the event that technical modifications are made in the future.

The specifications for purchased parts are summarized in the QAF

Information sheet 1 (Cost_model_ZF)The logic used by ZF Friedrichshafen AG to calculate overhead for the QAF.

Data sheet 1 (Summary)The introductory form, in which you provide details of your company, points of contact and shift models. Once you have filled out data sheets 2 to 4, you can also use this sheet tospecify your overhead percentages and profit expectations.

Data sheet 2 (Material)Details of all raw materials, purchased parts and external processing. For purchased parts and external processing, corresponding sub-QAFs must be collected from the relevantsubcontractors. Details of these requirements should be clarified with your contact at ZF.

Data sheet 3 (Manufacturing)Details of the production steps involved in in-house manufacturing. Please provide details of every step in the value chain. Please describe each production step to the level of detail specified.

Data sheet 4 (SME_R&D)Details of any special manufacturing equip-ment (SME) required for the various produc-tion steps. If this involves complex special ma-nufacturing equipment with a value exceeding50,000 euros, you should append a Tooling Analysis Form (TAF) to your quotation. Where appropriate, please also provide details of one-time expenses and costs allocated to research and development (R&D).

If you have any questions, please ask yourcontact at ZF for further assistance.

Structure of QAF


7

How to fill out the Quotation Analysis Form (QAF)

Before filling out the QAF, please read right through this User Guide. Then, in the“Summary” data sheet, plea-se complete the “Supplier de-tails” section and “Part data and calculation assumptions” section in full.

Once you have filled out the other data sheets, please return to the “Summary” datasheet and use appropriate parameters to complete all sections from the “Cost of production” section onward.

Costs can only be depicted transparently if the QAF is completed in full. Supplier quotations without a QAF or with an incomplete QAF will not be taken into conside-ration during the contract award process.

So please ensure that you return your fully completed QAF in the form of an Excel file to your official contact at ZF.

Using the QAF

„ The quotation price specified in the QAF should match the pricethat appearsin your official quotation.“

9

The TAF consists of a data sheet subdivided into five sections:

Structure and use of the TAF

General data

Tool data

Material costs

Manufacturing costs

Surcharges and breakdown of income


Before filling out the TAF, please read carefully right through this User Guide. Then complete each of the five sections of the TAF in full.

The quotation price specified in the TAF must correspond to the price that appears inyour official quotation.

Supplier quotations without a TAF or with an incomplete TAF will not be taken into consideration during the contract award process. So please ensure that you return your fully completed TAF in the form of an Excel file to your official contact at ZF.

If you have any questions about this part of the process, please ask your contact at ZFfor further assistance.

„ All five sections mustbe completed in full,in order to ensure thatcosts are presentedtransparently.“

10 11Cost EngineeringUser guide for QAF and TAF

02Cost Engineering More than the sum of its parts.

The ZF cost model is composed of the following overhead calculation components.

Material costsBoth the cost of scrap material and materialoverhead are calculated as a percentage over-head of the direct material cost. Packagingand transportation costs plus customs dutyrepresent the supplier’s logistics costs for procuring the necessary materials.

Material costs= direct material cost+ cost of packaging+ transportation+ customs duty+ cost of scrap material+ material overhead

Manufacturing costsThe residual manufacturing overhead and costof scrap are calculated as a percentage over-head of the labor cost, machine cost andsetup cost.

Manufacturing costs= labor cost+ machine cost+ setup cost+ residual manufacturing overhead+ cost of manufacturing scrap+ tooling maintenance cost

This illustration is a schematic repre-

sentation of the way the ZF cost model

is structured as part of the company’s

Cost Engineering initiative.

The individual items are explained on

the following pages.

The ZFCost Model

Material cost

Manufacturing cost

= Cost of production

Overhead

= Cost of goods sold

Profit

= Cash sales price excl. allocated costs

Payment conditions

= Net sales price ex factory excl. allocated costs

Delivery conditions

= Net sales price excl. allocated costs

Allocated costs

= Net sales price incl. allocated costs

Special manufacturing equipment

Research and development

= One-time expenses

1312 Cost EngineeringUser guide for QAF and TAF

Cost of productionThe cost of production is composed of thematerial costs plus manufacturing costs.

Cost of production= material costs+ manufacturing costs

OverheadManufacturing costs are used as the basis forselling, general and administrative (SG&A)expenses. Internal value added thus serves asthe assessment basis for covering SG&A costs.

Overhead= SG&A costs+ R&D overhead+ cost of risk+ other overhead

ProfitFor purposes of profit calculation, profit isdifferentiated into the following components:1. Profit on raw material2. Profit on purchased parts3. Profit on manufacturing

Profit= profit on raw material+ profit on purchased parts+ profit on manufacturing

Cash sales price excl. allocated costsThe cash sales price excluding allocated costsis composed of the cost of goods sold plusprofit.

Cash sales price excl. allocated costs= cost of goods sold+ profit

Other overheadYou can add another type of overhead under“Other overhead” if you need to.

Cost of goods soldCost of goods sold is composed of the cost ofproduction plus overhead.

Cost of goods sold= cost of production+ overhead

Payment conditionsPayment conditions are composed of theterms of payment plus the discount.

Payment conditions= terms of payment+ discount

Net sales price ex factoryexcl. allocated costsThe net sales price ex factory excluding allocated costs is composed of the cash sales price excluding allocated costs plus payment conditions.

Net sales price ex factoryexcl. allocated costs= cash sales price excl. allocated costs+ payment conditions


Delivery conditionsDelivery conditions are composed of freightand packaging costs plus customs duty.

