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- Kianian, Babak
(author)
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A comparative cost analysis of conventional wrought steel and powder metallurgy (PM) gear manufacturing technologies
- 2019
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Licentiate thesis (other academic/artistic)abstract
- The transportation industry landscape is going through a massive transformation due to trends such as autonomous and electrified vehicles. The electrification trend has already started to display its ample influence on the automotive industry. New modern power and drivetrains need to be designed and manufactured based on the raising automakers’ requirements e.g. higher performance, better noise vibration harshness (NVH) behaviour. Meanwhile, cost must be minimized in order to obtain or secure market competitiveness.In the highly cost-competitive atmosphere of the manufacturing sector,particularly within the automotive industry, which is the focus of this licentiate,manufacturing firms uninterruptedly seek to develop, adopt and utilise cost models and methods in order to evaluate e.g. their existing production systems or planning new investment for adoption and deployment of new technologies.The industrial case studies, investigated in this licentiate, have gearmanufacturing as the focus. The gear and transmission component manufacturingindustry is an important sector as it provides one of the basic mechanical parts toindustrial segments where motion and power transfer are needed. Two gearmanufacturing techniques namely conventional wrought steel and powdermetallurgy (PM) are compared from a cost perspective. Given the requiredperformance and quality for automotive transmission application, the gearmanufacturing processing routes and their production steps and cost drivers areanalysed and compared through the utilisation of the selected cost model, calledperformance part costing (PPC).The industrial applicability of PPC model is compared with the commonly usedstandard costing, its use and its modified variations among practitioners through the case studies. The pros and cons of each approach are discussed. Given the assumptions made and reported in this licentiate for two different scenarios, the gear manufacturing cost of the analysed PM processing route were 12% to 38% cheaper compared to the conventional wrought steel processing route. However, the acquisition cost for the analysed PM processing route were almost three times higher than that of the conventional wrought steel gear.
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| 2. |
- Kianian, Babak
(author)
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Comparing acquisition and operation life cycle costs of powder metallurgy and conventional wrought steel gear manufacturing techniques
- 2019
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In: 52nd CIRP Conference on Manufacturing Systems (CMS), Ljubljana, Slovenia, June 12-14, 2019. - : Elsevier BV. - 2212-8271. ; 81, s. 1101-1106
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Conference paper (peer-reviewed)abstract
- The automotive industry has striven for fuel economy and resource efficiency through the deployment of powder metallurgy (PM) manufacturing processes for few decades. However, PM technology for transmission gears is currently only used at a small scale within the automotive industry. This is mainly due to: its shortcomings in material properties and performance gaps for final parts; lack of advancement in pressing technologies (dimensional limitation); lack of data availability (e.g. on materials, load capacity calculations; gear design experimental confirmation); premature failed attempts on PM gears; economics of scale and large initial capital investments. This article reviews the current state of the art of PM gear manufacturing technology highlighting an important gap in technical and financial data availability for PM gear economic analysis. Thus, this study seeks to give some empirical evidence of the economic aspects of PM gear manufacturing. Data availability is still the major challenge with respect to PM cost calculations thus further studies are needed to quantify both the economic and non-economic benefits e.g., sustainability, noise vibration harshness (NVH) of PM adoption.
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| 3. |
- Kianian, Babak, et al.
(author)
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Comparing life cycle costing and performance part costing in assessing acquisition and operational cost of new manufacturing technologies
- 2019
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In: Procedia CIRP. - : Elsevier BV. - 2212-8271. ; 80, s. 428-433
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Conference paper (peer-reviewed)abstract
- Even if practitioners want to adopt new manufacturing technologies, there is a lack of comprehensive tools to support their decisions, regarding both cost and sustainability. This paper reviews and compares the practical use of Life Cycle Costing (LCC) with a performance part costing (PPC) model, chosen based upon the criteria of providing in-depth analysis capabilities and the prospect of integrating cost and sustainability assessment. A case study of a Swedish gear manufacturer is selected, where the company investigates adoption of a new manufacturing technology. Since, this type of decision requires heavy investments e.g. in new machines, tools, linking performance with costs would be a prerequisite for performing well-informed decisions. Based on interviews, the level of detail requirements e.g., performance indicators, when acquiring new technologies are identified. LCC model cost parameters are compared with the PPC cost drivers and the data availability and estimation are discussed.
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