The cost of forging enterprises is divided into six items: raw materials, fuel and power, wages and surcharges, waste loss, workshop expenses and enterprise management expenses. Press manufacturer
1. Raw materials; It refers to the steel consumed to form the forging entity (deducting the value of recyclable waste materials, such as rough edges, continuous skins, material heads, etc.). This part accounts for 50% - 70% of the total cost. The prices of different steel types are different. Carbon steel is lower and alloy steel is higher.
2. Fuel and power: refers to purchased and self-made fuel and power (electricity, steam, compressed air, etc.) directly used for forging and forging production. Free forging and large parts are mainly made of gas, and die forging is mainly made of electric heating. Therefore, frequent switching on and off of the gas furnace should be avoided in production to make full use of the furnace temperature. There will be a lot of losses when the furnace is heated from the cooling state to the required temperature. Eliminate inefficient production equipment such as old friction press and steam hammer.
3. Die: refers to various dies directly used to produce forgings. Accounting for 5% - 20% of the total, the cost will vary according to the batch size. The hot end is lower, and the warm forging and cold forging are higher. Select the molds with appropriate materials, arrange the production sequence scientifically according to the production batch, and try to avoid frequent replacement of molds or selection of inappropriate molds and processes, resulting in increased loss of molds.
4. Wages and surcharges of production workers: refers to the wages of workers directly participating in forging production and the wage surcharges drawn according to the specified proportion. Generally accounting for 2% - 8% (more than 10% on average abroad)
5. Waste loss: refers to the loss caused by waste products produced in production. About 1-5%. This data mainly depends on the utilization rate of forgings and the utilization rate of parts. The former determines the blanking loss, scrap (head, punch core material, burr, etc.), loss, burning loss and scrap loss, while the latter reflects the loss of forging surplus and allowance. Both of them are related to the forging process. Generally, cold and warm forging Z is high, die forging Z is medium and free forging Z is low.
6. Enterprise management fee and others: refers to the expenses incurred for the management and organization of full-length production. For the forging workshop of the factory, the cost is apportioned in proportion. About 10-15%. In terms of improvement, a complete computer database for document management can be established, and the information accumulated by the design department can be collated and utilized.