Delivery conditions= cost of freight+ cost of packaging+ customs duty

Net sales price excl. allocated costsThe net sales price excluding allocated costsis composed of the net sales price ex factoryexcluding allocated costs plus delivery condi-tions.

Net sales price excl. allocated costs= net sales price ex factory excl. allocated costs+ delivery conditions

Net sales price incl. allocated costsThe net sales price including allocated costs iscomposed of the net sales price excludingallocated costs plus allocated costs.

Net sales price incl. allocated costs= net sales price excl. allocated costs+ allocated costs

One-time expensesOne-time expenses are composed of specialmanufacturing equipment plus the cost ofresearch and development.

One-time expenses= special manufacturing equipment+ research and development (R&D)

Allocated costsAllocated costs are composed of the apportio-ned cost of R&D including specific materialcosts plus the apportioned follow-on toolingcosts.

Allocated costs= cost of R&D incl. specific material costs+ follow-on tooling costs

Costs allocated to the part price should bepresented as transparently as possible. Youcan provide a detailed breakdown of the allocated positions in the “SME_R&D” tab (Special manufacturing equipment/Research and development). As a rule, ZF reimburses the initial outlay for tools and equipment. Con-sequently these positions should not appear under allocated costs. Follow-on tooling costs are usually allocated to the part price (excep-tion: die-casting tools).

„ The net sales price including allocated costs should match the price that appears in your official quotation.“

17

Type of cost Contents

Material overhead


Residual manufacturing overhead

16 Cost EngineeringUser guide for QAF and TAF

How ZF structures overhead (%)

• Purchasing

• Procurement

• Incoming goods

• Incoming goods inspection

• Logistics department

• Warehousing (raw materials and supplies)

• Supplier audit

• Waste disposal

• Inventory, including interest paid on capital tied up in stocks of raw materials and supplies

• ...

• Production management

• Shopfloormanagement, operational preparations

• Assembly and production planning

• Internal transportation

• Logistics planning for production and assembly

• Warehousing, including interest paid on capital tied up in finished/unfinished goods

• Quality control and management in production

• Continuous improvement process

• Production equipment engineering

• Tooling and machine planning

• Layout and material flow planning

• Occupational health and safety

• Environmental protection

• In-house fire service

• Production controlling

• Technical training



Selling, general and administrative costs


Cost of risk

R&D overhead

Profit

• Senior management (e.g. CEO, Managing Director)

• Controlling and corporate finance

• Organization and communication

• Human resources

• Real estate / building management

• Insurance department

• Taxes

• Legal department

• Sales & distribution (S&D) management

• S&D planning, marketing, market research

• S&D controlling (where assigned to S&D)

• Advertising and sales promotions

• Business development / Sales

• Field sales service / Customer service

• Tendering, planning, quotation costing

• Order processing

• ...

• Warranty costs and goodwill from provisions and reim- bursements to customers

• Insurance costs associated with contingency policies

• Accounts receivable risk

• Guarantee and warranty risk

• … Where not already covered by allocated costs:

• Preliminary development costs, development cost of volume production and technology for highly innovative and/or simultaneous engineering products

• … Contribution to business performance

20 21Fill out the QAFUser guide for QAF and TAF

03Fill out the QAF

The following pages provide a detailed description of the structure and use of the individual data sheets in the QAF.

The “Summary” data sheet contains generalinformation subdivided into two sections: “Supplier details” and “Part data and calculati-on assumptions”. Furthermore, the “Summary” data sheet also illustrates the framework used for calculating overhead by ZF Friedrichshafen AG. All gray-colored fields in the data sheet must be completed in full. So please proceed as follows: first fill out the top section of the “Summary” sheet. This covers your supplier and part details, as well as the assumptions underlying your calculations. If you need assis-tance, you will find comments embedded inthe data entry field for each attribute. To call up a comment containing helpful information,simply hover your mouse over the data entry field for a given attribute.

How to correctly fill out the QAF

Information:You must fill out all of the fields colored gray in the data sheets.


Data sheet „Summary“

Figure 1: “Summary” data sheet

Fields colored blue

are for calculations, and

cannot be modified.

Fields colored dark blue

are for totals, and reproduce

the individual steps

in overhead calculations.

Fields colored light gray are

important data entry fields

that are required for checking

the plausibility of values.

Quotation Analysis Form 3

SummaryAll grey fields are mandatory. Blue fields are for calculations. Quotation based on terms as specified in the RfQ.

Supplier details:

Supplier: Quotation date: Quotation variant:Contact: Quotation valid till: Superordinate QAF name:Email: Quotation number: Superordinate QAF part number:Phone: ZF supplier number:

Part data and calculation assumptions:Designation: Incoterms: Production hours per shift:Part number: Delivery time [days]: Shifts per production day:Revision index: Terms of payment [days]/discount [%]: Production days per week:Product lifetime [years]: Quotation currency / quantity unit: Production weeks per year:Volume p.a.: Exchange rate to EUR:Delivery batch size: Interest rate [%]:

Material costs: Manufacturing costs:Direct material cost: Labor cost:Purchased parts and external processing: Machine cost:Packaging and carrier costs: Setup cost:Customs duty: Residual manufacturing overhead:Material overhead: Tooling maintenance cost:Material scrap: Manufacturing scrap:Total material cost: Total manufacturing cost:

Cost of production:

Overhead [%]: Explanation: Basis: Overhead [QC]:SG&A: R&D: Cost of risk: Other overhead: Cost of goods sold:

Profit [%]: Explanation: Basis: Profit [QC]:On raw material:On purchased parts:On manufacturing:Cash sales price excl. allocated costs:

