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Lecture_17
Course: ENGINEERIN 152, Spring 2012School: York University
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No.17 Chapter MakeorBuyDecision,Life CycleCostAnalysis,and DesignEconomics Lecture 6 Contemporary Engineering Economics Third Canadian Edition Copyright 2012 2012PearsonCanadaInc.,Toronto,Ontario 1 Lecture17Objectives How do firms decide whether to make a part inhouse or to buy it? How do firms conduct a life-cycle cost analysis? How do firms optimize parameters in engineering design?...
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No.17
Chapter MakeorBuyDecision,Life
CycleCostAnalysis,and
DesignEconomics
Lecture 6
Contemporary Engineering Economics
Third Canadian Edition
Copyright 2012
2012PearsonCanadaInc.,Toronto,Ontario
1
Lecture17Objectives
How do firms decide whether to make a part inhouse or to buy it?
How do firms conduct a life-cycle cost analysis?
How do firms optimize parameters in
engineering design?
2012PearsonCanadaInc.,Toronto,Ontario
2
MakeorBuyDecision
Step 1:
Step 2:
Step 3:
Step 4:
Step 5:
Step 6:
Step 7:
Step 8:
Determine the time span (planning horizon) for
which part (or product) will be needed.
Determine the annual quantity of the part (or
product).
Obtain the unit cost of purchasing the part (or
product) from the outside firm.
Determine the equipment, labour, and all other
resources required to make the part (or product).
Estimate the net cash flows associated with the
make option over the planning horizon.
Compute the annual equivalent cost of producing
the part (or product).
Compute the unit cost of making the part (or
product) by dividing the annual equivalent cost by
the required annual volume.
Choose the option with the minimum unit cost.
2012PearsonCanadaInc.,Toronto,Ontario
3
Example6.12:EquivalentWorth:Outsourcingthe
ManufactureofHardDriveCases
Make Option (annual costs):
Labour
$1,445,633
Materials
$2,048,511
Incremental overhead
$1,088,110
Total annual cost
$4,582,254
Buy Option:
Capital expenditure:
$ 405,000
$ 45,000
Annual Operating Costs:
Acquisition of a new loading machine
Salvage value at end of 7 years
Labour
Purchasing empty cassette ($0.85/unit)
Incremental overhead
Total annual operating costs
$ 251,956
$3,256,452
$ 822,719
$4,331,127
2012PearsonCanadaInc.,Toronto,Ontario
4
Example6.12:Solution
Make Option:
AEC(14%) = $4,582,254
Unit cost:
$4,582,254/3,831,120
= $1.20
Buy Option:
AEC(14%) = $4,421,376
Unit cost:
$4,421,376/3,831,120
= $1.15
2012PearsonCanadaInc.,Toronto,Ontario
5
LifeCycleCostAnalysis
Life-Cycle Cost Analysis (LCCA) is a way to
predict the most cost-effective solution by
allowing engineers to make a reasonable
comparison among alternatives within the limit of
the available data.
Makes sure the analyst examines both initial
costs and operating costs over the projects
useful life.
Used to predict the most cost-effective solution.
2012PearsonCanadaInc.,Toronto,Ontario
6
StagesofLifeCycleCost
2012PearsonCanadaInc.,Toronto,Ontario
7
Example6.13:PumpingSystemWitha
ProblemValve
2012PearsonCanadaInc.,Toronto,Ontario
8
Example6.13:PumpingSystemWitha
ProblemValve(continued)
Engineering Solution Alternatives
Option A: A new control valve can be installed to
accommodate the high-pressure differential.
Option B: The pump impeller can be trimmed so that the
pump does not develop as much head, resulting in a lower
pressure drop across the current valve.
Option C: A variable frequency drive (VFD) can be
installed, and the flow control valve removed. The VFD can
vary the pump speed and thus achieve the desired process
flow.
Option D: The system can be left as it is, with a yearly
repair of the flow control valve to be expected.
2012PearsonCanadaInc.,Toronto,Ontario
9
Example6.13:PumpingSystemWitha
ProblemValve(continued)
Life-Cycle Cost Elements
2012PearsonCanadaInc.,Toronto,Ontario
10
Example6.13:PumpingSystemWithaProblem
Valve(continued)
Cost Comparison for Options A D
2012PearsonCanadaInc.,Toronto,Ontario
11
SampleLCCCalculationforOptionA
2012PearsonCanadaInc.,Toronto,Ontario
12
ComparisonofLCCforOptionsAD
2012PearsonCanadaInc.,Toronto,Ontario
13
DesignE Throughconomics
Concept: Annual equivalent analysis is used to
determine optimal engineering designs.
