Event Objective- The Cost and Manufacturing Event aims to evaluate the team's comprehensive understanding of manufacturing processes and associated costs, emphasizing their ability to make informed trade-off decisions between content and cost. Teams are expected to demonstrate sound make-or-buy judgments and distinguish between prototype and mass production requirements.

The event encourages a focus on cost management without compromising safety and performance. It emphasizes value-optimized solutions and rewards teams that showcase efficient, well-justified cost strategies grounded in solid engineering decisions—not merely those with the lowest cost.

Cost Report Documents (CRD) The CRD consists of:

• Bill of Material (BOM) including DBOM and CBOM
• Supporting material file (optional)
• Cost explanation file (optional)

1.1. Bill of Material (BOM)

• Lists all parts and equipment fitted to the vehicle.
• Structured into systems, assemblies, and parts.
• Must use metric units only.
• Two systems must be presented in DBOM format.
• One of those DBOM systems must also include a CBOM.

1.2. Detailed Bill of Material (DBOM)

• Lists manufacturing processes for all parts in two selected BOM systems, excluding Motor and Drivetrain (MO).
• Each part must include material, processes, tooling, and fasteners.
• Each part classified as made or bought.

1.3. Costed Bill of Material (CBOM)

• Must be created for the Drivetrain (DT) system.
• Includes realistic costs of materials, fabrication, purchased parts, and assembly.
• Excludes R&D and capital costs.
• Costs must be in INR.
• Shows tooling, overheads, machining rates, and man-hour estimates.

2. Supporting Material File (Optional)

Should contain drawings, exploded views, and images to help judges understand BOM structure and parts.

3. Cost Explanation File (Optional)

Explains the cost model used, types of costs included, and specific cost figures (e.g., machine hourly rates).

Evaluation Process The rules are designed to:

• Provide a clear, logical, and time-efficient structure that supports students in achieving the event's goals.
• Enhance fairness through standardized cost tables that ensure pricing consistency across all teams.
• Reduce the burden of submitting numerous receipts while promoting the use of engineering documentation to illustrate manufacturing plans and decisions.

The evaluation consists of three components:

• Cost Report: The submission of a complete Cost Report Document (CRD) including BOM, DBOM, and CBOM.
• Discussion: An interactive discussion with judges during the competition to assess the cost accuracy and understanding of the manufacturing plan.
• Real Case: A practical challenge related to cost or manufacturing, requiring on-the-spot analysis and response.

Every team will receive a 35-minute evaluation slot in which they have to present:

• Setup Time: 2 Minutes
• Presentation Time: 13 Minutes
• Questionnaire Round: 15 Minutes
• Feedback: 5 Minutes

Presentations will be conducted online via Google Meet and will be recorded. There are no restrictions on slide count, but time limits must be observed.

Team Participation

A minimum of 2 and a maximum of 5 members may present. Up to 5 additional team members may observe.

Presentation Requirements Teams must address, but are not limited to, the following keywords in their presentation:

• Cost calculation methods
• Costed Bill of Materials of selected in-house manufactured assemblies
• Initial budget projections
• Financial and production risk management
• Prototype vs. mass production cost comparison
• Man-hour estimations in prototype manufacturing
• Make or buy decisions
• Lean manufacturing principles
• Cost estimations for Mass Production

Printed Reports–

Printed reports are not required. Only electronic documents may be presented.