Values in Quotation Currency: Explanation: Payment conditions [QC]:Terms of payment:Discount:Net sales price ex factory excl. allocated costs:

Values in Quotation Currency: Explanation: Delivery conditions [QC]:Cost of freight:Cost of packaging (material only):Customs duty:Net sales price excl. allocated costs:

One-time expenses / allocated costs: One-time expenses: Allocation to unit price [QC]:R&D cost incl. material:New project specific investment (for informational purposes only):Special manufacturing equipment total (for informational purposes only): Special manufacturing equipment (SME):Follow-up tooling cost:

Net price incl. allocated costs:

Remarks:

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©ZF Friedrichshafen AG

QAF - Quotation Analysis Form

Summary

25

Attributes Notes Attributes Notes

Supplier

Contact

Email

Phone

Quotation date

Quotation valid till

Quotation number

ZF supplier number

Quotation variant

Superordinate QAFname

Superordinate QAFpart number

Designation

Part number

Revision index

Product lifetime[year]

Volume p.a.

Delivery batch size

Incoterms

Delivery time [days]

Terms of payment [days] /discount [%]

Quotation currency /quantity unit

24

Enter your company name here.

Enter your first and last names here.

Enter your email address here.

Enter your telephone number here.

Enter the date of your quotation here, in the format DD.MM.YYYY.

Enter the date until which your quotation is valid here, in the format DD.MM.YYYY.

Enter your quotation number here.

If you are already an active supplier of ZF Friedrichshafen AG,enter your ZF supplier number here.

Select either initial quotation orrevised quotation.

Enter the name of the superordina-te QAF here, if there is one.

Enter the part number of the superordinate QAF here, if there is one.

Enter the part designation here. The designation should be identi-cal to the one in the ZF request for quotation.

Enter the requested part number here.

If available, enter the revision index from the drawing here.

Enter the total lifetime of the product here, from start of volume production to final phase-out.

Enter the basic number of units covered by your quotation here. The unit volume should reflect steady-state output. So for the QAF, you should use the sustaina-ble target volume.

Enter the batch sizes you propose to deliver here.

Here you can select either FCA (Free Carrier) or DAP (Delivery At Place) and enter your incoterms.

Enter the planned delivery time for the requested part here.

Enter your terms of payment here.

Select the quotation currency and quantity unit that are relevant to your quotation.

What you need to fill out in the “Summary” data sheet – part 1

Fill out the QAFUser guide for QAF and TAF

Supplier details Part data and calculation assumptions

27

Attributes Notes

Material costs

Direct material costincluding purchased partsand external processingPackaging and carrier costsCustoms dutyMaterial overheadMaterial scrap

Manufacturing costs

Labor costMachine costSetup costResidual manufacturing overheadTooling maintenance costManufacturing scrap

Cost of production

26

Subtotal of attributes from the “Material” data sheet

Subtotal of attributes from the “Manufacturing” data sheet

Total = material costs + manufacturing costs

sheet. The third step is to enter your overhead charging structure, profit expectations and logistical costs for the requested part. This will turn the “Summary” data sheet into an over-view of your cost structures, complete with your quotation price for the requested part.

Once you have filled out the abovementionedparameters for your company, the next step is to fill out the “Material”, “Manufacturing” and “SME_R&D” data sheets. Once the latter have been completed in full, the values from these sheets will be automatically summarized in the blue calculation fields in the “Summary” data


27

Explanation of the cost of production in the “Summary” data sheet

The cost of production is com-posed of the material costs and manufacturing costs combined.

Attributes Notes

Exchange rate to EUR

Interest rate [%]

Production hoursper shift

Shifts per per production day

Production daysper week

Production weeksper year

Enter the quotation currency’s exchange rate with the euro (EUR) here.

This should correspond to the average interest rate chargedwithin the company. You can specify additional interest ratesfor other manufacturing locations in your remarks.

Enter the defined number of hours per shift at your company here.

Enter the number of shifts per pro-duction day at your company here.

Enter the number of production days worked by your company each week here.

Enter the number of production weeks per year here.

Part data and calculation assumptions

„ Blue fields arecalculation ortransfer fields, andcannot be modified.Dark blue fields showthe totals for eachstep in the overheadcalculation.“

2928

What you need to fill out in the “Summary” data sheet – part 2


Attributes Notes Attributes Notes

SG&A

R&D

Cost of risk

Other overhead

Cost of goods sold

Profit on raw material

Profit on purchased parts

Profit on manufacturing

Cash sales price excl. allocated costs

Terms of payment

Discount

Net sales price ex factoryexcl. allocated costs

Cost of freight Cost of packaging (material only) Customs duty

Net sales price excl. allocated costs

Enter your percentage overhead for selling, general and adminis-trative (SG&A) costs here. SG&A overhead is based on manufactu-ring costs. This value is displayed in the “Basis” column. The cost model stipulates that SG&A over-head should be charged to internal value added. If you would prefer to use a different basis, please explain your rationale in the “Ex-planation” field.

Enter your percentage overhead for R&D here. R&D overhead is based on the cost of production.If you would prefer to use a dif-ferent basis, please explain your rationale in the “Explanation” field.

Enter your percentage overhead for cost of risk here. Cost of risk is based on the cost of production.If you would prefer to use a dif-ferent basis, please explain your rationale in the “Explanation” field.

Placeholder for other types of overhead. Please fill out this field as necessary, describing the over-head in the “Explanation” field. Once again, the cost of production should be used as the basis.

Calculated total = cost of production + overhead

Enter the profit you are expecting to make on raw materials here.

