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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 struc- tures 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
6 Working together as partnersUser guide for QAF and TAF
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
8 Working together as partnersUser guide for QAF and TAF
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
14 15Cost EngineeringUser guide for QAF and TAF
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
Type of cost Contents
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
18 19Cost EngineeringUser guide for QAF and TAF
Type of cost Contents
Selling, general and administrative costs
Type of cost Contents
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.
22 23Fill out the QAFUser guide for QAF and TAF
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:
V2.0
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©ZF Friedrichshafen AG
QAF - Quotation Analysis Form
Summary
25
Attributes Notes Attributes Notes
Supplier
Contact
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
Fill out the QAFUser guide for QAF and TAF
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
Fill out the QAFUser guide for QAF and TAF
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
30 31Fill out the QAFUser guide for QAF and TAF
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
Fields colored light gray are
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
V2.0
14.02.2018
QAF_ZF_V2.91_Update_Arbeitsversion.xlsm
©ZF Friedrichshafen AG
QAF - Quotation Analysis Form
Material
3534 Fill out the QAFUser guide for QAF and TAF
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 –, other- wise 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
36 37Fill out the QAFUser guide for QAF and TAF
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
3938 Fill out the QAFUser guide for QAF and TAF
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
40 Fill out the QAFUser guide for QAF and TAF
Figure 3: “Manufacturing” data sheet
41
The „Manufacturing“ data sheet
Fields colored light gray are
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 FormManufacturingPlease fill out and return to ZF contact
Quotation date: Designation: Supplier:
Quotation number: Part number: Contact:
Quotation variant: Revision index:
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]
Additional line: Please click the "add a line" button below
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
Fill out the QAFUser guide for QAF and TAF
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
4544 Fill out the QAFUser guide for QAF and TAF
What you need to fill out in the “Manufacturing” data sheet
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
Fill out the QAFUser guide for QAF and TAF
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
What you need to fill out in the “Manufacturing” data sheet
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
48 Fill out the QAFUser guide for QAF and TAF
Figure 4: “Special Manufacturing Equipment / Research & Development” data sheet
49
Fields colored light gray are
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.
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
Quotation date: Designation: Supplier:
Quotation number: Part number: Contact:
Quotation variant: Revision index:
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]
Additional line: Please click the "add a line" button below
Total
Designation
Development costTooling costAttributes
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QAF - Quotation Analysis Form
SME_R14.02.2018
5150 Fill out the QAFUser guide for QAF and TAF
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 selec- tion, 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
5352 Fill out the QAFUser guide for QAF and TAF
How ZF breaks down the “Special ManufacturingEquipment / Research & Development” data sheet
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
How ZF breaks down the “Special ManufacturingEquipment / Research & Development” data sheet
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.“
56 How to correctly fill out the TAF User guide for QAF and TAF
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:
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ZF Friedrichshafen AGTAF - Tooling Analysis Form
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 !
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58 How to correctly fill out the TAF User guide for QAF and TAF
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
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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:
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60 How to correctly fill out the TAF User guide for QAF and TAF
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