Goal: Find the optimal design parameter that
minimizes annual equivalent costs.
Typical Mathematical Equation:
c
AEC (i ) = a +bx +
x
where x is common design parameter
Analytical Solution:
x* =
c
b
2012PearsonCanadaInc.,Toronto,Ontario
14
Analyticalsolution
(a b) 0 a + b 2ab with equality
2
2
2
holding only when a = b.
c
bx + =
x
(
bx
)
AEC is minimized when
2
2
c
c
+
= 2 bc
2 bx
x
x
bx * =
c
x* =
x*
2012PearsonCanadaInc.,Toronto,Ontario
c
b
15
Example6.14:OptimalCrossSectional
Area
Necessary Service Requirements
Conduct 5,000 amps over a distance of 300 metres for 24 hours
a day, 365 days a year.
Copper price: $16.50/kg
Resistance: 1.7241x10-4 per metre
Cost of energy: $0.0375/kwh
Density of copper: 8,894 kg/m3
Useful life: 25 years
Salvage value: $1.65/kg
Interest rate: 9%
2012PearsonCanadaInc.,Toronto,Ontario
16
Example6.14:OptimalCrossSectionalArea
(continued)
Step 1: Energy loss in kilowatt-hour
I 2RT
I 2T
L
Energy loss =
=
1000 A 1000 A
50002 24 365 1.7241 10 4 300
=
1000
A
11,327,337
=
kWh
A
I = current flow in amperes
R = resistance in ohms
T = number of operating hours
A = cross-sectional area
= resistivity of material
L = length of conductor
2012PearsonCanadaInc.,Toronto,Ontario
17
Example6.14:OptimalCrossSectionalArea
Step 2: Total cost of energy loss in dollars per
year
11
,327,337
( )
A
11
,327,337
=
( $0.0375 )
A
$424,775
=
A
Annual energy loss cost =
where = cost of energy in dollars per k Wh.
2012PearsonCanadaInc.,Toronto,Ontario
18
Example6.14:OptimalCrossSectionalArea
(continued)
Step 3: Calculate total cost of conductor
material
Material mass in kilograms
300(8894) A
= 267 A
3
100
Material cost (required investment)
Total material cost = 267A($16.50)
= $4406A
2012PearsonCanadaInc.,Toronto,Ontario
19
Example6.14:OptimalCrossSectionalArea
(continued)
Step 4: Compute the capital recovery cost
CR (9%) = $4406 A $1.65 ( 267 A ) ( A / P,9%,25 )
+$1.65 ( 267 A ) ( 0.09 )
= $404 A + $40 A
= $444 A
2012PearsonCanadaInc.,Toronto,Ontario
20
Example6.14:OptimalCrossSectionalArea
(continued)
Step 5: Express the total annual equivalent cost
(AEC) as a function of a design variable (A) using
the formula:
c
AEC (i ) = a + bx +
x
Capital cost
6 74
48
424,775
AEC (9%) = $444 A +
A3
14 2 4
Operating cost
2012PearsonCanadaInc.,Toronto,Ontario
21
Example6.14:OptimalCrossSectional
Area(continued)
Step 5 Continued: Find the minimum annual equivalent cost using the
c
following formula AEC ( i ) = a + bx + :
x
dAEC (9%)
424, 755
= 444
=0
2
dA
A
424, 755
A=
444
= 31 cm 2
*
AEC (9%) =444(31) +
424, 755
31
=$27, 466
2012PearsonCanadaInc.,Toronto,Ontario
22
Example6.14:OptimalCrossSectional
Area(continued)
Optimal Cross-Sectional Area
2012PearsonCanadaInc.,Toronto,Ontario
23
Summary
Life-cycle cost analysis is a way to predict the most
cost-effective solution by allowing engineers to make a
reasonable comparison among alternatives within the
limit of the available data. Design economics can be
used to determine a design parameter that minimizes
annual equivalent costs.
2012PearsonCanadaInc.,Toronto,Ontario
24
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