Enter the profit you are expecting to make on purchased parts here.

Enter the profit you are expecting to make on manufacturing here. Manufacturing includes manufac-turing costs less manufacturing scrap cost.

Calculated total = cost of goods sold + profit

If relevant, you can enter your cost for the terms of payment here.

If relevant, you can enter your cost for the discount here. Calculated total = net sales price excl. allocated costs + terms of payment + discount

If relevant, enter your costs for freight, packaging and customs duty for the requested part here.These three positions are summa-rized in the “Delivery conditions” section.

Calculated total = net sales price ex factory excl.allocated costs + cost of freight + cost of packaging + customs duty

Overhead Profit

Payment conditions

Delivery conditions


Attributes Notes

R&D cost incl.specific material,New project-related investment,Special manufacturingequipment total,Special manufacturingequipment (SME),Follow-on tooling cost

Net sales priceincl. allocated costs

Remarks

The individual positions here are displayed as one-time expenses and/or costs allocated to the unit (part) price, according to the data you entered in the “SME_R&D” data sheet (in the tab marked “SME_R&D”).

Calculated total = net sales price excl. allocated costs+ allocated costs

Please note: the net sales price including allocated costs must correspond to the price in your official quotation.

You can enter any remarks concer-ning the completed QAF here.

Allocated costs

The following pages describe the structure and contents of the data sheets.

The calculation logic for each of the data sheets is descri-bed in this User Guide.The following illustration shows the “Material” data sheet. It consists of a totalof 21 data entry fields, five calculation fields and one transfer field displaying data from the “Summary” data sheet.

Each of the data sheets has approximately 22 lines forentering relevant data. If you need more space for entering data, you can add extra lines by clicking on the “add a line” button.

The top section of each sheet is writeprotected and repro-duces part of the contents of the “Summary” data sheet.Please fill out the gray and dark gray fields below the top section of each data sheet.

The “Material”, “Manufacturing” and “SME_R&D” data sheets are all structured in the same way, differing only in the information required.

Additionaldata sheets

„ Certain values in the“Material” data sheetmust be entered in thepurchasing currency[PC] or quotationcurrency [QC]. Thefields are labeledwith the appropriateabbreviation.“

32 Fill out the QAFUser guide for QAF and TAF

Figure 2: “Material” data sheet

33

The „Material“ data sheet


important data entry fields that are

required for checking the plausibility

of values.

Fields colored dark gray are linked

to the blue fields, so are actively

involved in calculating values.

Fields colored blue are calculation

fields which cannot be modified.

Quotation Analysis FormRaw material / purchased parts / external processingPlease fill out and return to ZF contact

Quotation date: Designation: Supplier:

Quotation number: Part number: Contact:

Quotation variant: Revision index:

Pos. No. Designation Part number Procurement type Supplier Production siteProduction

countryQuantity unit

Price per quantity unit

Gross weight / quantity / amount

Deployed weight

Raw weight

Net weight

Price per position

Purchasing currency

Quotation currency

Exchange rate

Reimburse-ment

Direct material

cost

Packaging cost per

part

Transportation cost per quantity

unit

Customs duty per quantity

unit

Material scrap

Material scrap

Material overhead

Material overhead

Material cost

[PC] [PC] [PC] [QC] [QC] [QC] [QC] [QC] [QC] [%] [QC] [%] [QC] [QC]

Additional line: Please click the "add a line" button below

Total

Material description Units of measurement in purchasing currency Material specifications in quotation currency

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Material


ZF’s breakdown of the “Material” data sheetCalculation fields explained

Price per position [PC]

= price per quantity unit [PC] x gross weight / quantity / amount

Direct material cost [QC]

= price per position [PC] x exchange rate – reimbursement [QC]

Material scrap [QC]

= direct material cost [QC] x (1/(1 – scrap material [%]) – 1)

Material overhead [QC]

= direct material cost [QC] x material overhead [%]

Material costs [QC]

= direct material cost [QC] + packaging cost per quantity unit [QC] + transportation cost per quantity unit [QC] + customs duty per quantity unit [QC] + material scrap [QC] + material overhead [QC]

Attributes Notes

Position number

Designation

Part number

Procurement type

Supplier

Position and numbering of the part. If the request forquotation consists of multiple components, you can usethe position number to indicate where each part shouldappear in the “Manufacturing” and “SME_R&D” data sheets.The “Material” sheet is used as the basis for this as follows: • “Material” sheet position number 1 = gear forging blank • “Manufacturing” sheet position number 1.1 = turning • “Manufacturing” sheet position number 1.2 = milling • “Manufacturing” sheet position number 1.3 = drilling

Designation of the part.

Enter the ZF part number for the part here – if available –, otherwise enter your own part number.

In-house production = material for use in manufacturing or assemblyPurchased = finished parts ordered from subcontractorsExternal processing = parts that you have had processed bysubcontractors (external manufac-turing step)Please note: If you select “Exter-nal processing”, you must also submit a sub-QAF.

Name of the part(s) supplier.

Material description


Attributes Notes

Production site

Production country

Quantity unit

Price per quantity unit [PC]

Gross weight / quantity / amount

Deployed weight

Raw weight

In which city / region is the part manufactured / processed?

Enter the country in which the part is produced here.

Drop-down menu: you can enter the appropriate quantity unit for the part here.

Enter the price for the specified quantity unit here, in the purcha-sing currency.For example: EUR 2.475 / kg

Weight of material required to manufacture a single part amount (including cutting waste, burr, end waste, etc.) / Quantity of material required/ Amount or number of units of material required.For additional information, see Annex 1 on page 61.

Weight of material required to manufacture a single blank(including burr, excluding cutting waste and end waste).

Weight of material required to manufacture a single finished part (excluding cutting waste, burr, endwaste, etc.) and is procured from the supplier.

Material description

Material specifications in purchasing currency

Attributes Notes

Net weight

Price per position [PC]

Purchasing currency [PC]

Quotation currency [QC]

Exchange rate

Reimbursement [QC]

Direct material cost [QC]

Weight of material that is left over after the machining process and is delivered to ZF (weight of finished part).

Material price per position, ex subcontractor’s factory, inthe purchasing currency.Formula applied: price per quantity unitx gross weight /quantity / amount

Drop-down menu: select the ap-propriate purchasing currency.

Transfer field from the “Summary” data sheet.

Enter the purchasing currency’s rate of exchange with the quota-tion currency. For example: PC = USD; QC = EUR; USD to EUR exchange rate = 0.85Please note: if purchasing currency = quotation currency, you should enter the number “1” as the exchange rate.

Income made by selling or recycling material / scrap material.Enter the value in the quotation currency.

Direct material cost is calculated from the price per position in the purchasing currency multiplied by the exchange rate minus the reimbursement in the quotation currency.

Material specifications in purchasing currency

Material specifications in quotation currency

What you need to fill out in the “Material” data sheet

What you need to fill out in the “Material” data sheetZF’s breakdown of the “Material” data sheet


Attributes Notes

Packaging cost per quantity unit [QC]

Transportation cost per quantity unit [QC]

Customs duty per quantity unit [QC]

Material scrap [%]

Material scrap [QC]

Material overhead [%]

Material overhead [QC]

Material costs [QC]

Cost of the packaging (in the quotation currency) per part or per quantity unit. The figure should include the subcontractor’s packa-ging costs.

Cost of transporting the part bet-ween the production and over- processing facilities, per quantity unit. The figure should include the subcontractor’s transportation costs.

Customs duty levied on the part between the production and over-processing facilities, per quantity unit.

Percentage of scrap material pro-duced during the product manufacturing process. Cost of scrap material per part or per quantity unit.

Percentage of material overhead allocated to the material. Material overhead =direct material cost x material overhead in % Material costs= direct material cost+ cost of packaging+ cost of transportation+ customs duty+ material scrap+ material overhead

Material specifications in quotation currency

What you need to fill out in the “Material” data sheet


Figure 3: “Manufacturing” data sheet

41

The „Manufacturing“ data sheet


important data entry fields that are

required for checking the plausibility

of values.






Quotation Analysis FormManufacturingPlease fill out and return to ZF contact




Pos. No. Process designation Part numberManufacturing

locationManufacturing

countryProduction

hours per yearCycle time

Parts per cycle

Number of direct

employees

Labor hourly rate

Labor cost per part

Machine (make and model)

Acquistion year

Machine investment

Utilization ratio

Hourly rate of machine operation

Machine cost per

part

Manufactu-ring batch

size

Setup time

Setup cost per part

Residual manufactu-

ring overhead

Residual manufactu-

ring overhead per part

Scrap per process

stepScrap cost

Tooling maintenance cost per part

Amount per quotation

Manufacturing cost

[h] [s] [QC/h] [QC] [QC] [%] [QC/h] [QC] [min] [QC] [%] [QC] [%] [QC] [QC] [QC]


Total

General data Cycle time Labor cost Machine cost Setup cost Other manufacturing costs Total manufacturing cost

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Manufacturing

4342

What you need to fill out in the “Manufacturing” data sheet


Attributes Notes

Position number

Process designation

Part number

Manufacturinglocation

Manufacturing country

Production hours per year [h]

Position and numbering of the part. If the request for quotation consists of multiple components, you can use the position number to indicate where each part shouldappear in the “Manufacturing” and “SME_R&D” data sheets. The “Material” sheet is used as the basis for this, as follows: • “Material” sheet position number 1 = gear forging blank • “Manufacturing” sheet position number 1.1 = turning • “Manufacturing” sheet position number 1.2 = milling• “Manufacturing” sheet position number 1.3 = drilling

Designation of the manufacturing process used.

Enter the number of the part for which the position is relevant here.

City in which the manufacturing process takes place.

Country in which the manufactu-ring process takes place.

Number of scheduled production hours per year for the specific production step relating to this part. Production hours are calculated from production hours per shift x number of shifts per production day x production days per week x production weeks per year.

General data

Attributes Notes

Cycle time [s]

Parts per cycle

Number of directemployees

Labor hourlyrate [QC/h]

Labor cost per part [QC]

Machine (make and model)

Machine acquisition year

Machine investment [QC]

Cycle time per operation in se-conds (without taking account ofsetup times, contingency allowan-ces, disruptions, downtime etc.)

Number of parts processed per operation.

Number of employees directly assigned to production operationson that machine/system. Where employees operate multiple machines, they should be assigned on a pro rata basis (e.g. 1.5 direct employees).

Hourly wage of direct employees in the quotation currency, inclu-ding non-wage labor costs and taking account of the utilization ratio.

Cycle time per part multiplied by the number of direct employees and the labor hourly rate, dividedby the number of parts per cycle.

Designation and model of machi-ne or system used.For example: Liebherr LCS 300

Year in which the machine or sys-tem was acquired. e.g. 2008

Enter the acquisition cost of the machine here, including peripheral and setup costs (e.g. construc-tion, installation), in the quotation currency.

Cycle time

Labor cost

Machine cost



Attributes Notes

Utilization ratio [%]

Hourly rate of machine operation [QC/h]

Machine cost per part [QC]

Manufacturing batch size

Setup time [min]

The utilization ratio is the ratio of productive machine time to production time, according to the shift model. Productive machine time is production time according to the shift model minus machi-ne-related downtime (technical availability) minus non-productive tasks (such as cleaning, transpor-tation) and minus setup times.

Machine hourly rate = machine / system costs per hour in the quotation currency. Machine hourly rate already takes account of the utilization ratio.

Machine cost is equal to cycle time per part multiplied by the machine hourly rate divided by the number of parts per cycle.

Quantity of the requested part manufactured in a single batch. Time required to set up the machine or system, in minutes.

Machine cost

Setup cost

Attributes Notes

Setup cost per part [QC]

Residual manufacturingoverhead [%]

Residual manufacturingoverhead per part [QC]

Scrap per processstep [%]

Scrap Cost [QC]

Setup cost = (number of employees x labor hourly rate + machine hourly rate) / 60 x setup time / manufacturing batch sizeExternal setup and setup for forging presses should be listed in a separate line. In this case, do not enter a machi-ne hourly rate [QC/h] but simply the labor hourly rate [QC/h] and number of direct employees → (number of employeesx labor hourly rate / 60 x setup time / batch size).

Percentage overhead allocated toresidual manufacturing overhead.

= (labor cost [QC] + machine cost [QC] + setup cost [QC])x residual manufacturing overhead (as a percentage)

Scrap allocated to each machining operation, as a percentage.

Scrap cost = (labor cost [QC]+ machine cost [QC] + setup cost [QC]) x (1 / (1 – scrap cost per process step (in %)) – 1)Please note: scrap cost only applies to lost added value. Thus scrap material should be accoun-ted for in the “Material” tab. It is possible to adjust the formula of the scrap cost calculation to speci-fic supplier conditions. If needed the original calculation can be restored by clicking the field „restore scrap formular“.

Setup cost

Other manufacturing costs

46

Calculation fields explained


Labor cost per part [QC]

= labor hourly rate [QC/h] x number of direct employees

3600x cycle time [s] / parts per cycle

Machine cost per part [QC]

= machine hourly rate [QC/h]

3600x cycle time [s] / parts per cycle

Setup cost per part [QC]

= (direct employees x labor hourly rate [QC/h] + machine hourly rate [QC/h]) / 60 x setup time [min]

manufacturing batch size

Residual manufacturing overhead per part [QC]

=(labor cost per part [QC] + machine cost per part [QC]+ setup cost per part [QC]) x residual manufacturing overhead [%]

Scrap cost [QC]

= (labor cost per part [QC] + machine cost per part [QC]+ setup cost per part [QC]) x (1/(1 – scrap per process step [%] )– 1)

Manufacturing costs [QC]

= (labor cost per part [QC] + machine cost per part [QC]+ setup cost per part [QC] + scrap cost [QC]

+ tooling maintenance cost per part [QC]) x amount per quotation

47


Attributes Notes

Tooling maintenance cost per part

Amountper quotation

Manufacturing cost [QC]

Enter the tooling maintenance cost per part [QC] here (excluding spare parts). Significant spare- part kits (inserting parts, core packages, …) should be accoun-ted for under tooling investment.Please note: this field should only be filled out for manufacturing pro-cesses involving primary forming / forming / cutting.

Amount or number of parts required for the quotation. How often does the part appear in the quotation?For example: 2 identical parts per quotation → amount = 2

Manufacturing cost =(labor cost [QC]+ machine cost [QC] + setup cost [QC]+ residual manufacturing overhead [QC] + scrap cost [QC]+ tooling maintenance cost per part [QC])x amount per part quoted

Other manufacturing costs

Total manufacturing costs


Figure 4: “Special Manufacturing Equipment / Research & Development” data sheet

49


important data entry fields that

are required for checking the

plausibility of values.






QAF – Structure and contents of the“SME_R&D” data sheetThe “SME_R&D” data sheet consists of a total of 17 data entry fields and 5 calculation fields. On this sheet, you can separate out your special manufacturing equipment and your research and development costs.

The calculation logic for each of the

data sheets is described in this User

Guide.

The „SME_R&D“ data sheet

Quotation Analysis FormSpecial manufacturing equipment / Research and developmentPlease fill out and return to ZF contact




TAF

Pos. No. Category Part number Detailed descriptionRunning

time (good parts)

Tooling and fixture costs

Allocation to unit price

Allocation relevant quantity

Allocation of special

manufacturing equipment

TAF relevance

R&D hoursHourly rate of R&D

R&D costR&D

Material cost

Allocation to part price

Allocation relevant quantity

Allocation of R&D costs incl. R&D

material cost per part

Notes

[QC] [QC] [h] [QC/h] [QC] [QC] [QC]


Total

Designation

Development costTooling costAttributes

V2.0

14.02.2018




SME_R14.02.2018


How ZF breaks down the “Special ManufacturingEquipment / Research & Development” data sheet

Attributes Notes

Position number

Category

Designation

Part number

Detailed description

Position and numbering of the part. If the request for quotation consists of multiple components, you can use the position number to indicate which part should appear in the “Manufacturing” and “SME_R&D” data sheets.The “Material” sheet is used as the basis for this as follows: • “Material” sheet position number 1 = gear forging blank• “Manufacturing” sheet position number 1.1 = turning• “Manufacturing” sheet position number 1.2 = milling• „“Manufacturing” sheet position number 1.3 = drilling

Drop-down menu: select “SME” for special manufacturing equipment or “R&D” for one-time develop-ment expenses.

Depending on your previous selection, an additional specification may appear here.SME → Initial tooling / Follow-on tooling / EquipmentR&D → Research and develop-ment, project management,application, experiment, test ben-ches, material, other

Enter the number of the part for which the position is relevant here.

Enter a detailed description of the position here.

Classification

Attributes Notes

Running time (good parts)

Tooling and fixturecosts [QC]

Allocation to unit price

Allocation-relevantquantity

Allocation of special manufacturing equipment [QC]

A tool’s running time is the useful life over which productive work can be done with this tool. Running time is usually defined in (process or machining) cycles, or in proces-sing quantity units (e.g. parts).Enter the amount of the tool’s running time allocated to good parts here.

Enter the tooling or equipment costs here in the quotation currency.

Drop-down menu: select “Yes” if the tooling or equipment costsare to be allocated to the unit price. Select “No” if the tooling orequipment costs are not to be allocated to the unit price.Please note: the initial outlay for tools and equipment is usuallyreimbursed by ZF Friedrichshafen AG and consequently should not be allocated to the unit price.

Enter the allocation-relevant quan-tity here. To which quantity should the SME be allocated?

Allocation of SME per part = tooling and equipment costs [QC] / allocation-relevant quantity

Classification

Tooling cost



Attributes Notes

R&D hours [h]

Hourly rate of R&D [QC/h]

R&D cost [QC]

R&D material cost [QC]

Allocation to part price

Allocation-relevantquantity

Allocation of R&D costincl. R&D material costper part [QC]

Notes

Fill out the number of hours you have spent on R&D here. Under R&D hours, you can list the number of hours spent on research and development, project management, applications, experiments, test ben-ches, material and other R&D-rela-ted activities.

Enter your hourly rate for R&D here in the quotation currency.

R&D cost [QC] = R&D hours [h] x R&D hourly rate [QC/h]

Enter the cost of your R&D materials here. R&D material cost includes e.g. expenditure on prototypes,samples, material expenses, etc.

Drop-down menu: select “Yes” if the R&D cost + R&D material cost should be allocated to the part price. Select “No” if the R&D cost + R&D material cost should not be allocated to the part price.

Enter the allocation-relevant quan-tity here. To which quantity should R&D cost + R&D material cost be allocated?

Allocation of R&D cost per part = (R&D material cost [QC] + R&D cost [QC]) / allocation-relevant quantity

In the event that you must also fill out a TAF, a reminder will appear in this field.

Development cost

TAF


Attributes Notes

TAF relevance Special manufacturing equipment > EUR 50,000 requires completion of a Tooling Analysis Form (TAF).So if SME > EUR 50,000 = “Yes”;if SME < EUR 50,000 = “No”.If “Yes” appears here, you should fill out a TAF.= „No“.

Tooling cost

54 How to correctly fill out the TAF User guide for QAF and TAF

55

It is especially important to follow the correct order when you are entering data in theTAF form. Otherwise an error message may appear, or you may find that not all of thecorrect selection options are displayed. It is also important to select the correct quota-tion variant (new tool, fol-low-on tool, etc.) and specify the quotation currency, as well as the current exchange rate with the euro.

When choosing the type of tool, you can select one of the following tool categories:

• Stamping

• Die casting

• Iron casting (rough)

• Iron casting (detailed)

• Inject

• Forging

Please note that you can only fill out the light gray fields (cells) in the TAF data sheet. The blue fields are calculation fields.

04How to correctly fill out the TAF

Detailed description of structure and use

„ First of all, you should specify your preferred language in the TAF header. Next, you must choose the type of toolyou want to describe.“


Figure 5: TAF – “General data” section

Figure 7: TAF – “Material costs” section

Figure 6: TAF – “Tool data” section

TAF – “Tool data” sectionThe attributes you are asked to describe in each of the various sections may vary, depending on the type of tool you select. The attributes in the “Contact” and “Compo-nent Data” sections do notchange, however, because

TAF – “Material costs” sectionYou should specify all the materials you usein the “Material costs” section. The level ofdetail here will vary, depending on the typeof tool you selected earlier.

You should specify the material used for each tool element, plus the weight and price of the material per kilogram. You can also specify whether the individual parts are produced internally or externally.

In addition, a “Comment” field is availablefor each tool element. If you make any entries in the “Special costs” section, you must provi-de full details of these costs in the “Comment” field.

In the “Tool comments” section below the “Material costs” section, you can document and provide further details of any special features of the tool (for example, how many spare part kits or inserting parts are included under material costs).

they do not depend on the type of tool you choose. The “Tool data” section does change according to the tool type – the following illus-tration shows the specific attributes for the “Die casting” category.

57

components Material Weight [kg] cost per kg comment Total

Cost due to basic construction

form panels, die block (fixed)

form panels, die block (movable)

basic construction, standard

Small parts

costs contour given level

Die insert (fixed)

Die insert (movable)

Inserting parts (cores,vane face)

Slide

shot sleeve

vacuum valve

Ejector

Tempering

Electrodes

Special costs

Material costs

Internal /External

V2.030.05.2018TAF_ZF_V2.9_update_deutsche Einstellung-Druckguss (2).xlsx

ZF Friedrichshafen AGTAF - Tooling Analysis Form

lenght [mm] Guaranteed lifetime, goodparts:

width [mm] casting cell

height [mm] Number of slides:

weight Lead time:

Number of cavities:

Mold concept:

Tool data:



Language: english

Type of tool (please choose) Date of offerQuotation number Quotation currencyQuotation variant Exchange rate to EUR

Supplier: Description

DUNS Part number

ZF Supplier ID Revision index

Name / Department Material

Phone / Mail Component weight [g]

Tool manufacturer part measurements LxWxH [mm]

Tool M. Address min. / max. wall thickness

Tool M. Country comment

Tooling Analysis Form (TAF)

Contact Component Data

Please add to your completed RFQ

Die CastingEUR

1,0000

Step 1 !

Step 2 !

V2.020.04.2018TAF_ZF_V2.9_update.xlsx



Figure 8: TAF – “Manufacturing costs” section

Figure 9: TAF – Establishing the tooling quotation price

Always specify the hourly ma-chine and labor rates (MHR/ LHR) for each position, as well as the number of proces-sing hours required (or, in the case of heat treatment, the weight and price per unit).

Totals are calculated automa-tically. Manufacturing costs should be broken down in detail – it is not sufficient to enter data for a single posi-tion to cover total manufactu-ring costs.

59

TAF – Surcharges and breakdown of incomeSubtotals are calculated auto-matically in the TAF, based on the preceding entries. Withreference to the calculated production costs, you have the option of entering the surcharge percentages you

have agreed with ZF to cover overhead. This will generate atotal figure for the cost of spe-cial manufacturing equipment (= material costs + manufac-turing costs + surcharges). Thus the actual quotation price will consist of the total cost as calculated above, plus profit.

Attributes Notes

Language

Type of tool (please choose)

Quotation number

Quotation variant

Date of offer

Drop-down menu: first of all, select the language you wishto use as you fill out the Tooling Analysis Form (TAF). You canwork on the document in either German or English.

Drop-down menu: second, select the appropriate type of tool.You can choose one of the following tool types:

• Stamping

• Die casting

• Iron casting (rough)

• Iron casting (detailed)

• Inject

• Forging

You can enter your quotation number here.

Here you can choose one of the following quotation variants:

• New tool

• Follow-on tool (complete)

• Prototype tooling

• Follow-on tool (mounting)

• Tool modification

• Serial tool (0-series application)

Enter the date of your quotation here, in the formatDD.MM.YYYY.

What you need to fill out in the TAF

Internal production: External production:

Material costs surcharges %

Profit %

Quotation price EUR

Material costs

Manufacturing costs

V2.006.06.2018TAF_ZF_V2.9_update.xlsx


Engineering Hours MHR / LHR Total Heat treatment kg Cost/kg Total

Calculation & Simulation harden & tempern

CAD - design Coating

CAM / CNC-Programming Miscellaneous

∑ ∑

mechanical machining hours MHR / LHR Total Correction loop hours MHR / LHR Total

milling, large (table: > 2500 x 1200) die block Type:

milling, medium-sized (table: < 2500 x 1200) die block Type:

milling, medium-sized (table: < 2500 x 1200) die insert Type:

milling, small (table: < 1000 x 500) die insert ∑

turning

Wire-cut EDM sampling inspection hours MHR / LHR Total

Die sink mold proving

grinding PSW (part submission warrent)

drilling, deep-hole drilling measuring device

drilling, deep-hole drilling die insert ∑

production electrodes

∑ logistics Total

Construction work hours MHR / LHR Total

Assembly

Spotting

Polish

costs die block

costs inserts∑

Transport

customs

Manufacturing costs:




61

Attributes Notes

Quotation currency

Exchange rate to EUR

Supplier

DUNS

ZF Supplier ID

Name / Department

Phone / Mail

Tool manufacturer

Tool M. address

Tool M. country

Description

Part number

Revision index

Material

Component weight [g]

Part measurements LxWxH [mm]

Min. / max. wall thickness

Comment

Select the quotation currency that you are using for your quotation.

Enter the quotation currency’s exchange rate with the euro (EUR) here.

Enter the name of your company here.

Enter your company’s DUNS number here.

If you are already an active supplier of ZF Friedrichshafen AG,enter your ZF supplier number here.

Enter your name and department here.

Enter your telephone number and your email address here.

Enter the name of your tool manufacturer here.

Enter your tool manufacturer’s address here.

Enter your tool manufacturer’s country of origin here.

Enter a description of the tool here.

Enter the part number here.

Enter the revision index here.

Enter the material used to fabricate the part here.For example: Alloy 2016; AlSi12CuNiMg

Enter the weight of the part here.

You can specify the part’s dimensions here, in millimeters.

Enter the minimum and maximum thickness of the part’s walls here.

You can add additional remarks or comments here.

If you have any questions about the

TAF, please ask your contact at ZF for

further assistance.

Diagrams illustrating gross weight, deployed weight, raw weight and net weight, using barstock as an example:

Annex

Barstock weighing around e.g. 30 kg, equivalent to 5 parts

Gross weight = 30 kg / 5 parts = 6 kg per part incl. cutting waste, end waste (plus burr)

Deployed weight = 6 kg – 1 kg cutting waste, end waste = 5 kg incl. burr, e.g. after forging

Raw weight = 5 kg – 0.5 kg burr = 4.5 kg e.g. after deburring

Net weight = 4.5 kg – 0.5 kg swarf = 4 kg e.g. after mechanical finishing

1 part

End wasteCutting wasteBurr

6362 NotesUser guide for QAF and TAF

NotesNotes

ZF Friedrichshafen AGCost Engineering88038 FriedrichshafenGermany

Phone +49 7541 77-0Fax +49 7541 77-90800www.zf.com

Documents

User Guide - zf.com · the entire production process provides useful starting points for optimizing the process and reducing waste. Technical modifications The detailed depiction